Description:DESCRIPTION:
Field of the invention:
[0001] The present disclosure generally relates to the technical field of construction materials, and in specific, relates to a composition that uses industrial wastes to prepare masonry blocks for constructing buildings, thereby reducing energy consumption for the constructed buildings.
Background of the invention:
[0002] Bricks continue to be one of the most widely used construction materials in developing nations. The availability of quality soil is essential for brick production. Fly ash, bagasse ash, rice husk ash, and other additives have recently been added to or substituted with clay to improve the performance of bricks. The use of trash from various industrial sectors is beneficial to the environment and the state's economy.

[0003] Commercially accessible building materials like bricks, concrete blocks, or mixtures are unsustainable and easy to use, but they also conduct heat well. Affecting the insulation of the building, however, leads to thermal discomfort for building occupants. Thermal conductivity has been one of the major concerns for the construction industry; in efforts associated to develop energy-efficient buildings as part of creating a sustainable environment.

[0004] Now, the construction industry is trying to shift focus from energy-consumptive materials such as cement and try to adopt sustainable materials for construction activities. One such material is an alkali-activated binder; which recycles multiple kinds of agricultural, industrial and municipal wastes. The creation of alkali-activates materials is most suited to certain wastes such as silica (Si) and alumina (Al) composition, which are commonly referred to as pozzolanic materials. Alkalis (sodium or potassium silicates) and alumina-silicate materials, such as pozzolanic minerals, are mixed together during the process. Alkali-activated materials are considered as a well-established materials, which are treated as an alternative to cementitious binders.

[0005] Finding an alternative to cement-based products may not be sufficient for sustainable building materials. Better performance and energy efficiency criteria should be the main focus of any strategy to address sustainability. The focus should be on adopting materials that conserve building energy requirements because there is a demand for insulated materials as a result of increased concerns about energy efficiency measures in the building sector.

[0006] Ceramic waste is generated in massive quantities by tile manufacturing industries. The ceramic tile materials possess a thermal conductivity ranges between 0.6 to 1.7 W/m.k based on density. The ceramic wastes have a pozzolanic action that is used for building materials. In general, the overall production of ceramic tile has reached up to reached 18,339 million sqm. Also, it is estimated that around 30% of waste generated is going to landfills, contributing significantly to environmental concerns. If the ceramic tile dust is disposed in nature that causes the soil, air and ground water pollutions. However, there is a need for finding alternative ways to recycle or reusing the ceramic tile dust waste.

[0007] In existing technology, a composition for preparing foamed glass powder geoplymer blocks is known. The composition for preparing foamed glass powder geopolymer blocks comprises glass powder, fly ash, sodium silicate, sodium hydroxide and crusher dust and alumina powder. The composition is achieved by mixing the glass powder, the fly ash and the crusher dust at a ratio of 30:40:30. However, the existing composition mainly depends on the reactive alumina and silica present in raw materials. In addition, the generated waste varies with chemical composition. In specific, the chemical composition also affect the workability, setting time as well as strength of the materials and also has a significant effect on physio-mechanical and thermal characteristics.

[0008] Therefore, there is a need for a composition that does not depend on the reactive alumina and silica present in the raw materials (i.e. industrial by-products). There is also a need for a composition that does not affect the workability, setting time as well as strength of the materials. There is also a need for a composition that does not have a significant effect on physio-mechanical and thermal characteristics. There is also a need for a composition that reduces operational energy and electric power consumption than the existing conventional clay bricks. Further, there is also a need for a composition that have environmental, social, economic and technical benefits over the conventional product.
Objectives of the invention:
[0009] The primary objective of the invention is to provide a composition that uses industrial wastes to prepare masonry blocks for constructing buildings, thereby reducing energy consumption for the constructed buildings.

[0010] Another objective of the invention is to provide a composition that reduces the cost of electric power up to 2.65%, 4.95% and 7.95% annually.

[0011] The other objective of the invention is to provide a composition that have environmental, social, economic and technical benefits over the conventional product.

