Porous glass ceramic composition and method for manufacturing the same

Abstract

The invention provides a porous glass ceramic composition manufactured using conventional raw materials and one or more waste materials, wherein the waste materials are capable of producing glass forming oxides, glass modifying oxides and pore forming oxides. The waste materials are selected from a group that includes cullet, pozzolanic waste and fly ash. The invention also provides a method for manufacturing the porous glass ceramic composition.

What is claimed is: 
     
         1 . A method for manufacturing a porous glass ceramic composition, the method comprising:
 grinding each raw material of at least one raw material independently, wherein a raw material of the at least one raw material is selected from a raw material group comprising pozzolanic waste, cullet and clay;   sieving each raw material of the at least one raw material independently to filter out particles having diameter more than about 90 microns;   mixing the at least one raw material in response to sieving to obtain a homogenous mixture;   drying the homogenous mixture to obtain a dried homogenous mixture;   pressing the dried homogenous mixture; and   firing the dried homogenous mixture at a temperature of about 800 degree Celsius (° C.) to about 1150° C., wherein the temperature is decreased with a rate of about 120° C. per minute to about 40° C. per minute until the temperature reaches 800° C., wherein the temperature is gradually decreased to room temperature for retaining porosity of the porous glass ceramic composition.   
     
     
         2 . The method of  claim 1 , wherein each raw material is ground in a ball mill with a speed of about 400 revolutions per minute for a period of 30 minutes. 
     
     
         3 . The method of  claim 1 , wherein the at least one raw material is mixed in a ball mill with a speed of about 300 revolutions per minute for a period of about 30 minutes. 
     
     
         4 . The method of  claim 1 , wherein the dried homogenous mixture is pressed using one of uniaxially cold pressing, biaxial cold pressing, dry pressing, semi-dry pressing, compacting, cold isostatic pressing, hot pressing, extrusion molding, injection molding, compression molding, gel casting, slip casting and tape casting. 
     
     
         5 . The method of  claim 1 , wherein the dried homogenous mixture is fired with a temperature of about 800° C. to about 1150° C. with a rate of about 40° C. per minute to about 120° C. per minute for a period of about 12 minutes to about 1 hour 30 minutes. 
     
     
         6 . The method of  claim 1 , wherein the at least raw materials comprises about 15 wt % to about 70 wt % of pozzolanic waste, about 30 wt % to about 100 wt % of cullet and about 0 wt % to about 15 wt % of clay. 
     
     
         7 . The method of  claim 1 , wherein the raw material group further comprises white sand and fly ash. 
     
     
         8 . The method of  claim 6 , wherein the at least one raw materials comprises about 30 weight percent (wt %) to about 70 wt % of pozzolanic wastes, about 0 wt % to about 20 wt % of white sand, about 0 wt % to about 30 wt % of clay, about 10 wt % to about 100 wt % of cullet and about 0 wt % to about 30 wt % of fly ash. 
     
     
         9 . The method of  claim 1 , wherein the cullet and the pozzolanic waste are in a weight ratio of about 15:70 to about 65:30 in the homogenous mixture. 
     
     
         10 . A method for manufacturing a light weight porous glass ceramic composition, the method comprising:
 grinding each raw material of at least one raw material independently, wherein a raw material of the at least one raw material is selected from a raw material group comprising pozzolanic waste, cullet and clay;   sieving each raw material of the at least one raw material independently to filter out particles having diameter more than about 90 microns;   mixing the at least one raw material in response to sieving to obtain a homogenous mixture;   drying the homogenous mixture to obtain a dried homogenous mixture;   dispersing the dried homogenous mixture on an iron plate;   moisturizing the dried homogenous mixture on the iron plate with water to obtain a moisturized homogenous mixture;   placing the moisturized homogenous mixture on the iron plate in an agglomerator; and   firing the moisturized homogenous mixture at a temperature of about 600° C. to about 1200° C.   
     
     
         11 . The method of  claim 10 , wherein each raw material of the at least one raw material is ground in a ball mill with a speed of about 400 revolutions per minute for a period of 30 minutes. 
     
     
         12 . The method of  claim 10 , wherein the at least one raw material are mixed in a ball mill with a speed of about 300 revolutions per minute for a period of about 30 minutes. 
     
     
         13 . The method of  claim 10 , wherein the homogenous mixture is pressed using one of uniaxially cold pressing, biaxial cold pressing, dry pressing, semi-dry pressing, compacting, cold isostatic pressing, hot pressing, extrusion molding, injection molding, compression molding, gel casting, slip casting and tape casting. 
     
     
         14 . The method of  claim 10 , wherein the moisturized homogenous mixture is fired with a temperature of about 600° C. to about 1000° C. with a rate of about 40° C. per minute to about 120° C. per minute for a period of about 12 minutes to about 1 hour 30 minutes. 
     
     
         15 . The method of  claim 10 , wherein the at least one raw material comprises about 15 wt % to about 70 wt % of pozzolanic waste, about 30 wt % to about 100 wt % of cullet and about 0 wt % to about 15 wt % of clay. 
     
     
         16 . The method of  claim 10 , wherein the raw material group further comprises white sand and fly ash. 
     
     
         17 . The method of  claim 16 , wherein the at least one raw material comprises about 30 weight percent (wt %) to about 70 wt % of pozzolanic wastes, about 0 wt % to about 20 wt % of white sand, about 0 wt % to about 30 wt % of clay, about 10 wt % to about 100 wt % of cullet and about 0 wt % to about 30 wt % of fly ash. 
     
     
         18 . The method of  claim 10 , wherein the cullet and the pozzolanic waste are in a weight ratio of about 15:70 to about 65:30 in the homogenous mixture. 
     
     
         19 . A composition of a porous glass ceramic comprising about 50 wt % to about 70 wt % of silicon dioxide (SiO 2 ), about 5 wt % to about 35 wt % of alumina (Al 2 O 3 ), about 5 wt % to about 12 wt % of calcium oxide (CaO), about 5 wt % to about 20 wt % of sodium oxide (Na 2 O), about 0.5 wt % to about 1.5 wt % of titanium dioxide (TiO 2 ), and about 2 wt % to about 10 wt % of ferric oxide (Fe 2 O 3 ). 
     
     
         20 . The composition of  claim 19 , wherein raw materials for preparing the composition of the porous glass ceramic comprises about 30 weight percent (wt %) to about 70 wt % of pozzolanic wastes, about 0 wt % to about 20 wt % of white sand, about 0 wt % to about 30 wt % of clay, about 10 wt % to about 100 wt % of cullet and about 0 wt % to about 30 wt % of fly ash. 
     
     
         21 . The composition of  claim 19 , wherein raw materials for preparing the composition of the porous glass ceramic comprises about 15 wt % to about 70 wt % of pozzolanic waste, about 30 wt % to about 100 wt % of cullet and about 0 wt % to about 15 wt % of clay.