Dry mix cement composition, methods and systems involving same

• US 7,691,198 B2
• Filed: 09/26/2008
• Issued: 04/06/2010
• Est. Priority Date: 03/29/2006
• Status: Active Grant

• Current Assignee: Zeobond Research Pty., Ltd.
• Original Assignee: Zeobond Research Pty., Ltd.
• Inventors: Feng, Dingwu, Van Deventer, Jan Stephanus Jakob, Duxson, Peter
• Primary Examiner(s): Marcantoni; Paul
• Application Number:
  US12/239,335
• Publication Number:
  US 20090071374A1
• Time in Patent Office: 557 Days
• Field of Search: 106/600, 106/737
• US Class Current: 106/600
• CPC Class Codes: B28C 7/0418 control systems therefor
• CPC Class Codes: B28C 7/12 Supplying or proportioning liquid ingredients
• CPC Class Codes: C04B 12/005 Geopolymer cements, e.g. reaction products of aluminosilicates with alkali metal hydroxides or silicates
• CPC Class Codes: C04B 14/041 Aluminium silicates other than clay
• CPC Class Codes: C04B 14/045 Alkali-metal containing silicates, e.g. petalite waterglass C04B12/04
• CPC Class Codes: C04B 14/14 Minerals of vulcanic origin granite C04B14/048
• CPC Class Codes: C04B 18/0409 Waste from the purification of bauxite, e.g. red mud
• CPC Class Codes: C04B 18/08 Flue dust , i.e. fly ash
• CPC Class Codes: C04B 18/12 from quarries, mining or the like
• CPC Class Codes: C04B 2111/00215 Mortar or concrete mixtures defined by their oxide composition
• CPC Class Codes: C04B 22/064 of the alkaline-earth metals
• CPC Class Codes: C04B 22/068 Peroxides, e.g. hydrogen peroxide
• 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 22/147 Alkali-metal sulfates; Ammonium sulfate
• CPC Class Codes: C04B 24/04 Carboxylic acids; Salts, anhydrides or esters thereof
• CPC Class Codes: C04B 28/006 containing mineral polymers, e.g. geopolymers of the Davidovits type
• CPC Class Codes: C04B 40/001 Electromagnetic waves
• CPC Class Codes: C04B 40/0014 Microwaves
• 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 40/0608 : Dry ready-made mixtures, e.g. mortars at which only water or a water solution has to be added before use
• CPC Class Codes: C04B 7/02 : Portland cement
• CPC Class Codes: Y02P 40/10 : Production of cement, e.g. improving or optimising the production methods; Cement grinding
• CPC Class Codes: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete

Abstract

A dry mix cement composition including an alkaline multi-phase aluminosilicate material, wherein the alkaline multi-phase aluminosilicate material provides a source of alkaline and soluble silicate to the cement composition.

Claims

1. A dry mix cement composition including an alkaline multi-phase aluminosilicate material, wherein the alkaline multi-phase aluminosilicate material provides a source of alkaline and soluble silicate to the cement composition, wherein the alkaline multi-phase aluminosilicate material is formed by activating an aluminosilicate material in the presence of an alkali material, wherein the alkali dosage is from 10-300% w/w of the aluminosilicate material to be activated, and wherein an oxidant is used during the activation.

2. A dry mix cement composition according to claim 1, wherein activation is selected from the group consisting of chemical activation at elevated temperature, mechanochemical activation, microwave heating performed in a microwave heating system until a matte is formed, and heating using infrared or electromagnetic energy.

3. A dry mix cement composition according to claim 1, wherein the alkali material is selected from the group consisting of K, Na, Ca and Li, carbonates of K, Na, Ca or Li, silicates of Na and K, and combinations thereof.

4. A dry mix cement composition according to claim 1, wherein the oxidant is selected from the group consisting of sodium peroxide, calcium peroxide, sodium nitrate, potassium nitrate, sodium perborate, sodium percarbonate, sodium hypochlorite, calcium hypochlorite, and calcium percarbonate.