[0012] Yet another objective of the invention is to provide a composition that uses industrial waste for preparation sustainable building products and reduces greenhouse gas emissions and carbon footprint during operational stage.

[0013] Further objective of the invention is to provide a composition that does not effect on physio-mechanical and thermal characteristics.
Summary of the invention:
[0014] The present disclosure proposes a composition for preparing foamed ceramic tile dust-based alkali-activated masonry blocks and method thereof. The following presents a simplified summary in order to provide a basic understanding of some aspects of the claimed subject matter. This summary is not an extensive overview. It is not intended to identify key/critical elements or to delineate the scope of the claimed subject matter. Its sole purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is presented later.

[0015] In order to overcome the above deficiencies of the prior art, the present disclosure is to solve the technical problem to provide a composition that uses industrial wastes to prepare masonry blocks for constructing buildings, thereby reducing energy consumption for the constructed buildings.

[0016] According to an aspect, the invention provides a method for preparing a composition of foamed ceramic tile dust-based alkali-activated masonry blocks. At one first, a fly ash (FA), a ceramic tile dust (CTD) and a crusher dust (CD) are mixed at a ratio of 20:30:50 for obtaining a consistent dry mix. In specific, the fly ash (FA) and the ceramic tile dust (CTD) comprises alumina-silicate oxides. At one step, an alkaline solution is added to the consistent dry mixture and the mixed for a time period of at least 2-5 minutes in a rotatory mixture machine for achieving a homogenous mix.

[0017] At one step, the homogenous mixture is transferred to one or more moulds for casting, thereby preparing a control alkali-activated mixture without foam formation. At one step, protein-based pre-foam is injected to the prepared control alkali-activated mixture using foam pressure injector for lowering the density. In specific, the foam pressure injector applies pressure of 75 psi. At one step, the foamed alkali-activated mixture is transferred into moulds for moulding. At one step, the each mould is separated upon formation of alkali-activated masonry block.

[0018] The alkali-activated masonry block reduces overall power energy requirement of a constructed building. The alkali-activated masonry block has a compressive strength of 15.7 MPa. The alkali-activated masonry block can be prepared with multiple target densities of 1500 kg/m3, 1700 kg/m3 and 1900 kg/m3 at a foam volume of 18.3 %, 20.8 % and 29.2 %. The alkali-activated masonry block reduce power consumption of 2.65 %, 4.95 % and 7.95 % annually at the foam volume of 18.3 %, 20.8 % and 29.2 %.

[0019] Further, objects and advantages of the present invention will be apparent from a study of the following portion of the specification, the claims, and the attached drawings.
Detailed description of drawings:
[0020] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate an embodiment of the invention, and, together with the description, explain the principles of the invention.

[0021] FIG. 1 illustrates a graphical representation of a relationship between the density, water absorption and porosity of a foamed ceramic tile dust-based alkali-activated masonry blocks, in accordance to an exemplary embodiment of the present invention.

[0022] FIGs. 2A-2B illustrate pictorial representations of the developed foamed binary alkali activated blocks, in accordance to an exemplary embodiment of the present invention.

[0023] FIG. 3 illustrates a graphical representation of compressive strength of alkali activated blocks, in accordance to an exemplary embodiment of the present invention.

[0024] FIG. 4 illustrates a graphical representation of thermal conductivity and heat capacity of alkali activated blocks, in accordance to an exemplary embodiment of the present invention.

[0025] FIG. 5 illustrates a pictorial representation of alkali activated block in eQuest software, in accordance to an exemplary embodiment of the present invention.

[0026] FIG. 6 illustrates a graphical representation of space cooling for alkali activated blocks and clay bricks, in accordance to an exemplary embodiment of the present invention.

[0027] FIG. 7 illustrates a graphical representation of total energy requirements for alkali activated blocks and clay bricks, in accordance to an exemplary embodiment of the present invention.

