阅读说明：本技术 具有石油灰分的泡沫混凝土 (Foamed concrete with petroleum ash ) 是由 ***·鹤山·阿勒-梅赫特尔 萨拉赫·H·阿勒-伊迪 ***·马斯莱胡丁 ***·*** 于 2018-01-31 设计创作，主要内容包括：一种泡沫混凝土,其具有包含水泥、砂子、粗骨料、石油灰分、水和泡沫溶液的成分。该泡沫混凝土的抗压强度为至少20MPa,导热系数小于0.41W/mK,并且最大重量为1650kg/m<Sup>3</Sup>。(A foamed concrete having ingredients comprising cement, sand, coarse aggregate, petroleum ash, water, and a foaming solution. The compressive strength of the foam concrete is at least 20MPa, the heat conductivity coefficient is less than 0.41W/mK, and the maximum weight is 1650kg/m 3 。)

1. A foamed concrete, the composition of which comprises:

cement;

sand;

coarse aggregate;

petroleum ash;

water; and

a foaming solution; wherein the content of the first and second substances,

the compressive strength of the foam concrete is at least 20MPa, the heat conductivity coefficient is less than 0.41W/mK, and the maximum weight is 1650kg/m³。

2. The foamed concrete according to claim 1 wherein the cement together with the water comprises from 75% to 80% by weight of the ingredients of the foamed concrete, based on the weight of the foamed concrete.

3. The foamed concrete according to claim 1 or claim 2 wherein the foamed concrete is free of fly ash, plasticizers, and fibers.

4. The foamed concrete according to any one of claims 1-3 wherein the compressive strength of the foamed concrete is in the range of 20MPa to 60 MPa.

5. The foamed concrete according to any one of claims 1-4 wherein the foamed concrete has a thermal conductivity of 0.40W/mK.

6. The foamed concrete according to any one of claims 1-5 wherein the foamed concrete has a weight of 1525kg/m³To 1650kg/m³Within the range of (1).

7. The foamed concrete according to any one of claims 1-6 wherein the cement comprises at least 50% by weight of the ingredients of the foamed concrete, based on the weight of the foamed concrete.

8. The foamed concrete according to any one of claims 1-7 wherein the ingredients of the foamed concrete comprise, each based on the weight of the foamed concrete:

the cement in an amount of 53 to 56 weight percent of the components of the foamed concrete;

the sand in an amount of 5 to 8% by weight of the components of the foamed concrete;

the coarse aggregate in an amount of 10 to 12% by weight of the components of the foamed concrete;

the petroleum ash in an amount of 3 to 6% by weight of the components of the foamed concrete;

the water in an amount of 21 to 25% by weight of the components of the foamed concrete; and

the foaming solution in an amount of 0.5 to 3.0% by weight of the components of the foamed concrete.

9. The foamed concrete according to any one of claims 1-7 wherein the ingredients of the foamed concrete comprise, each based on the weight of the foamed concrete:

the cement in an amount of 53.4% by weight of the components of the foamed concrete;

said sand in an amount of 5.3% by weight of the components of said foamed concrete;

the coarse aggregate in an amount of 10.6 wt% of the components of the foamed concrete;

the petroleum ash in an amount of 5.3% by weight of the components of the foamed concrete;

said water in an amount of 24.6% by weight of the ingredients of said foamed concrete; and

the foam solution in an amount of 0.8% by weight of the components of the foamed concrete.

10. A foamed concrete, the composition of which comprises:

cement in an amount of 15 to 65% by weight of the components of the foamed concrete;

sand in an amount of 1 to 10% by weight of the components of the foamed concrete;

coarse aggregate in an amount of 10 to 50 wt% of the components of the foamed concrete;

petroleum ash in an amount of 3 to 10% by weight of the components of the foamed concrete;

water in an amount of 10 to 30% by weight of the components of the foamed concrete; and a foaming solution in an amount of 0.5 to 5.0% by weight of the components of the foamed concrete.

11. The foamed concrete according to claim 10 wherein the foamed concrete has a compressive strength of at least 20MPa, a thermal conductivity of less than 0.41W/mK, and a maximum weight of 1650kg/m³。

12. The foamed concrete according to claim 10 or claim 11 wherein the cement comprises at least 50% by weight of the ingredients of the foamed concrete, based on the weight of the foamed concrete.

13. The foamed concrete according to any one of claims 10-12 wherein the cement together with the water comprises 75 to 80 weight percent of the ingredients of the foamed concrete based on the weight of the foamed concrete.

