Expansion agent for ceramic material, consisting of mixtures of wastes from aluminium production

Abstract: Expansion agent consisting of a mixture of wastes including: a) fine powders obtained by the grinding of foams from smelting furnaces of primary and/or secondary aluminium b) residue essentially consisting of saline slags from secondary aluminium production. The aforesaid agent when added to a ceramic material causes its expansion when the material is heated to its softening temperature. After calcination, the thus obtained ceramic material is practically water-tight and highly resistant both to the attack by chemical agents and to mechanical stresses.

Description: FIELD OF THE INVENTION This invention concerns an expansion agent for ceramic material, consisting of a mixture of wastes from primary and/or secondary aluminium production, the process for the preparation of said expansion agent, the expanded ceramic material containing said expansion agent, the process for the preparation of said ceramic material and the use of same in the building industry. PRIOR ART The wastes leaving the aluminium processing are a very serious ecological problem. It is known that aluminium is mainly produced by two different methods, i.e.: A) production of primary aluminium consisting of alumina baking in reducing furnaces. The aluminium ingots obtained can be either hot-rolled or melted again in proper furnaces; B) production of secondary aluminium obtained from aluminous scraps baking in the presence of flux salts in reducing furnaces. Also the aluminium ingots obtained by the latter method can be hot-or cold-rolled or melted again in proper furnaces with a view to manufacturing complex elements. As concerns secondary aluminium production, the addition of the said flux salts, essentially consisting of alkali metal chlorides, is meant for lowering the melting temperature and, at the same time, protecting from any possible oxidation the upper part of the material being melted. Therefore, the aluminium processing wastes are essentially of two types: a) fine powders obtained by the grinding of foams from smelting furnaces of primary or secondary aluminium ingots; b) saline slags forming the residue after secondary aluminium production. The fine powders obtained by foams grinding contain aluminium and/or aluminium/magnesium oxides in high concentrations (35-80%), aluminium slags in the metallic state and as nitride, sulphide, carbide (5-15%), silicon in the metallic state, as silicon oxide and silicates (5-30%), alkaline metal fluorides, chlorides, and sulphates (5-30%) as well as low quantities of other compounds, such as heavy metal oxides, sulphides, and sulphates (1-5%). The saline slags contain alkaline metal chlorides in high concentrations (50-75%), aluminium oxides (5-15%), silicon oxides (5-10%), or complex oxides of aluminium and of other heavy metals (5-20%) as well as aluminium and silicon in the metallic state (3-10%), complex silicon aluminates (1-5%), and other halides in trace amounts. The aforesaid wastes have the form of granules and of anhydrous blocks of variable particle size. Since both types of wastes contain metallic aluminium and halides, gas evolution takes place in a few minutes on their coming into contact with water. Besides hydrogen, which is evolved by reaction of metallic aluminium with water, said wastes produce considerable quantities of ammonia, phosphine, methane, and hydrogen sulphide. GB-A-1 341 652 describes a method of producing a gas developing agent for cellular concretes comprising crushing slags resulting from the melting of aluminium alloys, separating from the crushed slags the fraction having a particle size from 0,3 to 1,2 mm and containing up to 70 wt% of metallic particles, and grinding the said separated particle fraction. Japanese patent No. 89016795 describes a process for the production of concrete or lightened bricks based on the use, as expansion agents, of unidentified wastes from aluminium production. However, the process described in the aforesaid patent finds no application due to the evolution of said toxic gases taking place when the wastes, i.e. both the fines obtained by foams grinding and the saline slags, come into contact with water. It follows that the production of concrete and lightened bricks on the basis of said technology is hazardous and, therefore, hardly feasible. Furthermore, since said materials contain water-soluble chlorides and heavy metals oxides, the disposition of same in dumping sites is potentially hazardous. This is one reason why plants for chlorides separation by washing and recrystallization were implemented. The product obtained from the plants is used for the melting of new scraps, while the insoluble wastes are sent to dumping. However, the construction, operation, and maintenance costs of said plants are extremely high; likewise, the cost of the produced salts exceeds