[0028] FIG. 8 illustrates a bar graph of annual energy consumption bills for various wall materials, in accordance to an exemplary embodiment of the present invention.

[0029] FIG. 9 illustrates a flowchart of a method for preparing a composition of foamed ceramic tile dust-based alkali-activated masonry blocks, in accordance to an exemplary embodiment of the present invention.
Detailed invention disclosure:
[0030] Various embodiments of the present invention will be described in reference to the accompanying drawings. Wherever possible, same or similar reference numerals are used in the drawings and the description to refer to the same or like parts or steps.

[0031] The present disclosure has been made with a view towards solving the problem with the prior art described above, and it is an object of the present invention to provide a composition that uses industrial wastes to prepare masonry blocks for constructing buildings, thereby reducing energy consumption for the constructed buildings.

[0032] According to an exemplary embodiment of the invention, the development of the binary alkali-activated (BAA) and foamed binary alkali-activated (FBAA) depends upon the interaction between the alumina-silicate-based materials with alkali solution. The key ingredient having alumina-silicate oxides were flyash (FA) and ceramic tile dust (CTD). The dry mixture of flyash, ceramic tile dust and crusher dust was batched and mixture together for a consistent dry mixture as per the mixture design as depicted in Table 1.

[0033] Table 1:
Mix No. Target Density (Kg/m3) FA
(Kg/m3) CTD
(Kg/m3) CD
(Kg/m3) Na2SiO3
(Kg/m3) NaOH
(Kg/m3) Foam
Volume
(%)
Cntrl 2100 323.4 754.6 1078 385 154 0
FBAA1 1900 323.4 754.6 1078 385 154 18.3
FBAA2 1700 323.4 754.6 1078 385 154 20.8
FBAA3 1500 323.4 754.6 1078 385 154 29.2

[0034] For experimentation purpose three trial mixed were prepared (i.e. FBAA1 to FBAA 3) based on the varying target density of 1900 kg/m3 to 1500 kg/m3, respectively and it is compared with Control specimen(CTRL). The CTD, FA and Crusher dust (CD) are mixed. Along with the dry mix, ceramic tile dust was added in appropriate proportion. Further, mixing was done by adding an alkaline solution based on the mixture proportion. The wet mixing was performed for 2-5 minutes in a rotatory mixture machine to form a homogenous mix. The entire mixture was transferred to the moulds for casting the ceramic tile dust-based alkali-activated material.

[0035] The control alkali-activated mixture is prepared without foam. Further, to lower the density of alkali-activated blocks, protein-based pre-foam is injected using foam pressure injector. The pressure of injection of foam into the slurry is kept at 75 psi. The percentage of foamed volume was altered to achieve target density. The slurry was then transferred into the moulds of 100 × 100 × 100 mm. The demoulding was performed once the alkali-activated mixture hardened. Further, to enhance the reactivity, the moulds are kept for outdoor curing. Finally, the developed products are tested to understand various performance parameters.

[0036] According to another exemplary embodiment of the invention, FIG. 1 refers to a graphical representation 100 of a relationship between the density, water absorption and porosity of a foamed ceramic tile dust-based alkali-activated masonry blocks. In one embodiment herein, the introduction of 18.3% foam into FBAA1 alkali activated specimen indicate 9.52% reduction in the bulk density as compared to the CTRL specimen. However, on increasing the foaming from 18.3% to 29.2% (i.e. from FBAA1 to FBAA3), the reduction in bulk density is found to be gradual.

[0037] It is also observed that, injecting higher quantity of foam into the CTRL specimen resulted in greater reduction in the bulk density. The water absorption and porosity is inversely proportional to density i.e., the water absorption and porosity increases with decreases in density. In one embodiment herein, the graph is represented for the trails of the alkali-activated mixture i.e., Cntrl, FBAA1, FBAA2 and FBAA3. FIG. 2 is depicted that the porosity and the water absorption increases as the decrease of the target density.

