Title of Invention	THE PROCESS FOR PREPARATION OF CONSTRUCTIONAL BLOCKS, BRICKS, AND ARTIFICIAL CERAMIC STONE CHIPS UTILIZING RED MUD AS THE MAIN BASE MATERIAL
Abstract	A process for preparing constructional materials comprising the steps of: mixing 60 to 80% red mud, 20-30% plastic clay and 5-10% soap stone to form a formable paste; subjecting the said paste to the step of extrusion in the form of constructional materials if required shape and size; air drying the constructional materials for 60-80 hrs or drying below 150°C for 2 to 4 hrs; subjecting the dried constructional materials to the step of heat treatment at a temperature range of 900-1150°C for 1 to 3 hrs; crushing and grinding the constructional materials in crusher/and grinder to form artificial ceramic stone chips for desired size and shape.

Title of Invention

THE PROCESS FOR PREPARATION OF CONSTRUCTIONAL BLOCKS, BRICKS, AND ARTIFICIAL CERAMIC STONE CHIPS UTILIZING RED MUD AS THE MAIN BASE MATERIAL

Abstract

A process for preparing constructional materials comprising the steps of: mixing 60 to 80% red mud, 20-30% plastic clay and 5-10% soap stone to form a formable paste; subjecting the said paste to the step of extrusion in the form of constructional materials if required shape and size; air drying the constructional materials for 60-80 hrs or drying below 150°C for 2 to 4 hrs; subjecting the dried constructional materials to the step of heat treatment at a temperature range of 900-1150°C for 1 to 3 hrs; crushing and grinding the constructional materials in crusher/and grinder to form artificial ceramic stone chips for desired size and shape.

