Microstructured carbonatable calcium silicate clinkers and methods thereof

Patent metadata

Field	Value
Publication number	US-2018186696-A1
Application number	US-201815894826-A
Country	US
Kind code	A1
Filing date	Feb 12, 2018
Priority date	Mar 20, 2015
Publication date	Jul 5, 2018
Grant date	—

Abstract

The invention provides novel, microstructured clinker and cement materials that are characterized by superior grindability and reactivity. The disclosed clinker and cement materials are based on carbonatable calcium silicate and can be made from widely available, low cost raw materials via a process suitable for large-scale production. The method of the invention is flexible in equipment and processing requirements and is readily adaptable to manufacturing facilities of conventional Portland cement.

First claim

1 - 31 . (canceled)

32 . A non-hydraulic clinker material, comprising particles of uncarbonatable silica (SiO 2 ), having diameters from about 0.1 μm to about 1,000 μm, dispersed in a matrix comprising at least one carbonatable calcium silicate phase.

33 . The clinker material of claim 32 , wherein elemental Ca and elemental Si are present in the clinker at an atomic ratio from about 0.8 to about 1.2.

34 . The clinker material of claim 32 , further comprising an intermediate layer, comprising melilite ((Ca,Na,K) 2 (Al,Mg,Fe)[(Al,Si)SiO 7 ]) and/or an amorphous phase and surrounding the particles of uncarbonatable silica.

35 . The clinker material of claim 34 , wherein the intermediate layer comprises an amorphous phase comprising one or more components selected from Al 2 O 3 , Fe 2 O 3 , MgO, K 2 O and Na 2 O.

36 . The clinker material of claim 32 , wherein the clinker is suitable for carbonation with CO 2 at a temperature of about 30° C. to about 90° C. to form CaCO 3 , under an atmosphere of water and CO 2 having a pressure in the range from ambient atmospheric pressure to about 150 psi above ambient and having a CO 2 concentration ranging from about 10% to about 99% for about 1 hour to about 150 hours, with a mass gain of about 10% or more.

37 . The clinker material of claim 36 , wherein the clinker is suitable for carbonation with CO 2 at a temperature of about 40° C. to about 80° C. to form CaCO 3 , under an atmosphere of water and CO 2 having a pressure in the range from ambient atmospheric pressure to about 40 psi above ambient and having a CO 2 concentration ranging from about 50% to about 95% for about 10 hour to about 50 hours, with a mass gain of about 10% or more.

38 . The clinker material of claim 37 , comprising about 30% or less of metal oxides of Al, Fe and Mg by total oxide mass.

39 . A composite material produced by carbonation of a clinker material of claim 32 .

40 . A powdery material produced by grinding the clinker material of claim 32 , wherein the powdery material is characterized by
a mean particle size (d50) of about 8 μm to about 25 μm, with 10% of particles (d10) sized below about 0.1 μm to about 3 μm, and 90% of particles (d90) sized between about 30 μm to about 100 μm; and a surface at least 10% covered with the at least one carbonatable phase.

41 . The powdery material of claim 40 , wherein the particles comprise single-phase particles and multi-phase particles.

42 . The powdery material of claim 41 , wherein the single-phase particles comprise:
single-phase particles of carbonatable phases selected from wollastonite (CaSiO 3 ), rankinite (Ca 3 Si 2 O 7 ) and C2S (Ca 2 SiO 4 ); single-phase particles of partially reactive amorphous phases; or single-phase particles of uncarbonatable phases selected from melilite ((Ca,Na,K) 2 [(Mg,Fe 2+ ,Fe 3+ ,Al,Si) 3 O 7 ]) and crystalline silica (SiO 2 ); or a combination of any two or more types thereof.

43 . The powdery material of claim 41 , wherein the multi-phase particles comprise:
multi-phase particles having a combination of two or more reactive phases; multi-phase particles having a combination of at least one reactive phase with at least one uncarbonatable phase; multi-phase particles having a combination of two or more uncarbonatable phases; multi-phase particles having a combination of at least one reactive phase with a partially reactive amorphous phase; multi-phase particles having a combination of at least one uncarbonatable phase with a partially reactive amorphous phase; multi-phase particles having a combination of at least one reactive phase with at least one uncarbonatable phase and a partially reactive amorphous phase; or multi-phase particles that have internal or surface connected voids; or a combination of any two or more types thereof.

44 . A method for making a clinker material, comprising:
mixing one or more precursors to obtain a blended precursor composition wherein elemental Ca and elemental Si are present at an atomic 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; and heating the blended precursor composition to a temperature between about 800° C. and about 1400° C. for a sufficient time to produce the clinker material,
wherein,
the clinker material is non-hydraulic and comprises particles of uncarbonatable silica (SiO 2 ) having diameters from about 0.1 μm to about 1,000 μm, dispersed in a matrix comprising at least one carbonatable calcium silicate phase.

45 . The method of claim 44 , wherein metal oxides of Al, Fe and Mg are present at about 10% or less by mass.

46 . The method of claim 44 , wherein the precursors are selected from limestone, sand, silts, sandstones, silica-rich clays and diatomaceous earths.

47 . The method of claim 44 , wherein the blended precursor composition is heated to a temperature between about 1,000° C. and about 1,400° C. for a sufficient time to produce the clinker material.

48 . The method of claim 44 , wherein the blended precursor composition is heated for a period of about 10 minutes to 5 hours.

49 . The method of claim 44 , wherein heating the blended precursor composition is conducted under atmospheric pressure.

50 . A clinker material produced according to the method of claim 44 .

Assignees

• Solidia Technologies Inc
• Lafarge Sa

Inventors

• Sahu Sadananda
• Quinn Sean
• Atakan Vahit
• Decristofaro Nicholas
• Meyer Vincent
• Comparet Cédric
• Walenta Günther

Classifications

• C04B35/64

  Burning or sintering processes (C04B33/32 takes precedence {; powder metallurgy B22F}) · CPC title

• C04B2235/3206

  Magnesium oxides or oxide-forming salts thereof · CPC title

• C04B2235/5436

  micrometer sized, i.e. from 1 to 100 micron · CPC title

• C04B2235/3217

  Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina · CPC title

• C04B7/345

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