Synthetic formulations and methods of manufacturing and using thereof

• US 9,216,926 B2
• Filed: 06/07/2012
• Issued: 12/22/2015
• Est. Priority Date: 06/09/2011
• Status: Active Grant

• Current Assignee: Rutgers University
• Original Assignee: Rutgers University
• Inventors: Riman, Richard E, Atakan, Vahit, Li, Qinghua, Nye, Thomas E., Vakifahmetoglu, Cekdar, Tang, Ling
• Primary Examiner(s): MARCANTONI, PAUL D
• Application Number:
  US13/491,098
• Publication Number:
  US 20120312194A1
• Time in Patent Office: 1,293 Days
• Field of Search: 106/738, 106/801, 106/772, 423/220
• US Class Current: 1/1
• CPC Class Codes: C04B 14/22 Glass ; Devitrified glass
• CPC Class Codes: C04B 14/28 of calcium
• 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 18/101 Burned rice husks or other burned vegetable material
• CPC Class Codes: C04B 18/106 Fly ash from waste incinerators
• CPC Class Codes: C04B 18/12 from quarries, mining or the like
• CPC Class Codes: C04B 18/146 Silica fume
• CPC Class Codes: C04B 18/162 Cement kiln dust; Lime kiln dust
• CPC Class Codes: C04B 18/241 Paper, e.g. waste paper; Paper pulp
• CPC Class Codes: C04B 28/10 Lime cements or magnesium oxide cements
• CPC Class Codes: C04B 28/182 based on calcium silicate forming mixtures not containing lime or lime producing ingredients, e.g. waterglass based mixtures heated with a calcium salt
• CPC Class Codes: C04B 28/184 based on an oxide other than lime
• CPC Class Codes: C04B 38/00 Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof treating slag with gases or gas generating material C04B5/06 ; expanded graphite C04B35/536
• CPC Class Codes: C04B 40/0231 Carbon dioxide hardening
• CPC Class Codes: C04B 7/345 Hydraulic cements not provided for in one of the groups C04B7/02 - C04B7/34
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete

Abstract

A method for producing a reaction product including at least one synthetic formulation that carbonates sufficiently, said method comprising: providing a first raw material, having a first concentration of M; providing a second raw material, having a second concentration of Me; and mixing the first raw material and the second raw material to produce a reaction product that includes at least one synthetic formulation having the general formula M_aMe_bO_c, M_aMe_b(OH)_d, M_aMe_bO_c(OH)_d or M_aMe_bO(OH)_d•(H₂O)_e, wherein M comprises at least one metal that can react to form a carbonate and Me is at least one element that can form an oxide during the carbonation reaction, wherein the at least one synthetic formulation is capable of undergoing a carbonation reaction, and wherein the at least one synthetic formulation is capable of undergoing volume change during the carbonation reaction.

Claims

1. A method for producing a reaction product comprising:

providing a first raw material, having a first concentration of M;

providing a second raw material, having a second concentration of Me; and

mixing and heating the first raw material and the second raw material to produce a reaction product via a solid state reaction, the reaction product including at least one synthetic formulation having the general formula M_aMe_bO_c, M_aMe_b(OH)_d, M_aMe_bO_c(OH)_d or M_aMe_bO_c(OH)_d•

(H₂O)_e, wherein M comprises at least one metal that forms a carbonate in a subsequent carbonation reaction and Me is at least one element that forms an oxide during the carbonation reaction, wherein the ratio of a;

b is between 0.167;

1 and 2.5;

1, wherein c is 3 or greater, wherein d is 1 or greater, wherein e is 0 or greater, wherein the at least one synthetic formulation undergoes the carbonation reaction, and wherein the at least one synthetic formulation undergoes a volume change during the carbonation reaction.

2. The method of claim 1, wherein the at least one synthetic formulation undergoes volume expansion during the carbonation reaction.

3. The method of claim 1, wherein M comprises an alkaline earth element.

4. The method of claim 3, wherein the alkaline earth element is calcium.

5. The method of claim 3, wherein the alkaline earth element is magnesium.

6. The method of claim 1, wherein Me is selected from the group of elements consisting of silicon, titanium, aluminum, phosphorous, vanadium, tungsten, molybdenum, gallium, manganese, zirconium, germanium, copper, niobium, cobalt, lead, iron, indium, arsenic, sulfur, sodium, potassium, boron and tantalum.

