DESC:Filed Electronically

FORM 2

THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENTS RULES, 2003

COMPLETE SPECIFICATION
(See Section 10 and Rule 13)

1. Title of the Invention:

A Composition of Ternary Blended Concrete (TBC) mixture
2. Applicant(s):

Name: National Institute of Technology
Nationality: An Educational Institute
[Established by The National Institutes Of Technology, Science Education And Research Act, 2007 [ACT NO. 29 OF 2007; & has also been registered under the Societies Registration Act XXI of 1860 on 9th April, 2003]
[Formerly known as Regional Engineering College (REC)]
Country of Residence: INDIA
Address: Kurukshetra-136119, Haryana, INDIA

Name: Kurukshetra University
Nationality: An University (Education Institute) Organized under the Laws of INDIA
Country of Residence: INDIA
Address: Kurukshetra-136119, Haryana

3. Preamble to the Description:
COMPLETE SPECIFICATION:

The following specification particularly describes the Invention and the manner in which it is to be performed.

TITLE OF INVENTION:
A Composition of Ternary Blended Concrete (TBC) mixture.

TECHNICAL FIELD OF THE INVENTION:

Firstly, the present invention is not for the purpose of defence.

The present invention relates to a composition of ternary blended concrete (TBC) mixture, and a method of preparation thereof.

The present invention particularly relates to a cement concrete composition of ternary blended concrete (TBC), and a method of preparation thereof.

BACKGROUND OF THE INVENTION:

The production of cement contributes majorly in global warming by releasing CO2 gas in the environment. Further, the overuse of natural resources for cement manufacturing contributes to the environmental degradation.

The partial substitute of the cement is expected to have two-fold effect, i.e., safe disposal of stainless-steel industry waste by using it as a construction material and less usage of cement to further help in maintaining environmental stability and ecological balance.

Similarly, the partial substitute of the cement is expected to have additional two-fold effect, i.e., safe disposal of zinc ore industry waste by using it as a construction material and less usage of cement to further help in maintaining environmental stability and ecological balance.

The partial replacement of cement by Argon Oxygen Decarburization (AOD) steel slag, a waste from stainless steel plant, was earlier reported by the present Inventors:

1. Laboratory Investigation and Modeling of Concrete Pavements containing AOD steel slag; Tanvi Gupta and S. N. Sachdeva, Cement and Concrete Research 124 (2019) 105808, Published on line on 2 July 2019 (herein after may be referred to as Paper_1_AOD_slag_CCR); and
2. Experimental Study and Modeling of Concrete Containing AOD Steel Slag for Pavements, Tanvi Gupta and S. N. Sachdeva, Arabian Journal for Science and Engineering, Published on line on 25 May 2020 (herein after may be referred to as Paper_2_AOD_slag_Arabian).

The partial replacement of cement by jarosite, a waste material produced during the extraction of zinc ore concentrate using the hydrometallurgy operation, was earlier reported by the present Inventors:

3. Investigations on Jarosite Mixed Cement Concrete Pavements, Tanvi Gupta and S. N. Sachdeva, Arabian Journal for Science and Engineering, Published on line on 06 March 2019 (herein after may be referred to as Paper_3_Jarosite_Arabian); and
4. Study of mechanical, micro-structural and environmental properties of concrete containing zinc industry waste for pavements; Tanvi Gupta and S. N. Sachdeva, Construction and Building Materials 245 (2020) 118331, Published on line on 17 February 2020 (herein after may be referred to as Paper_4_Jarosite_CBM).