Full Text	FIELD OF THE INVENTION: The invention relates to the process for preparation of constructional blocks, bricks and artificial ceramic stone chips utilizing red mud as the main base material. BACKGROUND OF THE INVENTION: Bauxite is digested with caustic soda in the Bayer process for producing alumina try hydrate by dissolution of the alumina content of the bauxite followed by refining. The undigested bauxite containing iron oxide, certain quantity of un- reacted alumina and other materials viz: silica, titanium dioxide and residual caustic soda (alkali); is removed as the waste material called as red mud. Since red mud contains residual alkali to the tune of 2-4% Na2O, it is safely stored in a pond from the environment point of view which is the practice followed by all the alumina producers. For every ton of alumina produced about 1.2 to 1.4 ton of red mud is generated in the alumina plant. As on date, no commercial utilization of red mud has been possible in India, even though several attempts have been made to find a suitable utilization of the same. In the present invention, efforts have been made to develop a process for preparation of constructional blocks, bricks, artificial ceramic stone chips and similar range of products utilizing red mud as the main base material for its bulk utilization. OBJECTS OF THE INVENTION: An object of this invention is to prepare constructional blocks, bricks, artificial ceramic stone chips utilizing red mud as the main base material; Another object of this invention is to propose a process for preparation of dense and hollow constructional blocks, bricks using red mud. Still another object of this invention is to propose a process for the preparation of artificial stone chips of different sizes using red mud. Yet another object of this invention is to propose a process for preparation of dense and hollow constructional blocks, bricks of different shapes and sizes and artificial ceramic stone ships using red mud as the main base material along with other additives and further processing the mixture. DETAILED DESCRIPTION OF THE INVENTION: According to this invention there is provided a process for preparing constructional materials comprising the steps of: mixing 60 to 80% red mud, 20-30% plastic clay (or similar material), 5-10% soap stone and required quantity of water to form a formable paste; subjecting the said paste to the step of extrusion in the form of constructional materials if required shape and size; air drying the constructional materials for 60-80 hrs or drying below 150°C for 2 to 4 hrs; subjecting the dried constructional materials to the step of heat treatment at a temperature range of 900-1150°C for 1 to 3 hrs; crushing and grinding the constructional materials in crusher and grinder to form artificial ceramic stone chips for desired size and shape. Method of preparation: According to this invention there is provided a process for the preparation of constructional blocks, bricks and artificial ceramic stone chips utilizing red mud as the main base material which comprises mixing of 60-80% red mud (as is basis, containing 15-25% moisture), 20-30% plastic clay (or similar high siliceous clay material) and 5-10% soap stone or talk powder. Mixing is carried out for 15- 60 minutes with required quantity of water to form a formable paste. The mix is extruded in the form of either dense or hollow brick or block of required shape and is wire cut to the required dimensions for further heat treatment. In accordance with the above method red mud generated from the alumina plant (60-80%), plastic clay (20-30%), soap stone or talk powder (5-10%) are thoroughly mixed for 15-60 minutes using required water and extruded in the form of dense or hollow blocks of required size and shape and wire cut to the required length to produce the clots. The clots are subjected to air drying for 60- 80 hours. The drying can also be carried out by passing hot air below 150 deg. C temperature till free moisture is removed from the clots. The clots are heat treated at a temperature of 900 to 1300 deg. C with soaking period of 1-3 hours at the peak temperature to prepare the blocks or bricks for constructional application. The dense blocks are further subjected to crushing and grinding to the desired sizes for preparing artificial ceramic chips for construction application. The bricks and artificial ceramic stone chips prepared as above are characterized and compared with the standard specifications to establish its application for constructional purpose. To achieve the optimum experimental conditions in preparing constructional blocks, bricks and artificial ceramic chips utilizing red mud as the main base material, the following process parameters are studied: a) Red mud (60-80%) (as is basis with about 15-25% moisture), plastic clay (20-30%), soap stone/talk powder (5-10%) are mixed in a Muller mixer for 15-60 minutes with required quantity of water to form a paste mass (Mix). b) The Mix is extruded in the form of dense or hollow blocks of desired size which are wire cut for constructional building blocks and similarly dense block/briquette for artificial ceramic stone chips. c) The clots are air dried for 60-80 hours or by passing hot air below 150 deg.C for 2-4 hrs. d) Heat treatment is carried out in a kiln at 900-1150 deg.C for 1-3 hours soaking at peak temp, for constructional building blocks and at 1150-1300 deg.C for 1-3 hours soaking at peak temp, for artificial ceramic stone chips. e) For artificial ceramic stone chips, fired dense blocks/briquettes are crushed and ground into desired sizes using suitable crusher/grinder. Typical characteristics of main raw material, red mud are reported in table 1. Similarly, the typical characteristics of the final products viz: building blocks/ bricks and artificial ceramic stone chips prepared in this method are reported in comparison to the standard specification in table 2 and 3 respectively. The following examples illustrate the exact process of preparation of constructional blocks, bricks and artificial ceramic stone chips utilizing red mud as the main base material. EXAMPLE-1 65 gm of red mud containing 20% water was mixed with 25 gm of plastic clay and 10 gm of soap stone powder for 30 minutes to prepare a homogeneous paste. The mix was extruded and wire cut to dense clots of standard brick size (10" x 5" x 3"). The clots were air dried for 70 hrs to remove excess moisture after which they are heat treated at 1025 deg.C for 2.5 hours soaking time. The resulted product that is the brick prepared as above has been characterized to have a cold crushing strength (CCS) of 230 kg/cm2, water absorption of 17% and bulk density of 2.15 gm/cc quite comparable with the standard specification. EXAMPLE-2: 70 gm of red mud containing 18% water was mixed with 25gm of plastic clay and 5 gm of soap powder for 60 minutes to prepare a homogeneous paste. The mix was extruded and wire cut to hollow clots (two holes each 3" diameter with three inch gap between the holes) of standard brick size (10" x 5" x 3"). The clots were air dried for 60 hrs to remove excess moisture after which they are heat treated at 1100 deg.C for 2 hours soaking time. The resulted product that is the hollow brick prepared as above has been characterized to have a cold crushing strength (CCS) of 218 kg/cm2, water absorption of 14% and bulk density of 2.05 gm/cc quite comparable with the standard specification. EXAMPLE-3: 70 gm of red mud containing 25% water was mixed with 22 gm of plastic clay and 8 gm of soap powder for 30 minutes to prepare a homogeneous paste. The mix was extruded and wire cut to dense clots of a block size of 100" x 10" x 10". The clots were air dried for 75 hrs to remove excess moisture after which they are heat treated at 1200 deg.C for 3 hours soaking time. The block are crushed and ground to 1" size chips. The resulted product (artificial ceramic stone chips) prepared as above has been characterized to have water absorption of 4.5% and bulk density of 2.27 gm/cc and apparent porosity of 9.5% quite comparable with the standard specification. WE CLAIM: 1. A process for preparing constructional materials comprising the steps of: mixing 60 to 80% red mud, 20-30% plastic clay and 5-10% soap stone to form a formable paste; subjecting the said paste to the step of extrusion in the form of constructional materials of required shape and size; air drying the constructional materials for 60-80 hrs or drying below 150°C for 2 to 4 hrs; subjecting the dried constructional materials to the step of heat treatment at a temperature range of 900-1150°C for 1 to 3 hrs; crushing and grinding the constructional materials in crusher/and grinder to form artificial ceramic stone chips for desired size and shape. 2. The process as claimed in claim 1, wherein composition of red mud, plastic clay and soap stone/talk powder varies in the mix between 60-80%, 20-30% and 5-10% respectively with required water. 3. The process as claimed in claim 1, wherein the mix (clots) is extruded, wire cut to required size and shape either hollow or dense after air dried or drying by hot air below 150 deg.C. 4. The process as claimed in claim 1, wherein the constructional materials are dried for 60-80 hours or by hot air below 150 deg.C for 2-4 hr. 5. The process as claimed in claim 1, wherein the dried constructional materials are heat treated at 900-1300 deg.C to prepare the dense or hollow blocks/bricks of required size and shape. 6. The process as claimed in claim 1, wherein the heat treated dense blocks are crushed and ground to required size to prepare the artificial ceramic stone chips. 7. The process as claimed in claim 1, wherein constructional bricks, blocks and artificial ceramic stone ships as prepared above satisfies the standard specification for constructional bricks and chips. A process for preparing constructional materials comprising the steps of: mixing 60 to 80% red mud, 20-30% plastic clay and 5-10% soap stone to form a formable paste; subjecting the said paste to the step of extrusion in the form of constructional materials if required shape and size; air drying the constructional materials for 60-80 hrs or drying below 150°C for 2 to 4 hrs; subjecting the dried constructional materials to the step of heat treatment at a temperature range of 900-1150°C for 1 to 3 hrs; crushing and grinding the constructional materials in crusher/and grinder to form artificial ceramic stone chips for desired size and shape.

