Composite comprising a mineral wool comprising a sugar

Patent metadata

Field	Value
Publication number	US-10364183-B2
Application number	US-201515301864-A
Country	US
Kind code	B2
Filing date	Apr 9, 2015
Priority date	Apr 10, 2014
Publication date	Jul 30, 2019
Grant date	Jul 30, 2019

Abstract

The invention relates to a process for the preparation of a shaped composite, comprising the preparation of a mixture into which fragments of mineral wool comprising a size comprising a sugar, a non-cement silica carrier distinct from the wool, a non-cement alkali metal carrier distinct from the wool, and water, are introduced, the non-cement silica carrier and the non-cement alkali metal carrier forming, with the water, a mineral binder which gradually solidifies around the solid particles present in the mixture, and then the shaping of the mixture into a shaped composite, in particular into briquettes. The invention also relates to a process for the manufacture of mineral wool, in which a molten mass is produced which is converted into mineral wool by means of a fiberizing device, the shaped composite being introduced as vitrifiable charge into a melting chamber, such as a cupola furnace.

First claim

The invention claimed is:

1. A process for preparing a shaped composite, the process comprising:
mixing fragments of mineral wool sized with a sizing composition comprising a sugar with a non-cement silica carrier distinct from the wool, a non-cement alkali metal carrier distinct from the wool, and water, to obtain a mixture, wherein the non-cement silica carrier and the non-cement alkali metal carrier form, with the water, a mineral binder that gradually solidifies around solid particles present in the mixture; and then
shaping the mixture into a shaped composite.

2. The process of claim 1 , wherein a pH of the mixture is at least equal to 10.

3. The process of claim 1 , wherein the fragments of mineral wool comprise a rock wool or a glass wool.

4. The process of claim 1 , wherein the fragments of mineral wool are introduced into the mixture in a proportion of 10 to 60% by weight of the mixture.

5. The process of claim 1 , wherein a sum of weights of the non-cement silica carrier and the non-cement alkali metal carrier is from 5 to 30% by weight of the mixture.

6. The process of claim 1 , wherein the mixture comprises from 5 to 50% by weight of aggregates.

7. The process of claim 1 , wherein a sum of the moles of silica introduced into the mixture by the non-cement silica carrier and of the moles of alkali metal introduced into the mixture by the non-cement alkali metal carrier is greater than 0.5 mol per kg of mixture.

8. The process of claim 1 , wherein the sizing composition is present in the fragments of mineral wool in a proportion of 0.1 to 10% by weight of size dry matter with respect to a total weight of fragments of dry wool.

9. The process of claim 1 , wherein either no cement is introduced into the mixture or cement is introduced into the mixture in a proportion of less than 8% by weight of the mixture.

10. The process of claim 1 , wherein either no cement is introduced into the mixture or cement is introduced into the mixture such that a ratio of weight of the cement to weight of non-cement silica carrier is less than 1.

11. The process of claim 1 , wherein a ratio of number of moles of silica introduced into the mixture by the non-cement silica carrier to moles of alkali metal introduced into the mixture by the non-cement alkali metal carrier ranges from 0.2 to 3.

12. The process of claim 1 , wherein the non-cement silica carrier introduces into the mixture at least 0.1 mol of silica per kg of the mixture.

13. The process of claim 1 , wherein the non-cement alkali metal carrier introduces into the mixture at least 0.1 mol of alkali metal per kg of mixture.

14. The process of claim 1 , wherein the mixture further comprises a non-cement alkaline earth metal carrier distinct from the wool.

15. The process of claim 14 , wherein the non-cement alkaline earth metal carrier comprises Ca(OH) 2 or CaCO 3 .

16. The process of claim 14 , wherein:
the non-cement silica carrier and the non-cement alkaline earth metal carrier comprise one and the same slag, and the non-cement alkali metal carrier comprises sodium carbonate; and
cement is introduced into the mixture in a proportion of less than 8% by weight of the mixture.

17. The process of claim 16 , wherein the cement is introduced into the mixture in a proportion of at least 0.1% by weight of the mixture.