14. A method of treating petroleum ash by forming a foamed concrete, the method comprising the steps of:

the following ingredients were mixed together:

cement;

sand;

coarse aggregate;

petroleum ash; and

water;

adding a foaming solution to obtain a mixture having a compressive strength of at least 20MPa, a thermal conductivity of less than 0.41W/mK and a maximum weight of 1650kg/m³The foam concrete of (1).

15. The method of claim 14, further comprising curing the foamed concrete by applying water.

16. The method of claim 14 or claim 15, wherein the cement together with the water comprises 75 to 80 weight percent of the ingredients of the foamed concrete, based on the weight of the foamed concrete.

17. The method of any one of claims 14 to 16, wherein the foamed concrete is free of fly ash, plasticizers, and fibers.

18. The method of any one of claims 14 to 17, wherein the cement comprises at least 50 weight percent of the constituents of the foamed concrete, based on the weight of the foamed concrete.

19. The method of any of claims 14-18, wherein the ingredients of the foamed concrete comprise, each based on the weight of the foamed concrete:

the cement in an amount of 53 to 56 weight percent of the components of the foamed concrete;

the sand in an amount of 5 to 8% by weight of the components of the foamed concrete;

the coarse aggregate in an amount of 10 to 12% by weight of the components of the foamed concrete;

the petroleum ash in an amount of 3 to 6% by weight of the components of the foamed concrete;

the water in an amount of 21 to 25% by weight of the components of the foamed concrete; and

the foaming solution in an amount of 0.5 to 3.0% by weight of the components of the foamed concrete.

20. The method of any of claims 14-18, wherein the ingredients of the foamed concrete comprise, each based on the weight of the foamed concrete:

the cement in an amount of 53.4% by weight of the components of the foamed concrete;

said sand in an amount of 5.3% by weight of the components of said foamed concrete;

the coarse aggregate in an amount of 10.6 wt% of the components of the foamed concrete;

the petroleum ash in an amount of 5.3% by weight of the components of the foamed concrete; said water in an amount of 24.6% by weight of the ingredients of said foamed concrete; and the foaming solution in an amount of 0.8% by weight of the components of the foamed concrete.

Technical Field

The present disclosure relates to a foamed concrete having petroleum ash (oil ash). More particularly, the present disclosure relates to a lightweight concrete composition having petroleum ash as a filler and a method of preparing the same.

Background

Concrete can be used for various construction purposes. Some existing lightweight concrete has low compressive strength and therefore cannot be used in load bearing concrete applications, such as structural members. In order to provide sufficient compressive strength, heavy weight concrete (e.g., conventional concrete) can be used for the load-bearing concrete components. However, conventional concrete has a high thermal conductivity and a large weight, and thus the use of heavy concrete or a large amount of concrete results in a heavy or bulky structure.

Disclosure of Invention

Embodiments of the present disclosure provide a lightweight foamed concrete having a thermal conductivity lower than some conventional normal weight concretes and having a compressive strength higher than existing lightweight concretes. The compositions and methods described herein provide foamed concrete that can be used to make elongated structural members, and the reduction in size of the structural members reduces the overall cost of the building as compared to some existing concretes. The compressive strength of the disclosed foamed concrete is sufficiently high to enable the foamed concrete to be used for structural purposes as well as for masonry units, bricks and insulation. In addition, the thermal conductivity of the developed composition is lower than that of conventional concrete and some existing lightweight concrete. The compositions and methods described herein use petroleum ash as a filler.

In one embodiment of the present disclosure, the foamed concrete has ingredients including cement, sand, coarse aggregate, petroleum ash, water, and a foam solution. The compressive strength of the foam concrete is at least 20MPa, the heat conductivity coefficient is less than 0.41W/mK, and the maximum weight is 1650kg/m³。

In an alternative embodiment, the cement together with water may comprise 75 to 80% by weight of the components of the foamed concrete, based on the weight of the foamed concrete. The foamed concrete may be free of fly ash, plasticizers, and fibers. The compressive strength of the foamed concrete may be in the range of 20MPa to 60 MPa. The thermal conductivity of the foamed concrete may be 0.40W/mK. The weight of the foam concrete can be 1525kg/m³To 1650kg/m³Within the range of (1). The cement may comprise at least 50% by weight of the components of the foamed concrete, based on the weight of the foamed concrete.