As per disclosure of Paper_1_AOD_slag_CCR, cement concrete composition consisting of: cement and Argon Oxygen Decarburization (AOD) steel slag, a waste from stainless steel plant in various %amounts to partially replace the cement with the AOD steel slag were prepared and tested for the suitability as the concrete for construction of rigid pavements. The Inventors had found that when the cement is partially replaced with AOD steel slag, then, with increasing curing period, the compressive strength and flexural strength of all the compositions increases, but surprisingly the compressive strength and the flexural strength decreases with increase in percentage of the AOD steel slag (%amount of AOD steel slag) and more surprisingly, the compressive strength and the flexural strength is always lower than the compressive strength and the flexural strength of the control sample, as indicated by the compressive strength and flexural strength of M40 (concrete without AOD) – control sample Vs. S10 (having 10% by wt. of AOD slag), S15 (having 15% by wt. of AOD slag), S20 (having 20% by wt. of AOD slag), and S25 (having 25% by wt. of AOD slag). A reference to figures 4 and 5 of this publication may be drawn herein. The Inventors have further found that the %weight loss due to abrasion and acid attack not only increases with increasing amount of AOD steel slag, but it surprisingly was always substantially higher for the concrete compositions consisting of cement and AOD slag (S10, S15, S20, S25) when compared with the cement without AOD slag (M40). A reference to figures 10 and 12 of this publication may be drawn herein. Therefore, as per the disclosure and teachings of this publication, the addition of AOD alone neither results in increase of the compressive strength nor the Flexural strength nor the abrasion resistance, and nor results in increase of the resistance against the acid attack.

As per disclosure of Paper_2_AOD_slag_Arabian, cement concrete composition consisting of: cement and Argon Oxygen Decarburization (AOD) steel slag, a waste from stainless steel plant in various %amounts to partially replace the cement with the AOD steel slag were prepared and tested for the suitability as the concrete for construction of rigid pavements. The Inventors had found that when the cement is partially replaced with AOD steel slag, then, with increasing curing period, the compressive strength and flexural strength of all the compositions increases, but, surprisingly, the compressive strength and the flexural strength decreases with increase in percentage of the AOD steel slag (%amount of AOD steel slag) and more surprisingly, the compressive strength and the flexural strength is lower than the compressive strength and the flexural strength of the control sample for curing duration of up to 28 days, as indicated by the compressive strength and flexural strength of M40 (concrete without AOD) – control sample Vs. S10 (having 10% by wt. of AOD slag), S15 (having 15% by wt. of AOD slag), S20 (having 20% by wt. of AOD slag), and S25 (having 25% by wt. of AOD slag). The compressive strength and flexural strength do increase marginally, but only after substantially increased curing duration of 90 days or more, and such curing duration is not considered to be industrially viable. A reference to figures 3 and 4 of this publication may be drawn herein. The Inventors have further found that the %weight loss due to abrasion and acid attack not only increases with increasing amount of AOD steel slag, but it surprisingly was substantially higher for the concrete compositions consisting of cement and AOD slag (S10, S15, S20, S25) when compared with the cement without AOD slag (M40) except for the substantially increased curing durations of 180 days and 365 days, and such curing durations are not considered to be industrially viable. A reference to figures 5 and 7 of this publication may be drawn herein. Therefore, as per the disclosure and teachings of this publication, the addition of AOD alone neither results in increase of the compressive strength nor the Flexural strength nor the abrasion resistance, and nor results in increase of the resistance against the acid attack.

As per disclosure of Paper_3_Jarosite_Arabian, cement concrete composition consisting of: cement and jarosite, a waste material produced during the extraction of zinc ore concentrate using the hydrometallurgy operation, in various %amounts to partially replace the cement with the jarosite were prepared and tested for the suitability as the concrete for construction of rigid pavements. The Inventors had found that when the cement is partially replaced with jarosite, then, with increasing curing period, the compressive strength and flexural strength of all the compositions increases, but surprisingly the compressive strength and the flexural strength substantially decreases with increase in percentage of the jarosite (%amount of jarosite) and more surprisingly, the compressive strength and the flexural strength is always lower than the compressive strength and the flexural strength of the control sample, as indicated by the compressive strength and flexural strength of M40 (concrete without jarosite) – control sample Vs. J10 (having 10% by wt. of jarosite), J15 (having 15% by wt. of jarosite), J20 (having 20% by wt. of jarosite), and J25 (having 25% by wt. of jarosite). A reference to tables 5 and 6 of this publication may be drawn herein. The Inventors have further found that the %weight loss due to abrasion and acid attack not only increases with increasing amount of jarosite, but it surprisingly was always substantially higher for the concrete compositions consisting of cement and jarosite (J10, J15, J20, J25) when compared with the cement without jarosite (M40). A reference to tables 8 and 9 of this publication may be drawn herein. Therefore, as per the disclosure and teachings of this publication, the addition of jarosite neither results in increase of the compressive strength nor the Flexural strength nor the abrasion resistance, and nor results in increase of the resistance against the acid attack.

