Description:BACKGROUND
Field of Invention
[001] Embodiments of the present invention generally relate to a building construction material and more particularly to a paver mixer and a method of preparing the same.
Description of Related Art
[002] Sludge from wastewater treatment plant is one of the main factors for inadequate land space disposal. The dried state of sludge contains particles and fecal matter of random size. It is a type of wastewater produced by humans and industrial effluents. Sludge usually originates at one place and travel through plumbing to a place of decomposition or treatment. Major parameters such as, solid content, organic matter, nitrogen, phosphorus and fecal matter are deciding parameters before defining an optimal treatment of the sludge. It also contains pathogens like bacteria, viruses and helminths. Treatment of sewage includes collection and transport for release into the environment, after a treatment, discharge into water bodies, onto soil or for reuse applications. Sewage from industries can also include industrial wastewater, generated by processes like production, treatment or manufacture of goods. Industrial wastewater can contain very different pollutants at much higher concentrations than what is typically found in sewage. Pollutants can also be present in this waste which can include pharmaceutical, biocide, heavy metals and radionuclides.
[003] An alternative of discharging this sludge into the environment is to reuse it in a productive manner including areas like agriculture, urban land or industrial uses. However, the reuse must be in compliance with government defined regulations and requirements. One such use is Reinforced Concrete (RC). It is a composite material wherein cement has low elasticity and malleability. The reinforcement is generally provided using fibers which are typically implanted in substantial sets. The use of sludge as an alternative fuel in clinker production is another sustainable option. The sludge minerals will bind in the clinker.
[004] Despite of the advancements offered by the existing processes of preparing cement using sludge, there is no method for effective utilization of sludge in the cement mixture.
[005] There is thus a need for a method that can use the sludge to prepare a paver mixture.
SUMMARY
[006] Embodiments in accordance with the present invention provide a paver mixture. The paver mixture comprising of: a dry sludge ash to function as a base of the paver mixture; a solvent to soften and dissolve the dry sludge ash; a construction binder to hydraulically increase bonding properties between the dry sludge ash and the solvent; a fiber to provide a reinforcement strength to the construction binder; and a water reducer to slow down a setting rate of the paver mixture.
[007] Embodiments in accordance with the present invention provide a method of preparing a paver mixture. The method comprising steps of: collecting a dry sludge ash from a predefined source; mixing a solvent and a construction binder in a predefined ratio to form a first mixture; adding a first predefined amount of the characterized dry sludge ash in the first mixture to form a second mixture; adding second predefined amount of fiber in the second mixture to form a third mixture; and adding a water reducer to the third mixture to prepare the paver mixture.
[008] Embodiments of the present invention may provide a number of advantages depending on its particular configuration. First, embodiments of the present application may provide a paver mixture for building construction material.
[009] Next, embodiments of the present application may provide a method to effectively use septage waste in construction material.
[0010] Next, embodiments of the present application may provide a method to effectively use sludge treatment plant waste.
[0011] Next, embodiments of the present application may provide a method to prepare a reinforced paver mixture.
[0012] Next, embodiments of the present application may provide a sustainable building material.
[0013] Next, embodiments of the present application may provide an ecofriendly and cost-effective method to utilize sludge.
[0014] Next, embodiments of the present application may provide a method to increase strength of ash-based cement mixture.
[0015] These and other advantages will be apparent from the present application of the embodiments described herein.
[0016] The preceding is a simplified summary to provide an understanding of some embodiments of the present invention. This summary is neither an extensive nor exhaustive overview of the present invention and its various embodiments. The summary presents selected concepts of the embodiments of the present invention in a simplified form as an introduction to the more detailed description presented below. As will be appreciated, other embodiments of the present invention are possible utilizing, alone or in combination, one or more of the features set forth above or described in detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The above and still further features and advantages of embodiments of the present invention will become apparent upon consideration of the following detailed description of embodiments thereof, especially when taken in conjunction with the accompanying drawings, and wherein:
[0018] FIG. 1 illustrates a paver mixture, according to an embodiment of the present invention;
[0019] FIG. 2 illustrates a first mixture, according to an embodiment of the present invention;
[0020] FIG. 3 illustrates a second mixture, according to an embodiment of the present invention;
[0021] FIG. 4 illustrates a third mixture, according to an embodiment of the present invention; and
[0022] FIG. 5 depicts a flowchart of a method for preparing the paver mixture, according to an embodiment of the present invention.
[0023] The headings used herein are for organizational purposes only and are not meant to be used to limit the scope of the description or the claims. As used throughout this application, the word "may" is used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense (i.e., meaning must). Similarly, the words “include”, “including”, and “includes” mean including but not limited to. To facilitate understanding, like reference numerals have been used, where possible, to designate like elements common to the figures. Optional portions of the figures may be illustrated using dashed or dotted lines, unless the context of usage indicates otherwise.
