Foam concrete with oil ash

Patent metadata

Field	Value
Publication number	US-9796624-B1
Application number	US-201715420557-A
Country	US
Kind code	B1
Filing date	Jan 31, 2017
Priority date	Jan 31, 2017
Publication date	Oct 24, 2017
Grant date	Oct 24, 2017

Abstract

A foam concrete has constituents that include a cement, a sand, a coarse aggregate, an oil ash, a water, and a foam solution. The foam concrete has a compressive strength of at least 20 MPa, a thermal conductivity of less than 0.41 W/mK and a maximum weight of 1650 kg/m 3 .

First claim

What is claimed is:

1. A foam concrete, the constituents of the foam concrete comprising:
a cement;
a sand;
a coarse aggregate;
an oil ash;
a water; and
a foam solution; wherein
the foam concrete has a compressive strength of at least 20 MPa, a thermal conductivity of less than 0.41 W/mK and a maximum weight of 1650 kg/m 3 .

2. The foam concrete of claim 1 , wherein the cement and the water together comprise 75 wt % to 80 wt % of the constituents of the foam concrete, based on the weight of the foam concrete.

3. The foam concrete of claim 1 , wherein the foam concrete is free of fly ash, plasticizers and fiber.

4. The foam concrete of claim 1 , wherein the compressive strength of the foam concrete is in a range of 20 MPa to 60 MPa.

5. The foam concrete of claim 1 , wherein the thermal conductivity of the foam concrete is 0.40 W/mK.

6. The foam concrete of claim 1 , wherein the weight of the foam concrete is in a range of 1525 kg/m 3 to 1650 kg/m 3 .

7. The foam concrete of claim 1 , wherein the cement comprises at least 50 wt % of the constituents of the foam concrete, based on the weight of the foam concrete.

8. The foam concrete of claim 1 , wherein the constituents of the foam concrete include:
the cement in an amount of 53 wt % to 56 wt % of the constituents of the foam concrete;
the sand in an amount of 5 wt % to 8 wt % of the constituents of the foam concrete;
the coarse aggregate in an amount of 10 wt % to 12 wt % of the constituents of the foam concrete;
the oil ash in an amount of 3 wt % to 6 wt % of the constituents of the foam concrete;
the water in an amount of 21 wt % to 25 wt % of the constituents of the foam concrete; and
the foam solution in an amount of 0.5 wt % to 3.0 wt % of the constituents of the foam concrete, each based on the weight of the foam concrete.

9. The foam concrete of claim 1 , wherein the constituents of the foam concrete include:
the cement in an amount of 53.4 wt % of the constituents of the foam concrete;
the sand in an amount of 5.3 wt % of the constituents of the foam concrete;
the coarse aggregate in an amount of 10.6 wt % of the constituents of the foam concrete;
the oil ash in an amount of 5.3 wt % of the constituents of the foam concrete;
the water in an amount of 24.6 wt % of the constituents of the foam concrete; and
the foam solution in an amount of 0.8 wt % of the constituents of the foam concrete, each based on the weight of the foam concrete.

10. A foam concrete, the constituents of the foam concrete comprising:
a cement in an amount of 15 wt % to 65 wt % of the constituents of the foam concrete;
a sand in an amount of 1 wt % to 10 wt % of the constituents of the foam concrete;
a coarse aggregate in an amount of 10 wt % to 50 wt % of the constituents of the foam concrete;
an oil ash in an amount of 3 wt % to 10 wt % of the constituents of the foam concrete;
a water in an amount of 10 wt % to 30 wt % of the constituents of the foam concrete; and
a foam solution in an amount of 0.5 wt % to 5.0 wt % of the constituents of the foam concrete.

11. The foam concrete of claim 10 wherein the foam concrete has a compressive strength of at least 20 MPa, a thermal conductivity of less than 0.41 W/mK and a maximum weight of 1650 kg/m 3 .

12. The foam concrete of claim 10 , wherein the cement comprises at least 50 wt % of the constituents of the foam concrete, based on the weight of the foam concrete.

13. The foam concrete of claim 10 , wherein the cement and the water together comprise 75 wt % to 80 wt % of the constituents of the foam concrete, based on the weight of the foam concrete.

14. A method of disposing of an oil ash by forming a foam concrete, the method comprising the steps of:
mixing together the following constituents:
a cement;
a sand;
a coarse aggregate;
an oil ash; and
a water;

adding a foam solution to arrive at the foam concrete that has a compressive strength of at least 20 MPa, a thermal conductivity of less than 0.41 W/mK and a maximum weight of 1650 kg/m 3 .

15. The method of claim 14 , further including curing the foam concrete with the application of water.

16. The method of claim 14 , wherein the cement and the water together comprise 75 wt % to 80 wt % of the constituents of the foam concrete, based on the weight of the foam concrete.

17. The method of claim 14 , wherein the foam concrete is free of fly ash, plasticizers and fiber.

18. The method of claim 14 , wherein the cement comprises at least 50 wt % of the constituents of the foam concrete, based on the weight of the foam concrete.

19. The method of claim 14 , wherein the constituents of the foam concrete include:
the cement in an amount of 53 wt % to 56 wt % of the constituents of the foam concrete;
the sand in an amount of 5 wt % to 8 wt % of the constituents of the foam concrete;
the coarse aggregate in an amount of 10 wt % to 12 wt % of the constituents of the foam concrete;
the oil ash in an amount of 3 wt % to 6 wt % of the constituents of the foam concrete;
the water in an amount of 21 wt % to 25 wt % of the constituents of the foam concrete; and
the foam solution in an amount of 0.5 wt % to 3.0 wt % of the constituents of the foam concrete, each based on the weight of the foam concrete.

20. The method of claim 14 , wherein the constituents of the foam concrete include:
the cement in an amount of 53.4 wt % of the constituents of the foam concrete;
the sand in an amount of 5.3 wt % of the constituents of the foam concrete;
the coarse aggregate in an amount of 10.6 wt % of the constituents of the foam concrete;
the oil ash in an amount of 5.3 wt % of the constituents of the foam concrete;
the water in an amount of 24.6 wt % of the constituents of the foam concrete; and
the foam solution in an amount of 0.8 wt % of the constituents of the foam concrete, each based on the weight of the foam concrete.

Assignees

• Saudi Arabian Oil Co
• Univ King Fahd Pet & Minerals

Inventors

• Al-Mehthel Mohammed Heshan
• Maslehuddin Mohammed
• Al-Idi Saleh H
• Ibrahim Mohammed

Classifications

• C04B28/04 Primary

  Portland cements · CPC title

• C04B2201/52

  High compression strength concretes, i.e. with a compression strength higher than about 55 N/mm2, e.g. reactive powder concrete [RPC] · CPC title

• C04B2111/10

  Compositions or ingredients thereof characterised by the absence or the very low content of a specific material · CPC title

• C04B18/087

  from liquid fuels, e.g. oil · CPC title

• C04B2201/32

  for the thermal conductivity, e.g. K-factors · CPC title