that of the salts commonly available on the market. In addition, all plants meant for this purpose involve considerable operational problems, especially due to the variety of wastes to be treated. Therefore, the need of finding a possible utilization of the aforesaid two types of wastes, which would not bring about the drawbacks of the technologies known and described above, was deeply felt. THIS INVENTION The Applicant has actually found that the aforesaid wastes can be used as agents capable of expanding ceramic materials at a high temperature. Therefore, the subject of this invention is an expansion agent composed of a mixture of a) fine powders obtained by the grinding of foams from smelting furnaces of primary and/or secondary aluminium ingots; b) saline slags forming the residue after secondary aluminium production. In the expansion agent, subject of this invention, the weight ratio of component (a) to component (b) is generally of the order of 1 to 99%, preferably of 25 to 75%. The expansion agent as per this invention may be added with adsorbents with a view to preventing gas evolution on the mixture coming into contact with water; the preferred concentrations of said adsorbents (dry basis) range from 0.1 to 20% by wt. The adsorbers may be, for example, zeolites or diatomaceous rocks or sepiolites. The scope of this invention also includes the process for the preparation of said expansion agent, which consists of the following steps: I) separate dry-grinding of component (a) and of component (b) to an average particle size below 500µm, II) mixing of components (a) and (b) in the above ratios in the presence of the aforesaid adsorbents, if any. The scope of this invention also includes the expanded ceramic material containing the said expansion agent. In particular, the ceramic material contains the following components: 1) the expansion agent as per this invention in concentrations of 0.1 to 70% (dry basis), preferably of 3 to 25%; 2) a ceramic cement or a material with high contents of silicates and/or aluminates and/or silicon aluminates, preferably in the dry state and in variable ratios depending on the degree of expansion expected for the fired product. The following ceramic cements are preferred: clays, such as illite, smectite, montmorillonite, bauxite, and laterite; alumina, ground glass, minds from granite processing, red muds from bauxite processing, ashes from coal combustion, cinders from thermal decomposition, zeolite tuffs, diatomaceous rocks. Included in the scope of this invention is also the process for the preparation of the said ceramic material, which consists of the following steps: i) mixing of component (1), i.e. the expansion agent as per this invention, with component (2) in quantities giving the aforesaid concentrations of component (1) in the final dry mixture; ii) moistening of the mixture obtained in (i) generally by addition of water in quantities giving water concentrations in the mixture of 1 to 50% by wt., preferably of 5 to 25%; iii) machining of the raw mixture produced, i.e. - depending on the finished product to be obtained - drawing or granulating or pressure forming; iv) drying of the mixture obtained; v) firing of the ceramic material by heating same to the softening temperature for the time required for complete expansion; vi) slow cooling of the ceramic material to prevent embrittlement. For the purpose of preventing undesired gas evolutions from the raw and moist mixtures, the process, subject of this invention, envisages a shortened time lag between moistening (ii) and drying (iv). For this purpose, in the case of granular materials, granulation and drying should be better performed in a single apparatus, i.e. in a high turbulence drier. The kiln for ceramic material firing - step (v) of the process envisaged herein - may be of the static or tunnel or roller or fluidized-bed or rotary type, depending on the finished product to be obtained, on the thermal cycle selected, and on the desired material capacity. In any case, in said kiln the material is to be heated to its softening temperature, i.e. to the temperature range at which it becomes plastic and firing crystallization of silicates, if any, is completed (silicates crystallization on the nuclei of the alkaline and/or heavy metal oxides that are present both in clays and in silicate and silicon aluminium wastes). As a matter of fact, it is just at the softening temperature that the outer crust of each component of the ceramic material envisaged in this invention becomes vapourproof and the expansion stage starts. The softening and expansion temperatures of the single components of the ceramic material envisaged in this invention vary depending on the type of ceramic cement used, on the ratio of cement to expansion agent, on the ratio among wastes or of component (a) to component (b) in the expansion agent, on the temperature gradient; however, said