[0038] According to another embodiment of the invention, FIGs. 2A-2B refer to pictorial representations 200 of the developed foamed binary alkali activated blocks. The mechanical performance of ceramic materials depends on the binding matrix as well as the compactness of the material. The incorporation of ceramic tile dust and the binder within the cement matrix resulted in a slight increase in mechanical performance i.e. compressive strength, flexural strength and tensile strength. The incorporating ceramic waste increases in strength of alkali-activated-based mortars. The alkali-activated-based materials possess similar or enhanced mechanical characteristics as that of the cementitious binder material.

[0039] Only difference between the cementitious binder is that the binding property is not governed by formation of C-S-H gel, While the alkali activated based materials as a binding property is due to formation of silica (Si) and alumina (Al) polymeric chain consisting of oxygen molecule. The polymeric chain composition varies based on the varying ratios of metal oxides (i.e. Si, Al, Fe, etc.). The strength of developed alkali-activated materials depend on the combination of the interaction of polymeric chain with fly ash and ceramic tile dust and crusher dust which acts as a filler material.

[0040] According to another embodiment of the invention, FIG. 3 refers to a graphical representation 300 of compressive strength of alkali activated blocks. The foamed alkali activated blocks with porous size of 1-2mm. The compressive strength of ceramic tile dust incorporated alkali-activated blocks shows the 28 days strength value of 46.69 MPa for 1:1 mix. The binary blend of flyash and CTD formed a three-dimensional network structure of SiO2 tetrahedron and Al2O3 tetrahedron.

[0041] The ceramic tile dust based alkali activated material was supplemented N-A-S-H gel when the constituent alumina and silicate ions were in the saturated states, further the N-A-S-H gel dehydrates itself and forms the three-dimensional network tobermorite structure of the alkali activated materials. Thus, formation of alkali activated binder is constituted with the combination of flyash and ceramic tile dust as a source of alumina-silicate compounds. The flyash readily activates as the reactive alumina-silicate compounds, whereas the reactivity of ceramic tile dust is slower comparatively to form alkali activated binder. However, ceramic tile dust having higher percentage of Si content with very less reactive form of Si, which also takes part in alkali activation process by substituting Al3+.

[0042] However, the compressive strength due to addition of foaming is found to be decreasing. The average compressive strength of the developed blocks was found to be 25.87 MPa, 20.62 MPa, and 15.7 MPa with respect to the incorporation level of 18.3%, 20.8% and 29.2% of foaming agent as depicted in FIG. 2. However, on foaming, the strength of the CTRL specimen decreased with increase in the foaming and decrease in the density from 2000 kg/m3 to 1900 kg/m3 (i.e. FBAA1) and further reduction in density up to 1500 kg/m3 (i.e. FBAA3).

[0043] The reduction in compressive strength of CTRL specimen on foaming is attributed to the reduction in the density of the developed material, due to the fact that the strength of the specimen depends upon the compactness of the material. As the incorporation of protein based foaming agent increases, the volume occupied by the ceramic particle increases by losing its strength and rigidity. The incorporation of foaming agent shows a significant decline in strength performance by 44.5% (as FBAA1 Mix) than control mix.

[0044] The ceramic waste and also protein-based foaming agent creates more voids, and the interfacial zone between the alkali-activated matrix and also ceramic tile dust is weaker than crusher dust. The data suggests that further incorporation of a foaming agent can causes excess of loss of strength and also ceramic tile dust that incorporated blocks are not suitable for commercial application. Furthermore, the grinding of ceramic tile dust to very fine powder plays a vital role in influencing the compressive strength characteristic of the developed material.

[0045] According to another embodiment of the invention, FIG. 4 refers to a graphical representation 400 of thermal conductivity and heat capacity of alkali activated blocks. In one embodiment herein, the thermal performance of the materials is mainly governed by thermal conductivity property. As the thermal conductivity of the material decreases, the performance of thermal insulation increases, thereby resisting the heat flow through the material. The developed samples were subjected to thermal conductivity to understand the thermal insulation capability. The thermal conductivity of a material is obtained using hot guarded plate apparatus. The incorporation of foaming agent is greatly affects the thermal conductivity property of the material.