DETAILED DESCRIPTION
[0024] The following description includes the preferred best mode of one embodiment of the present invention. It will be clear from this description of the invention that the invention is not limited to these illustrated embodiments but that the invention also includes a variety of modifications and embodiments thereto. Therefore, the present description should be seen as illustrative and not limiting. While the invention is susceptible to various modifications and alternative constructions, it should be understood, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention as defined in the claims.
[0025] In any embodiment described herein, the open-ended terms "comprising", "comprises,”, and the like (which are synonymous with "including,", "having”, and "characterized by") may be replaced by the respective partially closed phrases "consisting essentially of,", “consists essentially of,", and the like or the respective closed phrases "consisting of", "consists of”, the like.
[0026] As used herein, the singular forms “a”, “an”, and “the” designate both the singular and the plural, unless expressly stated to designate the singular only.
[0027] FIG. 1 illustrates a paver mixture 100, according to an embodiment of the present invention. The paver mixture 100 may comprise constituents such as, but not limited to, a dry sludge ash 102, a solvent 104, a construction binder 106, a fiber 108, a water reducer 110 and so forth, according to an embodiment of the present invention. Embodiments of the present invention are intended to include or otherwise cover any type of the constituents of the paver mixture 100, including known, related art, and/or later developed technologies.
[0028] In an embodiment of the present invention, the dry sludge ash 102 may perform as a base of the paver mixture 100. In an embodiment of the present invention, the dry sludge ash 102 may be collected from a predefined source. The predefined source for collecting the dry sludge ash 102 may be, but not limited to, an industrial landfill site, a house effluent collection site, an industrial effluent site, a wastewater collection site, and so forth, according to an embodiment of the present invention. In a preferred embodiment of the present invention, the predefined source of the dry sludge ash 102 may be a thermal treatment plant. Embodiments of the present invention are intended to include or otherwise cover any type of the predefined source for collecting the dry sludge ash 102.
[0029] In another embodiment of the present invention, the dry sludge ash 102 may be prepared by drying a wet sludge. The wet sludge may be dried by using a drying method, according to an embodiment of the present invention. The drying method may be, but not limited to, a sun drying, an oven drying, a water-reduction machine and so forth, according to an embodiment of the present invention. Embodiments of the present invention are intended to include or otherwise cover any type of the drying method, including known, related art, and/or later developed technologies.
[0030] In an embodiment of the present invention, the dry sludge ash 102 may be characterized for sludge properties using a characterization technique. The sludge properties may be, but not limited to, a comprehensive strength, a flexural test, a split tensile test, and so forth, according to an embodiment of the present invention. Embodiments of the present invention are intended to include or otherwise cover any type of the sludge properties.
[0031] In an embodiment of the present invention, the solvent 104 may perform as a softening agent to dissolve the dry sludge ash 102. In an embodiment of the present invention, the solvent 104 may be, but not limited to, an ethanol, a methanol, an acetone, a reverse osmosis water, a wastewater and so forth, according to an embodiment of the present invention. In a preferred embodiment of the present invention, the solvent 104 may be water. Embodiments of the present invention are intended to include or otherwise cover any type of the solvent 104, including known, related art, and/or later developed technologies.
[0032] In an embodiment of the present invention, the construction binder 106 may increase a bonding property between the dry sludge ash 102 and the solvent 104. The construction binder 106 may be, but not limited to, a vinyl binder, a paper stock binder, a poly-material binder, an asphalt binder and so forth, according to an embodiment of the present invention. In a preferred embodiment of the present invention, the construction binder 106 may be cement. Embodiments of the present invention are intended to include or otherwise cover any type of the construction binder 106, including known, related art, and/or later developed technologies.
[0033] In an embodiment of the present invention, the fiber 108 may provide reinforcement strength to the construction binder 106. The fiber 108 may be, but not limited to, steel fiber, polypropylene fiber, glass fiber, asbestos fiber, carbon fiber, and so forth, according to an embodiment of the present invention. In an embodiment of the present invention, the fiber 108 may be synthetic fiber. Embodiments of the present invention are intended to include or otherwise cover any type of the fiber 108, including known, related art, and/or later developed technologies.
[0034] In an embodiment of the present invention, the water reducer 110 may slow down a setting rate of the paver mixture 100. The water reducer 110 may be, but not limited to, a water retardant, a lignosulfonate, a hydroxycarboxylic acid, a hydroxylated polymer, a salt of melamine formaldehyde sulfonate, and so forth, according to an embodiment of the present invention. In a preferred embodiment of the present invention, the water reducer 110 may be a superplasticizer. Embodiments of the present invention are intended to include or otherwise cover any type of the water reducer 110, including known, related art, and/or later developed technologies.
