DESC:CROSS-REFERENCE TO RELATED APPLICATIONS
This patent application claims the priority of the Indian Provisional Patent Application filed on May 24 2023, with the number 202341036079 and titled, "SYSTEM AND METHOD FOR IMPROVED CONCRETE STRUCTURES", the contents of which are incorporated herein by the way of reference.

A) TECHNICAL FIELD
[0001] The present invention is generally related to the field of construction materials. The present invention is particularly related to a system and method for enhancing the properties of concrete. The present is more particularly related to a system and methods for enabling Graphene-based dispersion for the development of concrete structures.

B) BACKGROUND OF THE INVENTION
[0002] Cement is the second most consumed material globally, only next to water. However, the production of 1 ton of cement leads to 650 to 900 kg of CO2 emissions. The use of cement has contributed to up to 8% of global CO2 emissions. CO2 being the single biggest contributor to climate change has recorded the highest emissions level in 2020, pushing humanity to take urgent steps towards decarbonizing key sectors such as construction. The International Energy Agency (IEA) states that promoting the material efficiency of cement could be a key strategy to reduce CO2 emissions. However, there are no sustainable solutions that can enable reducing the use of cement substantially without reducing the strength of concrete. Though different additives are added to cement for producing concrete, the current methods impact the properties of the resultant concrete.
[0003] Hence, there exists a need for providing systems and methods to enable the production of concrete by reducing the amount of cement used without compromising the strength and performance of concrete. There also exists a need for systems and methods for enabling Graphene-based dispersion for the development of concrete structures.
[0004] The abovementioned shortcomings, disadvantages, and problems are addressed herein, which will be understood by reading and studying the following specification.

C) OBJECT OF THE INVENTION
[0005] The primary object of the present invention is to provide a system and methods for enabling Graphene-based dispersion for the development of concrete structures.
[0006] Another object of the present invention is to provide a system and methods for enabling the manufacturing of concrete with improved compression strength, flexural strength, impact strength, and durability.
[0007] Yet another object of the present invention is to enable compatibility of dispersion of a plurality of materials to be incorporated directly into the concrete without additional methods or machinery.
[0008] Yet another object of the present invention is to enable a holistic improvement to the properties of concrete after reducing the amount of cement and water used for its preparation.
[0009] Yet another object of the present invention is to enable successful incorporation of industrial waste materials in concrete without compromising the strength and properties of concrete.
[0010] These and other objects and advantages of the present invention will become readily apparent from the following detailed description taken in conjunction with the accompanying drawings.

