Natural material-based ash mortar composition

Patent metadata

Field	Value
Publication number	US-2021363059-A1
Application number	US-202117397355-A
Country	US
Kind code	A1
Filing date	Aug 9, 2021
Priority date	Jul 25, 2019
Publication date	Nov 25, 2021
Grant date	—

Abstract

A mortar composition, which includes (i) a treated palm oil fuel ash, wherein the treated palm oil fuel ash is the only binder present, (ii) a fine aggregate, (iii) an alkali activator containing an aqueous solution of sodium hydroxide and sodium silicate, and (iv) aluminum hydroxide as a strength enhancer. A cured mortar made from the mortar composition is also disclosed with advantageous compressive strength properties.

First claim

1 . A mortar composition, comprising:
a treated palm oil fuel ash as a binder, wherein the treated palm oil fuel ash is the only binder present; a fine aggregate; an alkali activator comprising an aqueous solution of sodium hydroxide and sodium silicate; and aluminum hydroxide as a strength enhancer which is the only strength enhancer present in the mortar composition, wherein the treated palm oil fuel ash is present in an amount of 20 to 30 wt. %, based on a total weight of the mortar composition, wherein the treated palm oil fuel ash comprises, as constituent oxides, 60 to 72 wt. % SiO 2 , 4 to 8 wt. % Al 2 O 3 , 3 to 7 wt. % Fe 2 O 3 , 3 to 8 wt. % CaO, 1 to 5 wt. % MgO, 3 to 7 wt. % K 2 O, 0.2 to 0.5 wt. % SO 3 , 0.1 to 0.25 wt. % Na 2 O, and 1 to 5 wt. % of P 2 O 3 , each based on a total weight of the treated palm oil fuel ash, and wherein the treated palm oil fuel ash has a median particle size (d 50 ) of 0.5 to 2.0 μm.

2 . (canceled)

3 . The mortar composition of claim 1 , wherein the treated palm oil fuel ash is obtained sequentially from drying raw palm oil fuel ash at 80 to 120° C., sieving to a particle size of less than 300 μm, a first mechanical ball milling, calcining at 500 to 600° C., and a second mechanical ball milling.

4 . (canceled)

5 . (canceled)

6 . The mortar composition of claim 1 , wherein the treated palm oil fuel ash comprises, as constituent oxides, 66 to 68 wt. % SiO 2 , 6 to 7 wt. % Al 2 O 3 , 5 to 6.5 wt. % Fe 2 O 3 , 5 to 6 wt. % CaO, 2.5 to 3.5 wt. % MgO, 4.5 to 6 wt. % K 2 O, 0.3 to 0.35 wt. % SO 3 , 0.18 to 0.2 wt. % Na 2 O, and 3 to 4 wt. % of P 2 O 3 , each based on a total weight of the treated palm oil fuel ash.

7 . The mortar composition of claim 1 , wherein the treated palm oil fuel ash has a loss on ignition (LOT) of less 3 wt. %, based on a total weight of the treated palm oil fuel ash, and a specific surface area of 1.4 to 1.6 m 2 /g.

8 . The mortar composition of claim 1 , wherein a weight ratio of the fine aggregate to the treated palm oil fuel ash is 1:1 to 2:1.

9 . The mortar composition of claim 1 , wherein the fine aggregate has a fineness modulus of 1.8 to 2.1 and a saturated surface dry (SSD) specific gravity of 2.5 to 2.7.

10 . (canceled)

11 . The mortar composition of claim 1 , wherein a weight ratio of the alkali activator to the treated palm oil fuel ash is 0.3:1 to 0.7:1.

12 . The mortar composition of claim 1 , wherein a weight ratio of sodium silicate to sodium hydroxide is 1:1 to 3:1.

13 . The mortar composition of claim 1 , wherein the alkali activator is formed from an aqueous solution of sodium hydroxide having a sodium hydroxide concentration of 10 to 12 mol/L.

14 . The mortar composition of claim 1 , wherein a weight ratio of the aluminum hydroxide to the treated palm oil fuel ash is 0.01:1 to 0.05:1.

15 . (canceled)

16 . The mortar composition of claim 1 , which has weight ratio of water to the treated palm oil fuel ash of 0.2 to 0.98.

17 . The mortar composition of claim 1 , which consists of the treated palm oil fuel ash, the fine aggregate, sodium hydroxide, sodium silicate, aluminum hydroxide, and water.

18 . (canceled)

19 . (canceled)

20 . (canceled)

Assignees

• Univ King Fahd Pet & Minerals

Inventors

• Salami Babatunde Abiodun
• Johari Megat Azmi Megat
• Maslehuddin Mohammed
• Ahmad Zainal Arifin

Classifications

• Y02W30/91

  Use of waste materials as fillers for mortars or concrete · CPC title

• C04B2111/00215

  Mortar or concrete mixtures defined by their oxide composition · CPC title

• C04B26/003 Primary

  Oil-based binders, e.g. containing linseed oil · CPC title

• C04B28/021 Primary

  Ash cements, e.g. fly ash cements (fly ash as filler C04B18/08); Cements based on incineration residues, e.g. alkali-activated slags from waste incineration (alkali-activated combustion residues as such C04B7/243; mixtures of the lime-pozzuolane type C04B28/18); Kiln dust cements · CPC title

• C04B18/02

  Agglomerated materials {, e.g. artificial aggregates} · CPC title