Hybrid Magnesium Cement and Method of Manufacture

Patent metadata

Field	Value
Publication number	US-2016102017-A1
Application number	US-201514968214-A
Country	US
Kind code	A1
Filing date	Dec 14, 2015
Priority date	Jun 30, 2011
Publication date	Apr 14, 2016
Grant date	—

Abstract

A hybrid magnesium cement composition formed from an A-side component and a B-side component. The A-side component includes an A1-component including a light-burn grade magnesium-containing material, and an A2-component including a non-metallic oxide salt. A B-side component having a metal silicate polymer is included.

First claim

What is claimed is:

1 . A hybrid magnesium cement composition comprising:
a first composition having
a first component including a magnesium-containing material, and
a second component including a salt having a non-metallic oxide anion, the first composition being partially cured; and
a second composition having a metal silicate polymer, the second composition being partially cured, the hybrid magnesium cement composition being formed by combining the first composition with the second composition, the hybrid magnesium cement composition including inorganic polymer chains having at least 60 repeat units of SiP 2 O 7 .

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

3 . The hybrid magnesium cement composition of claim 2 , wherein the magnesium-containing material is a light-burn grade dolomite, pyroxenite, amphibolite, serpentine, dunite, or chlorite having a weight loss ranging from 23-28 dry wt. % relative to an uncalcined dolomite as measured by weighing dry dolomite after-calcining relative to before-calcining.

4 . The hybrid magnesium cement composition of claim 3 , wherein the light-burn grade dolomite includes sand and a first hydraulic additive and an optional second hydraulic additive.

5 . The hybrid magnesium cement composition of claim 4 , wherein the first hydraulic additive includes a ground granulated blast-furnace slag.

6 . The hybrid magnesium cement composition of claim 1 , further comprising water.

7 . The hybrid magnesium cement composition of claim 1 , wherein the metal silicate polymer comprises a mixture of a hydroxide anion and a silicate source including at least one of a flyash, slag, biomass ash and bottom ash.

8 . The hybrid magnesium cement composition of claim 1 , wherein the salt is a phosphate salt capable of being solubilized in amount ranging from 3.0 wt. % to 5.3 wt. % of the first composition on a dry weight basis.

9 . The hybrid magnesium cement composition of claim 1 , wherein a weight ratio of the salt to magnesium oxide ranges from 0.1 to 1.2.

10 . The hybrid magnesium cement composition of claim 1 wherein magnesium-containing material composition includes a magnesium oxide metal oxide salt.

11 . The hybrid magnesium cement composition of claim 1 wherein magnesium-containing material composition includes a light burn grade dolomite and a salt having a non-metal oxide anion.

12 . A method of manufacture of a hybrid magnesium cement composition, the method comprising the steps of:
(a) calcining a magnesium-containing material at a temperature in a range of 770° C. to 1,100° C. for a first time period; (b) mixing the magnesium-containing material with a first salt to form a magnesium oxide-containing inorganic polymer composition; (c) partially curing the magnesium oxide-containing inorganic polymer composition; and (d) mixing the magnesium oxide-containing inorganic polymer composition with a metal silicate polymer composition to form a hybrid magnesium-containing composition, wherein the hybrid magnesium cement composition includes inorganic polymer chains having at least 60 repeat units of SiP 2 O 7 .

13 . The method of claim 12 , further comprising the steps of:
(d) adding water to form a wetted hybrid magnesium-containing cement composition.

14 . The method of claim 13 , further comprising the step of:
(e) mixing a second salt to the wetted hybrid magnesium-containing cement composition to form a magnesium-containing shotcrete wet mix, the second salt being selected from the group consisting of phosphate salts, sulfate salts, chlorate salts, or nitrate salts.

15 . The method of claim 12 , further comprising the step of:
(d) mixing a second salt to the hybrid magnesium-containing composition forming a magnesium-containing shotcrete dry mix, the second salt being selected from the group consisting of phosphate salts, sulfate salts, chlorate salts, or nitrate salts.

16 . The method of claim 12 , further comprising the steps of:
(d) mixing a first hydraulic additive in the magnesium oxide-containing inorganic polymer composition; and (e) mixing a sand with the magnesium oxide-containing inorganic polymer composition and the first hydraulic additive.

17 . The method of claim 16 , further comprising the steps of:
(f) mixing a second hydraulic additive in the magnesium oxide-containing inorganic polymer composition.

18 . The method of claim 12 , wherein the metal silicate polymer composition includes a base, an accelerator, a hydraulic additive, sand, and a silicate selected from the group consisting of flyash, slag, biomass ash and bottom ash.

19 . A magnesium-containing material composition, comprising:
calcium carbonate; calcium oxide; magnesium carbonate; and magnesium oxide, wherein the magnesium-containing material composition including inorganic polymer chains having from about 60 to 120 repeat units of SiP 2 O 7 .

20 . The magnesium-containing material composition of claim 19 , comprising:
calcium carbonate present in an amount from 0 wt. % to 70 wt. % of the magnesium-containing material composition; calcium oxide in an amount less than 10 wt. % of the magnesium-containing material composition; magnesium carbonate in an amount less than 25 wt. % of the magnesium-containing material composition; and magnesium oxide present in an amount ranging from 18 wt. % to 70 wt. % of the magnesium-containing material composition.

21 . The magnesium-containing material composition of claim 19 , comprising:
calcium carbonate present in an amount from 50 wt. % to 60 wt. % the magnesium-containing material composition; calcium oxide present in an amount from 0.2. wt. % to 5 wt. % of the magnesium-containing material composition; magnesium carbonate in an amount less than 5 wt. % of the magnesium-containing material composition; and magnesium oxide present in an amount from 40 wt. % to 50 wt. % of the magnesium-containing material composition.

22 . The magnesium-containing material composition of claim 19 , further comprising sand.

Assignees

• Univ Wayne State

Inventors

• Wu Hwai-Chung
• Warnemuende Kraig

Classifications

• C04B2111/00017

  Aspects relating to the protection of the environment · CPC title

• C04B28/30

  containing magnesium cements {or similar cements}(magnesium oxide cements C04B28/10) · CPC title

• C04B9/20

  Manufacture, e.g. preparing the batches (preheating, burning, calcining or cooling lime stone, magnesite or dolomite C04B2/10) · CPC title

• C04B9/04 Primary

  Magnesium cements containing sulfates, nitrates, phosphates or fluorides · CPC title

• C04B28/003

  containing hybrid binders other than those of the polycarboxylate type · CPC title