Stone Sludge Granulation for Construction Reuse
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Solution Overview
Problem
Current methods for treating machining sludges from stone and ceramic materials do not fully eliminate the need for refuse collection centers due to residual powders, leading to inefficiencies and increased costs, and existing technologies do not effectively utilize these sludges for alternative uses.
Innovation Solution
A method involving mechanical water elimination, mixing with an inorganic binder, granulation, drying, and thermal treatment to produce insoluble granules devoid of organic substances, which can be reused in construction materials or disposed of easily as aggregate material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If concentrated sludge is disposed of in refuse collection centers, then waste disposal is simplified, but disposal costs increase and environmental impact worsens
Solution Approach 1:
The patent applies parameter changes by transforming the sludge through thermal treatment at specific temperatures (400-600°C) to alter its chemical composition. This converts organic substances into insoluble inorganic granules, changing the material's properties from disposable waste to reusable construction material, thereby eliminating disposal costs and environmental impact while maintaining operational simplicity.
Solution Approach 2:
The patent implements discarding and recovering by separating valuable components from the sludge. Through thermal treatment, organic substances are combusted and removed, while inorganic materials are recovered as reusable granules for construction applications. This recovers potential resources from waste, converting a cost center into a value-generating process.
2Adaptability or versatility
If organic substances are eliminated through calcination, then reusability in construction materials is achieved, but energy consumption increases
Solution Approach 1:
The patent utilizes phase transitions by heating sludge through distinct thermal stages: drying (removing moisture), calcination (combusting organics at 400-600°C), and cooling. These controlled phase transitions transform the material structure, making it suitable for construction use while managing energy input through staged heating rather than continuous high-energy processing.
Solution Approach 2:
The patent converts the harmful organic substances in sludge into beneficial outcomes. By combusting these organics during calcination, the process eliminates environmental hazards while generating thermal energy that can be utilized in the drying and heating stages, effectively converting a waste problem into an energy source that offsets part of the energy consumption.
3Quantity of substance
If water is mechanically eliminated from sludge, then concentration is improved, but water recycling efficiency decreases
Solution Approach 1:
The patent applies extraction by removing water from sludge through mechanical means (centrifugation or filtration) to concentrate the organic and inorganic materials. This separation allows the water to be recovered and recycled back into the process, while the concentrated sludge proceeds to thermal treatment. The extraction enables both concentration improvement and water recycling to occur in sequence without conflict.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process generates granules suitable for various applications in the building industry, reducing waste disposal costs and environmental impact by eliminating organic components, and allows for efficient recycling of water and energy recovery.
Implementation Method 1
drying the granular mix by evaporation of the water contained in said mixture
Implementation Method 2
heating the dried granules to a given temperature and keeping them at said temperature so as to render the binder insoluble, with elimination of the organic substances by means of combustion
Data Source
AI summary
A method and a plant for treating and using sludges comprising waste from the machining of slabs or blocks of stone, ceramic or agglomerated stone material. The machining sludges undergo at least one step for mechanical elimination of the water content, with formation of a concentrated sludge. The method comprises the steps of: (a) mixing the concentrated sludge with an inorganic binder in an aqueous solution; (b) reducing the mixture thus obtained into granules; (c) drying the granular mix by means of evaporation of the water content; (d) heating and keeping the dried granules at a temperature sufficient to render the inorganic binder insoluble and eliminate by means of combustion any organic substances contained in the granules.