[0001] The present disclosure relates to a field of building materials. More specifically, the present disclosure relates to a method for manufacturing of paver block and bricks from industrial waste.
BACKGROUND
[0002] Lead & Zinc concentrate are processed through hydrometallurgical and pyro metallurgical process. This results in generation of iron wastes such as Jarosite and lead-zinc slags from the respective processes. In addition, the Coal based power plants (CPP) generates fly ash as their waste. Part of this material is sold at very marginal realization while rest is stored in yards or in secured landfills. Further, various waste and residues are generated during extraction of Zn metal from its concentrates. At various stages of processing, the composition and physical properties of waste changes which provides a wide array of residues. Some of the wastes/residues that are of some economic value are used as secondary's within processing plants or sold off. In addition, large amount of waste with very low metals values are generated that cannot be used anywhere and thus dumped in secured landfills. Therefore there is need for the proper utilization of the industrial waste generated by various industries.
SUMMARY
[0003] In one aspect, the present disclosure provides a method for the manufacturing of paver block and bricks from industrial waste. The method includes a first step of

adding a first pre-defined quantity of cementitious materials in one or more mixers. In addition, the method includes a second step of adding a second pre-defined quantity of conventional aggregates in each of the one or more mixers. Further, the method includes a third step of adding a third pre-defined quantity of additives in each of the one or more mixers. Furthermore, the method includes a fourth step of adding a fourth pre-defined quantity of binding materials in each of the one or more mixers. Moreover, the method includes a fifth step of homogenizing the cementitious material, the conventional aggregates, the additives and the binding materials. Also, the method includes a sixth step of adding a fifth pre-defined quantity of hardner solution in each of the one or more mixers. Also, the method includes a seventh step of mixing homogenize material with the hardener solution for a pre-defined time interval of 5 minute to 30 minute. Also, the method includes an eighth step of casting mixture into a mould for making paver block and bricks. Also, the method includes a ninth step of curing the solidified part for about 5 to 28 days in atmospheric air. Homogenizing is done in each of the one or more mixers. Mixing is done in each of the one or more mixers. Mixture is obtained after completion of the mixing. During the curing process water is sprinkled for minimum 1 to 14 days.
[0004] In an embodiment of the present disclosure, the casting is performed by vibration in a machine or manually.
[0005] In an embodiment of the present disclosure, the casting is performed by compaction in a machine or manually.
[0006] In an embodiment of the present disclosure, the cementitious materials used for manufacturing paver block and bricks include fly ash and bottom ash.

[0007] In an embodiment of the present disclosure, the conventional aggregates used for manufacturing paver block and bricks include stone dust and grit.
[0008] In an embodiment of the present disclosure, the additives used for manufacturing paver block and bricks include Jarosite, slag and mine tailing.
[0009] In an embodiment of the present disclosure, the binding material used for manufacturing paver block includes cement and gypsum.
[0010] In an embodiment of the present disclosure, a composition for making paver block and bricks. The composition includes 0 to 50 % by weight of the cementitious materials, 0 to 80% by weight of the additives, 1 to 15% by weight of the binding material, balanced amount of the conventional aggregates and 0.5% to 5% by weight of the hardener solution.
OBJECT OF THE DISCLOSURE
[0011] A primary object of the present disclosure is to provide a method for utilization of industrial waste.
[0012] Yet another object of the present disclosure is to provide a method for the manufacturing of paver block and bricks.
[0013] Yet another object of the present disclosure is to manufacture paver block and bricks of different compressive strength depending on its usage in the pavements.
[0014] Yet another object of the present disclosure is partial or complete replacement of conventional raw materials for the manufacturing of paver block and bricks.

BRIEF DESCRIPTION OF THE FIGURES
[0015] Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein
[0016] FIG. 1A illustrates a flow chart for the manufacturing of the paver block from the industrial waste, in accordance with various embodiments of the present disclosure.
[0017] FIG. IB illustrates a flow chart for the manufacturing of the paver block from the industrial waste, in accordance with various embodiments of the present disclosure.
[0018] It should be noted that the accompanying figures are intended to present illustrations of exemplary embodiments of the present disclosure. These figures are not intended to limit the scope of the present disclosure. It should also be noted that accompanying figures are not necessarily drawn to scale.
DETAILED DESCRIPTION
[0019] It should be noted that the terms "first", "second", and the like, herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. Further, the terms "a" and "an" herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item.