Full Text

FIELD OF THE INVENTION:
The invention relates to the process for preparation of constructional blocks,
bricks and artificial ceramic stone chips utilizing red mud as the main base
material.
BACKGROUND OF THE INVENTION:
Bauxite is digested with caustic soda in the Bayer process for producing alumina
try hydrate by dissolution of the alumina content of the bauxite followed by
refining. The undigested bauxite containing iron oxide, certain quantity of un-
reacted alumina and other materials viz: silica, titanium dioxide and residual
caustic soda (alkali); is removed as the waste material called as red mud. Since
red mud contains residual alkali to the tune of 2-4% Na2O, it is safely stored in a
pond from the environment point of view which is the practice followed by all the
alumina producers. For every ton of alumina produced about 1.2 to 1.4 ton of red
mud is generated in the alumina plant. As on date, no commercial utilization of
red mud has been possible in India, even though several attempts have been
made to find a suitable utilization of the same. In the present invention, efforts
have been made to develop a process for preparation of constructional blocks,
bricks, artificial ceramic stone chips and similar range of products utilizing red
mud as the main base material for its bulk utilization.
OBJECTS OF THE INVENTION:
An object of this invention is to prepare constructional blocks, bricks, artificial
ceramic stone chips utilizing red mud as the main base material;

Another object of this invention is to propose a process for preparation of dense
and hollow constructional blocks, bricks using red mud.
Still another object of this invention is to propose a process for the preparation of
artificial stone chips of different sizes using red mud.
Yet another object of this invention is to propose a process for preparation of
dense and hollow constructional blocks, bricks of different shapes and sizes and
artificial ceramic stone ships using red mud as the main base material along with
other additives and further processing the mixture.
DETAILED DESCRIPTION OF THE INVENTION:
According to this invention there is provided a process for preparing
constructional materials comprising the steps of:
mixing 60 to 80% red mud, 20-30% plastic clay (or similar material), 5-10% soap
stone and required quantity of water to form a formable paste;
subjecting the said paste to the step of extrusion in the form of constructional
materials if required shape and size;
air drying the constructional materials for 60-80 hrs or drying below 150°C for 2
to 4 hrs;
subjecting the dried constructional materials to the step of heat treatment at a
temperature range of 900-1150°C for 1 to 3 hrs;
crushing and grinding the constructional materials in crusher and grinder to form
artificial ceramic stone chips for desired size and shape.

