One step process of making sustainable hybrid magnesium cement

Patent metadata

Field	Value
Publication number	US-12043579-B2
Application number	US-202117234131-A
Country	US
Kind code	B2
Filing date	Apr 19, 2021
Priority date	Apr 20, 2020
Publication date	Jul 23, 2024
Grant date	Jul 23, 2024

Abstract

An exemplary process for forming a cured hybrid magnesium cement composition may include first combining a mixture of magnesium-containing material, a metal silicate inorganic polymer having a repeat unit of SiP 2 O 7 , and a salt having a non-metallic oxide anion, and then mixing the mixture with water.

First claim

What is claimed is:

1. A process for forming a cured hybrid magnesium cement (HMC) composition, the process comprising:
combining together in one step a mixture of magnesium-containing material, a metal silicate inorganic polymer having a repeat unit of SiP 2 O 7 , and a salt having a non-metallic oxide anion; and
then adding water and mixing the mixture with water.

2. The process of claim 1 , further comprising adding hydraulic additives, activators, linear silicon polymer, and/or sand.

3. The process of claim 1 , wherein the magnesium-containing material includes calcium carbonate in the amount from 0 wt. % to 70 wt. % of the magnesium-containing material, calcium oxide in the less than 10% of the magnesium-containing material, magnesium carbonate in the amount of 0 wt. % to 25 wt. % of the magnesium-containing material, and magnesium oxide in the amount from 18 wt. % to 70 wt. % of the magnesium-containing material.

4. The process of claim 1 , wherein the magnesium-containing material is a light-burn, hard-burn or dead-burn grade magnesite, dolomite, pyroxenite, amphibolite, serpentine, dunite, or chlorite having a weight loss ranging from 23-28 dry wt. % relative to an uncalcined magnesium-containing material as measured by weighing the dry magnesium-containing material after calcining relative to before calcining.

5. The process of claim 2 , wherein the hydraulic additive includes a ground granulated blast-furnace slag.

6. The process of claim 2 , further comprising adding a silicate source including calcium silicates and calcium aluminate silicate.

7. The process of claim 2 , comprising adding a silicate source including at least one of a metakaolin, fly ash, slag, biomass ash and bottom ash.

8. The process of claim 1 , wherein the salt is a phosphate salt capable of being solubilized in water, the phosphate salt provided in the amount ranging from 1.5 wt. % to 11 wt. % on a dry weight basis.

9. The process of claim 1 , further comprising adding magnesium oxide, wherein a weight ratio of the salt to magnesium oxide ranges from 0.1 to 1.2.

10. The process of claim 1 , wherein the magnesium-containing material composition includes a light-burn, hard-burn, or dead-burn grade magnesite and a salt having a non-metal oxide anion.

11. The process of claim 1 , comprising adding a cement activator source including at least one of a free lime, hydrated lime, alkali hydroxide, sodium sulfate and sodium carbonate.

12. The process of claim 1 , wherein the metal silicate inorganic polymer has at least 60 repeat units of SiP 2 O 7 .

13. The process of claim 1 , comprising adding a linear silicon polymer including at least one silicone resin polymer comprising a siloxane-oxygen structure R—SiO, where R represents alkyl and aryl organic groups.

14. The process of claim 13 , wherein the R—SiO siloxane-oxygen resin polymer ranges from 0.03 wgt. % to 5 wgt. % and contains at least 40 wgt. % SiO 2 , where the R represents a phenol:methyl ratio of 0.6:1, a molecular weight of <5,000 daltons and a Tg between 40° C. and 70° C.

15. A process comprising:
first mixing together in one step a mixture of a magnesium-containing material, a metal silicate polymer, a salt having a non-metallic oxide anion, and one or more of a linear silicone polymer, a hydraulic additive, a cement activator, and sand; and
then mixing water with the mixture to form a cured hybrid magnesium cement (HMC) composition.

16. The process of claim 15 , further comprising spraying, shotcreting, 3D printing, or casting the HMC composition into at least one mold.

17. The process of claim 16 , further comprising testing the HMC composition to failure, and measuring at least one of a compressive strength, a flexural strength, and a tensile strength of the HMC composition.

18. The process of claim 15 , wherein the magnesium-containing material includes at least magnesium oxide.

19. The process of claim 15 , wherein the salt is a dipotassium phosphate.

20. A process for forming a cured hybrid magnesium cement (HMC) composition, the process comprising:
combining together a mixture of magnesium-containing material, a metal silicate inorganic polymer having a repeat unit of SiP 2 O 7 , and a salt having a non-metallic oxide anion;
mixing the mixture with water;
adding a linear silicon polymer including at least one silicone resin polymer comprising a siloxane-oxygen structure R—SiO, where R represents alkyl and aryl organic groups, wherein the R—SiO siloxane-oxygen resin polymer ranges from 0.03 wgt. % to 5 wgt. % and contains at least 40 wgt. % SiO 2 , where the R represents a phenol:methyl ratio of 0.6:1, a molecular weight of <5,000 daltons and a Tg between 40° C. and 70° C.

21. The process of claim 20 , wherein the linear silicon polymer is added to the mixture in one step together with the magnesium-containing material, the metal silicate inorganic polymer, and the salt before adding water to the mixture.

Assignees

• Univ Wayne State

Inventors

• Wu Hwai-Chung

Classifications

• C04B2111/00019

  Carbon dioxide sequestration · CPC title

• C04B22/10

  containing carbon in the anion, e.g. carbonates · CPC title

• C04B40/0046

  characterised by their processing, e.g. sequence of mixing the ingredients when preparing the premixtures · CPC title

• B33Y70/00

  Materials specially adapted for additive manufacturing · CPC title

• B28B1/001

  Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material (selective deposition modelling of metallic powder B22F10/00; rapid manufacturing of 3D objects in general and in particular of plastics B29C64/00) · CPC title