D) SUMMARY OF THE INVENTION
[0011] The various embodiments of the present invention provide a system and methods for enabling Graphene-based dispersion for the development of concrete structures. The embodiments also provide a system and methods for enabling the manufacturing of concrete with improved compression strength, flexural strength, impact strength, and durability.
[0012] According to one embodiment of the present invention, a system is provided for enabling Graphene-based dispersion for the development of concrete structures. The system comprises a ball milling apparatus including a grinding media and a cooling system, a ribbon blender, a wet jet milling apparatus, a plurality of chemicals including a process control aid, Graphene precursor, a functionalization aid, Xanthum gum, functionalized graphite nanoplatelets, Polyethylene glycol nonenyl phenyl ether, Sodium benzoate and, commercial APEO-free silicone-based defoamer.
[0013] According to one embodiment of the present invention, a method is provided for ball milling of Graphite. The method includes: mixing preset amounts of itaconic acid (AR grade) and methanol (USP grade) to produce a mixture; subjecting the mixture to diffusion mixing in a lab-scale ribbon blender for preset period of time; feeding the resultant itaconic acid paste into a powder ball milling unit in a Nitrogen or Oxygen environment; ball milling of precursors at a preset speed to obtain functionalized Graphite nanoplatelets; and, filtering, washing and drying of the obtained Graphite nanoplatelets.
[0014] According to one embodiment of the present invention, a method is provided for jet milling of precursors for the production of functionalized Graphene.
[0015] According to one embodiment of the present invention, the ball milling process fine-tunes the particle size of graphite, enhancing the yield of Graphene. This process also involves adding appropriate chemicals to achieve edge functionalization of graphite, improving dispersion characteristics. In this specific method, itaconic acid is used to obtain edge-functionalized graphene, while methanol serves as a process control agent to prevent the agglomeration of milled graphite and ensure even dispersion of itaconic acid within the system. The chemical used for the functionalization of graphene is preferably selected from the group consisting of propionic acid, butyric acid, phthalic acid, naphthoic acid, malonic acid, valeric acid, isobutyric acid, itaconic acid, and glycolic acid. The chemical used as a process control aid for ball milling is preferably selected from the group consisting of 1-propanol, dodecanol, 1-heptanol, methanol, cyclohexanol, isobutanol, 2-butoxy ethanol, isopropyl alcohol and 1-butanol. Besides Itaconic acid After ball milling, the resultant powder is washed in deionized (DI) water and dried at 80 degrees Celsius for 12 hours.
[0016] According to one embodiment of the present invention, the preparation of graphene dispersion involves blending chemicals with graphite, which increases the viscosity of the solution. The typical viscosity range of dispersions blended in this step is 20,000 to 30,000 centipoise (cps).
[0017] [0016] According to one embodiment of the present invention, wet jet milling is used to produce high-quality dispersions by utilizing the kinetic energy of the liquid dispersion to reduce particle size. A high-performance compressor coupled with the wet jet milling unit generates adequate pressure to guide the dispersion stream, causing collisions under high-pressure conditions to yield smaller particles efficiently.
[0018] These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating the preferred embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.
E) BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The other objects, features and advantages will occur to those skilled in the art from the following description of the preferred embodiment and the accompanying drawings in which:
[0020] FIG.1 illustrates a system for enabling Graphene-based dispersion for the development of concrete structures, according to one embodiment of the present invention.
[0021] FIG. 2 illustrates high-resolution transmission electron microscopy images of graphene nanoplatelets, according to one embodiment of the present invention.
[0022] FIG. 3 illustrates high-resolution field emission electron microscopy images of graphene nanoplatelets, according to one embodiment of the present invention.
[0023] FIG. 4 illustrates X-ray diffraction results of Graphene nanoplatelets, according to one embodiment of the present invention.
[0024] FIG. 5 illustrates mapping of available X-ray diffraction pattern obtained for Graphene nanoplatelets with JCPDS database for carbon, according to one embodiment of the present invention.
[0025] FIG. 6 illustrates the Raman spectra of graphene nanoplatelets, according to one embodiment of the present invention.
[0026] FIG. 7 illustrates the presence of functional groups identified using Fourier transform infrared spectroscopy, according to one embodiment of the present invention.
[0027] FIG. 8 illustrates the p–p* transition wavelength of graphene nanoplatelets, according to one embodiment of the present invention.
[0028] Although the specific features of the present invention are shown in some drawings and not in others. This is done for convenience only as each feature may be combined with any or all of the other features in accordance with the present invention.