Method of preparation:
According to this invention there is provided a process for the preparation of
constructional blocks, bricks and artificial ceramic stone chips utilizing red mud
as the main base material which comprises mixing of 60-80% red mud (as is
basis, containing 15-25% moisture), 20-30% plastic clay (or similar high siliceous
clay material) and 5-10% soap stone or talk powder. Mixing is carried out for 15-
60 minutes with required quantity of water to form a formable paste. The mix is
extruded in the form of either dense or hollow brick or block of required shape
and is wire cut to the required dimensions for further heat treatment.
In accordance with the above method red mud generated from the alumina plant
(60-80%), plastic clay (20-30%), soap stone or talk powder (5-10%) are
thoroughly mixed for 15-60 minutes using required water and extruded in the
form of dense or hollow blocks of required size and shape and wire cut to the
required length to produce the clots. The clots are subjected to air drying for 60-
80 hours. The drying can also be carried out by passing hot air below 150 deg. C
temperature till free moisture is removed from the clots. The clots are heat
treated at a temperature of 900 to 1300 deg. C with soaking period of 1-3 hours
at the peak temperature to prepare the blocks or bricks for constructional
application.
The dense blocks are further subjected to crushing and grinding to the desired
sizes for preparing artificial ceramic chips for construction application. The bricks
and artificial ceramic stone chips prepared as above are characterized and
compared with the standard specifications to establish its application for
constructional purpose.

To achieve the optimum experimental conditions in preparing constructional
blocks, bricks and artificial ceramic chips utilizing red mud as the main base
material, the following process parameters are studied:
a) Red mud (60-80%) (as is basis with about 15-25% moisture), plastic clay
(20-30%), soap stone/talk powder (5-10%) are mixed in a Muller mixer for
15-60 minutes with required quantity of water to form a paste mass (Mix).
b) The Mix is extruded in the form of dense or hollow blocks of desired size
which are wire cut for constructional building blocks and similarly dense
block/briquette for artificial ceramic stone chips.
c) The clots are air dried for 60-80 hours or by passing hot air below 150
deg.C for 2-4 hrs.
d) Heat treatment is carried out in a kiln at 900-1150 deg.C for 1-3 hours
soaking at peak temp, for constructional building blocks and at 1150-1300
deg.C for 1-3 hours soaking at peak temp, for artificial ceramic stone
chips.
e) For artificial ceramic stone chips, fired dense blocks/briquettes are
crushed and ground into desired sizes using suitable crusher/grinder.
Typical characteristics of main raw material, red mud are reported in table 1.
Similarly, the typical characteristics of the final products viz: building blocks/
bricks and artificial ceramic stone chips prepared in this method are reported in
comparison to the standard specification in table 2 and 3 respectively.

The following examples illustrate the exact process of preparation of
constructional blocks, bricks and artificial ceramic stone chips utilizing red mud
as the main base material.
EXAMPLE-1
65 gm of red mud containing 20% water was mixed with 25 gm of plastic clay
and 10 gm of soap stone powder for 30 minutes to prepare a homogeneous
paste. The mix was extruded and wire cut to dense clots of standard brick size

