Compositions and methods for controling setting of carbonatable calcium silicate cements containing hydrating materials

• US 10,196,311 B2
• Filed: 10/02/2015
• Issued: 02/05/2019
• Est. Priority Date: 10/03/2014
• Status: Active Grant

• Current Assignee: Solidia Technologies, Inc.
• Original Assignee: Solidia Technologies, Inc.
• Inventors: Quinn, Sean, Sahu, Sadananda
• Primary Examiner(s): Green, Anthony J
• Application Number:
  US14/874,350
• Publication Number:
  US 20160096773A1
• Time in Patent Office: 1,222 Days
• CPC Class Codes: C04B 2103/22 Set retarders
• CPC Class Codes: C04B 2111/00017 Aspects relating to the protection of the environment
• CPC Class Codes: C04B 22/0013 Boron compounds
• CPC Class Codes: C04B 22/16 containing phosphorus in the anion, e.g. phosphates
• CPC Class Codes: C04B 24/06 containing hydroxy groups
• CPC Class Codes: C04B 24/10 Carbohydrates or derivatives thereof
• CPC Class Codes: C04B 28/10 Lime cements or magnesium oxide cements
• CPC Class Codes: C04B 28/188 the Ca-silicates being present in the starting mixture
• CPC Class Codes: C04B 28/24 containing alkyl, ammonium or metal silicates; containing silica sols reaction mixtures resulting in mineral polymers C04B28/006; polymeric reaction products of alkali metal silicates with isocyanates C08G18/3895
• CPC Class Codes: C04B 40/0231 Carbon dioxide hardening
• CPC Class Codes: Y02P 40/18 Carbon capture and storage [CCS]

Abstract

The invention provides compositions and methods for controlling setting of carbonatable calcium silicate compositions that are contaminated with hydrating materials. These carbonatable calcium silicate cements are suitable for use as non-hydraulic cement that hardens by a carbonation process and may be applied in a variety of concrete components in the infrastructure, construction, pavement and landscaping industries.

Claims

1. A carbonatable calcium silicate composite comprising:

a calcium silicate CS, wherein CS is wollastonite, pseudowollastonite, or a combination thereof;

at least one hydraulic species;

one or more set-retarding or hydration-controlling compounds or admixtures,

wherein the calcium silicate has a composition and is present in an amount such that it can be cured by carbonation with CO₂ at a temperature of about 30°

C. to about 90°

C. to form CaCO₃ with a mass gain of about 10% or more, and form bonding elements that hold the composite together.

2. The carbonatable calcium silicate composite of claim 1, wherein elemental Ca and elemental Si are present in the composition at a molar ratio from about 0.8 to about 1.2;

and metal oxides of Al, Fe and Mg are present in the composition at about 30% or less by mass.

3. The carbonatable calcium silicate composite of claim 2, wherein the set-retarding or hydration-controlling compounds or admixtures comprise one or more of organic compounds.

4. The carbonatable calcium silicate composite of claim 3, wherein the one or more of organic compounds are selected from the group consisting of lignosulfonates, hydroxycarboxylic acid and salts thereof, phosphonates, and sugars.

5. The carbonatable calcium silicate composite of claim 1, wherein the set-retarding or hydration-controlling compounds or admixtures comprise one or more of inorganic compounds.

6. The carbonatable calcium silicate composite of claim 5, wherein the one or more of inorganic compounds are selected from borates and phosphates.

7. The carbonatable calcium silicate composite of claim 1, wherein the set-retarding or hydration-controlling compounds or admixtures comprise one or more of organic compounds and one or more of inorganic compounds.

8. The carbonatable calcium silicate composite of claim 7, wherein the set-retarding compound or admixture comprises a sugar-based compound.

9. The carbonatable calcium silicate composite of claim 1, wherein the set-retarding compound or admixture comprises a gluconate-based compound.

10. The carbonatable calcium silicate composite of claim 1, wherein the set-retarding compound or admixture comprises a sugar-based compound and a gluconate-based compound.

11. The carbonatable calcium silicate composite of claim 2, wherein the hydraulic species comprises Ordinary Portland Cement.

12. The carbonatable calcium silicate composite of claim 2, wherein the hydraulic species comprises a hydrating phase of CaO.

13. The carbonatable calcium silicate composite of claim 1, wherein the hydraulic species are present in an amount of 1% or less.

14. The carbonatable calcium silicate composite of claim 1, wherein the hydraulic species comprises one or more of:

CaO, Ca₂SiO₄, Ca₄Al₂Fe₂O₁₀, Ca₃Al₂O₆, Ca₃SiO₅, CaSO₄.2H₂O, CaSO₄.0.5H₂O, and 4CaO.3Al₂O₃.SO₃.

15. The carbonatable calcium silicate composite of claim 1, wherein the at least one hydraulic species is present in an amount of 5% or less.