, Description:DESCRIPTION
A FLY ASH BRICK AND METHOD OF MANUFACTURING THE SAME
FIELD OF THE INVENTION
[001] The present disclosure, in general, relates to fly ash bricks and, more particularly, to a composition comprising ferrochrome slag for producing fly ash bricks and a method thereof.
BACKGROUND OF THE INVENTION
[002] Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
[003] Generally, in ferrochrome plant, during production of ferrochrome huge quantity of ferrochrome slag is generated and the slag are stored in pits. In addition to storage and handling, environment is a major concern due to the presence of harmful elements for example chromium, silicate etc. Various attempts have been made in the past to use this ferrochrome slag in various different applications.
[004] Attempts have been made to utilize the ferrochrome slag in place of concreate. Publications for example Panda et al. titled ‘Environmental and technical assessment of ferrochrome slag as concrete material’ and Susheel et al. titled ‘Development of Normal Strength Concrete using Ferrochrome Slag Aggregate as Replacement to Coarse Aggregate’ disclose utilization of ferrochrome slags as castables. Further, publication Ismail et al. titled ‘An Investigation of Utilization of Ferrochrome Slag in Brick Production’ discloses production of bricks using different proportions of ferrochrome slag with the brick ash. The publication discloses development of bricks using different proportion of ferrochrome slag i.e. 70 %, 60% etc with different proportion of brick ash percentage. Further, publication Willem A. Gericke titled ‘Environmental solutions to waste products from ferrochrome products’ discloses use of ferrochrome slag to make bricks by adding clay. Indian patent no. 237111, discloses a method to generate bricks using the granulated slag with alkaline activators along with cementous binders. In the study granulated slag of 85 to 90% weight was used. Also 10 to 15% of alkaline activator was used in the mixture. Most of the applications have failed due to the poor quality and have not emerged as an accepted alternative.
[005] Thus there is a requirement of a composition that utilizes ferrochrome slag.
OBJECTIVES OF THE INVENTION
[006] It is therefore the object of the invention to overcome aforementioned and other drawbacks existing in prior systems.
[007] Another object of the present invention is to provide a composition for producing fly ash bricks.
[008] Another object of the present invention is to provide a fly ash brick comprising a ferrochrome slag.
[011] Still another object of provide a fly ash brick that is easy to produce.
[013] Still another object of the present invention is to provide a method to produce fly ash bricks.
[014] These and other objects and advantages of the present invention will be apparent to those skilled in the art after a consideration of the following detailed description.
SUMMARY OF THE INVENTION
[015] The present invention provides a composition for use in production of fly ash bricks and a method thereof.
[016] In accordance with an embodiment of the invention, there is provided a composition for use in production of fly ash bricks. The composition comprising ground fly ash, granulated ferrochrome slag, cement and hydrated lime.
[017] In accordance with an embodiment of the invention, the ground fly ash is 50-70 % by weight of the composition.
[018] In accordance with an embodiment of the invention, the granulated ferrochrome slag is 25-30% by weight of the composition.
[019] In accordance with an embodiment of the invention, the cement is 10-15% by weight of the composition.
[020] In accordance with an embodiment of the invention, the hydrated lime is 5-10% by weight of the composition.
[021] In accordance with an embodiment of the invention, the granulated ferrochrome slag comprises 8 to 9% Chromium(III) oxide (Cr2O3), 1.56 to 2.5 % Calcium oxide (Cao), 28 to 30% Magnesium oxide (MgO), 24-28% Aluminium oxide (Al2O3), 28 to 30 % Silicon dioxide (SiO2), 0.068 to 0.08 % Potassium oxide (K2O) and 0.5-1% Fe by weight%.
[022] In accordance with another embodiment of the invention, the invention provides a method (100) for making a fly ash brick, comprising:
? mixing (101) 50-70% by weight ground fly ash, 25-30% granulated ferrochrome slag and 10-15 % cement with 5-10% hydrated lime;
? mixing (102) the mixtures with required amount of water to obtain a semi-dry mix;
? casting (103) the semi-dry mix to obtain brick moulds in manual hydraulic press brick machine;
? subjecting (104) the said moulds to consolidation methods;
? demoulding (105) the bricks so formed; and
? curing (106) at 100 percent humidity at room temperature.
[023] In accordance with said embodiment, the size of the granulated ferrochrome slag size of the granulated ferrochrome slag is 0.5 mm -4.0 mm.
[024] In accordance with said embodiment, the casting is done by a manual hydraulic press brick machine.
[025] In accordance with said embodiment, the fly ash brick has strength in range of 7.5 to 15N/mm2.
[026] Various objects, features, aspects, and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments.
[027] It is to be understood that the aspects and embodiments of the disclosure described above may be used in any combination with each other. Several aspects and embodiments may be combined to form a further embodiment of the disclosure.