[0020] In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present technology. Unless otherwise defined, all scientific terms used herein have the same meaning as commonly understood by ordinary skilled in the art to which this 5 invention belongs. The materials, methods, and examples provided herein are illustrative only and not intended to be limiting.
[0021] FIG. 1A and FIG. 1B illustrates a flowchart 100 for a method for manufacturing of paver block and bricks from industrial waste, in accordance with
10 various embodiments of the present disclosure. The flowchart 100 starts at step 102 as shown in FIG. 1A. The flowchart 100 illustrates a step by step method for the manufacturing of the paver blocks and bricks. It may be noted that the flowchart 100 may have lesser or more number of steps. In general, the paver block is a paving stone, tile, brick or brick-like piece of concrete commonly used as exterior flooring.
15 The Paver block is used in the construction of footpath on both side of road. The paver block is manufactured of different shape and size based on the requirement. The paver block is used in various places and industry based on the requirement of the physical property of the paver block. The bricks are a concrete bars used in the construction industry for the construction of building, house and the like. In an
20 embodiment of the present disclosure, the bricks are manufactured based on the requirement. In an example, if a skyscraper is being built than it is necessary that the bricks should be light weight and the shape of the bricks should cover a larger volume.
25 [0022] The industrial waste includes the residue which is left after a particular process has been performed in an industry. The industrial waste is made used in the manufacturing of the paver block and bricks such that the industrial waste can be
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utilized and the same physical property can be achieved which is present in the paver block and bricks.
[0023] For the manufacturing of the paver block and bricks the method includes a 5 first step of adding a first pre-defined quantity of cementitious materials in one or more mixers as mentioned 104 in the flowchart 100 in FIG. 1A. The first pre¬defined quantity of cementitious materials for the manufacturing of paver block and bricks are taken in the range of 0% to 50 % by weight. In an embodiment of the present disclosure, the first pre-defined quantity of cementitious materials may range
10 based on the compressive strength which need to be attained by the paver block and bricks. In general, the cementitious materials are those materials which hold the concrete together. The comentitious materials for the manufacturing of paver block and bricks include fly ash and bottom ash. In an embodiment of the present disclosure, the cementitious materials include any material which can hold the
15 concrete together. The cementitious materials fly ash and bottom ash is obtained from the coal based power plants which generate fly ash and bottom ash as their waste. In an embodiment of the present disclosure, the fly ash and bottom ash can be obtained from any other industry which creates fly ash as a waste product of a process which is being performed in that industry.
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[0024] The one or more mixers are mixtures used for mixing ingredients together with each other in order to get same proportions of its components throughout the mixture. The one or more mixers are mechanical mixers. In an embodiment of the present disclosure, the one or more mixers are manual mixers.
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[0025] The method further includes adding a second pre-defined quantity of conventional aggregates in each of the one or more mixers as mentioned in step 106 of the flowchart 100 in FIG. 1A. The second pre-defined quantity of conventional
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aggregates for the manufacturing of paver block and bricks are taken based on the compressive strength and size which needs to be achieved by the paver block and bricks. The weight of the conventional aggregates should be balanced for the manufacturing of the paver block and bricks. The conventional aggregates used for 5 the manufacturing of paver block and bricks include stone dust and grit. In an embodiment of the present disclosure, the conventional aggregates include sand, gravel, crushed stone, slag, recycled concrete, geosynthetic aggregates and the like. In general, the grit is a small loose particle of stone or sand. The grit is considered as a industrial waste which may be used for the manufacturing of paver block and bricks. 10 In general, the stone dust is a byproduct of crushing stone.
[0026] The method further includes adding a third pre-defined quantity of additives in each of the one or more mixers as mentioned in step 108 of the flowchart 100 in FIG. 1A. The third pre-defined quantity of additives for the manufacturing of paver
15 block and bricks are taken in the range of 0% to 80 % by weight. In an embodiment of the present disclosure, the third pre-defined quantity of additives may range based on the properties which need to be attained by the paver block and bricks. In general, the additives are also called as admixtures. The additives are those chemical compounds that are used to modify certain properties of the paver block and bricks.
20 The additives used for the manufacturing of paver block and bricks include slag, Jarosite and mine tailing. In an embodiment of the present disclosure, the addictives may be any other chemical compound which is to be added for the manufacturing of paver block and bricks in order to attain desired properties of the paver block and bricks. The slag used for the manufacturing of paver block and bricks are Iron waste
25 produced during Lead and Zinc (Zn/Pb) pyro metallurgical operation though vertical, horizontal furnaces. In general, the pyro metallurgical operation is the process of thermal treatment of minerals and metallurgical ores and concentrates to bring about physical and chemical transformations in the materials to enable recovery of valuable
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metals. The Jarosite used for the manufacturing of paver block and bricks are the Iron residue consists of sulphate, hydroxyl ion and silicates, which is generated during hydrometallurgical processing of Zn concentrates. In an embodiment of the present disclosure, the Jarosite is obtained from ores, deposits, byproduct in a 5 chemical plant, residue or waste of a chemical plant and the like. The mine tailing used of the manufacturing of paver block and bricks are the industrial waste which is generated during ore beneficiation process.
[0027] The method further includes adding a fourth pre-defined quantity of binding
10 materials in each of the one or more mixers as mentioned in step 110 of the flowchart 100 in FIG. 1A. The fourth pre-defined quantity of binding materials for the manufacturing of paver block and bricks are taken in the range of 1% to 15 % by weight. In an embodiment of the present disclosure, the fourth pre-defined quantity of additives may range based on the properties which need to be attained by the paver
15 block and bricks. In general, the binding materials are any material which holds the other material together to form bonding between the materials. The binding materials provide setting and hardening speeds to the paver block and bricks. The binding materials used for the manufacturing of the paver block and bricks include cement and gypsum. In an embodiment of the present disclosure, the binding materials may
20 be any other material based on the requirements of the properties which need to be attained by the paver block and bricks. In general, the cement is a binder which is used for construction that sets, hardens and adheres to others materials, binding them together. The cement is used as a binder for the manufacturing of the paver block and bricks such that the desired properties of the paver block and bricks may be
25 achieved based on the requirements. In general, gypsum is a soft sulfate mineral which is mined and is used for providing the setting and hardening speed to the paver block and bricks.
