Settable composition and uses therefor

• US 6,200,381 B1
• Filed: 07/02/1999
• Issued: 03/13/2001
• Est. Priority Date: 12/05/1995
• Status: Expired due to Fees

• Current Assignee: Dolomatrix International Limited
• Original Assignee: Periclase Pty., Ltd.
• Inventors: Rechichi, Dino
• Primary Examiner(s): MARCANTONI, PAUL D
• Application Number:
  US09/346,588
• Time in Patent Office: 620 Days
• Field of Search: 106/800, 106/801, 106/802, 106/803
• US Class Current: 106/801
• CPC Class Codes: C04B 14/06 Quartz; Sand
• CPC Class Codes: C04B 14/16 porous, e.g. pumice
• CPC Class Codes: C04B 14/18 Perlite
• CPC Class Codes: C04B 14/22 Glass ; Devitrified glass
• CPC Class Codes: C04B 14/28 of calcium
• CPC Class Codes: C04B 14/303 Alumina
• CPC Class Codes: C04B 14/361 Soil, e.g. laterite
• CPC Class Codes: C04B 14/386 Carbon carbon nanotubes C04B14/026
• CPC Class Codes: C04B 14/42 Glass
• CPC Class Codes: C04B 14/46 Rock wool ; Ceramic or silicate fibres C04B14/40, C04B14/42 take precedence
• CPC Class Codes: C04B 18/0409 Waste from the purification of bauxite, e.g. red mud
• CPC Class Codes: C04B 18/0472 Waste material contaminated by heavy metals
• CPC Class Codes: C04B 18/064 Gypsum
• CPC Class Codes: C04B 18/08 Flue dust , i.e. fly ash
• CPC Class Codes: C04B 18/16 from building or ceramic industry
• CPC Class Codes: C04B 18/248 from specific plants, e.g. hemp fibres
• CPC Class Codes: C04B 18/26 Wood, e.g. sawdust, wood shavings
• CPC Class Codes: C04B 2/102 of magnesia, e.g. dead burning
• CPC Class Codes: C04B 20/0048 Fibrous materials
• CPC Class Codes: C04B 22/10 containing carbon in the anion
• CPC Class Codes: C04B 22/147 : Alkali-metal sulfates; Ammonium sulfate
• CPC Class Codes: C04B 24/04 : Carboxylic acids; Salts, anhydrides or esters thereof
• CPC Class Codes: C04B 28/105 : Magnesium oxide or magnesium carbonate cements
• CPC Class Codes: C04B 9/04 : Magnesium cements containing sulfates, nitrates, phosphates or fluorides
• CPC Class Codes: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete

Abstract

A dry powdered flowable cement composition contains calcium carbonate and a partially decarbonated magnesium carbonate. A slurry of the composition will set hard with various organic fillers including waste products and toxic waste. The composition can be slurried with contaminated water such as sea water, mineral laden ground water and muddy water. A high percentage of filler can be added while still having an acceptable set.

Claims

1. A settable binder composition, consisting essentially of a mixture of a calcium carbonate and a caustic magnesium oxide, the mixture selected from the group consisting of:

(a) a naturally-occurring dolomite, wherein the dolomite is heated at a temperature within the range of 500°

C. to 800°

C. to cause preferential decarbonization of the magnesium carbonate by liberating carbon dioxide, whereby between 2% to 50% of the carbon dioxide is retained within the magnesium carbonate without substantially decarbonizing the calcium carbonate resulting in a mixture of magnesium oxide, magnesium carbonate, and calcium carbonate (MgO, MgCO₃, and CaCO₃); and

,

(b) a synthetic blend formed by mixing calcium carbonate with preformed caustic magnesium oxide, the preformed caustic magnesium oxide being prepared by heating magnesium carbonate to 500°

C. to 800°

C. to partially drive off carbon dioxide whereby between 2% to 50% of the carbon dioxide is retained within the magnesium carbonate, and wherein the calcium carbonate retains substantially all of its carbon dioxide resulting in a mixture of magnesium oxide, magnesium carbonate and calcium carbonate (MgO, MgCO₃ and CaCO₃).

2. The composition of claim 1, wherein the

dolomite is a magnesium deficient dolomite and to which is added additional caustic magnesium oxide.

4. The composition of claim 1, wherein the caustic magnesium oxide has between 2%-20% of the carbon dioxide retained within the magnesium carbonate.

5. The composition of claim 4, wherein the composition has a particle size of 50-80 micron with 90% passing through a 160 micron sieve.

16. An article of manufacture comprising a set composition of claim 1.

18. The article of claim 16, wherein the article is selected from the group consisting of a brick, block, paver, tile, mortar, pipe, board, panel, cladding, paving, structure, statue, monument, sleeper, post, pole, storage tank, boat, pile, wharf and marina.

