Hydraulic cements comprising carbonate compound compositions

• US 7,735,274 B2
• Filed: 05/23/2008
• Issued: 06/15/2010
• Est. Priority Date: 05/24/2007
• Status: Active Grant

• Current Assignee: Arelac, Inc.
• Original Assignee: Calera Corporation
• Inventors: Ryan, Cecily, Clodic, Laurence, Constantz, Brent R.
• Primary Examiner(s): Drodge; Joseph W
• Application Number:
  US12/126,776
• Publication Number:
  US 20090020044A1
• Time in Patent Office: 753 Days
• Field of Search: 210/639, 210/650, 210/652, 210/702, 210/710, 210/714, 210/717, 210/718, 210/723, 210/724, 210/726, 210768-774, 210/806, 203/10, 203/39, 423/170, 423/184, 423/430, 423/431, 423/437.1, 423/438, 423/439, 423/441, 423/165, 423/220, 423/223, 423/232, 423/155, 423/158, 423/186, 423/189, 423/265, 106/461, 106/462, 106/638, 106/640, 106/647, 106/654, 106/668, 106/705, 106813-819, 106/713, 106/733, 106/738, 106/739, 106/745, 404/17, 404/44, 588/249, 588/252, 588/313, 588/400, 588/404, 522/94, 527/50
• US Class Current: 52/294
• CPC Class Codes: C04B 14/26 Carbonates
• CPC Class Codes: C04B 28/04 Portland cements
• CPC Class Codes: Y02W 10/33 using wind energy
• CPC Class Codes: Y02W 10/37 using solar energy
• CPC Class Codes: Y10T 428/2982 Particulate matter [e.g., sphere, flake, etc.]

Abstract

Hydraulic cement compositions that include a carbonate compound composition, e.g., a salt-water derived carbonate compound composition containing crystalline and/or amorphous carbonate compounds, are provided. Also provided are methods of making and using the hydraulic cements, as well as settable compositions, such as concretes and mortars, prepared therefrom. The cements and compositions produced therefrom find use in a variety of applications, including use in a variety of building materials and building applications.

Claims

1. A settable composition comprising a hydraulic cement composition, wherein the hydraulic cement composition is a dry particulate composition comprising particles having an average particle size of 0.1 to 100 microns, and wherein the hydraulic cement composition comprises a carbonate compound composition comprising carbon from a gaseous source of carbon dioxide, wherein the carbonate compound composition comprises a metastable carbonate compound characterized by being more stable in salt water than in fresh water, wherein the metastable carbonate comprises crystalline aragonite, and optionally vaterite or amorphous calcium carbonate or combinations thereof, and wherein strontium is present in the carbonate composition in an amount ranging from 3 to 10,000 ppm, wherein the strontium is present in the crystal lattice of the aragonite, wherein sodium is present in the carbonate composition in an amount less than 20,000 ppm, and wherein the settable composition, upon combination with water and setting and hardening, has a compressive strength of 20-70 MPa.

2. The settable composition of claim 1 wherein the metastable carbonate composition comprises magnesium and calcium.

3. The settable composition of claim 1 wherein, upon combination with water, the setting time of the composition is from 30 minutes to 48 hours.

4. The settable composition of claim 1 wherein said hydraulic cement composition has an average surface area from 0.5 m²/gm to 50 m²/gm.

5. The settable composition according to claim 1, wherein said settable composition further comprises a portland cement clinker, an aggregate, or a combination thereof.

6. A building or construction material comprising a settable composition according to claim 1.

7. The building material according to claim 6, wherein said building or construction material is a pavement or architectural structure is selected from the group consisting of:

a building, foundation, a motorway, road, overpass, parking structure, brick, block, wall, footing for a gate, fence or pole, and combinations thereof.