In other alternative embodiments, the components of the foamed concrete may comprise, each based on the weight of the foamed concrete:

cement in an amount of 53 to 56% by weight of the components of the foamed concrete;

sand in an amount of 5 to 8% by weight of the components of the foamed concrete;

coarse aggregate in an amount of 10 to 12 wt% of the components of the foamed concrete;

petroleum ash in an amount of 3 to 6% by weight of the components of the foamed concrete;

water in an amount of 21 to 25% by weight of the components of the foamed concrete; and

a foaming solution in an amount of 0.5 to 3.0% by weight of the components of the foamed concrete.

In still other alternative embodiments, the ingredients of the foamed concrete may comprise, each based on the weight of the foamed concrete:

cement in an amount of 53.4% by weight of the components of the foamed concrete;

sand in an amount of 5.3% by weight of the components of the foamed concrete;

coarse aggregate in an amount of 10.6 wt% of the components of the foamed concrete;

petroleum ash in an amount of 5.3% by weight of the components of the foamed concrete;

water in an amount of 24.6% by weight of the components of the foamed concrete; and

a foam solution in an amount of 0.8% by weight of the components of the foamed concrete.

In an alternative embodiment of the present disclosure, the ingredients of the foamed concrete comprise:

cement in an amount of 15 to 65% by weight of the components of the foamed concrete;

sand in an amount of 1 to 10% by weight of the components of the foamed concrete;

coarse aggregate in an amount of 10 to 50 wt% of the components of the foamed concrete;

petroleum ash in an amount of 3 to 10% by weight of the components of the foamed concrete;

water in an amount of 10 to 30% by weight of the components of the foamed concrete; and

a foaming solution in an amount of 0.5 to 5.0% by weight of the components of the foamed concrete.

In an alternative embodiment, the foamed concrete may have a compressive strength of at least 20MPa, a thermal conductivity of less than 0.41W/mK, and a maximum weight of 1650kg/m³. The cement may comprise at least 50% by weight of the components of the foamed concrete, based on the weight of the foamed concrete. The cement, along with water, may comprise 75 to 80 weight percent of the components of the foamed concrete, based on the weight of the foamed concrete.

In another alternative embodiment of the present disclosure, a method of treating petroleum ash by forming a foamed concrete includes the step of mixing together: cement; sand; coarse aggregate; petroleum ash; and water. A foaming solution may be added to obtainA compressive strength of at least 20MPa, a thermal conductivity of less than 0.41W/mK and a maximum weight of 1650kg/m³The foam concrete.

In an alternative embodiment, water may be applied at ambient pressure to cure the foamed concrete. The cement, along with water, may comprise 75 to 80 weight percent of the components of the foamed concrete, based on the weight of the foamed concrete. The foamed concrete may be free of fly ash, plasticizers, and fibers. The cement may comprise at least 50% by weight of the components of the foamed concrete, based on the weight of the foamed concrete.

In other alternative embodiments, the components of the foamed concrete may comprise, each based on the weight of the foamed concrete:

cement in an amount of 53 to 56 weight percent of the components of the foamed concrete;

sand in an amount of 5 to 8% by weight of the components of the foamed concrete;

coarse aggregate in an amount of 10 to 12 wt% of the components of the foamed concrete;

petroleum ash in an amount of 3 to 6% by weight of the components of the foamed concrete;

water in an amount of 21 to 25% by weight of the components of the foamed concrete; and

a foaming solution in an amount of 0.5 to 3.0% by weight of the components of the foamed concrete.

In still other alternative embodiments, the ingredients of the foamed concrete may comprise, each based on the weight of the foamed concrete:

cement in an amount of 53.4% by weight of the components of the foamed concrete;

sand in an amount of 5.3% by weight of the components of the foamed concrete;

coarse aggregate in an amount of 10.6 wt% of the components of the foamed concrete;

petroleum ash in an amount of 5.3% by weight of the components of the foamed concrete;

water in an amount of 24.6% by weight of the components of the foamed concrete; and

a foam solution in an amount of 0.8% by weight of the components of the foamed concrete.

Drawings

So that the manner in which the above recited features, aspects and advantages of the disclosed embodiments, as well as others which will become apparent, are attained and can be understood in detail, a more particular description of the disclosure briefly summarized above may be had by reference to the embodiments thereof which are illustrated in the appended drawings, which form a part of this specification. It is to be noted, however, that the appended drawings illustrate some embodiments of this disclosure and are therefore not to be considered limiting of its scope, for the disclosure may admit to other equally effective embodiments.

Fig. 1 is a graph showing bottom and top temperatures of a foamed concrete slab as a function of time according to an embodiment of the present disclosure.

Detailed Description

The compositions and methods described in this disclosure provide a foamed concrete having ingredients including cement, sand, coarse aggregate, petroleum ash, water, and a foaming solution.

