Magnesium cement

• US 4,838,941 A
• Filed: 01/06/1987
• Issued: 06/13/1989
• Est. Priority Date: 01/07/1986
• Status: Expired due to Fees

• Current Assignee: Ausmintec Corporation Limited 113 Tapleys Hill RD Hendon South Australia Australia
• Original Assignee: Ausmintec Corporation Limited (Unilife Corp.)
• Inventors: Hill, Robert G. D.
• Primary Examiner(s): BELL, MARK LEE
• Application Number:
  US07/000,599
• Time in Patent Office: 889 Days
• Field of Search: 106/105, 106/106, 423/163, 423/178, 423/472, 423/473
• US Class Current: 106/685
• CPC Class Codes: C01B 7/035 Preparation of hydrogen chloride from chlorides
• CPC Class Codes: C01B 9/02 Chlorides
• CPC Class Codes: C01F 11/00 Compounds of calcium, strontium, or barium C01F7/00 takes precedence
• CPC Class Codes: C01F 5/00 Compounds of magnesium
• CPC Class Codes: C01F 5/30 Chlorides
• CPC Class Codes: C04B 2/102 of magnesia, e.g. dead burning
• CPC Class Codes: C04B 22/00 Use of inorganic materials as active ingredients for mortars, concrete or artificial stone, e.g. accelerators , shrinkage compensating agents
• CPC Class Codes: C04B 22/0006 Waste inorganic materials
• CPC Class Codes: C04B 22/08 Acids or salts thereof C04B22/0013 takes precedence
• CPC Class Codes: C04B 22/10 containing carbon in the anion
• CPC Class Codes: C04B 22/12 containing halogen in the anion
• CPC Class Codes: C04B 22/16 containing phosphorus in the anion, e.g. phosphates
• CPC Class Codes: C04B 28/32 Magnesium oxychloride cements, e.g. Sorel cement
• CPC Class Codes: C04B 40/06 Inhibiting the setting, e.g. mortars of the deferred action type containing water in breakable containers ; Inhibiting the action of active ingredients
• CPC Class Codes: C04B 9/00 Magnesium cements or similar cements
• CPC Class Codes: C04B 9/20 Manufacture, e.g. preparing the batches preheating, burning, calcining or cooling lime stone, magnesite or dolomite C04B2/10

Abstract

A reaction product of at least one of magnesium carbonate and magnesium silicate, with a metal chloride at a temperature exceeding 300° C. Such a product, when mixed with water, sets to be an immensely strong magnesium cement. It may have aggregates of various types mixed with it.

Claims

1. A cement product which requires only the addition of water to produce a cement, in which the cement product is composed of two basic cementing ingredients, one ingredient consisting essentially of a material selected from the group consisting of a mixture of dried and calcined magnesium sulphate, calcium chloride, sodium chloride, and anhydrous magnesium oxychloride, and a combination of said mixture with one or more other halides and salts of alkalis and alkali earth elements, which are in general, neutral to mildly acid in reaction,

the other ingredient consisting essentially of a material selected from the group consisting of carbonates, and a mixture of carbonates and a member selected from the group consisting of bicarbonates, borates, phosphates, silicates, and alumino silicates, all of the foregoing of alkalis and alkali earth elements which are, in general, neutral to mildly alkaline in reaction,

the two basic ingredients in each case containing substantial amounts of magnesium oxide and being finely ground and intimately mixed.

2. A method for producing a product which, when mixed with water, sets to a magnesium cement, and which is a reaction product of metal chloride with a material selected from the group consisting of magensium carbonate, magnesium silicate and mixtures, and represented by the general formula MgO-MCl, where M is a metal, said method comprising reacting a metal chloride and water with a magnesium containing substance which includes a material selected from the group consisting of magnesium carbonate, magnesium silicate and mixtures, in a kiln space at a temperature between 300°

C. and 1000°

C. to release hydrogen chloride, and thereby in turn produce reactive magnesium oxide in combination with other compounds of magnesium and said metal.

