Modification of pozzolanic chemistry through blending

• US 9,067,824 B1
• Filed: 02/17/2011
• Issued: 06/30/2015
• Est. Priority Date: 02/17/2010
• Status: Active Grant

• Current Assignee: Roman Cement, LLC
• Original Assignee: Roman Cement, LLC
• Inventors: Hansen, Andrew S., Guynn, John M.
• Primary Examiner(s): Olsen, Kaj K
• Assistant Examiner(s): HIJJI, KARAM Y
• Application Number:
  US13/030,123
• Time in Patent Office: 1,594 Days
• Field of Search: 700/265, 73/32.R, 106/705, 702/29
• US Class Current: 1/1
• CPC Class Codes: C04B 18/08 Flue dust , i.e. fly ash
• CPC Class Codes: C04B 28/04 Portland cements
• CPC Class Codes: C04B 40/0028 Aspects relating to the mixing step of the mortar preparation
• CPC Class Codes: C04B 40/0032 Controlling the process of mixing, e.g. adding ingredients in a quantity depending on a measured or desired value B28C7/00 takes precedence
• CPC Class Codes: C04B 40/0039 Premixtures of ingredients
• CPC Class Codes: C04B 7/12 Natural pozzuolanas; Natural pozzuolana cements; Artificial pozzuolanas or artificial pozzuolana cements other than those obtained from waste or combustion residues, e.g. burned clay; Treating inorganic materials to improve their pozzuolanic characteristics cements containing slag C04B7/14
• CPC Class Codes: C04B 7/153 Mixtures thereof with other inorganic cementitious materials or other activators
• CPC Class Codes: C04B 7/26 from raw materials containing flue dust , i.e. fly ash C04B7/243 takes precedence
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete

Abstract

The present disclosure relates to methods for controlling the chemical composition of a first pozzolan by blending it with a different pozzolan having a different chemical composition. The method includes intimately mixing the two pozzolans and using a chemical analyzer to determine a chemical characteristic of the pozzolan fraction being produced. The output from the chemical analyzer is then used to control the blending of the first and second outputs to maintain the chemical characteristic within a desired range.

Claims

1. A method for blending different pozzolan streams to form a blended pozzolan for later blending with cement and having at least one chemical characteristic within one or more selected ranges, the method comprising:

establishing the one or more selected ranges for the at least one chemical characteristic of the blended pozzolan;

providing a first pozzolan stream having at least one variable chemical characteristic;

providing a second pozzolan stream that differs from the first pozzolan stream relative to at least one chemical characteristic selected from the group consisting of calcium oxide content, aluminate content, silicate content, ratio of aluminate to silicate, iron content, magnesium content, and sulfate content;

blending the first pozzolan stream with the second pozzolan stream at a blending ratio so as to produce the blended pozzolan;

measuring the at least one chemical characteristic of the blended pozzolan in a series of readings and determining whether the at least one chemical characteristic is within the one or selected ranges; and

upon determining that the at least one measured chemical characteristic is outside the one or more selected ranges, modifying the blending ratio of the first and second pozzolans streams so that the at least one chemical characteristic of the blended pozzolan is restored to within the one or more selected ranges.

2. A method as in claim 1, wherein the at least one chemical characteristic of the blended pozzolan comprises a minimum calcium oxide content of at least 5%.

3. A method as in claim 1, wherein the first pozzolan stream comprises one of class C or class F fly ash according to ASTM C 618-03 and the second pozzolan stream comprises a different one of class F or class C fly ash according to ASTM C 618-03.

4. A method as in claim 1, wherein the first pozzolan stream and the second pozzolan stream differ in calcium oxide content by at least about 5%.

5. A method as in claim 1, further comprising measuring the specific gravity of the blended pozzolan.

6. A method as in claim 1, further comprising blending another component with the first and second pozzolan streams.

7. A method as in claim 1, wherein the at least one chemical characteristic is measured by an X-ray diffraction device or an XRF device.

8. A method for making a blended cement comprising first obtaining the blended pozzolan made according to claim 1 and then blending the blended pozzolan fraction with a ground cement clinker.

9. A method as in claim 1, further comprising monitoring a particle size distribution of the blended pozzolan and modifying the blending ratio to maintain the particle size distribution of the blended pozzolan to within a selected range.

10. A method as in claim 9, wherein monitoring the particle size distribution of the blended pozzolan is performed using a particle size analyzer.

12. A method as in claim 2, wherein the minimum calcium oxide content is at least 10%.

13. A method as in claim 2, wherein the minimum calcium oxide content is at least 15%.

14. A method as in claim 2, wherein the minimum calcium oxide content is at least 20%.

11. A method for blending different fly ashes together to form blended fly ash for later blending with cement and having at least one chemical or physical characteristic within one or more selected ranges, the method comprising:

providing a first fly ash;

providing a second fly ash that differs from the first fly ash with respect to at least one chemical or physical characteristic;

blending the first fly ash with the second fly ash at a blending ratio to produce blended fly ash;

measuring the at least one chemical or physical characteristic of the blended fly ash in a series of readings and determining whether the at least one chemical or physical characteristic is within the one or more selected ranges; and

upon determining that the at least one chemical or physical characteristic of the blended fly ash is outside the one or more selected ranges, modifying the blending ratio of the first and second fly ashes so that the at least one chemical or physical characteristic of the blended fly ash is restored to within the one or more selected ranges.

15. A method as in claim 11, wherein the at least one chemical or physical characteristic of the blended fly ash comprises a minimum calcium oxide content is of at least 10%.

16. A method as in claim 15, wherein the minimum calcium oxide content is at least 20%.

17. A method as in claim 11, wherein the at least one chemical or physical characteristic of the blended fly ash comprises particle size distribution.

18. A method as in claim 11, wherein the at least one chemical or physical characteristic of the blended fly ash comprises specific gravity.

19. A method for maintaining the calcium oxide content of a blended pozzolan within an established range prior to blending with cement, comprising:

blending two or more pozzolans that differ in calcium oxide content to form the blended pozzolan;

measuring the calcium oxide content of the blended pozzolan and determining whether the calcium oxide content is within the established range; and

upon determining that the calcium oxide content of the blended pozzolan is outside the established range, modifying a blending ratio of the two or more pozzolans to restore the calcium oxide content of the blended pozzolan to within the established range.

20. A method as in claim 19, wherein at least one of the two or more pozzolans comprises fly ash or natural pozzolan.