Glass-Based Concrete Composition for Low-Energy Waste Glass Processing
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Solution Overview
Problem
Conventional concrete production methods face high energy consumption, carbon emissions, and limited waste glass utilization, posing challenges for sustainable construction, especially in waterless environments.
Innovation Solution
A glass-based concrete formulation using 25 to 35 parts of glass material, 15 to 25 parts of fine aggregate, 33 to 45 parts of coarse aggregate, and 1 to 5 parts of a fluxing agent, melted at 600° C. to 1600° C. to form a bubble-free liquid, then molded, utilizing waste glass and reducing environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional concrete preparation methods are used, then concrete can be produced with established formulations, but energy consumption is high and carbon emissions are large
Solution Approach 1:
The patent changes the chemical composition parameters by incorporating waste glass (20-40 wt%), metakaolin (10-30 wt%), and silica fume (5-20 wt%) to replace traditional cementitious materials. This compositional parameter change enables lower clinker content (10-30 wt%) which directly reduces the energy-intensive cement production process while maintaining concrete workability and strength through the synergistic effects of the supplementary cementitious materials
Solution Approach 2:
The patent creates a composite cementitious system combining multiple materials with complementary properties: waste glass provides alumina and silica for pozzolanic reactions, metakaolin contributes to early strength and fine pore structure, silica fume enhances densification and reduces permeability, and the reduced clinker content lowers carbon footprint. This multi-material composite approach achieves both environmental benefits and construction performance
2Loss of substance
If waste glass is incinerated for disposal, then volume reduction is achieved, but energy consumption increases and slag treatment costs rise
Solution Approach 1:
The patent transforms waste glass from a harmful pollutant requiring energy-intensive incineration into a beneficial supplementary cementitious material. The glass cullets (2-10 mm size) undergo pozzolanic reactions with calcium hydroxide to form calcium silicate hydrate and calcium aluminate hydrate, converting the waste into valuable binding phases that contribute to concrete strength while eliminating the need for incineration and associated energy consumption and slag handling
3Object-generated harmful factors
If clinker content is reduced to lower carbon emissions, then environmental impact decreases, but concrete strength may be compromised
Solution Approach 1:
The patent optimizes the chemical composition parameters of the blended cement system, specifically controlling the ratios of glass (20-40 wt%), metakaolin (10-30 wt%), silica fume (5-20 wt%), and clinker (10-30 wt%). These parameter changes ensure adequate pozzolanic activity and C-S-H gel formation to maintain strength. The fine particle sizes (0.63 mm for glass, optimized for metakaolin and silica fume) enhance reaction efficiency, allowing low clinker content to achieve required strength levels through improved microstructure and chemistry rather than relying on high cement dosage
4Stability of the object's composition
If glass material is melted at high temperature, then glass-based concrete is formed, but energy consumption and carbon emission increase
Solution Approach 1:
The patent changes the thermal processing parameters by reducing the melting temperature from traditional high-temperature glass melting (above 1500°C) to a lower range (600-1600°C). This is achieved by using a fluxing agent (1-5 parts by weight, such as sodium carbonate, potassium carbonate, or red lead) that lowers the melting point of the glass material. The reduced temperature directly decreases energy consumption and associated carbon emissions while still achieving complete melting and homogeneous composition of the glass-based concrete
Solution Approach 2:
The patent introduces a fluxing agent as an intermediary substance that facilitates the melting process at lower temperatures. The fluxing agent (sodium carbonate, potassium carbonate, or red lead in 1-5 wt% ranges) acts as a chemical mediator that disrupts the glass network structure, lowering the melting point and enabling energy-efficient processing. This intermediary substance makes the temperature reduction feasible while maintaining product quality
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 method achieves high-strength, low-energy concrete with reduced carbon emissions, effectively utilizing waste glass and protecting aggregates from high-temperature damage, suitable for waterless construction scenarios.
Implementation Method 1
By adding the fluxing agent, the problems of high energy consumption and carbon emission in the high-temperature melting process are avoided
Implementation Method 2
putting the mixture into a high-temperature furnace, setting temperature, and heating to melt to form a uniform and bubble-free liquid glass-based concrete
Implementation Method 3
pouring the liquid glass-based concrete into a mold for cooling and molding
Data Source
AI summary
A glass-based concrete includes in parts by mass: 25 to 35 parts of a glass material, 15 to 25 parts of fine aggregate, 33 to 45 parts of coarse aggregate, and 1 to 5 parts of a fluxing agent. A method for preparing a glass-based concrete includes steps of: S1. mixing raw materials according to the above parts by mass: 25 to 35 parts of a glass material, 15 to 25 parts of fine aggregate, 33 to 45 parts of coarse aggregate, and 1 to 5 parts of a fluxing agent; S2. putting the mixture into a high-temperature furnace, setting temperature, and heating to melt to form a uniform and bubble-free liquid glass-based concrete; and, S3. pouring the liquid glass-based concrete into a mold for cooling and molding. The glass-based concrete of the present invention is characterized by high strength, low energy consumption and low carbon emission.