Hydraulic cements comprising carbonate compound compositions

• US 8,857,118 B2
• Filed: 10/20/2010
• Issued: 10/14/2014
• Est. Priority Date: 05/24/2007
• Status: Active Grant

• Current Assignee: Arelac, Inc.
• Original Assignee: Calera Corporation
• Inventors: Constantz, Brent R., Ryan, Cecily, Clodic, Laurence
• Primary Examiner(s): DRODGE, JOSEPH W
• Application Number:
  US12/908,095
• Publication Number:
  US 20110054084A1
• Time in Patent Office: 1,455 Days
• Field of Search: 522/201, 522/236, 522/94, 523/06, 523/091.2, 523/091.7, 527/450.5, 951/29, 951/34, 951/35, 95141-143, 106/461, 106/462, 106/638, 106/705, 106/708, 106713-715, 106/718, 106/723, 106/738, 106/739, 106811-818, 210/702, 210/710, 210/714, 210/717, 210/718, 210/724, 210/726, 210/749, 210768-774, 210/748.01, 210/806, 404/17, 404/34, 404/44, 423/155, 423/165, 423/173, 423/220, 423/230, 423/232, 423/158, 423/242.1, 423/243.01, 423/245.1, 423/419.1, 423430-432, 423/402
• US Class Current: 52/223.6
• 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 cement composition, comprising greater than 75% w/w crystalline carbonate comprising vaterite wherein said composition upon combination with water, setting, and hardening has a compressive strength in a range of 20-70 MPa wherein said composition comprises strontium in an amount ranging from 3 to 10,000 ppm and wherein said composition is a dry particulate composition.

2. The composition of claim 1, wherein said composition is a hydraulic cement composition.

3. The composition of claim 1, wherein said composition has an average particle size of 0.1 to 100 microns.

4. The composition of claim 1, wherein said carbonate is a metastable carbonate.

5. The composition of claim 1, wherein said carbonate comprises carbon from a gaseous source of carbon dioxide.

6. The composition of claim 5, wherein said gaseous source of carbon dioxide comprises a waste stream or product from an industrial plant selected from power plant, chemical processing plant, or other industrial plant that produces CO₂ as a byproduct.

7. The composition of claim 1, wherein said composition comprises calcium, magnesium, or combination thereof.

8. The composition of claim 1, wherein said composition has an average surface area from 0.5 m²/gm to 50 m²/gm.

9. The composition of claim 1, wherein said composition further comprises Portland cement, aggregate, admixture, or combination thereof.

10. The composition of claim 1, wherein said compressive strength is in a range of 20-40 MPa.

11. The composition of claim 1, wherein said settable composition upon combination with water has a setting time of from 30 minutes to 48 hours.

12. The composition of claim 1, wherein said composition further comprises calcium oxide, calcium hydroxide, magnesium oxide, magnesium hydroxide, or combination thereof.

13. The composition of claim 1, wherein said composition further comprises a set retarder.

14. The composition of claim 13, wherein said set retarder is selected from the group consisting of oxy-boron compound, corn syrup, lignin, polyphosphonic acid, carboxylic acid, hydroxycarboxylic acid, polycarboxylic acid, hydroxylated carboxylic acid, borax, lignosulfonates, ascorbic acid, isoascorbic acid, sulphonic acid-acrylic acid copolymer and their corresponding salts, polyhydroxysilane, polyacrylamide, carbohydrates, and mixtures thereof.

15. The composition of claim 14, wherein said hydroxylated carboxylic acid is fumaric, itaconic, malonic, gluconic, or tartaric acid.

16. A building or a construction material, comprising the composition of claim 1.