Methods and compositions using calcium carbonate and stabilizer

• US 9,139,472 B2
• Filed: 12/10/2014
• Issued: 09/22/2015
• Est. Priority Date: 04/28/2011
• Status: Active Grant

• Current Assignee: Arelac, Inc.
• Original Assignee: Calera Corporation
• Inventors: Fernandez, Miguel, Chen, Irvin, Lee, Patricia Tung, Ginder-Vogel, Matthew
• Primary Examiner(s): Olsen, Kaj K
• Assistant Examiner(s): HIJJI, KARAM Y
• Application Number:
  US14/566,304
• Publication Number:
  US 20150096470A1
• Time in Patent Office: 286 Days
• Field of Search: 106/738, 106/817, 423/430, 423/232, 423/637, 423/186
• US Class Current: 1/1
• CPC Class Codes: C01F 11/182 Preparation of calcium carbonate by carbonation of aqueous solutions and characterised by an additive other than CaCO3-seeds
• CPC Class Codes: C01F 11/183 the additive being an organic compound
• CPC Class Codes: C01F 11/184 Preparation of calcium carbonate by carbonation of solutions based on non-aqueous solvents
• CPC Class Codes: C01P 2006/37 Stability against thermal decomposition
• CPC Class Codes: C04B 14/28 of calcium
• CPC Class Codes: C04B 22/141 Acids
• CPC Class Codes: C04B 22/142 Sulfates
• CPC Class Codes: C04B 22/147 Alkali-metal sulfates; Ammonium sulfate
• CPC Class Codes: C04B 22/16 containing phosphorus in the anion, e.g. phosphates
• CPC Class Codes: C04B 22/165 Acids
• CPC Class Codes: C04B 24/02 Alcohols; Phenols; Ethers
• CPC Class Codes: C04B 24/04 Carboxylic acids; Salts, anhydrides or esters thereof
• CPC Class Codes: C04B 24/045 Esters, e.g. lactones
• CPC Class Codes: C04B 24/18 Lignin sulfonic acid or derivatives thereof, e.g. sulfite lye
• CPC Class Codes: C04B 24/32 Polyethers, e.g. alkylphenol polyglycolether
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 28/28 containing organic polyacids, e.g. polycarboxylate cements , i.e. ionomeric systems
• CPC Class Codes: C04B 7/345 Hydraulic cements not provided for in one of the groups C04B7/02 - C04B7/34

Abstract

Provided herein are compositions, methods, and systems for a material containing metastable carbonate and stabilizer. Methods for making the compositions and using the compositions are also provided.

Claims

1. A method for making a composition, comprising:

contacting CO₂ from a CO₂ source with a solution comprising proton removing agent, alkaline earth-metal ions and a stabilizer under one or more conditions to make a composition comprising at least 50% w/w activated vaterite and the stabilizer wherein the stabilizer is sulfate and wherein the stabilizer in the solution is between 0.1-1 wt %, and

combining the composition with water and facilitating vaterite transformation to aragonite when the composition sets and hardens to form cement.

2. The method of claim 1, wherein the facilitating the aragonite formation results in one or more of better linkage or bonding, higher tensile strength, or higher impact fracture toughness, after cementation of the composition.

3. The method of claim 1, wherein the composition after combination with water, setting and hardening has a compressive strength in a range of 14-40 MPa.

4. The method of claim 1, wherein the composition is a precipitate, slurry, or a dry powder.

5. The method of claim 1, wherein the stabilizer comprises the stabilizer incorporated in crystal lattice of the activated vaterite in the composition.

6. The method of claim 1, wherein the sulfate is sulfate in sea water, an alkali metal sulfate, alkaline earth metal sulfate, lignosulfate, or combination thereof.

7. The method of claim 1, wherein more than 90% of the sulfate in the composition is from the stabilizer.

8. The method of claim 1, wherein the sulfate is an alkali metal sulfate.

9. The method of claim 1, wherein the one or more conditions are selected from the group consisting of mixing, stirring, temperature, pH, precipitation, residence time of the precipitate, dewatering of precipitate, washing precipitate with water, ion ratio, concentration of additives, drying, milling, grinding, storing, aging, and curing.

10. The method of claim 1, comprising activating the composition by nuclei activation, thermal activation, mechanical activation, chemical activation, or combination thereof.

11. The method of claim 10, wherein the activation comprises adding one or more of aragonite seed, inorganic additive or organic additive.

12. The method of claim 11, wherein the inorganic additive or organic additive are selected from the group consisting of sodium decyl sulfate, lauric acid, sodium salt of lauric acid, urea, citric acid, sodium salt of citric acid, phthalic acid, sodium salt of phthalic acid, taurine, creatine, dextrose, poly(n-vinyl-1-pyrrolidone), aspartic acid, sodium salt of aspartic acid, magnesium chloride, acetic acid, sodium salt of acetic acid, glutamic acid, sodium salt of glutamic acid, strontium chloride, gypsum, lithium chloride, sodium chloride, glycine, sodium citrate dehydrate, sodium bicarbonate, magnesium sulfate, magnesium acetate, sodium polystyrene, sodium dodecylsulfonate, poly-vinyl alcohol, or combinations thereof.

13. The method of claim 11, wherein the composition comprises between 0.1-5% w/w inorganic additive or organic additive.

14. The method of claim 1, wherein the one or more conditions comprise having ratio of calcium to carbonate during formation of vaterite to be between 1:

1 to 1.5;

1.

15. The method of claim 1, wherein the composition is formed with an average particle size of between 0.1-100 microns.