Petroleum ash ("OA") is a residue (residue) produced from the combustion of heavy or cracked oils. Heavy oil is generally defined as a fuel oil having a relatively long hydrocarbon chain (e.g., carbon length of about 12 to 70 carbon atoms or about 20 to 70 carbon atoms). Heavy fuel oils can be classified as "fuel oil No. 5" or "fuel oil No. 6" as classified by the American Society for Testing and Materials (ASTM). Due to the high viscosity of heavy fuel oils, it is sometimes preheated prior to combustion, for example in a power plant.

In the refining industry, cracking generally refers to the breakdown of complex organic molecules into simpler molecules by breaking long-chain hydrocarbons into shorter hydrocarbon chains. Various methods may be used to crack the oil, including, for example, catalytic methods. After the cracking process, the resulting hydrocarbons can be separated into various types of fuels, including, for example, fuel gas, liquefied petroleum gas, gasoline, light cycle oil, and heavy fuel oil. The heavy fuel oil produced by the cracking process may be referred to as "cracked fuel oil". For the purposes of this application, unless otherwise indicated, both cracked fuel oil and heavy fuel oil are referred to as heavy oils. Power generation plants and desalination plants can use heavy oil and it is expected that more and more heavy oil will be used in the future. The combustion of heavy oil produces residues, including ash. As one of ordinary skill will appreciate, due to environmental constraints, petroleum ash can (and to some extent must) be captured rather than released into the air.

OA is a black powder type waste material produced from the combustion of heavy oil. OA has unique properties compared to other types of ash. In order to control air pollution, OA was collected in an electrostatic precipitator installed on a residue-burning boiler. The current method for treating OA is to bury it in special lined containment pits, which is very expensive and requires a large area to be reserved as a dump site.

Typically, OA comprises greater than about 90 wt% carbon. The remaining less than about 10 wt.% OA may typically comprise sulfur, magnesium and vanadium. OA can include various particle sizes. In one embodiment, about 16% by weight of the OA is retained on the #325 sieve, while about 84% by weight of the material passes through the #325 sieve. This indicates that about 84 wt% of the ash may be finer than about 45 microns. In an alternative embodiment, approximately all of the OA passes through a #200 sieve. This indicates that approximately all of the ash may be finer than about 75 microns. As used herein, the term "about" should be understood to include values within 5% of the stated value.

Scanning electron microscopy studies have shown that OA is an aggregate of spherical spheres of different diameters. Energy dispersive X-ray analysis indicated the presence of primarily carbon, followed by sulfur and trace amounts of magnesium and silicon.

OA may comprise various elements. For example, table 1 shows an example of chemical analysis of OA. The content of each element may vary depending on the source of OA.

TABLE 1

Table 2 shows compound composition examples of OA. The content of each compound may vary depending on the source of OA.

TABLE 2

The elemental and compound compositions of OA used in embodiments of the present disclosure are significantly different from the elemental and compound compositions of conventional fly ash previously used in concrete.

Unlike OA, conventional fly ash is typically produced by burning coal. The main chemical component of the traditional fly ash is silicon dioxide (SiO)₂) Calcium oxide (CaO), aluminum oxide (Al)₂O₃) And iron oxide (Fe)₂O₃) And conventional fly ash is consistent with ASTM C618. Fly ash is generally classified according to the type of coal being burned. For example, class F fly ash is produced by burning anthracite and bituminous coals, while class C fly ash is produced by burning lignite or sub-bituminous coals. Since fly ash contains silica, it reacts with lime produced during hydration of the cement, making the cement dense and impermeable, while OA is primarily carbon, which does not promote the formation of supplementary cement (supplementary cement). However, due to the low density OA can be used instead of heavy components in concrete (such as cement and aggregates, especially sand) to produce lightweight concrete. Furthermore, the use of OA appears to have an improved compressive strength compared to the use of fly ash. OA is more readily available in fuel oil burning areas. Embodiments of the present disclosure do not contain fly ash.

Concrete is a composition made of cement, water and aggregates (aggregates or aggregates). Although "aggregates" may be plural, the term "aggregates" generally refers to aggregates of more than one type or more than one size. Cement is a binder that binds aggregates together. Ordinary portland cement ("OPC") is one such bonding agent that can bond to other materials, such as fine and coarse aggregates, thereby securing the other materials together. A material that is a slurry that can harden in the manner of cement to bond multiple materials together is referred to as a cementitious material or has cementitious properties. One skilled in the art will appreciate that water may be added to the dry cement to prepare the cement slurry. The water-cement ratio ("w/c ratio") of an OPC is typically about 0.20 to 0.5. Illustratively, a w/c ratio of 0.20 indicates that one part of water is present in five parts of portland cement (1/5 ═ 0.20). A w/c ratio of 0.5 indicates one part water to two parts cement. The cement of embodiments of the present disclosure may be, for example, type I portland cement. However, any type of cement (including pozzolan cement) can be used to produce the lightweight concrete developed in this disclosure. In certain embodiments, a pozzolanic material may alternatively be used as a filler.

