Composition of materials for production of acid resistant cement and concrete and methods thereof

• US 6,749,679 B2
• Filed: 01/23/2002
• Issued: 06/15/2004
• Est. Priority Date: 01/23/2002
• Status: Expired due to Fees

• Current Assignee: Advanced Materials Technologies, LLC
• Original Assignee: Advanced Materials Technologies, LLC
• Inventors: Shi, Caijun
• Primary Examiner(s): MARCANTONI, PAUL D
• Application Number:
  US10/055,554
• Publication Number:
  US 20030136305A1
• Time in Patent Office: 874 Days
• Field of Search: 106/600, 106/602, 106/705, 106/716, 106/737, 106/792, 106/793, 106/DIG.1
• US Class Current: 106/600
• CPC Class Codes: C04B 14/06 Quartz; Sand
• CPC Class Codes: C04B 14/10 Clay sepiolite C04B14/042; grog C04B18/025
• CPC Class Codes: C04B 14/22 Glass ; Devitrified glass
• CPC Class Codes: C04B 14/386 Carbon carbon nanotubes C04B14/026
• CPC Class Codes: C04B 14/46 Rock wool ; Ceramic or silicate fibres C04B14/40, C04B14/42 take precedence
• CPC Class Codes: C04B 14/48 Metal
• CPC Class Codes: C04B 16/06 fibrous
• CPC Class Codes: C04B 18/08 Flue dust , i.e. fly ash
• CPC Class Codes: C04B 18/141 Slags
• CPC Class Codes: C04B 18/142 Steelmaking slags, converter slags
• CPC Class Codes: C04B 18/162 Cement kiln dust; Lime kiln dust
• CPC Class Codes: C04B 18/165 Ceramic waste
• CPC Class Codes: C04B 18/24 Vegetable refuse, e.g. rice husks, maize-ear refuse; Cellulosic materials, e.g. paper , cork
• CPC Class Codes: C04B 2111/23 Acid resistance, e.g. against acid air or rain
• CPC Class Codes: C04B 28/26 Silicates of the alkali metals
• CPC Class Codes: C04B 7/02 Portland cement
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete
• CPC Class Codes: Y10S 106/01 Fly ash

Abstract

A cement composition for use in acidic environment containing liquid alkali silicate, vitreous silicate setting agent, lime containing material and inert filler and building materials made therefrom as well as the method of making such building materials. The liquid alkali silicate may include sodium silicate or potassium silicate. The vitreous silicate setting agent may include soda-lime glass powder or coal fly ash. The lime containing material refers to the materials containing more than 20% lime and may include quicklime, hydrated lime, Portland cement, blast furnace slag or steel slag. The inert fillers include ground quartz, ground ceramic, and/or clay.

Claims

1. An acid resistant cement, which comprises:

a) a liquid alkali silicate with a SiO₂ to Na₂O or K₂O ratio ranging from at least 2.2 to about 3.0;

1 and present at about 20% to about 50%, by weight;

b) a vitreous silicate present at about 10% to about 50%, by weight, as a hardener;

c) a lime containing material present at about 2% to about 20%, by weight, and

d) an inert filler at about 10% to 40%, by weight.

2. The composition of claim 1 wherein the vitreous silicate is a glass powder consisting essentially of ground container glass or plate glass.

3. The composition of claim 1 wherein the vitreous silicate is coal fly ash.

4. The composition of claim 1 wherein the lime containing material contains more than about 20% lime, by weight, and is selected from the group consisting of ground granulated blast furnace slag, ground steel slag, Portland cement, cement kiln dust, lime, and mixtures thereof.

5. The composition of claim 1 wherein the inert filler is selected from the group consisting of silica flour, ground ceramics, clays, and mixture thereof.

6. The composition of claim 1 including fibrous materials selected from the group consisting of ceramic, graphite, steel, cellulose fibers, synthetic organic fibers, and mixtures thereof.

7. A method for making acid resistant cement, comprising the steps of:

mixing, by weight, a liquid alkali silicate having a SiO₂ to Na₂O or K₂O ratio ranging from at least 2.2 to about 3.0;

1 and present at about 20% to about 50% with a vitreous silicate present at about 10% to about 50% as a hardener, an inert filler of about 10% to about 40% and a lime containing material present at about 2% to about 20%.

8. The method of claim 7 including providing the vitreous silicate as a glass powder consisting essentially of ground container glass or plate glass.

9. The method of claim 7 including providing the vitreous silicate as coal fly ash.

10. The method of claim 7 including providing the lime containing material containing more than about 20% lime, by weight, and being selected from the group consisting of ground granulated blast furnace slag, ground steel slag, Portland cement, cement kiln dust, lime, and mixture thereof.

11. The method of claim 7 including mixing a filler selected from the group consisting of silica flour, ground ceramics, clays, and mixture thereof.

12. The method of claim 7 including mixing a fibrous material selected from the group consisting of ceramic, graphite, steel, cellulose fibers, synthetic organic fibers, and mixtures thereof.

13. An acid resistant construction material, which comprises, by weight:

a) a liquid alkali silicate with a SiO₂ to Na₂O ratio of about 2.58;

1 and present at about 20% to about 50%;

b) a vitreous silicate present at about 10% to about 50% as a hardener;

c) a lime containing material present at about 2% to about 20%, and

d) an inert filler of 10% to 40%, by weight.

14. The acid resistant construction material of claim 13 wherein the vitreous silicate is a glass powder consisting essentially of ground container glass or plate glass.

15. The acid resistant construction material of claim 13 wherein the vitreous silicate is coal fly ash.

16. The acid resistant construction material of claim 13 wherein the lime containing material contains more than about 20% lime, by weight, and as selected from the group consisting of ground granulated blast furnace slag, ground steel slag, Portland cement, cement kiln dust, lime, and mixture thereof.

17. The acid resistant construction material of claim 13 further including a fibrous material selected from the group consisting of ceramic, graphite, steel, cellulose fibers, synthetic organic fibers, and mixtures thereof.

18. The acid resistant construction material of claim 13 characterized as having been cured at an elevated temperature.

19. The acid resistant construction material of claim 13 characterized as having been cured at an elevated temperature for at least about 5 hours.

20. The acid resistant construction material of claim 13 including a filler selected from the group consisting of silica flour, ground ceramics, clays, and mixture thereof.