19. The composition of claim 1, wherein the mixture of calcium carbonate and caustic magnesium oxide contains up to 14% calcium carbonate, and wherein after heating to cause preferential decarbonization of the magnesium carbonate less than 1.5% free lime is produced.

20. The composition of claim 1, wherein the caustic magnesium oxide has between 23% to 28% of the carbon dioxide retained within the magnesium carbonate.

3. A settable binder composition, the composition consisting essentially of a mixture of a calcium carbonate and a caustic magnesium oxide, the mixture selected from the group consisting of

(a) a naturally-occurring dolomite, wherein the dolomite is heated at a temperature within the range of 500°

C. to 800°

C. to cause preferential decarbonization of the magnesium carbonate by liberating carbon dioxide, whereby between 2% to 50% of the carbon dioxide is retained within the magnesium carbonate without substantially decarbonizing the calcium carbonate resulting in a mixture of magnesium oxide, magnesium carbonate and calcium carbonate (MgO, MgCO₃ and CaCO₃); and

,

(b) a synthetic blend formed by mixing calcium carbonate with preformed caustic magnesium oxide, the preformed caustic magnesium oxide being prepared by heating magnesium carbonate to 500°

C. to 800°

C. to partially drive off carbon dioxide whereby between 2% to 50% of the carbon dioxide is retained within the magnesium carbonate, and wherein the calcium carbonate retains substantially all of its carbon dioxide resulting in a mixture of magnesium oxide, magnesium carbonate and calcium carbonate (MgO, MgCO₃ and CaCO₃), and, wherein 0.1%-15% of a suitable inorganic salt is added to enhance the preferential decarbonization of the magnesium carbonate.

6. A settable binder composition, the composition consisting essentially of a mixture of a calcium carbonate and a caustic magnesium oxide, the mixture selected from the group consisting of:

(a) a naturally-occurring dolomite, wherein the dolomite is heated at a temperature within the range of 500°

C. to 800°

C. to cause preferential decarbonization of the magnesium carbonate by liberating carbon dioxide, whereby between 2% to 50% of the carbon dioxide is retained within the magnesium carbonate without substantially decarbonizing the calcium carbonate resulting in a mixture of magnesium oxide, magnesium carbonate and calcium carbonate (MgO, MgCO₃ and CaCO₃); and

,

(b) a synthetic blend formed by mixing calcium carbonate with preformed caustic magnesium oxide, the preformed caustic magnesium oxide being prepared by heating magnesium carbonate to 500°

C. to 800°

C. to partially drive off carbon dioxide whereby between 2% to 50% of the carbon dioxide is retained within the magnesium carbonate, and wherein the calcium carbonate retains substantially all of its carbon dioxide resulting in a mixture of magnesium oxide, magnesium carbonate and calcium carbonate (MgO, MgCO₃ and CaCO₃); and

, further including a sulfate additive present between 0.01% up to 10%.

7. The composition of claim 6, wherein the sulfate additive is selected from the group consisting of:

(a) sulfuric acid (b) magnesium sulfate and (c) aluminum sulfate.

8. A settable binder composition, the composition consisting essentially of a mixture of a calcium carbonate and a caustic magnesium oxide, the mixture selected from the group consisting of:

(a) a naturally-occurring dolomite, wherein the dolomite is heated at a temperature within the range of 500°

C. to 800°

C. to cause preferential decarbonization of the magnesium carbonate by liberating carbon dioxide, whereby between 2% to 50% of the carbon dioxide is retained within the magnesium carbonate without substantially decarbonizing the calcium carbonate resulting in a mixture of magnesium oxide, magnesium carbonate and calcium carbonate (MgO, MgCO₃ and CaCO₃); and

,

(b) a synthetic blend formed by mixing calcium carbonate with preformed caustic magnesium oxide, the preformed caustic magnesium oxide being prepared by heating magnesium carbonate to 500°

C. to 800°

C. to partially drive off carbon dioxide whereby between 2% to 50% of the carbon dioxide is retained within the magnesium carbonate, and wherein the calcium carbonate retains substantially all of its carbon dioxide resulting in a mixture of magnesium oxide, magnesium carbonate and calcium carbonate (MgO, MgCO₃ and CaCO₃); and

, further including a carbonate additive which produces a source of carbonation during the setting process.

9. The composition of claim 8, wherein the carbonate additive is selected from the group consisting of:

(a) sodium carbonate;

(b) citric acid;

(c) lemon acid;

(d) acetic acid;

(e) glycolic acid;

(f) oxalic acid;

acids (b)-(f) being able to react to liberate carbon dioxide.