5. A dry mix cement composition according to claim 1, wherein the oxidant dosage is from 10-200% w/w of the alkali material.

6. A dry mix cement composition according to claim 1, wherein the aluminosilicate material used to form the alkaline multi-phase aluminosilicate material is selected from the group consisting of shales, clays, feldspars, plagioclase, feldspathic materials, zeolite, pyroxene, amphibole, volcanic ashes, mine tailings, flyashes, slags, discards from coal or ore mining, Portland cements and any combination thereof.

7. A dry mix cement composition according to claim 1, wherein the Si/Al ratio in the aluminosilicate material or mixture of aluminosilicate materials used to form the alkaline multi-phase aluminosilicate material is from 1 to 6.

8. A dry mix cement composition according to claim 1, wherein the alkaline multi-phase aluminosilicate material has an average particle size of less than 50 microns.

9. A dry mix cement composition according to claim 1, including Portland cement in an amount of up to 30% (w/w), a setting control agent, or at least one additional aluminosilicate material.

10. A dry mix cement composition according to claim 1, including, as a source of calcium, a glassy calcium silicate material.

11. A dry mix cement composition according to claim 10, including a glassy sodium or potassium silicate material.

12. A dry mix cement composition including an alkaline multi-phase aluminosilicate material, wherein the alkaline multi-phase aluminosilicate material provides a source of alkaline and soluble silicate to the cement composition, and also including sodium sulphate, as a solid activator, in an amount of up to 8% (mass ratio of the dry mix).

13. A dry mix cement composition according to claim 12, wherein the aluminosilicate material used to form the alkaline multi-phase aluminosilicate material is selected from the group consisting of shales, clays, feldspars, plagioclase, feldspathic materials, zeolite, pyroxene, amphibole, volcanic ashes, mine tailings, flyashes, slags, discards from coal or ore mining, Portland cements and any combination thereof.

14. A dry mix cement composition according to claim 12, wherein the Si/Al ratio in the aluminosilicate material or mixture of aluminosilicate materials used to form the alkaline multi-phase aluminosilicate material is from 1 to 6.

15. A dry mix cement composition according to claim 12, wherein the alkaline multi-phase aluminosilicate material has an average particle size of less than 50 microns.

16. A dry mix cement composition according to claim 12, including Portland cement in an amount of up to 30% (w/w), a setting control agent, or at least one additional aluminosilicate material.

17. A dry mix cement composition according to claim 12, including, as a source of calcium, a glassy calcium silicate material.

18. A dry mix cement composition according to claim 12, including a glassy sodium or potassium silicate material.

19. A dry mix cement composition including an alkaline multiphase aluminosilicate material, wherein the alkaline multi-phase aluminosilicate material provides a source of alkaline and soluble silicate to the cement composition, and wherein carboxylic acids and/or polycarboxylic acids are selectively absorbed to the surface of glassy materials within the dry mix cement composition.

20. A dry mix cement composition according to claim 19, wherein the carboxylic acid is 2,3-dihydroxybutanedioic acid.

21. A dry mix cement composition according to claim 19, wherein the aluminosilicate material used to form the alkaline multi-phase aluminosilicate material is selected from the group consisting of shales, clays, feldspars, plagioclase, feldspathic materials, zeolite, pyroxene, amphibole, volcanic ashes, mine tailings, flyashes, slags, discards from coal or ore mining, Portland cements and any combination thereof.

22. A dry mix cement composition according to claim 19, wherein the Si/Al ratio in the aluminosilicate material or mixture of aluminosilicate materials used to form the alkaline multi-phase aluminosilicate material is from 1 to 6.

23. A dry mix cement composition according to claim 19, wherein the alkaline multi-phase aluminosilicate material has an average particle size of less than 50 microns.

24. A dry mix cement composition according to claim 19, including Portland cement in an amount of up to 30% (w/w), a setting control agent, or at least one additional aluminosilicate material.

25. A dry mix cement composition according to claim 19, including, as a source of calcium, a glassy calcium silicate material.

26. A dry mix cement composition according to claim 25, including a glassy sodium or potassium silicate material.