F) DETAILED DESCRIPTION OF THE INVENTION
[0029] In the following detailed description, a reference is made to the accompanying drawings that form a part hereof, and in which the specific embodiments that may be practiced is shown by way of illustration. These embodiments are described in sufficient detail to enable those skilled in the art to practice the embodiments and it is to be understood that other changes may be made without departing from the scope of the embodiments. The following detailed description is therefore not to be taken in a limiting sense.
[0030] The various embodiments of the present invention provide a system and methods for enabling Graphene-based dispersion for the development of concrete structures. The embodiments also provide a system and methods for enabling the manufacturing of concrete with improved compression strength, flexural strength, impact strength, and durability.
[0031] According to one embodiment of the present invention, a system is provided for enabling Graphene-based dispersion for the development of concrete structures. The system comprises a ball milling apparatus including a grinding media and a cooling system, a ribbon blender, a wet jet milling apparatus, and plurality of chemicals including a process control aid, Graphene precursor, a functionalization aid, Xanthum gum, functionalized graphite nanoplatelets, Polyethylene glycol nonenyl phenyl ether, Sodium benzoate and, commercial APEO-free silicone-based defoamer. The chemical used as a stabilizer for graphene is preferably selected from the group consisting of polyacrylic acid, gellan gum, xanthum gum, carbomer, sodium alginate, agar, and guar gum. The chemical used as a dispersant for graphene is preferably selected from the group consisting of xanthone, chloroguaiacol, fluorophenyl ether, 4-hyroxy-3-methoxybezaldehyde, polyphenylene oxide, Polyethylene glycol nonenyl phenyl ether and anisole. The ancillary additives for graphene used in the above formulation are preferably selected from the group containing sorbic acid, propylene glycol, sodium benzoate, sodium nitrite, sodium nitrate, sodium sulfite, sodium sulfate, sodium sulfide, citric acid, polydimethylsiloxane, hydroxylated polydimethylsiloxane, sorbitan monostearate, aluminum stearate and vinegar.
[0032] According to one embodiment of the present invention, a method is provided for ball milling of Graphite. The method includes: mixing preset amounts of itaconic acid (AR grade) and methanol (USP grade) to produce a mixture; subjecting the mixture to diffusion mixing in a lab-scale ribbon blender for preset period of time; feeding the resultant itaconic acid paste into a powder ball milling unit in a Nitrogen or Oxygen environment; ball milling of precursors at a preset speed to obtain functionalized Graphite nanoplatelets; and, filtering, washing and drying of the obtained Graphite nanoplatelets.
[0033] According to one embodiment of the present invention, a method is provided for jet milling of precursors for the production of functionalized Graphene. The method includes: stirring preset amount of Xanthum gum (USP grade) in preset quantity of water at a preset temperature until complete dissolution; adding a solution of polyethylene glycol nonenyl phenyl ether to the above and stirring for preset time period; enabling a homogenous dispersion of functionalized graphite nanoplatelets in the above by adding the graphite nanoplatelets at periodic; adding and stirring preset amounts of sodium benzoate and silicone defoamer to the above to obtain the stock solution; subjecting the stock solution to jet milling for preset time; and, centrifuging the above at preset speed to remove large graphite flakes and storing the resultant supernatant.
[0034] According to one embodiment of the present invention, a system is provided for enabling Graphene-based dispersion for the development of concrete structures. The system comprises a ball milling apparatus including a grinding media and a cooling system, a ribbon blender, a wet jet milling apparatus, and a plurality of chemicals including a process control aid, Graphene precursor, functionalization aid, Xanthum gum, functionalized graphite nanoplatelets, Polyethylene glycol nonenyl phenyl ether, Sodium benzoate, and a commercial APEO-free silicone-based defoamer. This system enables the production of concrete with improved compression strength, flexural strength, impact strength, and durability.
[0035] According to one embodiment of the present invention, the ball milling apparatus in the system for enabling Graphene-based dispersion is a planetary ball mill operating at 350 to 400 RPM, equipped with a chilled water-based cooling system, utilizing ceramic balls with a diameter of 1 mm, maintaining a ball-to-powder ratio of 10:1, and operating within a nitrogen atmosphere.
[0036] According to one embodiment of the present invention, the ribbon blender within the system for enabling Graphene-based dispersion is a helical agitator type with a material loading capacity of 40-50%, an inner lining of hard steel, and operates at 35-50 RPM. This configuration enables the blending of chemicals to achieve a viscosity range of 20,000 cps to 30,000 cps in the dispersion.
[0037] According to one embodiment of the present invention, the wet jet milling apparatus in the system for enabling Graphene-based dispersion is configured to process the graphite dispersion at a pressure of 150 MPa and perform 10-20 passes to achieve the required particle size for Graphene nanoplatelets.
[0038] According to one embodiment of the present invention, the process control aid in the system for enabling Graphene-based dispersion is methanol, which prevents the agglomeration of the milled graphite and aids in the even dispersion of itaconic acid during the ball milling process.
[0039] According to one embodiment of the present invention, the plurality of chemicals in the system for enabling Graphene-based dispersion includes Xanthum gum as a stabilizer, Polyethylene glycol nonenyl phenyl ether as a dispersing agent, and Sodium benzoate as a preservative to improve the service life of the Graphene dispersion.
[0040] According to one embodiment of the present invention, a method is provided for producing Graphene-based dispersion for the development of concrete structures. The method includes mixing itaconic acid and methanol to produce a mixture, subjecting the mixture to diffusion mixing in a ribbon blender, feeding the mixture into a ball milling unit in a nitrogen environment, ball milling the mixture to obtain functionalized graphite nanoplatelets, washing and drying the resultant nanoplatelets, blending the functionalized graphite nanoplatelets with Xanthum gum, Polyethylene glycol nonenyl phenyl ether, and Sodium benzoate using a ribbon blender, and subjecting the blended dispersion to wet jet milling to produce a Graphene dispersion.
[0041] FIG.1 illustrates a system for enabling Graphene-based dispersion for the development of concrete structures. The system comprises a ball milling apparatus 101, a ribbon blender 102, a wet jet milling apparatus 103 and a materials module 104. The ball milling apparatus further includes a grinding media and a cooling system. The materials module stores a plurality of chemicals including a process control aid, Graphene precursor, a functionalization aid, Xanthum gum, functionalized graphite nanoplatelets, Polyethylene glycol nonenyl phenyl ether, Sodium benzoate and, commercial APEO-free silicone-based defoamer. The system also embodies the method for enabling Graphene-based dispersion for the development of concrete structures. The first step involves the edge functionalization of graphite followed by the blending of raw materials required for the dispersion of stabilization of graphene. The third step wet jet milling helps exfoliate edge-functionalized graphite into high-quality graphene nanoplatelets. The materials module discusses the type of materials used for manufacturing graphene nanoplatelets using the present method.
[0042] FIG. 2 illustrates high-resolution transmission electron microscopy images of graphene nanoplatelets. The transparent regions across the edges demonstrate the presence of few-layered graphene nanoplatelets in the sample.
[0043] FIG. 3 illustrates high-resolution field emission electron microscopy images of graphene nanoplatelets. By utilizing the scale bar as a reference, it is identified that most of the nanoplatelets have a thickness ranging from 50 to 200 nm.
[0044] FIG. 4 illustrates X-ray diffraction results of Graphene nanoplatelets.
[0045] FIG. 5 illustrates mapping of available X-ray diffraction pattern obtained for Graphene nanoplatelets with JCPDS database for carbon. The presence of high-quality shar peaks at 26 and 57 degrees and the absence of a peak at 11 degrees, which is typical for graphene oxide samples demonstrate the pristine, unoxidized nature of prepared graphene nanoplatelets.
[0046] FIG. 6 illustrates the Raman spectra of graphene nanoplatelets. The presence of a small D peak close to 1350 cm-1 is due to slight surface oxidation incurred due to exfoliation process. The nature of surface oxidation and presence of functional groups are further demonstrated in the FTIR spectra below.
[0047] FIG. 7 illustrates the presence of functional groups identified using Fourier transform infrared spectroscopy. The strong presence of O-H functional groups demonstrates the dispersibility of prepared graphene nanoplatelets in water.
[0048] FIG. 8 illustrates the p–p* transition wavelength of graphene nanoplatelets. The presence of this peak corroborates the formation of well-dispersed graphene nanoplatelets.
[0049] Although the embodiments herein are described with various specific embodiments, it will be obvious for a person skilled in the art to practice the embodiments herein with modifications.

