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

Patent metadata

Field	Value
Publication number	US-10633288-B2
Application number	US-201816135318-A
Country	US
Kind code	B2
Filing date	Sep 19, 2018
Priority date	Mar 21, 2014
Publication date	Apr 28, 2020
Grant date	Apr 28, 2020

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 building product, comprising:
a granular material; and
a binder consisting of steel slag, wherein the steel slag has a cumulative calcium silicate content of at least about 20% and a free lime content of less than about 7%;
wherein the building product is a construction block wherein said construction block has a durability and mechanical properties meeting masonry units requirements assessed under standards BS 6073 (2008), CSA A23.1 (2009) and ASTM C90.

2. The building product of claim 1 , wherein the steel slag has a silicon dioxide content of at least about 6%.

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

4. The building product of claim 3 , wherein the steel slag comprises a mixture of EAF and BOF slags.

5. The building product of claim 4 , wherein the steel slag comprises ladle slag.

6. The building product of claim 1 , wherein the steel slag comprises slag of a fineness greater than about 150 m 2 /kg.

7. The building product 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.

8. The building product of claim 1 , comprising at least 30% of steel slag with reference to the total mass of the building product.

9. The building product of claim 1 , wherein the steel slag has a cumulative calcium silicate content of at least about 30%.

10. The building product of claim 1 , wherein the steel slag has a cumulative calcium silicate content of at least about 40%.

11. The building product of claim 1 , comprising at least 40% of steel slag with reference to the total mass of the building product.

12. The building product of claim 1 , comprising at least 50% of steel slag with reference to the total mass of the building product.

13. The building product of claim 1 , comprising at least 60% of steel slag with reference to the total mass of the building product.

Assignees

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

Inventors

• Shao Yixin
• Mahoutian Mehrdad
• Ghouleh Zaid

Classifications

• 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

• B28B11/245

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

• C04B28/082 Primary

  Steelmaking slags; Converter slags · CPC title