Carbonate-bonded construction products from steel-making residues and method for making the same

Patent metadata

Field	Value
Publication number	US-10112871-B2
Application number	US-201515124856-A
Country	US
Kind code	B2
Filing date	Mar 23, 2015
Priority date	Mar 21, 2014
Publication date	Oct 30, 2018
Grant date	Oct 30, 2018

Abstract

A building product is made from granular material and a binder that includes steel slag. A process for making the building product includes combining the granular material and the binder and then curing the combined granular material and binder with carbon dioxide. A building material includes a mixture of steel slag and a silica-rich material. The steel slag and silica-rich material is treated by heating. The silica-rich material may be waste glass and/or fly ash. A process for making the building material includes mixing the steel slag and silica-rich material and further heating the mixture.

First claim

The invention claimed is:

1. A method for making a construction block, comprising
providing granular material and a binder consisting of steel slag;
combining the granular material, the binder with water to a first water-to-slag ratio;
molding the combined granular material, binder and water;
reducing the quantity of water in the molded granular material, binder and water to a second water-to-slag ratio that is lower than the first water-to-slag ratio;
curing said molded granular material, binder and water having said second water-to-slag ratio with carbon dioxide.

2. The method of claim 1 , wherein the steel slag comprises at least one of electric arc furnace (EAF) slag and basic oxygen furnace (BOF) slag.

3. The method of claim 1 , wherein the granular material is chosen from natural lightweight aggregate, expanded clay aggregate, expanded shale aggregate, expanded slag aggregate, expanded steel slag aggregate and expanded iron slag aggregate.

4. The method of claim 1 , wherein said reducing the quantity of water to the second water-to-slag ratio comprises applying an air flow to the molded granular material, binder and water.

5. The method of claim 1 , wherein the first water-to-slag ratio is at least about 0.15 and wherein the second water-to-slag ratio is less than about 0.12.

6. The method of claim 1 , wherein the first water-to-slag ratio is at least about 0.2 and wherein the second water-to-slag ratio is less than about 0.10.

7. The method of claim 1 , wherein said combined granular material, binder and water is comprising at least 30% of steel slag with reference to the total mass of the combined granular material, binder and water.

8. The method of claim 1 , wherein said a block is hydrated after said step of curing.

Assignees

• The Royal Institution For The Advancement Of Learning/Mcgill Univ

Inventors

• Shao Yixin
• Mahoutian Mehrdad
• Ghouleh Zaid

Classifications

• B28B11/245

  Curing concrete articles (B28B11/242 takes precedence) · CPC title

• C04B28/082 Primary

  Steelmaking slags; Converter slags · CPC title

• Y02P40/18

  Carbon capture and storage [CCS] · CPC title

• B28B1/14

  by simple casting, the material being neither forcibly fed nor positively compacted (for molten material B28B1/54) · CPC title

• E04C1/00

  Building elements of block or other shape for the construction of parts of buildings (of relatively thin form E04C2/00; structural elongated elements designed for load-supporting E04C3/00, e.g. columns or pillars E04C3/30; manufacture or material of building bricks, stones, or the like B28, C03, C04; paving elements E01C; general building constructions E04B, e.g. walls E04B2/00, floors E04B5/00, roofs E04B7/00, ceilings E04B9/00; {roof coverings E04D; coverings for walls or ceilings E04F13/00; floorings E04F15/00;} structural elements specially designed for built-in conduit shafts E04F17/00; {elements for buildings for particular purposes E04H7/00}; special elements for building ovens or furnaces F24B, F27D) · CPC title