G) ADVANTAGES OF THE INVENTION
[0050] The various embodiments of the present invention provide a system and methods for enabling Graphene-based dispersion for the development of concrete structures. The embodiments also provide a system and methods for enabling the manufacturing of concrete with improved compression strength, flexural strength, impact strength, and durability. The Graphene-based dispersion enabled by the present invention is compatible with Ordinary Portland Cement and Portland Pozzolana Cement, as well slag-based cement, enabling wider possibilities for mix design, which is not possible with traditional admixtures. The present invention also enables a substantial reduction in the amount of water required for curing concrete. Besides, the developed mix design of concrete, using Graphene, has low water permeability, enabling development of specialized concrete structures for marine environment. The invention enables scalable production of Graphene dispersion with improved workability of concrete mix.
[0051] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such as specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modifications. However, all such modifications are deemed to be within the scope of the claims.
,CLAIMS:We claim:
1. A system for enabling Graphene-based dispersion for the development of concrete structures, the system comprising:
a ball milling apparatus including a grinding media and a cooling system;
a ribbon blender;
a wet jet milling apparatus; and
a plurality of chemicals including a process control aid, a Graphene precursor, a functionalization aid, Xanthum gum, functionalized graphite nanoplatelets, Polyethylene glycol nonenyl phenyl ether, Sodium benzoate, and a commercial APEO-free silicone-based defoamer,
wherein the system enables the production of concrete with improved compression strength, flexural strength, impact strength, and durability.

