Wood-based cement additive

• US 9,914,131 B2
• Filed: 02/09/2016
• Issued: 03/13/2018
• Est. Priority Date: 06/12/2012
• Status: Active Grant

• Current Assignee: Fiber Resources, Inc.
• Original Assignee: Fiber Resources, Inc.
• Inventors: Weaver, William R.
• Primary Examiner(s): Li, Aiqun
• Application Number:
  US15/019,477
• Publication Number:
  US 20160159688A1
• Time in Patent Office: 763 Days
• Field of Search: 507104
• CPC Class Codes: B02C 23/08 Separating or sorting of material, associated with crushing or disintegrating B02C23/18 takes precedence ; beater mills combined with sifting devices B02C13/13, B02C13/14; for tumbling mills B02C17/1835
• CPC Class Codes: C04B 18/26 Wood, e.g. sawdust, wood shavings
• CPC Class Codes: C04B 20/0076 characterised by the grain distribution
• CPC Class Codes: C04B 20/026 Comminuting, e.g. by grinding or breaking; Defibrillating fibres other than asbestos
• CPC Class Codes: C04B 20/04 Heat treatment
• CPC Class Codes: C04B 2111/40 Porous or lightweight materials
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C09K 2208/08 Fiber-containing well treatment fluids
• CPC Class Codes: C09K 8/467 containing additives for specific purposes
• CPC Class Codes: C09K 8/473 Density reducing additives, e.g. for obtaining foamed cement compositions
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete

Abstract

A wood-based cement additive is formed by mixing high-density pellet particles of various sizes. The additive is to be introduced into a cement source to create a slurry mixture. The density of the mixture of pellet particles is selected to be less than the density of the particular cement type in which the pellet particles are introduced. The pellet particles are formed from sawdust or fiber pressed under high pressure, resulting in brittle pellets. The pellets may then be crumbled and screened into particles of an appropriate size. The particles do not disassociate into their constituent materials when mixed with the cement, and thus maintain their density during use in the cementing process.

Claims

1. An additive for mixing with cement from a cement source to form a slurry, the additive comprising a plurality of crumbled pellet particles of a plurality of grades, the crumbled pellet particles consisting essentially of wood fiber and moisture excluding an additional binder material, wherein each of said crumbled pellet particles comprises a particle diameter, further wherein said plurality of grades comprises a coarse particle grade and a medium particle grade, wherein said particle diameter of said crumbled pellet particles of said coarse particle grade is larger than 0.0394 inches, further wherein said particle diameter of said crumbled pellet particles of said medium particle grade is between 0.0098 inches and 0.0394 inches, wherein the crumbled pellet particles have a specific gravity greater than 1.0 but less than that of the cement, and further wherein the crumbled pellet particles function to remain substantially integral when mixed with the cement.

2. The additive of claim 1, wherein said wood fiber consists essentially of hardwood wood fiber.

3. The additive of claim 2, wherein said wood fiber consists essentially of oak wood fiber.

4. The additive of claim 1, wherein the specific gravity of the crumbled pellet particles is in the range of 1.1 to 1.3.

5. The additive of claim 1, wherein the moisture comprises 4 to 8% of the crumbled pellet particles by weight.

6. A method for manufacturing an additive for introduction into cement to form a slurry, said additive consisting essentially of wood and water, said method comprising the steps of:

a. drying a wood source material to a desired moisture content;

b. pelletizing the source material to produce a plurality of pellets, wherein the specific gravity of the plurality of pellets is greater than 1.0;

c. crumbling the pellets into smaller crumbled pellet particles, wherein said crumbled pellet particles comprise a particle diameter;

d. screening the crumbled pellet particles through a plurality of mesh screens to produce a plurality of crumbled pellet particle size grades, wherein said plurality of mesh screens comprise an 18 mesh size screen, and a 60 mesh size screen, further wherein said crumbled pellet particle size grades comprise a coarse particle grade, a medium particle grade, and a fine particle grade, wherein said particle diameter of said crumbled pellet particles of said coarse particle grade is greater than 0.0394 inches, further wherein said particle diameter of said crumbled pellet particles of said medium particle grade is between 0.0098 inches and 0.0394 inches, further wherein said particle diameter of said crumbled pellet particles of said fine particle grade is between 0.0029 inches and 0.0098 inches, to produce a plurality of crumbled pellet particle size grades, further wherein said crumbled pellet particles of said coarse particle grade are captured by said 18 mesh size screen, further wherein said crumbled pellet particles of said medium particle grade pass through said 18 mesh size screen and are captured by said 60 mesh size screen, further wherein said crumbled pellet particles of said fine particle grade pass through said 18 mesh size screen and said 60 mesh size screen and are captured by a 200 mesh size screen; and

e. mixing the crumbled pellet particles of said coarse size grade and the crumbled pellet particles of said medium size grade to produce a mixture of crumbled pellet particle grades.

7. The method of claim 6, wherein said drying step comprises the step of drying the source material to 10% to 14% moisture content by weight.

8. The method of claim 7, further comprising the step of grinding the source material to a uniform size prior to the pelletizing step.

9. The method of claim 8, wherein the pellets produced in the pelletizing step comprise a bulk density in the range of 22 pounds per cubic foot to 34 pounds per cubic foot.

10. The method of claim 9, wherein the screening step further comprises the step of returning any oversized crumbled pellet particles to the crumbling step.

11. The method of claim 10, wherein a specific gravity of the mixture of crumbled pellet particle grades is less than a specific gravity of the cement.

12. A lightweight cement slurry, comprising cement and a plurality of crumbled pellet particles of a plurality of grades, the crumbled pellet particles consisting essentially of wood fiber and moisture excluding an additional binder material, wherein each of said crumbled pellet particles comprises a particle diameter, further wherein said plurality of grades comprises a coarse particle grade and a medium particle grade, wherein said particle diameter of said crumbled pellet particles of said coarse particle grade is larger than 0.0394 inches, further wherein said particle diameter of said crumbled pellet particles of said medium particle grade is between 0.0098 inches and 0.0394 inches, wherein the crumbled pellet particles have a specific gravity greater than 1.0 but less than that of the cement, and further wherein the crumbled pellet particles remain substantially integral when mixed with the cement.

13. The lightweight cement slurry of claim 12, wherein said wood fiber consists essentially of hardwood wood fiber.

14. The lightweight cement slurry of claim 13, wherein said wood fiber consists essentially of oak wood fiber.

15. The lightweight cement slurry of claim 12, wherein the specific gravity of the crumbled pellet particles is in the range of 1.1 to 1.3.

16. The lightweight cement slurry of claim 12, wherein the moisture comprises 4 to 8% of the crumbled pellet particles by weight.

17. The lightweight cement slurry of claim 12, wherein the slurry comprises 24 to 192 pounds of crumbled pellet particles per cubic yard of cement.

18. A lightweight cement slurry, comprising cement and a plurality of crumbled pellet particles of a plurality of grades, the crumbled pellet particles consisting essentially of wood fiber and moisture excluding an additional binder material, wherein the crumbled pellet particles have a specific gravity greater than 1.0 but less than that of the cement, and further wherein the crumbled pellet particles remain substantially integral when mixed with the cement.

19. The lightweight cement slurry of claim 18, wherein the specific gravity of the crumbled pellet particles is in the range of 1.1 to 1.3.