[0046] The average thermal conductivity of the foamed binary alkali activated blocks are incorporated with the foaming agent of 18.3%, 20.8% and 29.2% is found to be 0.758 W/m.K, 0.592 W/m.K and 0.45 W/m.K respectively. The values are affected by the percentage incorporation of foaming agent. As the volume of foaming agent increases, the overall thermal conductivity of the blocks reduces due to the insulated behaviour of flyash and ceramic tile dust, which restricts the propagation of heat. As the volume increases the resistance to heat transfer rate also increased.

[0047] In one example embodiment herein, the energy efficiency of the material indicates the operational benefits of using a material as the walling material. For this purpose, the analysis of energy usage and total energy requirement of the walling system consisting of foam-injected alkali activated blocks is carried out using a building energy simulation software “eQuest”. A building consisting of ground floor with a floor area of 2000 sq. ft. is considered for this simulation and is denoted as Ground building. Considering the warm-humid climatic condition of the developing city. All the parameters for the simulation are constant except the density and thermal properties of wall system i.e. U-value (depends on the thickness and thermal conductivity of material). The input data used for building energy simulation is represented in Table 2. Also, modelled building used for “eQuest” energy simulation as depicted in FIG.5.

[0048] Table 2:
Building Type Low rise Residental building (exterior entries)
Building Area 2000 Sq. ft.
Roof Surface 6 Inch. Reinforce Concrete
Insulation (Roof/Floor/Slab) None
Occupancy 4 People
Window to Wall ratio 0.10
Living Area (%) 21%
Bedroom (%) 44%
Restroom (%) 8%
Kitchen (%) 11%
Religious Worship (%) 4%

[0049] In one embodiment herein, the amount of foam injected into the alkali activated blocks play the crucial role in the amount of energy spent on space cooling as well as on the total energy requirement of the building envelope. The blocks with a higher amount of foaming depicts high energy saving compared to the control specimen. The energy analysis of the model building shows saving in the range between 3.09 % and 5.16 % for space cooling (Air Conditioning System) by using foamed alkali-activated blocks as the walling material as reported in Fig. 6.

[0050] Further, the energy saving can be high in the case of lower density alkali activated blocks, which is attributed to the lower thermal conductivity of air entrapped in the voids of foamed alkali activated blocks. Thus, will lead to significant savings in energy, as energy spent on space cooling is about 56 % – 61 % of the total energy requirement of the building. Similarly, the total energy requirements (Air Conditioning, Lighting and other Miscellaneous equipment’s) of the building was also reduced by about 3.39 % – 8.29 %, depending upon the density of the alkali-activated blocks used as walling material in the energy analysis as depicted in FIG. 7.

[0051] In one embodiment herein, the average annual energy cost of using different foamed alkali-activated blocks as walling material is depicted in FIG.8. The annual reduction of the energy costing varies between 4.17% and 9.63% for the developed FBAA blocks based on the foamed alkali activated block density. The reduction of density due to the addition of the foam is proven to be an economical, considering the fact that people often neglect the operational performance of material in terms of energy efficiency. The total annual energy savings was found out to be 2.59, 4.87, 7.54%, if FBAA1, FBAA2 and FBAA3 blocks are adopted as a building walling material compared with commercial clay bricks. As far as monetary benefits are concerned, the cost savings can be reach up to 2.65, 4.95% and 7.95% annually.

[0052] According to another embodiment of the invention, FIG. 9 refers to a flowchart 900 of a method for preparing a composition of foamed ceramic tile dust-based alkali-activated masonry blocks. At step 902, a fly ash (FA), a ceramic tile dust (CTD) and a crusher dust (CD) are mixed at a ratio of 20:30:50 for obtaining a consistent dry mix. In specific, the fly ash (FA) and the ceramic tile dust (CTD) comprises alumina-silicate oxides. At step 904, an alkaline solution is added to the consistent dry mixture and the mixed for a time period of at least 2-5 minutes in a rotatory mixture machine for achieving a homogenous mix.

