Self-foaming geopolymer composition containing aluminum dross

Patent metadata

Field	Value
Publication number	US-2016257616-A1
Application number	US-201415030462-A
Country	US
Kind code	A1
Filing date	Oct 7, 2014
Priority date	Oct 31, 2013
Publication date	Sep 8, 2016
Grant date	—

Abstract

The present invention relates to a self-foaming geopolymer composition comprising at least one hydraulic binder; at least one binder selected from latent hydraulic binders, pozzolanic binders, and mixtures thereof; at least one alkaline activator; and aluminum dross. It moreover relates to the use of that geopolymer composition for the production of geopolymer foams and/or foamed geopolymer products.

First claim

1 . A self-foaming geopolymer composition comprising:
at least one hydraulic binder; at least one binder selected from latent hydraulic binders, pozzolanic binders, and mixtures thereof; at least one alkaline activator; and aluminum dross.

2 . The composition of claim 1 , wherein the latent hydraulic binder is selected from blast furnace slag, electrothermic phosphorus slag, steel slag, and mixtures thereof.

3 . The composition of claim 1 , wherein the latent hydraulic binder is blast furnace slag.

4 . The composition of claim 1 , wherein the pozzolanic binder is selected from amorphous silica, precipitated silica, pyrogenic silica, microsilica, ground glass, fly ash, brown-coal fly ash, mineral-coal fly ash, metakaolin, natural pozzolanas, tuff, trass, volcanic ash, natural zeolites, synthetic zeolites, and mixtures thereof.

5 . The composition of claim 4 , wherein the pozzolanic binder is selected from pyrogenic silica, microsilica, fly ash, metakaolin, and mixtures thereof.

6 . The composition of claim 5 , wherein the pozzolanic binder is metakaolin.

7 . The composition of claim 1 , wherein the alkaline activator is selected from alkali metal carbonates, alkali metal fluorides, alkali metal hydroxides, alkali metal aluminates, alkali metal silicates, and mixtures thereof.

8 . The composition of claim 7 , wherein the alkaline activator is selected from alkali metal hydroxides, alkali metal silicates, and mixtures thereof.

9 . The composition of claim 8 , wherein the alkali metal silicate is selected from compounds having the empirical formula m SiO 2 .n M 2 O, in which M is the alkali metal, Li, Na, K or a mixture thereof, and the molar ratio of m:n is 4.0.

10 . The composition of claim 1 , wherein the aluminum dross comprises 50 to 99.9% by weight oxides and/or nitrides, and 0.1 to 50% by weight metallic aluminum.

11 . The composition of claim 10 , wherein the aluminum dross comprises 75 to 99% by weight oxides and/or nitrides, and 1 to 25% by weight metallic aluminum.

12 . The composition of claim 11 , wherein the oxides comprise Al 2 O 3 and SiO 2 .

13 . The composition of claim 1 , wherein the hydraulic binder is selected from portland cement, high alumina cement, calcium sulphoaluminate cement, portland composite cement according to classes CEM II to V, and mixtures thereof.

14 . The composition of claim 13 , wherein the hydraulic binder is portland cement.

15 . The composition of claim 1 , further comprising a surfactant.

16 . The composition of claim 15 , wherein the surfactant is an alkyl polyglucoside.

17 . The composition of claim 1 , further comprising water.

18 . The composition of claim 17 , further comprising a gas phase comprising hydrogen gas.

19 . The composition of claim 1 , wherein the molar ratio of metallic aluminum to alkali metal (Al/M) is 0.3.

20 . A method comprising mixing together liquid and solid components of a geopolymer composition as defined in claim 1 for the production of geopolymer foams and/or foamed geopolymer products.

Assignees

• Construction Research & Technology Gmbh

Inventors

• Walther Burkhard
• Feichtenschlager Bernhard
• Zhou Shengzhong

Classifications

• C04B38/10

  by using foaming agents (C04B38/02 takes precedence){or by using mechanical means, e.g. adding preformed foam} · CPC title

• C04B28/04

  Portland cements · CPC title

• C04B28/006 Primary

  containing mineral polymers, e.g. geopolymers of the Davidovits type · CPC title

• Y02W30/91

  Use of waste materials as fillers for mortars or concrete · CPC title

• Y02P40/10

  Production of cement, e.g. improving or optimising the production methods; Cement grinding · CPC title