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1. WO2020109861 - NOUVEAU PROCÉDÉ DE PRODUCTION DE SABLE CÉRAMIQUE LÉGER SYNTHÉTIQUE ET SES UTILISATIONS

Note: Texte fondé sur des processus automatiques de reconnaissance optique de caractères. Seule la version PDF a une valeur juridique

[ EN ]

What is Claimed is:

1. A method of manufacturing lightweight ceramic sand comprising:

(a) dry spraying fly ash into moist bauxite residue cake while simultaneous rotation of rotor and pan followed by utilising high intensity shear mixer to form granules;

(b) drying said granules by fluidised bed drying process to obtain dried granules

(c) high temperature sintering of said dried granules thereby obtaining said lightweight ceramic sand.

2. A method of claim 1 , wherein said moist bauxite residue cake is preferably between 50-95 wt% and fly ash between 50-5 wt%.

3. A method of claim 1 , wherein bentonite is added to the fly ash or to the moist bauxite residue cake, before forming granules.

4. A method of claim 2, wherein said moist bauxite residue cake is between 50-95 wt%, fly ash 45-5 wt% and bentonite between 5-0%.

5. A method of claim 1 , wherein fine silica is added to the fly ash or to the moist bauxite residue cake, before forming granules.

6. A method of claim 5, wherein said moist bauxite residue cake is between

50-95wt%, fly ash between 40-5wt% and fine silica between 10-0wt%.

7. A method of claim 1 , wherein said drying is fluidized bed drying between 150-300°C.

8. A method of claim 1 , wherein said high temperature sintering is between 1 ,015-1 ,275°C.

9. A method of claim 1 , wherein size of said lightweight ceramic sand is between 0.075 mm to 3 mm.

10. A method of claim 1 , wherein size of said lightweight ceramic sand conforms to size gradation as per harmonized DIN 13139 (sand for plaster).

11. A method of claim 1 , wherein size of said lightweight ceramic sand conforms to size gradation as per harmonized DIN 12620 (fine aggregates for concrete).

12. A method of claim 1 , wherein size of said lightweight ceramic sand conforms to lightweight aggregates definition as per harmonized DIN

13055:2016.

13. A method of claim 1 , wherein bulk density of said lightweight ceramic sand is between 1 ,020 kg/m3 to 1 , 180 kg/m3.

14. A method of claim 1 , wherein said lightweight ceramic sand had crush strength between 10-40 MPa for mesh 20/40.

15. The product obtained by methods claimed in 1 to 14.