[028] The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
The illustrated embodiments of the subject matter will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout. The following description is intended only by way of example, and simply illustrates certain selected embodiments of devices, systems, and methods that are consistent with the subject matter as claimed herein, wherein:
Figure-1 illustrates the flow chart for the method of manufacturing the fky ash brick according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[029] While the embodiments of the disclosure are subject to various modifications and alternative forms, specific embodiment thereof have been shown by way of example in the figures and will be described below. It should be understood, however, that it is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alterative falling within the scope of the disclosure.
[030] As used in the description herein and throughout the claims that follow, the meaning of "a," "an," and "the" includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of "in" includes "in" and "on" unless the context clearly dictates otherwise.
[031] The terms "comprises", "comprising", or any other variations thereof used in the disclosure, are intended to cover a non-exclusive inclusion, such that a device, system, assembly that comprises a list of components does not include only those components but may include other components not expressly listed or inherent to the system, or assembly, or device. In other words, one or more elements in a system or device proceeded by "comprises... a" does not, without more constraints, preclude the existence of other elements or additional elements in the system, apparatus or device.
[032] Hereinafter a composition for use in production of fly ash bricks and a method thereof is explained in more detail.
[033] The present invention relates to a composition for use in production of fly ash bricks. The composition comprises:
? ground fly ash;
? granulated ferrochrome slag;
? cement; and
? hydrated lime.
[034] The composition in accordance with a preferred embodiment comprises ground fly ash in 50-70 % by weight of the composition, granulated ferrochrome slag in 25-30% by weight of the composition, cement in 10-15% by weight of the composition and hydrated lime in 5-10% by weight of the composition.
[035] In accordance with the preferred embodiment, the granulated ferrochrome slag comprises 8 to 9% Chromium(III) oxide (Cr2O3), 1.56 to 2.5 % Calcium oxide (Cao), 28 to 30% Magnesium oxide (MgO), 24-28% Aluminium oxide (Al2O3), 28 to 30 % Silicon dioxide (SiO2), 0.068 to 0.08 % Potassium oxide (K2O) and 0.5-1% Fe by weight%.
In accordance with an embodiment of the disclosure, the size of the granulated ferrochrome slag is 0.5 mm -4.0 mm.
[036] In accordance with said embodiment, the ferrochrome slag of 3.1 mm size (90 % weight of the particle size passes through the 3.1 mm and 50% of the weight of the particles passes through 1.5 mm).
[037] In accordance with another embodiment of the invention, there is provided a method (100) for producing fly ash bricks. The method (100) comprises the steps of:
? mixing (101) 50-70% by weight ground fly ash, 25-30% granulated ferrochrome slag and 10-15 % cement with 5-10% hydrated lime;
? mixing (102) the mixtures with required amount of water to obtain a semi-dry mix;
? casting (103) the semi-dry mix to obtain brick moulds in manual hydraulic press brick machine;
? subjecting (104) the said moulds to consolidation methods;
? demoulding (105) the bricks so formed; and
? curing (106) at 100 percent humidity at room temperature.
[038] In accordance with the embodiment, the granulated ferrochrome slag comprises 8 to 9% Chromium(III) oxide (Cr2O3), 1.56 to 2.5 % Calcium oxide (Cao), 28 to 30% Magnesium oxide (MgO), 24-28% Aluminium oxide (Al2O3), 28 to 30 % Silicon dioxide (SiO2), 0.068 to 0.08 % Potassium oxide (K2O) and 0.5-1% Fe by weight%.
[039] In accordance with the embodiment, wherein size of the granulated ferrochrome slag comprises 90% of particles below 3.1 mm and 50% of the particles below 1.4 mm.
In accordance with an embodiment of the disclosure, the size of the granulated ferrochrome slag is 0.5 mm -4.0 mm.
[040] The mixture is thoroughly mixed with few percent of water to obtain the semi-dry mix which is used for making bricks by pressing in a manual hydraulic press brick making machine.
[041] After generation of the bricks the bricks were kept for 4-5 days to get their strength naturally gained from moisture and after natural drying, curing was done and the brick tests were done at different times 7 days, 14 days and 28 days accordingly. The method provides bricks of compressive strength 7.5 to 15 N/mm2, water absorption 15 to 16 % .
[042] The bricks after being demoulded were cured under 100 percent humidity at room temperature for a period of around 7-14-28 days. The mechanism of strength development in the bricks may be attributed to the overall physico-chemical and pozzolonic reactions occurring within the granulated ferrochrome slag and fly ash along with hydrated lime in contact with water reacts very fast and the reaction ceases because of the formation of a thin layer of silica gel over the surface.
[043] Another important factor contributing to the strength development of bricks is due to the particle size of the ferrochrome slag used and this results in a well packed matrix with minimum voids. When the pressure applied besides providing dense mass, the closer interaction of the lime and slag particles and solid to solid reaction takes place which contributes towards the development of strength.