As per disclosure of Paper_4_Jarosite_CBM, cement concrete composition consisting of: cement and jarosite, a waste material produced during the extraction of zinc ore concentrate using the hydrometallurgy operation, in various %amounts to partially replace the cement with the jarosite were prepared and tested for the suitability as the concrete for construction of rigid pavements. The Inventors had found that when the cement is partially replaced with jarosite, then, with increasing curing period, the compressive strength and flexural strength of all the compositions increases, but surprisingly the compressive strength and the flexural strength decreases with increase in percentage of the jarosite (%amount of jarosite) and more surprisingly, the compressive strength and the flexural strength is always lower than the compressive strength and the flexural strength of the control sample, as indicated by the compressive strength and flexural strength of M40 (concrete without jarosite) – control sample Vs. J10 (having 10% by wt. of jarosite), J15 (having 15% by wt. of jarosite), J20 (having 20% by wt. of jarosite), and J25 (having 25% by wt. of jarosite). A reference to figures 3 and 4 of this publication may be drawn herein. The Inventors have further found that the %weight loss due to abrasion not only substantially increases with increasing amount of jarosite, but it surprisingly was always substantially higher for the concrete compositions consisting of cement and jarosite (J10, J15, J20, J25) when compared with the cement without jarosite (M40). A reference to figure 5 of this publication may be drawn herein. Therefore, as per the disclosure and teachings of this publication, the addition of jarosite neither results in increase of the compressive strength nor the Flexural strength nor the abrasion resistance.

Problems of the Prior Art / Publications:

THEREFORE, it can be concluded that as per disclosure and teaching of the publications, none of the publications provide a solution to the existing problem, including the mechanical problems, such as, the compressive strength and the flexural strength; and durability problems, such as, abrasion resistance and acid attack. As per disclosure and teaching of the publications, the compressive strength, the flexural strength, the abrasion resistance, and the acid attack resistance were found to substantially decreasing for the cement compositions comprising AOD slag alone or jarosite alone, and these publications have left it to be solved by quality control at the time of construction and by adding chemical admixtures to minimize their impact, and such processes and resulted compositions are not considered to be industrially viable.

NEED OF THE INDUSTRY:

Therefore, not only the cement industry, but also the stainless-steel industry producing the AOD steel slag, and the zinc ore industry producing the jarosite are still looking for a cement composition, wherein the AOD steal slag, a waste material from the stainless-steel industry; and jarosite, a waste material from the zinc ore industry, can be consumed with aim to overcome the existing problems of these industries, but with increased compressive strength, flexural strength, abrasion resistance and acid attack resistance.

PROBLEM TO BE SOLVED BY THE INVENTION:

Accordingly, main aim of the present invention is to solve the problems of the cement industry, and also the stainless-steel industry producing the AOD steel slag, and the zinc ore industry producing the jarosite by providing a cement composition, wherein both: the AOD steal slag and the jarosite can be consumed with aim to overcome the existing problems of these industries, but with increased compressive strength, flexural strength, abrasion resistance and acid attack resistance.

OBJECTS OF THE INVENTION:
Therefore, main object of the present invention is to provide a cement composition comprising:
(a) cement;
(b) argon oxygen decarburization (AOD) steel slag, a waste from stainless steel plant; and
(c) jarosite, a waste material from the zinc ore industry;
with aim to overcome the above-discussed existing problems of these industries, but with increased compressive strength, flexural strength, abrasion resistance and acid attack resistance.