18. The process of claim 16 , wherein more than 50% of moles of silica introduced into the mixture by the non-cement silica carrier and more than 50% of moles of alkaline earth metal introduced into the mixture by the non-cement alkaline earth metal carrier are introduced into the mixture by the same slag.

19. The process of claim 16 , wherein more than 50% of moles of alkali metal introduced into the mixture by the non-cement alkali metal carrier are introduced into the mixture by sodium carbonate.

20. The process of claim 1 , wherein the non-cement silica carrier comprises a sodium silicate or a slag, said slag comprising at least 10% by weight of silica, being amorphous to more than 80% of its weight and its D50 being less than or equal to 100 μm.

21. The process of claim 1 , wherein the non-cement alkali metal carrier comprises sodium hydroxide, sodium silicate or sodium carbonate.

22. The process of claim 1 , wherein the water is present in the mixture in a proportion of 5 to 30%6 of the weight of the mixture.

23. The process of claim 1 , wherein the sugar is present in the sizing composition in a proportion of 30 to 90% by weight of the dry matter of the size.

24. The process of claim 1 , wherein a D50 of the non-cement silica carrier is less than or equal to 100 μm.

25. The process of claim 1 , wherein the shaped composite in the form of briquettes, in which conversion of the mixture into the briquettes occurs by molding and optionally compaction.

26. A process for manufacturing mineral wool, the process comprising producing a molten mass that is converted into mineral wool with a fiberizing device, wherein the shaped composite of claim 1 is introduced as a vitrifiable charge into a melting chamber.

27. A process for preparing a shaped composite, the process comprising:
mixing fragments of mineral wool sized with a sizing composition comprising a sugar with a non-cement silica carrier distinct from the wool, a non-cement alkali metal carrier distinct from the wool, and water to obtain a mixture, wherein the non-cement silica carrier and the non-cement alkali metal carrier form, with the water, a mineral binder that gradually solidifies around solid particles present in the mixture; and then
shaping the mixture into a shaped composite
wherein a ratio of number of moles of silica introduced into the mixture by the non-cement silica carrier to moles of alkali metal introduced into the mixture by the non-cement alkali metal carrier ranges from 0.2 to 3, and
wherein the water is present in the mixture in a proportion of 5 to 30% of the weight of the mixture.

28. The process of claim 27 , wherein:
the non-cement silica carrier and the non-cement alkaline earth metal carrier comprise one and the same slag, and the non-cement alkali metal carrier comprises sodium carbonate; and
cement is introduced into the mixture in a proportion of less than 8% by weight of the mixture.

29. The process of claim 27 , wherein:
the non-cement silica carrier and the non-cement alkaline earth metal carrier comprise one and the same slag, and the non-cement alkali metal carrier comprises sodium carbonate;
cement is introduced into the mixture in a proportion of less than 8% by weight of the mixture; and
more than 50% of moles of silica introduced into the mixture by the non-cement silica carrier and more than 50% of moles of alkaline earth metal introduced into the mixture by the non-cement alkaline earth metal carrier are introduced into the mixture by the same slag.

30. A process for preparing a shaped composite, the process comprising:
mixing fragments of mineral wool sized with a sizing composition comprising a sugar with a non-cement silica carrier distinct from the wool, a non-cement alkali metal carrier distinct from the wool, a non-cement alkaline earth metal carrier distinct from the wool, and water to obtain a mixture, wherein the non-cement silica carrier and the non-cement alkali metal carrier form, with the water, a mineral binder that gradually solidifies arou

Assignees

• Saint Gobain Isover

Inventors

• Yammine Joumana
• Bouny Elodie
• Obert Edouard

Classifications

• C04B28/04

  Portland cements · CPC title

• C03C25/47 Primary

  containing particles, fibres or flakes, e.g. in a continuous phase · CPC title

• C04B14/42

  Glass · CPC title

• C04B28/18

  containing mixtures of the silica-lime type · CPC title

• C04B28/26

  Silicates of the alkali metals · CPC title