7. The method of claim 1, wherein Me comprises Silicon.

8. The method of claim 1, wherein the first raw material is a calcium-rich mineral selected from the group of minerals consisting of Aragonite, Calcite, Dolomite, Gypsum, Marl, Chlorites, Sulfates and Limestone.

9. The method of claim 1, wherein the first raw material is a magnesium-rich mineral.

10. The method of claim 9, wherein the magnesium-rich mineral is Magnesite.

11. The method of claim 9, wherein the magnesium-rich mineral is Talc.

12. The method of claim 1, wherein the second raw material is a silicon-rich mineral selected from the group consisting of Silicate, Zeolite, Shale, Slate, Clay, Argillite, Sandstone, Conglomerate, Basalt, Feldspar, Mica, Granite, Granodiorite, Diorite, Chert, Sand and Amorphous Silicate.

13. The method of claim 1, wherein the first raw material is a calcium-rich byproduct selected from the group of byproducts consisting of slag, recycled cement, lime kiln dust (LKD), cement kiln dust (CKD), precipitated calcium carbonate, recycled paper, flue gas desulfurization (FGD) calcium sulfate, phosphorgypsum and silica-rich biomass.

14. The method of claim 1, wherein the second raw material is silicon-rich byproduct selected from the group of byproducts consisting of flyash, incinerator dust, fiberglass cullet, consumer glass, mine tailings, silica-rich biomass, rice husk and red mud.

15. A method of manufacturing a composite material using a reaction product produced from a solid state reaction between a first raw material, having a first concentration of M and a second raw material, having a second concentration of Me, said method of manufacturing a composite material comprising:

introducing a liquid solvent into pores of a solid body that includes the reaction product, wherein the reaction product includes at least one synthetic formulation having the general formula M_aMe_bO_c, M_aMe_b(OH)_d, M_aMe_bO_c(OH)_d or M_aMe_bO_c(OH)_d•

(H₂O)_e, wherein M comprises at least one metal that can react to form a carbonate and Me is at least one element that can form an oxide during the carbonation reaction, wherein the ratio of a;

b is between 0.167;

1 and 2.5;

1, wherein c is 3 or greater, wherein d is 1 or greater, wherein e is 0 or greater, wherein the at least one synthetic formulation undergoes the carbonation reaction, and wherein the at least one synthetic formulation undergoes a volume change during the carbonation reaction; and

introducing a gaseous reactant into the pores of the solid body, whereby particles of the at least one synthetic formulation are transformed into bonding elements that comprise;

a core having a first chemical composition that includes one or more chemical elements;

a first layer at least partially covering a peripheral portion of the core, the first layer having a second chemical composition different than the first chemical composition, the second chemical composition including cations corresponding to one of the chemical elements of the first chemical composition; and

a second layer at least partially covering a peripheral portion of the first layer, the second layer having a third chemical composition different than the first and second chemical compositions, the third chemical composition including cations corresponding to one of the chemical elements of the first chemical composition.

16. The method of claim 15, wherein the at least one synthetic formulation undergoes volume expansion during the carbonation reaction.

17. The method of claim 15, wherein M comprises an alkaline earth element.

18. The method of claim 15, wherein Me is selected from the group of elements consisting of silicon, titanium, aluminum, phosphorous, vanadium, tungsten, molybdenum, gallium, manganese, zirconium, germanium, copper, niobium, cobalt, lead, iron, indium, arsenic, sulfur, sodium, potassium, boron and tantalum.

19. The method of claim 15, wherein the first raw material is a calcium-rich mineral selected from the group of minerals consisting of Aragonite, Calcite, Dolomite, Gypsum, Marl, Chlorites, Sulfates and Limestone.

20. The method of claim 15, wherein the second raw material is a silicon-rich mineral selected from the group consisting of Silicate, Zeolite, Shale, Slate, Clay, Argillite, Sandstone, Conglomerate, Basalt, Feldspar, Mica, Granite, Granodiorite, Diorite, Chert, Sand and Amorphous Silicate.