Further objects and advantages of the present invention would be apparent from the following description of the invention.

DESCRIPTION and EMBODIMENTS OF THE INVENTION:
With aim to solve the above-discussed problems of the industry, the inventors have found that a cement composition essentially comprising:
(a) cement;
(b) argon oxygen decarburization (AOD) steel slag; and
(c) jarosite;
overcomes the above-discussed existing problems of the cement, stainless-steel and zinc ore industries, that’s too with an increased compressive strength, flexural strength, abrasion resistance and acid attack resistance.

Therefore, in accordance with first embodiment, the present invention relates to a cement composition, wherein the cement composition essentially comprises a combination of:
(a) cement;
(b) argon oxygen decarburization (AOD) steel slag; and
(c) jarosite.

In accordance with one of the preferred embodiments, the argon oxygen decarburization (AOD) steel slag is a waste from a stainless-steel plant.

In accordance with one of the preferred embodiments, the jarosite is a waste material from the zinc ore industry.

It may be noted that the scope of the present invention is not restricted to the source of the cement, AOD steel slag and the jarosite.

It may also be noted that the scope of the present invention is not restricted to the manner in which the AOD steel slag and the jarosite are added to the cement. In accordance with one of the embodiments, the AOD steel slag and the jarosite may be added to the cement after pre-mixing or one after the other or the AOD steel slag may be added before addition of the jarosite, or vice-versa.

It may also be noted that the scope of the present invention is not restricted to the composition of the cement. In accordance to one of the exemplary embodiments, the composition of the cement of the present invention may have the following typical chemical composition (Table 1):

Table 1: Exemplary Chemical Composition of Cement

Chemical Composition of Cement
(% by wt.)
SiO2 20.05
CaO 62.11
Al2O3 4.34
Fe2O3 3.21
MgO 3.53
K2O + Na2O 1.82
SO3 3.03

It may also be noted that the scope of the present invention is not restricted to the composition of the jarosite. In accordance to one of the exemplary embodiments, the composition of the jarosite of the present invention may have the following typical chemical composition (Table 2):

Table 2: Exemplary Chemical Composition of Jarosite

Chemical Composition of Jarosite
(% by wt.)
Fe2O3 38.745
SO3 29.118
SiO2 14.647
Pb 2.548
Zn 3.127
Al2O3 3.576
CaO 2.689
Cd 2.403
K2O + Na2O 1.543
Cu 0.227
MnO 0.114
P2O5 0.0674
TiO2 0.158
MgO 0.345
Ag 0.023
Other heavy metals 0.6696

It may also be noted that the scope of the present invention is not restricted to the composition of the AOD steel slag. In accordance to one of the exemplary embodiments, the composition of the AOD steel slag of the present invention may have the following typical chemical composition (Table 3):

Table 3: Exemplary Chemical Composition of AOD Steel Slag
Chemical Composition of AOD steel slag
(% by wt.)
SiO2 33.52
CaO 38.64
Al2O3 4.76
FeO 1.63
MgO 11.98
MnO 6.95
Cr2O3 2.5

Accordingly, with aim to overcome the existing problems of the cement, stainless-steel and zinc ore industries, the present invention, in one of the preferred embodiments, relates to a cement composition, wherein the cement composition essentially comprises a combination of:
(a) cement;
(b) argon oxygen decarburization (AOD) steel slag; and
(c) jarosite;
wherein (characterized in that)
the jarosite is taken in an amount varying from about 5% by wt. to about 30% by weight of the total composition; and
the AOD steel slag is taken in an amount varying from about 5% by wt. to about 30% by weight of the total composition.

In accordance with one of the preferred embodiments, the presently provided cement composition comprises the jarosite in an amount varying from about 7% by wt. to about 20% by weight of the total composition.

In accordance with one of the preferred embodiments, the presently provided cement composition comprises the jarosite in an amount varying from about 8% by wt. to about 15% by weight of the total composition.