As will be appreciated by those of ordinary skill, various types of conventional aggregate materials may be used as a filler in concrete. As will be understood by those skilled in the art, the term "aggregate" may refer to various types or sizes of aggregate. The aggregate may include, for example, sand, gravel, crushed stone, slag, or any other type of aggregate. When aggregate is used in concrete, the cement typically covers the aggregate and then binds the aggregate together in a matrix. When aggregates of various sizes are used, the smaller aggregate material can fill the voids between the larger aggregate material, resulting in a denser matrix. The aggregate used in concrete can be defined as coarse aggregate and fine aggregate. The fine aggregate (also referred to as "fines") may comprise natural sand, crushed stone or other suitable fine particles, the majority of which are less than 5mm in size. Coarse aggregates typically comprise gravel or crushed stone, the majority of which is larger than 5mm in grain and typically 9.5mm to 37.5mm in grain.

A foaming solution, such as a commercially available blowing agent that forms a solution when mixed with water, may be used. One such commercially available blowing agent is the EABASSOC blowing agent available from E-A-B Associates. Other commercially available blowing agents may alternatively be used and in each case prepared according to the instructions of the supplier. For example, compressed air may be introduced into the blowing agent and water to form the foam. As described in this disclosure, the water mixed with the foaming agent to form the foam solution is different than the water content used as the sole component of the foamed concrete. In the present specification, water used for mixing with a foaming agent to form a foaming solution will be referred to as foaming water.

In preparing foamed concrete, ranges of weight percent of each of the ingredients including cement, sand, coarse aggregate, petroleum ash, water and foam solution can be found in table 3. As used in this disclosure, the unit weight% is measured relative to the weight of the foamed concrete.

TABLE 3

In certain embodiments, the cement comprises at least 50% by weight of the ingredients of the foamed concrete, based on the weight of the foamed concrete. For example, in certain embodiments, the cement may constitute 53% to 56% by weight of the components of the foamed concrete. In determining the ratio of the ingredients, the combination of water and cement may constitute 75 to 80 weight percent of the ingredients of the foamed concrete, based on the weight of the foamed concrete. Both water and cement need to form a slurry that can easily bind the aggregate.

In alternative embodiments, the weight% of each ingredient may be within other ranges. For example, the sand may be 5 to 8 weight percent of the components of the foamed concrete. In certain embodiments, the coarse aggregate may be present in an amount of 10 to 12% by weight of the components of the foamed concrete. In certain embodiments, the petroleum ash content may be from 3% to 6% by weight of the constituents of the foamed concrete. In certain embodiments, the water may be present in an amount of 21 to 25% by weight of the components of the foamed concrete. In certain embodiments, the foaming solution may be present in an amount of 0.5 to 3.0% by weight of the components of the foamed concrete. The foam concrete does not contain fly ash, plasticizer and fiber. No plasticizer needs to be added since the foamed concrete will be in semi-liquid form and can be easily placed. The presence of fibres will hinder the formation of the foamed concrete. Thus, plasticizers and fibrous materials do not provide advantages to the foamed concrete and can increase the cost of the resulting product.

The resulting foam blendConcrete is a lightweight concrete product that can be used as an insulating member and a structural load bearing member. For example, the concrete product formed according to the present disclosure may have a compressive strength of at least 20MPa, and may range from 20MPa to 60MPa, a thermal conductivity of less than 0.41W/mK (e.g., 0.40W/mK), and a maximum weight of 1650kg/m³(the range is 1525kg/m³To 1650kg/m³)。

To form the foamed concrete, cement, sand, coarse aggregate, petroleum ash and water may be mixed in a conventional manner. A foam solution may be prepared and added to the other premixed ingredients to obtain a foamed concrete. The foam concrete may be cured by applying water at ambient pressure. For example, the foamed concrete may be cured by water immersion, water soaking, fogging, or wet covering. In certain embodiments, the foaming may be performed by forming a dyke (dyke) around the foam concrete component such that a layer of water remains on the foam concrete component for the duration of the curing period.