Processes for quantitative calcium sulfate phase analysis and uses thereof

Patent metadata

Field	Value
Publication number	US-2024025807-A1
Application number	US-202318225221-A
Country	US
Kind code	A1
Filing date	Jul 24, 2023
Priority date	Jul 22, 2022
Publication date	Jan 25, 2024
Grant date	—

Abstract

The present disclosure relates generally to processes for phase analysis of calcium sulfate materials useful in making gypsum products. In various aspects, the disclosure provides processes for providing a computer-implemented system for determining a phase content of a test calcium sulfate material; processes for determining the phase content of a test calcium sulfate material; processes for providing stucco feedstocks; and production processes for gypsum products.

First claim

We claim:

1 . A process for providing a computer-implemented system for determining a phase content of a test calcium sulfate material, the method comprising:
providing a plurality of first reference calcium sulfate samples, each having a known content of calcium sulfate dihydrate (DH), calcium sulfate hemihydrate (HH), soluble calcium sulfate anhydrite (AIII); inert calcium sulfate (IN) and free moisture (FM); for each of the plurality of first reference calcium sulfate samples, providing
a first plurality of parameters associated with a dehydration weight loss curve of the first reference calcium sulfate sample, the first plurality of parameters comprising a first plurality of fit parameters associated with a fit of the dehydration weight loss curve of the first reference calcium sulfate sample, and
a second plurality of parameters associated with a hydration temperature rise curve of the first reference calcium sulfate sample, the second plurality of parameters comprising a second plurality of fit parameters associated with a fit of the hydration curve of the first reference calcium sulfate sample,
providing the first plurality of parameters and the second plurality of parameters for each of the first reference calcium sulfate samples to a computing device; via the computing device, correlating the first plurality of parameters and the second plurality of the parameters with the known contents of DH, HH, AIII, IN and FM of the first reference calcium sulfate samples, thereby providing a testing model that correlates the first plurality of parameters and the second plurality of parameters of a test calcium sulfate sample to contents of one or more of DH, HH, AIII, IN and FM of the test sample.

2 . The process of claim 1 , wherein the plurality of first reference calcium sulfate samples comprises at least 300 first reference calcium sulfate samples.

3 . The process of claim 1 , wherein
for at least 80% of the plurality of first reference calcium sulfate samples, the known amount of DH is in the range of 3-20 wt %. for at least 80% of the plurality of first reference calcium sulfate samples, the known amount of HH is in the range of 50-90 wt %. for at least 80% of the plurality of first reference calcium sulfate samples, the known amount of AIII is up to 30 wt %. for at least 80% of the plurality of first reference calcium sulfate samples, the known amount of IN is in the range of 5-10 wt %.

4 . The process of claim 1 , wherein the dehydration weight loss curve of each first reference calcium sulfate sample is provided by thermogravimetrically measuring weight loss of the first reference calcium sulfate sample at a temperature of at least 100° C.

5 . The process of claim 1 , wherein the fit of the dehydration weight loss curve is a fit of a moisture change rate as a function of time.

6 . The process of claim 1 , wherein the first plurality of parameters includes at least four parameters.

7 . The process of claim 1 , wherein the hydration temperature rise curve of each first reference calcium sulfate sample is provided by measuring the temperature rise as a function of time of a mixture of the first reference calcium sulfate sample and water.

8 . The process of claim 1 , wherein the hydration temperature rise curve is fit to a combination of a positive-skewed Gaussian function and a non-skewed Gaussian function.

9 . The process of claim 1 , wherein the second plurality of fit parameters comprises at least five parameters.

10 . The process of claim 1 , wherein the second plurality of parameters includes at least five parameters.

11 . The process of claim 1 , wherein the computing system includes a processor programmed to perform a machine learning algorithm that is an artificial neural network algorithm.

12 . The process of claim 1 , further comprising
providing a plurality of second reference calcium sulfate samples, each having a known content of calcium sulfate dihydrate (DH), calcium sulfate hemihydrate (HH), soluble calcium sulfate anhydrite (AIII); inert calcium sulfate (IN) and free moisture (FM); for each of the plurality of second reference calcium sulfate samples, providing
a third plurality of parameters associated with a dehydration weight loss curve of the second reference calcium sulfate sample, the third plurality of parameters comprising a third plurality of fit parameters associated with a fit of the dehydration weight loss curve of the second reference calcium sulfate sample, and
a fourth plurality of parameters associated with a hydration temperature rise curve of the second reference calcium sulfate sample, the fourth plurality of parameters comprising a fourth plurality of fit parameters associated with a fit of the hydration curve of the second reference calcium sulfate sample;
for each of the plurality of second reference calcium sulfate samples, providing the third plurality of parameters and the fourth plurality of parameters to the testing model; and using the testing model, determining the contents of one or more of DH, HH, AIII, IN and FM of each second reference calcium sulfate sample.

13 . A process for determining the phase content of a test calcium sulfate material, the method comprising:
providing a dehydration weight loss curve of the test calcium sulfate material; providing a hydration temperature rise curve of the test calcium sulfate material; providing
a first plurality of parameters associated with the dehydration weight loss curve of the test calcium sulfate sample, the first plurality of parameters comprising a first plurality of fit parameters associated with a fit of the dehydration weight loss curve of the test calcium sulfate sample, and
a second plurality of parameters associated with the hydration temperature rise curve of the test calcium sulfate sample, the second plurality of parameters comprising a second plurality of fit parameters associated with a fit of the hydration curve of the test calcium sulfate sample;
providing a testing model that correlates the first plurality of parameters and the second plurality of parameters of a test calcium sulfate sample to contents of one or more of DH, HH, AIII, IN and FM of the test sample; providing the first plurality of parameters and the second plurality of parameters to the testing model; and using the testing model, determining the contents of one or more of DH, HH, AIII, IN and FM of the test calcium sulfate sample.

14 . The process according to claim 13 , wherein the testing model is created by a method comprising:
providing a plurality of first reference calcium sulfate samples, each having a known content of calcium sulfate dihydrate (DH), calcium sulfate hemihydrate (HH), soluble calcium sulfate anhydrite (AIII); inert calcium sulfate (IN) and free moisture (FM); for each of the plurality of first reference calcium sulfate samples, providing
a first plurality of parameters associated with a dehydration weight loss curve of the first reference calcium sulfate sample, the first plurality of parameters comprising a first plurality of fit parameters associated with a fit of the dehydration weight loss curve of the first reference calcium sulfate sample, and
a second plurality of parameters associated with a hydration temperature rise curve of the first reference calcium sulfate sample, the second plurality of parameters comprising a second plurality of fit parameters associated with a fit of the hydration curve of the first reference calcium sulfate sample,
providing the first plurality of parameters and the second plurality of parameters for each of the first reference calcium sulf

Assignees

• Certainteed Gypsum Inc

Inventors

• Jones Roger
• Khalkhali Mohammad
• Lu Yi
• Liu Qingxia
• Ghosh Anirban
• Lespiat Remi

Classifications

• C04B11/0281 Primary

  Kettles; Marmites; Autoclaves · CPC title

• B01J6/004

  using hot gas streams in which the material is moved · CPC title

• G01N33/383 Primary

  Concrete or cement · CPC title

• G16C20/20

  Identification of molecular entities, parts thereof or of chemical compositions · CPC title