temperatures are generally higher than 600°C and lower than 1300°C, preferably between 900°C and 1200°C. The ceramic material shall remain at its softening temperature to complete expansion, the time necessary for said expansion being generally in the range of 1 to 10 min., preferably of 3 to 8 min. Then, it is to be cooled slowly to prevent any thermal shock that might cause its embrittlement. Cooling generally takes 1 to 10 hrs., preferably 4 to 6 hrs. During expansion, when component (2) in the ceramic material as per this invention essentially consists either of silicates or of silicon aluminates, firing crystallization of the ceramic material takes place, i.e. silicates crystallization on the nuclei of alkaline and/or heavy metal oxides, which are present both in clays and in silicate and silicon aluminium wastes. Said crystallization makes the ceramic material both water-tight and highly resistant to the attack by chemical agents and to mechanical stresses. Tests carried out on the expanded ceramic material as per this invention showed volume gravity of 400 to 1,500 kg/m3, with water absorption values after 24 hrs. below 5%, generally from 1 to 2%, and compressive strength values between 2 and 100 N/mm2. The expanded ceramic material being the subject of this invention is used either as an aggregate for highly heat insulating hydraulic and/or bituminous mixes or as is for the production of construction elements meant for lining, stopping off, and heat insulating. The following examples are outlined for illustrating, purposes of this invention. EXAMPLE 1 Saline slags (20 parts by wt.) from a secondary aluminium production unit and fine powders (80 parts by wt.) obtained by the grinding of foams from melted primary and secondary aluminium ingots, are dry-ground to a particle size below 200µm. The mixture obtained is thoroughly mixed with dry illite (400 parts by wt.) of particle size below 500µm. The resulting mixture is moistened with water (20%) and granulated in a pan granulator. The granules are dried in a ventilated oven at 105°C to constant weight; then, they are fed to a static muffle kiln where they are heated in 4 hrs. to 1,200°C. After a 5-minute residence at 1,200°C they are cooled in 4 hrs. to room temperature. The obtained ceramic granules have the following characteristics: Average vol.mass of the granules 700 kg/m3 (UNI 7549/5) Soaking coefficient after 24 hrs. 3% (UNI 7549/6) Compressive strength 3N/mm2 (UNI 7549/7) Soluble chlorides content <0.05% (UNI 8520/12) By extraction tests in acetic acid according to CNR IRSA's method, said granules show eluate values below the limit values established in Table A of the Decree of the President of the Republic 915/82. EXAMPLE 2 Saline slags (30 parts by wt.) from a secondary aluminium production unit and fine powders (70 parts by wt.) obtained by the grinding of foams from melted primary and secondary aluminium ingots, are dry-ground to a particle size below 200µm. The mixture obtained is thoroughly mixed with dry diatomaceous rock (350 parts by wt.) of particle size below 500µm. The resulting mixture is moistened with water (25%) and granulated in a pan granulator. The granules are dried in a ventilated oven at 105°C to constant weight; then, they are fed to a static muffle kiln where they are heated for 4 hrs. to 1,180°C. After a 5-minute residence at 1,180°C they are cooled in 4 hrs. to room temperature. The ceramic granules obtained have the following characteristics: Average vol.mass of the granules 800 kg/m3 (UNI 7549/5) Soaking coefficient after 24 hrs. 2% (UNI 7549/6) Compressive strength 8N/mm2 (UNI 7549/7) Soluble chlorides content <0.05% (UNI 8520/12) By extraction tests in acetic acid according to CNR IRSA's method, said granules show eluate values below the limit values established in Table A of the Decree of the President of the Republic 915/82. EXAMPLE 3 Saline slags (35 parts by wt.) from a secondary aluminium production unit and fine powders (65 parts by wt.) obtained by the grinding of foams from melted primary and secondary aluminium ingots, are dry-ground to a particle size below 200µm. The resulting mixture is moistened with water (20%) and granulated in a pan granulator. The granules are dried in a ventilated oven at 105°C to constant weight; then, they are fed to a static muffle kiln where they are heated in 4 hrs. to 1,210°C. After a 7-minute residence at 1,210°C they are cooled in 4 hrs. to room temperature. The ceramic granules obtained have the following characteristics: Mean abs.gr. of the granules 900 kg/m3 (UNI 7549/5) Soaking coefficient after 24 hrs. 1% (UNI 7549/6) Compressive strength 9N/mm2 (UNI 7549/7) Soluble chlorides content <0.05% (UNI 8520/12) By extraction tests in acetic acid according to CNR IRSA's method, said granules show eluate values below the limit values established in Table A of the Decree of the President of the Republic 915/82.