2. The system as claimed in claim 1, wherein the ball milling apparatus is a planetary ball mill operating at 350 to 400 RPM, with a chilled water-based cooling system, ceramic balls of 1 mm diameter, a ball-to-powder ratio of 10:1, and operates in a Nitrogen atmosphere.

3. The system as claimed in claim 1, wherein the ribbon blender is a helical agitator type with material loading capacity of 40-50%, an inner lining of hard steel, and operates at 35-50 RPM, enabling the blending of chemicals to achieve a viscosity range of 20,000 cps to 30,000 cps.

4. The system as claimed in claim 1, wherein the wet jet milling apparatus is configured to process the graphite dispersion at a pressure of 150 MPa and perform 10-20 passes to achieve the required particle size for Graphene nanoplatelets.

5. The system as claimed in claim 1, wherein the process control aid is methanol, which prevents the agglomeration of the milled graphite and aids in the even dispersion of itaconic acid during the ball milling process.

6. The system as claimed in claim 1, wherein the plurality of chemicals includes Xanthum gum as a stabilizer, Polyethylene glycol nonenyl phenyl ether as a dispersing agent, and Sodium benzoate as a preservative to improve the service life of the Graphene dispersion.

7. A method for enabling Graphene-based dispersion for the development of concrete structures, the method comprising:
mixing itaconic acid and methanol to produce a mixture;
subjecting the mixture to diffusion mixing in a ribbon blender;
feeding the mixture into a ball milling unit in a nitrogen environment;
ball milling the mixture to obtain functionalized graphite nanoplatelets;
washing and drying the resultant nanoplatelets;
blending the functionalized graphite nanoplatelets with Xanthum gum, Polyethylene glycol nonenyl phenyl ether, and Sodium benzoate using a ribbon blender; and
subjecting the blended dispersion to wet jet milling to produce a Graphene dispersion.

8. The method as claimed in claim 7, wherein the ball milling process is conducted at a speed of 350-400 RPM for 6 hours, with a ball-to-powder ratio of 10:1 and in a nitrogen atmosphere.

9. The method as claimed in claim 7, wherein the blending process in the ribbon blender involves setting the RPM to 50 and blending for 30 minutes to achieve a viscosity range of 20,000 cps to 30,000 cps.

10. The method as claimed in claim 7, wherein the wet jet milling process involves passing the dispersion through the milling apparatus 10-20 times at a pressure of 150 MPa to achieve the required particle size for Graphene nanoplatelets.