In accordance with one of the preferred embodiments, the presently provided cement composition comprises the jarosite in an amount varying from about 9% by wt. to about 10% by weight of the total composition.

In accordance with one of the preferred embodiments, the presently provided cement composition comprises the AOD steel slag in an amount varying from about 5% by wt. to about 30% by weight of the total composition.

In accordance with one of the preferred embodiments, the presently provided cement composition comprises the AOD steel slag in an amount varying from about 10% by wt. to about 30% by weight of the total composition.

In accordance with one of the preferred embodiments, the presently provided cement composition comprises the AOD steel slag in an amount varying from about 15% by wt. to about 25% by weight of the total composition.

In accordance with one of the preferred embodiments, the presently provided cement composition comprises the AOD steel slag in an amount varying from about 17% by wt. to about 23% by weight of the total composition.

Further objects, embodiments and advantages of the present invention would be apparent from the following examples of the invention, which are not intended to limit scope of the present invention.

EXAMPLES:

In accordance with the exemplary embodiments of the present invention following cement compositions were prepared:
• Cement composition comprising 10% by weight of jarosite and 20% by weight of AOD steel slag of the total cement composition and this composition is referred to as J10S20;
• Cement composition comprising 9% by weight of jarosite and 21% by weight of AOD steel slag of the total cement composition and this composition is referred to as J9S21;
• Cement composition comprising 15% by weight of jarosite and 15% by weight of AOD steel slag of the total cement composition and this composition is referred to as J15S25;
• Cement composition comprising 21% by weight of jarosite and 9% by weight of AOD steel slag of the total cement composition and this composition is referred to as J21S9;
• Cement composition comprising 20% by weight of jarosite and 10% by weight of AOD steel slag of the total cement composition and this composition is referred to as J20S10.
• The cement without jarosite and AOD steel slag is a control / blank sample referred to as M40.
• The cement compositions consisting of the cement and the AOD steel slag (referred to as S10, S15, S20, S25), or consisting of the cement and the jarosite (referred to as J10, J15, J20, J25) are the one discussed in the Inventor’s prior publications as discussed herein.

The cement compositions prepared as per exemplary embodiments of the present invention were evaluated for the compressive strength, flexural strength, abrasion resistance and acid attack resistance by the methods known in the prior art.

For example, the Mechanical Properties were evaluated as follows:
Compressive Strength:
According to IS: 516 (BIS 1959), the evaluation of compressive strength was done on cubes with dimensions of 150x150x150 mm. The concrete cubes underwent a compressive strength test after 7 and 28 of curing.

Flexural Strength:
The concrete beams with the dimensions 100x100x500 mm were cast in accordance with the process outlined in IS: 516 (BIS 1959), and their flexural strength was assessed after 7 and 28 of curing.
For example, the Durability Properties were evaluated as follows:

Abrasion Resistance:
To measure the abrasion resistance of 100 x 100 x 100 mm cubes, the Cantabro test was used. The Los Angeles (LA) abrasion machine was used for the test without any steel ball charges. Concrete specimens measuring 100 mm in height, width, and depth were cast for the test, and they underwent 7 and 28 days of curing. The concrete blocks were weighed and moved for 12 minutes in the Los Angeles (LA) abrasion machine after curing. Further, the weight loss of the cubes after the test was observed in order to characterize their abrasion resistance.

Acid Attack:
A 5% sulfuric acid (H2SO4) solution was used to establish an acidic environment in the lab, and concrete specimens measuring 150×150×150 mm were cured for 28 days before being placed in tanks containing H2SO4 solution in accordance with ASTM C267. In order to keep the solutions' concentration levels constant throughout the experiment, they were routinely checked and refilled after 14 days. The concrete samples were removed from the H2SO4 solution after 28 days, cleaned with tap water and a cloth, and their Saturated Surface Dried (SSD) masses were also recorded. Additionally, there was a difference in the SSD mass of the samples before and after exposure to the acidic environment. This difference in SSD mass demonstrated the concrete specimens' resilience to the acidic environment. Further, these specimens' compressive strengths were observed which decreased after being exposed to an acidic environment.