Claims: Expansion agent for expanded ceramic material consisting of a mixture of: a) fine powders obtained by the grinding of foams from primary and/or secondary aluminium ingots smelting furnaces; b) saline slags from secondary aluminium production. Expansion agent as per claim 1 characterized by component (a) being composed of: aluminium and/or aluminium-magnesium oxides in concentrations of 35 to 80% by wt., aluminium in the metallic state and as nitride, sulphide, carbide, in total concentrations of 5 to 15%, silicon in the metallic state, as silicon dioxide and silicates in concentrations of 5 to 30% by wt., alkaline metal fluorides, chlorides, and sulphates in concentrations of 5 to 30% by wt., and heavy metal oxides, sulphides, and sulphates in concentrations of 1 to 5% by wt. Expansion agent as per claim 1 characterized by component (b) being composed of alkaline metal chlorides in concentrations of 50 to 75% by wt., aluminium oxides in concentrations of 5 to 15% by wt., silicon oxides in concentrations of 5 to 10% by wt., complex oxides of aluminium and of other heavy metals in concentrations of 5 to 20% by wt., aluminium and silicon in the metallic state in concentrations of 3 to 10% by wt., complex silicon aluminates in concentrations of 1 to 5%, and other halides in trace quantities. Expansion agent as per claim 1 characterized by component (a) to component (b) weight ratios ranging from 1 to 99%. Expansion agent as per claim 4 characterized by component (a) to component (b) weight ratios ranging from 25 to 75%. Expansion agent as per claim 1 characterized by the presence, if any, of an additive c) consisting of gas adsorbers. Expansion agent as per claim 6 characterized by the presence of adsorbents in concentrations of 0.1 to 20% by wt. (dry basis). Expansion agent as per claim 6 characterized by the adsorbers being zeolites or diatomaceous rocks or sepiolites. Process for the preparation of the expansion agent as per claims 1 through 8 consisting of the following steps: I) separate dry-grinding of components (a) and (b) to an average particle size below 500µm; II) mixing of component (a) with component (b) in quantities giving (a) to (b) ratios of 1 to 99%; additive (c) may also be added in concentrations of 0.1 to 20% by wt. (dry basis). The process for the preparation of the expansion agent as per claim 9 characterized by component (a) being mixed with component (b) in step I in (a) to (b) ratios of 25 to 75% by wt. Expanded ceramic material containing the expansion agent as per claims 1 through 8. The expanded ceramic material as per claim 11 consisting of: 1) expansion agent in a 0.1 to 70% ratio 2) a ceramic cement or a material with high contents of silicates and/or aluminates and/or silicon aluminates. The ceramic material as per claim 12 containing the expansion agent in concentrations of 3 to 25% by wt. The ceramic material as per claim 12 characterized by component (2) being clay. The ceramic material as per claim 14 characterized by the clay being illite or smectite or montmorillonite or bauxite or laterite. The expanded ceramic material as per claim 12 characterized by component (2) being alumina or ground glass or muds from granite processing or red muds from bauxite processing or ashes from coal combustion or cinders from thermal decomposition or zeolite tuffs or diatomaceous rocks. Process for the preparation of the ceramic material as per claim 12, consisting of the following steps: i) mixing of component (1) with component (2) in quantities giving component (1) concentrations in the final dry mixture of 0.1 to 70%; ii) moistening of the mixture obtained in step (i) generally by addition of water in quantities giving water concentrations in the mixture of 1 to 50% by wt.; iii) processing of the raw mixture obtained depending on the finished product to be obtained; iv) drying of the mixture obtained; v) firing of the ceramic material by heating the same to the softening temperature until complete expansion; vi) slow cooling of the ceramic material to prevent embrittlement. The process as per claim 17 characterized by component (1) being mixed with component (2) in step (i) in quantities giving component (2) concentrations in the final dry mixture of 3 to 25%. The process as per claim 17 characterized by water being added in step (ii) in quantities giving water concentrations in the raw mixture of 5 to 25%. The process as per claim 17 characterized by the raw mixture being drawn or granulated or pressure formed in step (iii). The process as per claim 20 characterized - on the raw mixture granulation - by granulation (iii) and drying (iv) being carried out in a single apparatus. The process as per claim 21 characterized by the drier being high-turbulence type. The process as per claim 17 characterized by the temperatures of step (v) being higher than 600°C and lower than 1300°C. The process as per claim 23 characterized by the temperatures of step (vi) ranging from 900°C to 1200°C. The process as per claim 17 characterized by a residence time of the ceramic material at the softening temperature (step vi) lasting from 1 to 10 min. The process as per claim 25 characterized by a residence time lasting from 3 to 8 min. The process as per claim 17 characterized by cooling (vi) lasting from 1 to 10 hrs. The process as per claim 27 characterized by the cooling lasting from 4 to 6 hrs. The process as per claim 17 characterized by step (v) being carried out in a static- or tunnel- or roller- or fluidized-bed- or rotary-type kiln. Use of the expanded ceramic material as per claim 11 as an aggregate for highly heat insulating hydraulic and/or bituminous mixes. Use of the expanded ceramic material as it is according to claim 11 for the production of construction elements meant for lining, stopping off, and heat insulating.

Inventors: CIOFFI FLAVIO, CONTENTO MARIA PIA, CIOFFI, FLAVIO, CONTENTO, MARIA PIA
Applicants: CONTENTO TRADE DI CIOFFI ILARI, CONTENTO TRADE DI CIOFFI ILARIA E C. S.A.S.
Application year: 1992
Main classification: C04B38
IPC codes: C03C11, C04B38, C04B22