[0053] At step 906, the homogenous mixture is transferred to one or more moulds for casting, thereby preparing a control alkali-activated mixture without foam formation. At step 908, protein-based pre-foam is injected to the prepared control alkali-activated mixture using foam pressure injector for lowering the density. In specific, the foam pressure injector applies pressure of 75 psi. At step 910, the foamed alkali-activated mixture is transferred into moulds of 100 × 100 × 100 for moulding. At step 912, the each mould if separated upon formation of alkali-activated masonry block.

[0054] The alkali-activated masonry block reduces overall power energy requirement of a constructed building. The alkali-activated masonry block has a compressive strength of 15.7 MPa. The alkali-activated masonry block can be prepared with multiple target densities of 1500 kg/m3, 1700 kg/m3 and 1900 kg/m3 at a foam volume of 18.3 %, 20.8 % and 29.2 %. The alkali-activated masonry block reduce power consumption of 2.65 %, 4.95 % and 7.95 % annually at the foam volume of 18.3 %, 20.8 % and 29.2 %.

[0055] Numerous advantages of the present disclosure may be apparent from the discussion above. In accordance with the present disclosure, a composition for preparing foamed ceramic tile dust-based alkali-activated masonry blocks is disclosed. The proposed composition uses industrial wastes to prepare masonry blocks for constructing buildings, thereby reducing energy consumption for the constructed buildings. The proposed composition that reduces the cost of electric power up to 2.65%, 4.95% and 7.95% annually.

[0056] The proposed composition have environmental, social, economic and technical benefits over the conventional product. The proposed composition uses industrial waste for preparation sustainable building products and reduces greenhouse gas emissions and carbon footprint during operational stage. The proposed composition does not effect on physio-mechanical and thermal characteristics.

[0057] It will readily be apparent that numerous modifications and alterations can be made to the processes described in the foregoing examples without departing from the principles underlying the invention, and all such modifications and alterations are intended to be embraced by this application.

, Claims:CLAIMS:
I / We Claim:
1. A method for preparing a composition of foamed ceramic tile dust-based alkali-activated masonry blocks, comprising:
mixing fly ash (FA), ceramic tile dust (CTD) and crusher dust (CD) at a ratio of 20:30:50 for obtaining a consistent dry mixture;
adding an alkaline solution to the consistent dry mixture and mixing for a time period of at least 2-5 min in a rotatory mixture machine for achieving a homogenous mixture;
transferring the homogenous mixture to one or more moulds for casting, thereby preparing a control alkali-activated mixture without foam formation;
injecting protein-based pre-foam to the prepared control alkali-activated mixture using a foam pressure injector for lowering the density;
transferring the foamed alkali-activated mixture into the moulds for moulding; and
separating the each mould upon formation of alkali-activated masonry blocks.
2. The method as claimed in claim 1, wherein the foam pressure injector applies pressure of 75 psi.
3. The method as claimed in claim 1, wherein the fly ash (FA) and the ceramic tile dust (CTD) comprises alumina-silicate oxides.
4. The method as claimed in claim 1, wherein the alkali-activated masonry block reduces overall power energy requirement of a constructed building.
5. The method as claimed in claim 1, wherein the alkali-activated masonry block has a compressive strength of 15.7 MPa.
6. The method as claimed in claim 1, wherein the alkali-activated masonry block can be prepared with multiple target densities of 1500 kg/m3, 1700 kg/m3 and 1900 kg/m3 at a foam volume of 18.3 %, 20.8 % and 29.2 %.
7. The method as claimed in claim 6, wherein the alkali-activated masonry block reduce power consumption of 2.65 %, 4.95 % and 7.95 % annually at the foam volume of 18.3 %, 20.8 % and 29.2 %.