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[0028] The method further includes homogenizing the cementitious materials, the conventional aggregates, the additives and the binding materials in each of the one or more mixers as mentioned in step 114 of the flowchart 100 in figure 1B. The homogenizing is the process where all the materials are mixed together to form a 5 homogenous mixture which has the same proportions of its components throughout the admixtures. Homogenizing is done in each of the one or more mixers manually or by the mechanical mixer. In an embodiment of the present disclosure, the homogenizing is performed till all the materials are mixed to form a homogeneous mixture.
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[0029] The method further includes adding a fifth pre-defined quantity of hardener solution in each of the one or more mixers as mentioned in step 116 of the flowchart 100 in figure 1B. The fifth pre-defined quantity of hardener solution for the manufacturing of paver block and bricks are taken in the range of 0.5% to 5 % by
15 weight. In an embodiment of the present disclosure, the fifth pre-defined quantity of additives may range based on the properties which need to be attained by the paver block and bricks. The hardener solution is a retarding super plasticizing admixture for developing concrete. The hardener solution is having slump retaining properties for the manufacturing of paver block and bricks. The hardener solution is prepared
20 by using synthetic polymer, a sulphonated naphthalene polymer based formulation. In an embodiment of the present disclosure, the hardener solution is prepared by using material which can provide slump retaining properties to the hardener.
[0030] The method further includes mixing the homogenize material obtained in step 25 114 after homogenizing with the hardener solution for a pre-defined time interval in each of the one or more mixers. The mixing of the homogenize material with the hardener solution is as mentioned in step 118 of the flowchart 100 in figure 1B. The pre-defined time interval for the mixing of homogenize material with the hardener
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solution is in the range of about 5 minute to 30 minute. In an embodiment of the present disclosure, the pre-defined time interval depends on the time required by the materials to mix with each other. The mixing is done in order to mix all the ingredients together to form a homogeneous mixture which has the same proportions 5 of its components throughout the mixture. Mixing is done in each of the one or more mixers manually or by the mechanical mixer.
[0031] The method further includes casting the mixture obtained in step 118 after mixing the homogenize material with the hardener solution. The casting of the
10 mixture is as mentioned in step 120 of the flowchart 100 in FIG. 1B. The casting is performed on the mixture by pouring the mixture obtained from step 118 into a mould for making the paver block and bricks. In general, the mould is a hollow container used to give shape to molten material when it cools and hardens. The mould used for making the paver block and bricks depends on the requirement, shape
15 and size of the paver block and bricks. In an embodiment of the present disclosure, the different shape and size mould are required based on the requirements. The mould is made of any material which includes but may not be limited to wood, metal, plastic. The casting is performed by vibration in a machine or manually. In an embodiment of the present disclosure, the casting is performed by compaction in a
20 machine or manually. In another embodiment of the present disclosure, the casting is performed by any other process which provide the desired shape and size such the mixture is divided equally in the mould. After the casting has been performed on the mixture the solidified part is obtained which is further processed for getting the paver block and the bricks with the desired properties.
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[0032] The method further includes curing the solidified part obtained in step 120. The curing is the process during which the solidified part is left out by exposing the paver block and bricks in atmospheric air as mentioned in step 122 of the flowchart in
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FIG. 1B. The curing is performed for about 5 to 28 days and water is sprinkled for minimum 1 to 14 days in order to prevent the concrete from drying such that the desired properties can be achieved. The water is sprinkled on the solidified part during curing in order to achieve the desired result by the paver block and bricks. In 5 an embodiment of the present disclosure, the curing time based on the requirement of the paver block and bricks property which needs to be attained. After the completion of the curing the mould is removed and the desired compressive strength and size paver block and bricks are received. The method terminates at step 124 as shown in FIG. 1B.
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[0033] In an example, the binding material used for the manufacturing of the paver block and bricks is 3% by weight. The cementitious material used for the manufacturing of the paver block and bricks is 21% by weight. The conventional aggregate used for the manufacturing of the paver block and bricks is 0% by weight.
15 The additive used for the manufacturing of the paver block and bricks is 76% by weight. The results provides that the compressive strength achieved by the paver block and bricks after 28 days curing is about 6.5 MPa and the aggregates size is about 2-10mm.
20 [0034] In another example, the binding material used for the manufacturing of the paver block and bricks is 7% by weight. The cementitious material used for the manufacturing of the paver block and bricks is 20% by weight. The conventional aggregate used for the manufacturing of the paver block and bricks is 10% by weight. The additive used for the manufacturing of the paver block and bricks is 63% by
25 weight. The results provides that the compressive strength achieved by the paver block and bricks after 28 days curing is about 25 MPa and the aggregates size is about 2-10 mm.
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[0035] In yet another example, the binding material used for the manufacturing of the paver block and bricks is 10% by weight. The cementitious material used for the manufacturing of the paver block and bricks is 14% by weight. The conventional aggregate used for the manufacturing of the paver block and bricks is 35% by weight. 5 The additive used for the manufacturing of the paver block and bricks is 41% by weight. The results provides that the compressive strength achieved by the paver block and bricks after 28 days curing is about 40 MPa and the aggregates size is about 2-10 mm.
10 [0036] In yet another example, the binding material used for the manufacturing of the paver block and bricks is 11% by weight. The cementitious material used for the manufacturing of the paver block and bricks is 5% by weight. The conventional aggregate used for the manufacturing of the paver block and bricks is 54% by weight. The additive used for the manufacturing of the paver block and bricks is 30% by
15 weight. The results provides that the compressive strength achieved by the paver block and bricks after 28 days curing is about 60 MPa and the aggregates size is about 2-20 mm.
[0037] The foregoing descriptions of specific embodiments of the present technology 20 have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present technology to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the present technology and its practical application, to 25 thereby enable others skilled in the art to best utilize the present technology and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omissions and substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but such are
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intended to cover the application or implementation without departing from the spirit or scope of the claims of the present technology.
[0038] While several possible embodiments of the invention have been described above and illustrated in some cases, it should be interpreted and understood as to have been presented only by way of illustration and example, but not by limitation. Thus, the breadth and scope of a preferred embodiment should not be limited by any of the above-described exemplary embodiments.