10. The composition of claim 9, wherein the carbonate additive is present between 0.01%-5%.

11. A settable binder composition, the composition consisting essentially of a mixture of a calcium carbonate and a caustic magnesium oxide, the mixture selected from the group consisting of:

(a) a naturally-occurring dolomite, wherein the dolomite is heated at a temperature within the range of 500°

C. to 800°

C. to cause preferential decarbonization of the magnesium carbonate by liberating carbon dioxide, whereby between 2% to 50% of the carbon dioxide is retained within the magnesium carbonate without substantially decarbonizing the calcium carbonate resulting in a mixture of magnesium oxide, magnesium carbonate and calcium carbonate (MgO, MgCO₃ and CaCO₃); and

,

(b) a synthetic blend formed by mixing calcium carbonate with preformed caustic magnesium oxide, the preformed caustic magnesium oxide being prepared by heating magnesium carbonate to 500°

C. to 800°

C. to partially drive off carbon dioxide whereby between 2% to 50% of the carbon dioxide is retained within the magnesium carbonate, and wherein the calcium carbonate retains substantially all of its carbon dioxide resulting in a mixture of magnesium oxide, magnesium carbonate and calcium carbonate (MgO, MgCO₃ and CaCO₃); and

, further including the following additives;

(i) aluminum sulfate and (ii) a carboxylic acid, the additives comprising about 3% to about 15% of the composition.

12. A settable binder composition, the composition consisting essentially of a mixture of a calcium carbonate and a caustic magnesium oxide, the mixture selected from the group consisting of:

(a) a naturally-occurring dolomite, wherein the dolomite is heated at a temperature within the range of 500°

C. to 800°

C. to cause preferential decarbonization of the magnesium carbonate by liberating carbon dioxide, whereby between 2% to 50% of the carbon dioxide is retained within the magnesium carbonate without substantially decarbonizing the calcium carbonate resulting in a mixture of magnesium oxide, magnesium carbonate and calcium carbonate (MgO, MgCO₃ and CaCO₃); and

,

(b) a synthetic blend formed by mixing calcium carbonate with preformed caustic magnesium oxide, the preformed caustic magnesium oxide being prepared by heating magnesium carbonate to 500°

C. to 800°

C. to partially drive off carbon dioxide whereby between 2% to 50% of the carbon dioxide is retained within the magnesium carbonate, and wherein the calcium carbonate retains substantially all of its carbon dioxide resulting in a mixture of magnesium oxide, magnesium carbonate and calcium carbonate (MgO, MgCO₃ and CaCO₃); and

further including the following additives;

(i) aluminum sulfate, (ii) a carboxylic acid and (iii) a salt, wherein (i) is present between 40%-80%;

(ii) is present between 10%-60% and (iii) is present between 1%-20% of the additives, the additives comprising about 3% to about 15% of the composition.

17. An article of manufacture comprising a set composition of claim 12.

13. A settable binder composition, the composition consisting essentially of a mixture of a calcium carbonate and a caustic magnesium oxide, the mixture selected from the group consisting of:

(a) a naturally-occurring dolomite, wherein the dolomite is heated at a temperature within the range of 500°

C. to 800°

C. to cause preferential decarbonization of the magnesium carbonate by liberating carbon dioxide, whereby between 2% to 50% of the carbon dioxide is retained within the magnesium carbonate without substantially decarbonizing the calcium carbonate resulting in a mixture of magnesium oxide, magnesium carbonate and calcium carbonate (MgO, MgCO₃ and CaCO₃); and

,

(b) a synthetic blend formed by mixing calcium carbonate with preformed caustic magnesium oxide, the preformed caustic magnesium oxide being prepared by heating magnesium carbonate to 500°

C. to 800°

C. to partially drive off carbon dioxide whereby between 2% to 50% of the carbon dioxide is retained within the magnesium carbonate, and wherein the calcium carbonate retains substantially all of its carbon dioxide resulting in a mixture of magnesium oxide, magnesium carbonate and calcium carbonate (MgO, MgCO₃ and CaCO₃); and

further including a sulfate additive present between 0.01% up to 10% and at least one filler.

14. The composition of claim 13, wherein the filler comprises between 3-90% of the total composition.

15. The composition of claim 14,

wherein the at least one filler is selected from the group consisting of power station ash, volcanic ash, alumina, red mud, crushed rock, sand coral, pumice, glass, cenospheres, perlite, vermiculate, styrene bead, sawdust, shredded rubber, straw, rice husk, coconut fiber, wood chip, wood bark, paper, cardboard, plastic, concrete rubble, soil, lead concentrate, litharge, lead wood, boron, lithium, cadmium, L A batteries, metal dusts and chemically precipitated gypsum, steel, glass fiber, carbon straw and mixtures thereof.