3. A method according to claim 2 wherein said magnesium containing substance includes at least one of:

space="preserve" listing-type="tabular">______________________________________ CARBONATES SILICATES ______________________________________ Magnesite Albite Dolomite Oligoclase Trona Labradorite Hydromagnesite Leucite Marl Nepheline Syenite Natron Sodalite Siderite Lazurite Calcite Hypersthene Limestone Biotite Hornblende Olivine Talc Meeschaum Scapolite Wollastonite Allophane Kaolin Axinite Blast Furnace Slags Analcite Natrolite Apophyllite Chabazite Prehnite Thomsonite Heulandite Stilbite Phillipsite Harmotome Pectolite Laumontite Pyrope Bentonite Serpentine. ______________________________________

4. A method according to claim 2 comprising extracting HCl gas from the flue gases of at least one said kiln, and absorbing the HCl gas in water to thereby form hydrochloric acid.

5. A method according to claim 2 comprising establishing a stockpile with metal carbonates, extracting flue gases from at least one said kiln, absorbing an HCl gas component of the flue gases into water in an absorption device, and reacting said aqueous hydrochloric acid so formed with the metal carbonates to form metal chloride in said stockpile.

6. A method according to claim 5 further comprising reacting waste acids with the metal carbonates to form metal salts thereof.

7. A method according to claim 2 wherein some of said magnesium oxide in combination with said other compounds is heated in a further kiln space to a temperture exceeding 300°

C. to at least partially convert same to magnesium chloride compounds by decomposition in the presence of further hydrochloric acid and release by that decomposition of hydrated magnesium chloride or chlor-oxy-hydroxy compounds.

8. A method for producing a product which, when mixed with water, sets to a magnesium cement, and which is a reaction product of metal chloride with a material selected from the group consisting of magnesium carbonate, magnesium silicate and mixtures, and represented by the general formula MgO-MCl, where M is a metal, said method comprising reacting brines with calcium chloride and removing sulphates contained in the brines as gypsum and anhydrite,

crushing materials which include at least one material selected from the group consisting of magnesium carbonate, magnesium silicate and mixtures, and mixing with some but not all of the sulphate free brines, and calcining in a kiln at a temperature exceeding 300°

C. to release hydrogen chloride and thereby in turn produce a first anhydrous product containing reactive magnesium oxide in combination with other compounds,

feeding back at least some of said calcined product to a reaction tank and reacting it with the remainder of the sulphate free brines to form chlor-oxy-hydroxy compounds of magnesium wherein the ratio of magnesium to the chloride radical exceeds 3.6, separating the said chlor-oxy-hydroxy compounds from residual liquir and calcining in a kiln at a temperature between 300°

C. and 1000°

C. to release hydrogen chloride and thereby in turn produce a second anhydrous calcined product containing reactive magnesium oxide in combination with other compounds of magnesium and said metal, and blending said calcined products together.

9. A method according to claim 8 further comprising separating magnesium hydroxide from said residual liquor.

10. A method according to claim 9 further comprising calcining said magnesium hydroxide in a kiln at between 300°

C. and 900°

C. and thereby producing caustic magnesium oxide.

11. A method according to claim 9 further comprising calcining said magnesium hydroxide in a kiln at between 1400°

C. and 1600°

C. and thereby producing refractory magnesium oxide.

12. A method according to claim 8 further comprising separating sodium chloride from said residual liquor by evaporation of water therefrom.

13. A method according to claim 8 further comprising separating potassium chloride from said residual liquor by cooling and crystallization of dissolved potassium chloride.

14. A method according to claim 8 wherein said minerals include calcium carbonates.

15. A method according to claim 8 further comprising reacting brines with said calcined reactive magnesium oxide in combination with other compounds, when said other compounds include calcium oxide, so as to convert such calcium oxide to calcium chloride and other salts.

16. A method according to claim 8 wherein said silicates include alumino silicate minerals.

17. A method according to claim 8 wherein said kilns are separate kilns, and further comprising producing said reactive magnesium oxide and said other compounds in different particle sizes from said kilns.

18. A method according to claim 8 further comprising adjusting the pH of the product by selecting raw materials and controlling infeed thereof to said kilns to include minerals which are alkaline.