(10" x 5" x 3"). The clots were air dried for 70 hrs to remove excess moisture after
which they are heat treated at 1025 deg.C for 2.5 hours soaking time. The
resulted product that is the brick prepared as above has been characterized to
have a cold crushing strength (CCS) of 230 kg/cm2, water absorption of 17% and
bulk density of 2.15 gm/cc quite comparable with the standard specification.
EXAMPLE-2:
70 gm of red mud containing 18% water was mixed with 25gm of plastic clay and
5 gm of soap powder for 60 minutes to prepare a homogeneous paste. The mix
was extruded and wire cut to hollow clots (two holes each 3" diameter with three
inch gap between the holes) of standard brick size (10" x 5" x 3"). The clots were
air dried for 60 hrs to remove excess moisture after which they are heat treated
at 1100 deg.C for 2 hours soaking time. The resulted product that is the hollow
brick prepared as above has been characterized to have a cold crushing strength
(CCS) of 218 kg/cm2, water absorption of 14% and bulk density of 2.05 gm/cc
quite comparable with the standard specification.
EXAMPLE-3:
70 gm of red mud containing 25% water was mixed with 22 gm of plastic clay
and 8 gm of soap powder for 30 minutes to prepare a homogeneous paste. The
mix was extruded and wire cut to dense clots of a block size of 100" x 10" x 10".
The clots were air dried for 75 hrs to remove excess moisture after which they
are heat treated at 1200 deg.C for 3 hours soaking time. The block are crushed
and ground to 1" size chips. The resulted product (artificial ceramic stone chips)
prepared as above has been characterized to have water absorption of 4.5% and

bulk density of 2.27 gm/cc and apparent porosity of 9.5% quite comparable with
the standard specification.

WE CLAIM:
1. A process for preparing constructional materials comprising the steps of:
mixing 60 to 80% red mud, 20-30% plastic clay and 5-10% soap stone to form a
formable paste;
subjecting the said paste to the step of extrusion in the form of constructional
materials of required shape and size;
air drying the constructional materials for 60-80 hrs or drying below 150°C for 2
to 4 hrs;
subjecting the dried constructional materials to the step of heat treatment at a
temperature range of 900-1150°C for 1 to 3 hrs;
crushing and grinding the constructional materials in crusher/and grinder to form
artificial ceramic stone chips for desired size and shape.
2. The process as claimed in claim 1, wherein composition of red mud, plastic
clay and soap stone/talk powder varies in the mix between 60-80%, 20-30% and
5-10% respectively with required water.
3. The process as claimed in claim 1, wherein the mix (clots) is extruded, wire cut
to required size and shape either hollow or dense after air dried or drying by hot
air below 150 deg.C.
4. The process as claimed in claim 1, wherein the constructional materials are
dried for 60-80 hours or by hot air below 150 deg.C for 2-4 hr.
5. The process as claimed in claim 1, wherein the dried constructional materials
are heat treated at 900-1300 deg.C to prepare the dense or hollow blocks/bricks
of required size and shape.

6. The process as claimed in claim 1, wherein the heat treated dense blocks are
crushed and ground to required size to prepare the artificial ceramic stone chips.
7. The process as claimed in claim 1, wherein constructional bricks, blocks and
artificial ceramic stone ships as prepared above satisfies the standard
specification for constructional bricks and chips.

A process for preparing constructional materials comprising the steps of: mixing
60 to 80% red mud, 20-30% plastic clay and 5-10% soap stone to form a
formable paste; subjecting the said paste to the step of extrusion in the form of
constructional materials if required shape and size; air drying the constructional
materials for 60-80 hrs or drying below 150°C for 2 to 4 hrs; subjecting the dried
constructional materials to the step of heat treatment at a temperature range of
900-1150°C for 1 to 3 hrs; crushing and grinding the constructional materials in
crusher/and grinder to form artificial ceramic stone chips for desired size and
shape.

Documents:

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Patent Number

269327

Indian Patent Application Number

472/KOL/2009

PG Journal Number

42/2015

Publication Date

16-Oct-2015

Grant Date

15-Oct-2015

Date of Filing

17-Mar-2009

Name of Patentee

MANISHREE REFRACTORY & CERAMICS PVT.LTD.

Applicant Address

MADHUPATANA, CUTTACK-753010

Inventors:

#	Inventor's Name	Inventor's Address
1	B.K. SATPATHY	NATIONAL ALUMINIUM COMPANY LIMITED
2	S. MOHANTY	MANISHREE REFRACTORY & CERAMICS PVT.LTD.
3	AMBAR ROY	MANISHREE REFRACTORY & CERAMICS PVT.LTD.

PCT International Classification Number

C04B30/00

PCT International Application Number

N/A

PCT International Filing date

PCT Conventions:

#	PCT Application Number	Date of Convention	Priority Country
1			NA