[0035] FIG. 2 illustrates a first mixture 200, according to an embodiment of the present invention. The first mixture 200 may be prepared by mixing the solvent 104 with the construction binder 106 in a predefined ratio, according to an embodiment of the present invention. The predefined ratio of the solvent 104 and the construction binder 106 may be, but not limited to, 1:7, 1:3, 1:5, 2:5, 2:3, and so forth, according to an embodiment of the present invention. In a preferred embodiment of the present invention, the predefined ratio of the solvent 104 and the construction binder 106 may be 1:2. Embodiments of the present invention are intended to include or otherwise cover any predefined ratio of the solvent 104 and the construction binder 106.
[0036] FIG. 3 illustrates a second mixture 300, according to an embodiment of the present invention. The second mixture 300 may be prepared by adding a first predefined amount of the dry sludge ash 102 in the first mixture 200, according to an embodiment of the present invention. The first predefined amount of the dry sludge ash 102 may be, but not limited to, 5 percent (%), 35 percent (%), 40 percent (%), 45 percent (%), and so forth, according to an embodiment of the present invention. In a preferred embodiment of the present invention, the first predefined amount of the dry sludge ash 102 may be in a range of 10 percent (%) to 30 percent (%). In an exemplary embodiment of the present invention, the first predefined amount of the dry sludge ash 102 may be 20 percent (%). Embodiments of the present invention are intended to include or otherwise cover any first predefined amount of the dry sludge ash 102.
[0037] FIG. 4 illustrates a third mixture 400, according to an embodiment of the present invention. The third mixture 400 may be prepared by adding a second predefined amount of the fiber 108 in the second mixture 300. The second predefined amount of the fiber 108 may be, but not limited to, 5 percent (%), 10 percent (%), 15 percent (%), 50 percent (%), and so forth, according to an embodiment of the present invention.
[0038] According to an embodiment of the present invention, the paver mixture 100 may be prepared by adding the water reducer 110 in the third mixture 400. In an embodiment of the present invention, the paver mixture 100 may be prepared by adding a third predefined amount of the water reducer 110 in the third mixture 400. The third predefined amount of the water reducer 110 may be, but not limited to, 5 percent (%), 10 percent (%), 15 percent (%), 50 percent (%), and so forth, according to an embodiment of the present invention.
[0039] According to an embodiment of the present invention, the paver mixture 100 may be used in building construction material, road material, pavement construction, building blocks, and so forth. Embodiments of the present invention are intended to include or otherwise cover any use of the paver mixture 100.
[0040] According to an embodiment of the present invention, the paver mixture 100 may be shaped in distinct forms to form a pavement block and building block. The distinct forms may be, but not limited to, a square shape, a rectangular shape, a star shape, a round shape, and so forth, according to an embodiment of the present invention. Embodiments of the present invention are intended to include or otherwise cover any distinct form of the paver mixture 100.
[0041] According to an embodiment of the present invention, the paver mixture 100 may be characterized for stress properties. In a preferred embodiment of the present invention, the stress properties may be durability test and micro-characterization. Embodiments of the present invention are intended to include or otherwise cover any stress properties, including known, related art, and/or later developed technologies.
[0042] According to an embodiment of the present invention, the paver mixture 100 may undergo strength testing. In a preferred embodiment of the present invention, the strength testing may involve a tensile strength and a compressive strength. Embodiments of the present invention are intended to include or otherwise cover any strength testing, including known, related art, and/or later developed technologies.
[0043] In an embodiment of the present invention, a color may also be added in the paver mixture 100. The color may be, but not limited to, a concrete color, a fabric color, an acid-fast dye, and so forth, according to an embodiment of the present invention. Embodiments of the present invention are intended to include or otherwise cover any type of color, including known, related art, and/or later developed technologies.
[0044] FIG. 5 depicts a flowchart of a method 500 for preparing the paver mixture 100, according to an embodiment of the present invention.
[0045] At step 502, the dry sludge ash 102 may be collected from the predefined sources.
[0046] At step 504, the dry sludge ash 102 may be characterized for the performance attribute.
[0047] At step 506, the solvent 104 may be mixed with the construction binder 106 in the predefined ratio to form the first mixture 200.
[0048] At step 508, the first predefined amount of the characterized dry sludge ash 102 may be added in the first mixture 200 to form the second mixture 300.
[0049] At step 510, the second predefined amount of the fiber 108 may be added in the second mixture 300 to form the third mixture 400.
[0050] At step 512, the water reducer 110 may be added to the third mixture 400 to form the paver mixture 100.
[0051] While the invention has been described in connection with what is presently considered to be the most practical and various embodiments, it is to be understood that the invention is not to be limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.
[0052] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope the invention is defined in the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements within substantial differences from the literal languages of the claims.
, Claims:I/We Claim:
1. A paver mixture (100), comprising:

