Structural materials with nearly zero carbon emissions

Patent metadata

Field	Value
Publication number	US-9388074-B2
Application number	US-74678108-A
Country	US
Kind code	B2
Filing date	Dec 16, 2008
Priority date	Dec 20, 2007
Publication date	Jul 12, 2016
Grant date	Jul 12, 2016

Abstract

Processes and methods of making and preparing, compositions and structural products therefrom are provided, whereby the surface area of alumino-silicate based powders is greatly increased and rendered chemically active so that when the functionalized powders are mixed with water poly-condensation reactions occur between the surfaces binding the powders together to form a structural material with negligible emission of carbon compounds. In another embodiment, the surface functionalized powders can be mixed with an additive; a dry aggregate, such as sand and water to make a slurry that can be poured or cast into any desired shape and rapidly cured to a hardened shape suitable for use as a structural material with the mechanical strength equivalent to Portland-cement based concrete products. In additional embodiments, the alumino-silicate based powders are nano-functionalized and foam functionalized to provide light weight and structurally strong materials that can also be used in combination with or as replacement for Portland-cement.

First claim

We claim:

1. A process for preparing a structural product, comprising the steps of:
a) selecting an alumino-silicate based powder from the group consisting of industrial power plant fly-ash, mining tailings, sand, and mixtures thereof;
b) treating the powder with a liquid reagent to form a mixture (I) wherein the powder becomes functionalized with each particle having a chemically active surface area; and
c) drying the functionalized powder to produce a dried activated powder; and
d) contacting the dried activated powder with an alcohol/acid solution to form a structural product with no emission of carbon compounds;
wherein treating comprises refluxing, stirring, and distilling the mixture (I) at a temperature in a range from 120 ° C. to 150 ° C.

2. The process and method of claim 1 , wherein the liquid reagent is selected from at least one of sodium hydroxide (NaOH), and a mixture of ethylene glycol and acid.

3. The process and method of claim 1 , wherein refluxing, stirring and distilling the mixture (I) is for a time period from 4 hours to 24 hours.

Assignees

• Seal Sudipta
• Hench Larry L
• Krishna Moorthy Suresh Babu
• Reid David
• Karakoti Ajay
• Univ Central Florida Res Found

Inventors

• Seal Sudipta
• Hench Larry L
• Krishna Moorthy Suresh Babu
• Reid David
• Karakoti Ajay

Classifications

• C04B12/005 Primary

  Geopolymer cements, e.g. reaction products of aluminosilicates with alkali metal hydroxides or silicates · CPC title

• C04B7/243

  Mixtures thereof with activators or composition-correcting additives, e.g. mixtures of fly ash and alkali activators · CPC title

• C04B2111/00017

  Aspects relating to the protection of the environment · CPC title

• Y02P40/165

  Cross-Sectional Technologies · mapped topic

• Y02P40/145

  Cross-Sectional Technologies · mapped topic