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5,494,513 78 hydrates and/or calcium aluminosilicate hydrates. For example,whenthelimecontentislessthan10wt.% ofsolid (zeoliteandOPC),drydensitydecreaseswiththeincreaseof lime content, and the compressive strength increases. A further increase of lime content to exceed the requirement forhydrationandformationofcalciumsilicatesreducesthe compressive strength of zeolite-based concrete. The opti mum valuewillchangewithzeolitesource. Fine silica particles have been proven to be a major strengthcontributorinautoclavedconcreteproducts.Zeolite l0 contains at least 60% silica that may contribute to the strength. High silica content increases dry density. For example, a zeolite-based concrete product containing 9.6% silica ?our had a 10% increase in dry density but double valueofthecompressivestrength. Silica sand as an aggregate in zeolite-based concrete productswillalsocontributetothestrength.Highsilicasand content also increases dry density. For example, the com— pressive strength of the concrete increased from 6.7 to 9.2 MPawithanincreaseofsandcontentfrom9to17wt.%of20 solids(zeoliteandPortlandcement).A furtherincreaseof sandcontentsigni?cantlyreducedstrength.Crushedzeolite rockhavingthesizeof2-6mm indiametercanbeusedin zeolite-based concrete products as lightweight aggregate to minimizemicrocracksduetodryingshrinkageastheprod 25 ucts were cured at ambient pressure. The zeolite aggregate/ solids (zeolite powder and Portland cement) weight ratio wassuggestedintherangeofl-l.5.No signi?cantchange on the compressive strength of the products was found when zeolite aggregate was added in this range. A number of factors affect the water requirement of mixtures containing zeolite, including zeolite ?neness and source, mix proportions, etc. The water content of the mixture should be such that satisfactory workability and air-generationisachieved. 35 Salts containing sodium ions, such as sodium sulphate, sodium nitrate, sodium chloride, etc., and salts containing sulphate ions, such as calcium sulphate and potassium sulphate,canbeusedasstrengtheningagentsintheproduc— tion of zeolite-based lightweight concrete products. Research indicates that sodium and sulphate ions can acti vate the pozzolanic activity of zeolite to form calcium aluminosilicate hydrates, e.g. stratlintgite (CZASHB). Sodium and sulphate ions may substitute in some structural positions of calcium aluminosilicate crystals and reduce 45 crystallizationenergy.Thesesaltswillsigni?cantlyenhance the strength of zeolite-based concrete products. For example, the compressive strength of a zeolite-based con creteproductincreasedfrom 10to18MPa when 5% sodium sulphate by weight of zeolite and Portland cement was 50 added. The sodium sulphate content used is usually in the range of 3-8% by weight of solids (zeolite and Portland cement) to achieve high strength. Superplasticizers, such as sodium sulfonated napthalene formaldehyde(SNP),sodiumsulfonatedmelamineformal 55 dehyde(SMF),etc.,canalsobeusedtoincreasethestrength ofzeolite-basedlightweightconcreteproducts.Forexample, the compressive strength of the product doubled when 1% SMF byweightofsolid(zeoliteandPortlandcement)was used to reduce water in the mixture by 16%. The content of 60 superplasticizerusedisusuallyintherangeof05-15% by weight of the solid (zeolite and Portland cement). Mineral ?bre such as Wollastonite can be used to strengthen zeolite-based cement matrices and prevent microcrackformationduetodryingshrinkage.Wollastonite65 is a naturally occurring calcium metasilicate having an acicular particle morphology. The composition of Wollasto niteincludesabout50% SiO2and47% CaO.Additionof Wollastonitedoesnotreducethevalueofdryingshrinkage oftheproducts.However,rnicrocracksduetodryingshrink age can be signi?cantly reduced on the surface of the product containing 15-20% Wollastonite by weight of solids (zeoliteandPortlandcement). Air-bubble-stabilization (ABS) agents, such as polyvinyl alcohol (PVA), oxidized paraf?n soap (C,,H2,,+1COONa, n:5—22), oleic acid-triethanolarnine-water mixture (C17H33COOH:N(C2H4OH)3: H2O: 1:3:36byweight),etc., havebeenwidelyusedintheproductionofaeratedconcrete to stabilize and optimize the cellular structure. Our research indicated that these ABS agents were also bene?cial to 15 calcinedzeolitebasedaeratedconcrete(zeolitebeingcal cinedat400°—600°C.).TheABS agentwasaddedinthe mix-water before mixing. The concrete which contained ABS agentshowedabetterworkabilityandmoreuniform cellularstructure.ThecontentoftheABS agentwas0.1-0.6 wt.%bythetotalweightofzeoliteandPortlandcementin the cementing material. > 30 Our tests have shown that large amount of ettringite (Aft phase) form in the zeolite-lime~hemihydrate-sodium sul phate-water system (FIG. 2). This is attributed to the reac tionbetweenthealuminaphaseinzeoliteandthesulphate in presence of calcium. Addition of aluminum sulphate will signi?cantlyincreasetheformationofettringite.Thishydra tion system is believed to be well suitable for hazardous waste stabilization. The stabilization mechanisms can be explained as follows: (1) The mixture containing zeolite, lime, hemihydrate, aluminumsulphateandsodiumsulphatesetsrapidlyin about l0-20 minutes. This allows the hazardous waste to be quickly ?xed. (2) Zeolite as a major component .will adsorb a large amount of heavy metal ions in a very short period because of its physical adsorption characteristics. (3)Theseadsorbedheavymetalionscanbesubstitutedin thecrystalstructureoftheAftphaseduringhydration. Ettn'ngite, in which heavy metal ions have been ?xed, is stable and has very low solubility at normal ambient temperature. The leakage of heavy metal ions from such waste solidi?ed material therefore is expected to be signi?cantly reduced. Compositions for use in haz ardouswastestabilizationinclude40-60wt.% natural zeolite,15-20wt.% lime,15-20wt.% hemihydrate (CaSO4OI/zHZO),3-8wt.% sodiumsulphateand0-8 wt. % aluminum sulphate. In example 10, below, a watersolutioncontaining0.625wt% CdCl2bytotal solid was added to the mixture. The material was mixed for 3 minutes and then cast in moulds. Setting time of the mixture was about 15 minutes. The compressive strength of stabilized materials was determined after 28 days moist-curing at 23° C. The compressive strength was 7 to 12 MPa. X-ray diffraction analysis was carried outonthesamplesalsoafter28dayscuring.A strong ettringite peak was detected. EXAMPLE 1 Thisexampleillustratestheuseofcalcinedzeolite(550° C.)toproduceaeratedconcreteproductshavingverylow density.Applicationsincludeinsulationand/orlowload bearingblocksforconstruction.Thetestresultsareshownin the following table:PDF Image | ZEOLITE-BASED LIGHTWEIGHT CONCRETE PRODUCTS
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