Steam-assisted production of metal silicate cements, compositions and methods thereof

Patent metadata

Field	Value
Publication number	US-2017121223-A1
Application number	US-201615335520-A
Country	US
Kind code	A1
Filing date	Oct 27, 2016
Priority date	Oct 28, 2015
Publication date	May 4, 2017
Grant date	—

Abstract

The invention provides a novel, steam-assisted production methodology and associated compositions and methods of use in the manufacture of carbonatable or non-carbonatable metal silicate or metal silicate hydrate (e.g., calcium silicate or calcium silicate hydrate) compositions. These metal silicate compositions and related phases are suitable for use hydraulic, partially hydraulic or non-hydraulic cement that sets and hardens by a hydration process, a carbonation process or a combination thereof, and may be applied in a variety of concrete components in the infrastructure, construction, pavement and landscaping industries.

First claim

1 . A method for producing metal silicate, or metal silicate hydrate product capable of carbonation or hydration to form a cementitious product, comprising:
(a) providing a ground mixture comprising source materials of metal oxide and silica; (b) providing a gas comprising a steam of water over the ground mixture of source materials at a pressure, wherein the steam of water has a partial pressure that ranges from atmospheric pressure to supercritical water pressure; and (c) subjecting the ground mixture of source materials (i) to a temperature and for a time sufficient to calcine the ground mixture, and (ii) to a temperature and for a time sufficient to fuse the calcined ground mixture to form the cementitious product.

2 . The method of claim 1 , wherein the temperature sufficient to heat the ground mixture is lower than about 1,200° C.

3 . The method of claim 2 , wherein the temperature sufficient to heat the ground mixture is lower than about 800° C.

4 . The method of claim 1 , wherein the temperature sufficient to fuse the ground mixture is lower than about 1,200° C.

5 . The method of claim 4 , wherein the temperature sufficient to fuse the ground mixture is lower than about 800° C.

6 . The method of claim 1 , wherein the steam of water is substantially in supercritical condition.

7 . The method of claim 1 , further comprising cooling the cement product to ambient temperature.

8 . The method of claim 1 , further comprising grinding the cement agglomorate to form powdery cement.

9 . The method of claim 8 , further comprising, before grinding, adding one or more set-controlling admixtures to the cementitious product.

10 . The method of claim 1 , wherein the source materials of metal oxide and silica are selected from magnesium silicates, magnesium oxide and silica source, calcium oxide and silica source, magnesium carbonate and silica source, calcium carbonate and silica source, low grade limestone having calcium and silicone, magnesium calcium aluminates, magnesium calcium aluminum silicates, and magnesium calcium silicates.

11 . A cement material produced according to claim 1 .

12 . A powdery cement material produced according to claim 1 .

13 . A method for curing the cement material of claim 11 , comprising mixing the powdery cement material and one or more aggregates or fillers with water and allowing the mixture to set for a time and at a temperature sufficient to form a concrete product.

14 . The method of claim 13 , wherein the curing process is performed in a CO 2 -rich atmosphere.

15 . An article of manufacture produced by the method of claim 13 .

Assignees

• Solidia Technologies Inc

Inventors

• Atakan Vahit

Classifications

• C04B12/04

  Alkali metal or ammonium silicate cements {; Alkyl silicate cements; Silica sol cements; Soluble silicate cements (alkali metal silicates per se, their preparation C01B33/32; ammonium silicates per se, their preparation C01C1/00)} · CPC title

• C04B7/4476

  Selection of the kiln atmosphere · CPC title

• Y02P40/121

  Energy efficiency measures, e.g. improving or optimising the production methods · CPC title

• C04B28/188

  the Ca-silicates being present in the starting mixture · CPC title

• C04B7/43 Primary

  Heat treatment, e.g. precalcining, burning, melting; Cooling {(aspects only relating to the installation F27B)} · CPC title