Experimental Results and Discussion:

The experimental results of the above-discussed experiments are presented in the following Table 4:

Table 4
Contd…………

Properties of Composition M40 J15S15 J20S10 J21S9 J9S21 J10S20 J5S20 J20S5
Compressive Strength after 7 days curing 29 MPa
28.47 MPa 28 MPa 27.6 MPa 29.8 MPa
28.7 MPa
28.05 MPa 27.5 MPa
Compressive Strength after 28 days curing 51 MPa
50.47 MPa 49.82 MPa 49.6 MPa 53.89 MPa
53 MPa
52.65 MPa 49.5 MPa
Flexural Strength after 7 days curing 4 MPa
3.78 MPa 3.97 MPa 3.94 MPa 4.93 MPa
4.6 MPa
4.28 MPa 3.5 MPa
Flexural Strength after 28 days curing 5 MPa
5.0 MPa 4.83 MPa 4.78 MPa 6.38 MPa
6 MPa
5.73 MPa 4.35 MPa
Percentage weight loss due to Abrasion (after 7 days curing) 0.38%
0.378% 0.392% 0.4% 0.35%
0.37%
0.375% 0.4%
Percentage weight loss due to Abrasion (after 28 days curing) 0.27%
0.26% 0.283% 0.29% 0.21%
0.25%
0.252% 0.297%
Percentage weight loss due to acid attack 6%
(28 days curing) 5.8% 6% 6.2% 4.89%
5.12%
5.0% 6%

As can be observed from the foregoing experimental data, the existing problems of the industries have been solved by the present invention.
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,CLAIMS:We Claim:

1. A cement composition having improved compressive strength, flexural strength, abrasion resistance and / or acid attack resistance, wherein the cement composition essentially comprises a combination of:
(a) cement;
(b) argon oxygen decarburization (AOD) steel slag; and
(c) jarosite.

2. The cement composition as claimed in claim 1, wherein the argon oxygen decarburization (AOD) steel slag is a waste from a stainless-steel plant.

3. The cement composition as claimed in claim 1 or claim 2, wherein the jarosite is a waste material from the zinc ore industry.

4. The cement composition as claimed in any one of the preceding claims 1 to 3, wherein the jarosite is taken in an amount varying from about 5% by wt. to about 30% by weight of the total composition.

5. The cement composition as claimed in any one of the preceding claims 1 to 3, wherein the jarosite is taken in an amount varying from about 7% by wt. to about 20% by weight of the total composition.

6. The cement composition as claimed in any one of the preceding claims 1 to 3, wherein the jarosite is taken in an amount varying from about 8% by wt. to about 15% by weight of the total composition.

7. The cement composition as claimed in any one of the preceding claims 1 to 3, wherein the jarosite is taken in an amount varying from about 9% by wt. to about 10% by weight of the total composition.

8. The cement composition as claimed in any one of the preceding claims 1 to 7, wherein the AOD steel slag is taken in an amount varying from about 5% by wt. to about 30% by weight of the total composition.
9. The cement composition as claimed in any one of the preceding claims 1 to 7, wherein the AOD steel slag is taken in an amount varying from about 10% by wt. to about 30% by weight of the total composition.

10. The cement composition as claimed in any one of the preceding claims 1 to 7, wherein the AOD steel slag is taken in an amount varying from about 15% by wt. to about 25% by weight of the total composition.

11. The cement composition as claimed in any one of the preceding claims 1 to 7, wherein the AOD steel slag is taken in an amount varying from about 17% by wt. to about 23% by weight of the total composition.

Dated: this 14th day of April 2023.
E-Signed & E-Filed

Dr. Ramesh Kumar MEHTA
Patent Attorney for the Applicant
Advocate & Regd. Patent Attorney (Regn. No. IN/PA-267)
Honorary Professor, IPR & Technology Transfer,
Kurukshetra University, Kurukshetra
c/o Mehta & Mehta Associates