What is claimed

1. A method for manufacturing of paver block and bricks from industrial waste residue, the method comprising:
adding a first pre-defined quantity of cementitious materials in one or more mixers;
adding a second pre-defined quantity of conventional aggregates in each of the one or more mixers;
adding a third pre-defined quantity of additives in each of the one or more mixers;
adding a fourth pre-defined quantity of binding materials in each of the one or more mixers;
homogenizing the cementitious material, the conventional aggregates, the additives and the binding materials, wherein the homogenizing is done in each of the one or more mixers;
adding a fifth pre-defined quantity of hardener solution in each of the one or more mixers;
mixing homogenize material with the hardener solution for a pre-defined time interval of 5 minute to 30 minute, wherein mixing is done in each of the one or more mixers;

casting mixture into a mould for making the paver block and bricks, wherein the mixture is obtained after completion of the mixing; and
curing solidified part for about 5 to 28 days in atmospheric air, wherein the solidified part is obtained after the casting, wherein during the curing process water is sprinkled for minimum 1 to 14 days on the solidified part.
The method as recited in claim 1, wherein the casting is performed by vibration in a machine or manually.
The method as recited in claim 1, wherein the casting is performed by compaction in a machine or manually.
The method as recited in claim 1, wherein the cementitious material used for the manufacturing of the paver block and bricks comprises of fly ash and bottom ash.
The method as recited in claim 1, wherein the conventional aggregates used for the manufacturing of the paver block and bricks comprises of stone dust and grit.
The method as recited in claim 1, wherein the additives used for the manufacturing of the paver block and bricks comprises of Jarosite, slag and mine tailing.
The method as recited in claim 1, wherein the binding material used for the manufacturing of the paver block and bricks comprises of cement and gypsum.

The method as recited in claim 1, wherein the hardener solution used for the manufacturing of the paver block and bricks comprises a synthetic polymer and a sulphonated naphthalene polymer.
A composition for making the paver block and bricks, the composition comprising:
0 to 50% by weight of the cementitious material;
0 to 80% by weight of the additives;
1 to 15% by weight of the binding material; balanced amount of the conventional aggregates; and 0.5 to 5 % by weight of the hardener solution.