a dry sludge ash (102) to function as a base of the paver mixture (100);

a solvent (104) to soften and dissolve the dry sludge ash (102);

a construction binder (106) to increase bonding properties between the dry sludge ash (102) and the solvent (104);

a fiber (108) to provide a reinforcement strength to the construction binder (106); and

a water reducer (110) to slow down a setting rate of the paver mixture (100).

2. The paver mixture (100) as claimed in claim 1, wherein the solvent (104) is water.

3. The paver mixture (100) as claimed in claim 1, wherein the construction binder (106) is a cement.

4. The paver mixture (100) as claimed in claim 1, wherein the fiber (108) is a synthetic fiber.

5. The paver mixture (100) as claimed in claim 1, wherein the water reducer (110) is a super plasticizer.

6. A method (500) of preparing a paver mixture (100), wherein the method (500) comprising steps of:

collecting a dry sludge ash (102) from a predefined source;

mixing a solvent (104) and a construction binder (106) in a predefined ratio to form a first mixture (200);

adding a first predefined amount of the dry sludge ash (102) in the first mixture (200) to form a second mixture (300);

adding a second predefined amount of fiber (108) in the second mixture (300) to form the third mixture (400); and

adding a water reducer (110) to the third mixture (400) to form the paver mixture (100).

7. The method (500) as claimed in claim 6, comprising a step of characterizing the paver mixture (100) for a durability and a micro-characterization test.

8. The method (500) as claimed in claim 6, comprising a step of shaping the paver mixture (100) to form a building block and a paver block.

9. The method (500) as claimed in claim 6, wherein the predefined ratio of the solvent (104) and the construction binder (106) is 1:2.

10. The method (500) as claimed in claim 6, wherein the first predefined amount of the dry sludge ash (102) is in a range of 10 percent (%) to 30 percent (%).

Date: 17 June, 2022
Place: Noida
Nainsi Rastogi
Agent for the Applicant
(IN/PA-2372)