White carbonatable calcium silicate-based cements and methods of preparation and use thereof

Patent metadata

Field	Value
Publication number	US-2017253530-A1
Application number	US-201715449736-A
Country	US
Kind code	A1
Filing date	Mar 3, 2017
Priority date	Mar 4, 2016
Publication date	Sep 7, 2017
Grant date	—

Abstract

The invention provides a new class of carbonatable calcium silicate-based, white clinkers and the ground cement produced from these clinkers, as well as methods of their production and use thereof. The disclosed white clinkers and the ground cement exhibit a high brightness and are suitable for use in products with high aesthetic considerations.

First claim

1 . A white carbonatable calcium silicate cement composition, comprising:
one or more discrete calcium silicate phases selected from CS (wollastonite or pseudowollastonite), C3S2 (rankinite), C2S (belite, larnite, bredigite), and an amorphous calcium silicate phase, wherein the one or more discrete calcium silicate phases form about 30% or more by mass of the total phases, and wherein elemental Ca and elemental Si are present in the composition at a molar ratio from about 0.8 to about 1.2; and metal oxides of Al, Fe and Mg are present at about 30% or less by mass, wherein the total color-imparting oxides of one or more of metals selected from Fe, Ti, Mn and Cr are present about 2.5% or less by mass of the total cement composition, wherein the cement composition is characterized by a reflectance value (L*) of greater than about 85%.

2 . The composition of claim 1 , wherein the cement composition is suitable for carbonation with CO 2 at a temperature of about 30° C. to about 90° C. to form a composite material comprising a binder matrix with a mass gain of about 10% or more.

3 . The composition of claim 1 , comprising one or more residual SiO 2 and CaO phases.

4 . The composition of claim 1 , comprising one or more melilite phases having the general formula (Ca,Na,K) 2 [(Mg, Fe 2+ ,Fe 3+ ,Al,Si) 3 O 7 ].

5 . The composition of claim 1 , wherein the composition comprises one or more calcium silicate phases existing in an amorphous state and one or more calcium silicate phases existing in a crystalline state.

6 . The composition of claim 1 , wherein the composition comprises calcium silicate phases existing only in an amorphous state.

7 . The composition of claim 1 , wherein the composition comprises calcium silicate phases existing in both the crystalline state and the amorphous state.

8 . The composition of claim 1 , wherein the composition is a powder having a reflectance value (L*) of greater than about 85%.

9 . The composition of claim 8 , wherein the composition is a powder having a reflectance value (L*) of greater than about 90%.

10 . The composition of claim 9 , wherein the composition is a powder having a reflectance value (L*) of greater than about 95%.

11 . The composition of claim 1 , wherein the metal oxides of one or more metal selected from Fe, Ti, Mn and Cr are incorporated into a melilite phase.

12 . The composition of claim 11 , wherein the metal oxides of one or more metal selected from Fe, Ti, Mn and Cr are incorporated into an amorphous phase.

13 . The composition of claim 11 , wherein the metal oxides of one or more metal selected from Fe, Ti, Mn and Cr are incorporated into a melilite phase and an amorphous phase.

14 . The composition of claim 4 , wherein the one or more melilite phases are characterized by a refractive index between about 1.5 and about 1.8.

15 . A composite material formed by carbonation of a cement composition according to claim 1 .

16 . A method for producing a white carbonatable calcium silicate cement, comprising:
providing a raw material set comprising CaO and SiO 2 ; grinding the raw material set to obtain a precursor mixture, wherein the molar ratio of CaO to SiO 2 is from about 0.8 to about 1.2, wherein the precursor mixture comprises: (i) less than about 21.2% by mass the oxides of Al, Fe and Mg, and (ii) less than about 1.5% by mass metal oxides of one or more metals selected from Fe, Ti, Mn and Cr; firing the precursor mixture to a temperature in the range from about 800° C. to about 1,400° C. to obtain a white carbonatable calcium silicate clinker; and grinding the white carbonatable calcium silicate clinker to a fineness of about 200 to about 800 m 2 /kg to produce the white carbonatable calcium silicate cement having a reflectance value (L*) of greater than about 85%.

17 . The method of claim 16 , wherein the precursor mixture is prepared from a raw material set selected from limestone, sand, silts, sandstones, silica-rich clays, diatomaceous earths, marl, fly ash, and silica fume.

18 . The method of claim 17 , wherein the raw material set is selected to achieve a precursor mixture with less than about 1.5% by mass of transition metal oxides.

19 . The method of claim 17 , wherein the raw material set is selected to achieve a precursor mixture with less than about 1.5% by mass of metal oxides of one or more metal selected from Fe, Ti, Mn and Cr.

20 . The method of 16 , wherein firing the precursor mixture is performed at a temperature between about 1,300° C. to about 1,400° C.

21 . The method of 16 , wherein after firing the white carbonatable calcium silicate clinker is subjected to cooling by forced air in the range of about 1,400° C. to about 500° C. under an uncontrolled atmosphere.

22 . The method of 16 , wherein after firing the white carbonatable calcium silicate clinker is subjected to cooling by forced air in the range of about 1,400° C. to about 500° C. under a reducing atmosphere.

23 . The method of 16 , wherein after firing the white carbonatable calcium silicate clinker is subjected to a cooling in the range of about 1,400° C. to about 500° C. by quenching in water.

24 . The method of 16 , wherein grinding the raw material set to obtain a precursor mixture is performed in a grinder with a steel grinding surface.

25 . The method of 16 , wherein grinding the white carbonatable calcium silicate clinker achieves a fineness of about 200 m 2 /kg to about 400 m 2 /kg to produce the white carbonatable calcium silicate cement.

26 . The method of 16 , wherein grinding the white carbonatable calcium silicate clinker achieves a fineness of about 400 m 2 /kg to about 800 m 2 /kg to produce the white carbonatable calcium silicate cement.

27 . The method of 26 , wherein grinding the white carbonatable calcium silicate clinker achieves a fineness of about 400 m 2 /kg to about 600 m 2 /kg to produce the white carbonatable calcium silicate cement.

Assignees

• Solidia Technologies Inc

Inventors

• Sahu Sadananda
• Quinn Sean
• Seth Anuj
• Bryant Jayson
• Ravikumar Deepak

Classifications

• C04B2111/802

  White cement · CPC title

• Y02P40/18

  Carbon capture and storage [CCS] · CPC title

• C04B28/188 Primary

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

• C04B7/345 Primary

  Hydraulic cements not provided for in one of the groups C04B7/02 - C04B7/34 · CPC title

• C04B2111/00019

  Carbon dioxide sequestration · CPC title