[044] Good quality bricks of compressive strength ranging from 7.5 to 15 N/mm2 can be produced from different compositions of fly ash – ferrochrome slag – lime with cementitious binder. The manufacturing method of these bricks are less complicated and do not require any specialized plant and machinery.
[045] The following table illustrates variation in compressive strength of the fly ash bricks with variation in composition of the respective fly ash bricks:
Raw Material Used (%) (Compressive strengh) of bricks N/mm2
Fly Ash Cement FeCr slag Lime
1. 50 10 30 10 10.794
2. 60 10 25 5 7.904
3. 55 10 30 5 7.932

Advantages of the invention:
[045] The present disclosure provides a composition that comprises ferrochrome slag thereby providing an economical composition and method of producing fly ash bricks.
[046] The present disclosure provides usage of the ferrochrome slag in fly ash brick is the utilization of industrial waste in the conventional brick making method.
[047] The present disclosure provides a method of making fly ash bricks that is comparatively less complicated and do not require any sophisticated plant & machinery and requires less moulding pressure compared to other bricks.
[048] The present disclosure provides a composition and method for producing fly ash bricks that is environment friendly.
[049] With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity.
[050] It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as "open" terms (e.g., the term "including" should be interpreted as "including but not limited to," the term "having" should be interpreted as "having at least," the term "includes" should be interpreted as "includes but is not limited to," etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases "at least one" and "one or more" to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles, ‘a', or "an" limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases "one or more" or "at least one" and indefinite articles such as "a" or "an" (e.g., "a" and/or "an" should typically be interpreted to mean "at least one" or "one or more"); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of "two recitations," without other modifiers, typically means at least two recitations, or two or more recitations).
[051] The above description does not provide specific details of manufacture or design of the various components. Those of skill in the art are familiar with such details, and unless departures from those techniques are set out, techniques, known, related art or later developed designs and materials should be employed. Those in the art are capable of choosing suitable manufacturing and design details.
[052] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present disclosure. It will be appreciated that several of the above-disclosed and other features and functions, or alternatives thereof, may be combined into other systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may subsequently be made by those skilled in the art without departing from the scope of the present disclosure as encompassed by the following claims.
[053] The claims, as originally presented and as they may be amended, encompass variations, alternatives, modifications, improvements, equivalents, and substantial equivalents of the embodiments and teachings disclosed herein, including those that are presently unforeseen or unappreciated, and that, for example, may arise from applicants/patentees and others.
[054] While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.

Claims:We claim:
1. A fly ash brick comprising:
? a ground fly ash;
? a granulated ferrochrome slag;
? a cement; and
? a hydrated lime.
2. The fly ash brick as claimed in claim 1, wherein the ground fly ash is 50-70 % by weight of the composition.
3. The fly ash brick as claimed in claim 1, wherein the granulated ferrochrome slag is 25-30% by weight.
4. The fly ash brick as claimed in claim 1, wherein the size of the granulated ferrochrome slag is 0.5 mm -4.0 mm.
5. The fly ash brick as claimed in claim 1, wherein the cement is 10%-15% by weight of the composition.
6. The fly ash brick as claimed in claim 1, wherein the hydrated lime is 5-10% by weight of the composition.
7. The fly ash brick as claimed in claim 1, wherein the granulated ferrochrome slag comprises 8 to 9% Chromium(III) oxide (Cr2O3), 1.56 to 2.5 % Calcium oxide (Cao), 28 to 30% Magnesium oxide (MgO), 24-28% Aluminium oxide (Al2O3), 28 to 30 % Silicon dioxide (SiO2), 0.068 to 0.08 % Potassium oxide (K2O) and Fe- 0.5-1% by weight%.
8. A method (100) for making a fly ash brick, comprising:
? mixing (101) 50-70% by weight a ground fly ash, 25-30% a granulated ferrochrome slag and 10 %-15% a cement with 5-10% a hydrated lime;
? mixing (102) the mixtures with required amount of water to obtain a semi-dry mix;
? casting (103) the semi-dry mix to obtain brick moulds in manual hydraulic press brick machine;
? subjecting (104) the said moulds to consolidation methods;
? demoulding (105) the bricks so formed; and
? curing (106) at 100 percent humidity at room temperature.
9. The method as claimed in claim 8, wherein the granulated ferrochrome slag comprises 8 to 9% Chromium(III) oxide (Cr2O3), 1.56 to 2.5 % Calcium oxide (Cao), 28 to 30% Magnesium oxide (MgO), 24-28% Aluminium oxide (Al2O3), 28 to 30 % Silicon dioxide (SiO2), 0.068 to 0.08 % Potassium oxide (K2O) and 0.5-1% Fe by weight%.
10. The method as claimed in claim 8, wherein size of the granulated ferrochrome slag is 0.5 mm -4.0 mm.
12. The method as claimed in claim 8, wherein the fly ash brick has strength in a range of 7.5 to 15 N/mm2.