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(12) Patent Application Publication (10) Pub. No.: US 2014/0290535 A1 Devaraj Et Al

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(12) Patent Application Publication (10) Pub. No.: US 2014/0290535 A1 Devaraj Et Al US 20140290535A1 (19) United States (12) Patent Application Publication (10) Pub. No.: US 2014/0290535 A1 Devaraj et al. (43) Pub. Date: Oct. 2, 2014 (54) BINDER COMPOSITION (52) U.S. Cl. (75) Inventors: Amutha Rani Devaraj, Barkingside CPC. C04B 9/00 (2013.01); C04B 9/12 (2013.01); (GB); Hai Xiang Lee, London (GB); C04B 28/105 (2013.01); C04B 21 1 1/00017 Diego Alfonso Martinez Velandia, (2013.01) London (GB); Nikolaos Vlasopoulos, USPC .......................................................... 106/801 London (GB) (73) Assignee: CALIX LIMITED, Pymble, NSW (AU) (57) ABSTRACT (21) Appl. No.: 13/820,222 New cement binders characterised by including: 30-80% by weight of a first component having MgO and at least one (22) PCT Filed: Aug. 8, 2011 magnesium carbonate having the general formula: W (86). PCT No.: PCT/EP2O11?063629 MgCOX MgOy Mg(OH).ZHO (A) in which w is a number S371 (c)(1), equal to or greater than 1; at least one of x, y or Z is a number (2), (4) Date: May 8, 2013 greater than 0 and W, X, y and Z may be (but need not be) integers and 20-70% by weight of a second component (30) Foreign Application Priority Data including a least one silicon and/or aluminium oxide contain Sep. 2, 2010 (GB) ................................... 101.4577.9 ing material are disclosed. They can be used to produce build ing materials (cements, mortars, grouts and the like) having Publication Classification improved structural properties relative to prior art materials. In particular, their manufacture is less energy intensive than (51) Int. Cl. C04B 9/00 (2006.01) e.g. Portland cement making them environmentally friendly C04B 28/10 (2006.01) in the sense that processes for their manufacture have a rela C04B 9/12 (2006.01) tively low carbon footprint. US 2014/0290535 A1 Oct. 2, 2014 BNDER COMPOSITION used as a “moderating Substance' to enable the salt and the 0001. This invention relates to a cement binder suitable for MgO to perform the chemical reactions necessary to set, use in construction products. which are similar to those of the other Sorel cements. These 0002 Emissions of greenhouse gases, and predomi cements require the use of hard-burnt MgO, which is gener nantly carbon dioxide (CO), are thought to contribute to an ally produced by high-temperature treatment (~1000°C.) of increase in the atmospheric and Surface temperatures of the magnesite (MgCO), which causes CO emissions not only Earth—a phenomenon commonly referred to as global from the calcining of magnesite but also from the burning of warming. Such temperature increases are predicted to have fossil fuel. serious environmental consequences. The main contributor to 0009 U.S. Pat. No. 5,897,703 discloses binder composi this increase in man-made CO is the burning of fossil fuels tions based on mixing MgO with a hardening agent, propy Such as coal and petroleum. lene carbonate. The magnesium oxide used can be any mix 0003 Portland cement is the most common type of cement ture of soft-burnt and hard-burnt MgO. It is known that in the in general use at this time. It is an essential element of con presence of water, propylene carbonate decomposes to car crete, mortar and non-speciality grouts. Portland cement con bon dioxide and propylene glycol and so the addition of the sists of over 90% Portland cement clinker, up to 5% gypsum propylene carbonate provides a source of CO to carbonate and up to 5% other minor constituents. Portland cement clin the magnesium oxide. ker is a hydraulic material consisting mainly of di-calcium (0010 U.S. Pat. No. 6,200,381 discloses a dry powdered silicate (2CaO.SiO), tri-calcium silicate (3CaO.SiO), tri cement composition derived from dolomite (a magnesium calcium aluminate (3CaO. Al2O) and calcium aluminoferrite and calcium carbonate mineral: MgCO.CaCO). The dolo (4CaO. Al-O FeO) phases. Magnesium oxide (MgO), can mite is heated to decarbonate the MgCO so that the compo also be present in Portland cement, although its amount must sition contains CaCO and a partially decarbonated MgCO, not exceed 5% by mass as its delayed hydration is believed to i.e. a mixture of MgCO and MgO. Certain additives may be give rise to unsoundness in concrete. Gypsum (CaSO4.2H2O) included in the composition (e.g. aluminium Sulphate (Al is added to Portland cement clinker to control its setting time, (SO4)), citric acid, Sulphuric acid (H2SO4), NaCl, etc.), and the mixture is ground to give a fine powder. On reaction which assist the composition to set on addition of water; the with water, the constituents of the cement hydrate forming a water may be contaminated water, e.g. sea water. The CaCO Solid complex calcium silicate hydrate gel and other phases. component of the cement composition reacts with several of 0004. The manufacture of Portland cement is a highly the specified additives that are used. For example, the addition energy intensive process that involves heating high volumes of HSO will react with CaCO, yielding hydrated CaSO of raw materials to around 1450° C. In addition to the CO (e.g. CaSO4.2H2O) and CO. The CO released assists the generated from burning fossil fuels to reach these tempera carbonation of MgO and Mg(OH). NaCl may be added tures, the basic raw material used in making Portland cement before the thermal treatment of dolomite to decrease the is calcium carbonate (limestone, CaCO), and this decom decarbonation temperature of MgCO, and in the bindercom poses during processing to calcium oxide, releasing addi position as an additive, where it appears to assist in achieving tional geologically sequestered CO. As a result, the manu an early strength to the composition, which is probably due to facture of Portland cement typically emits approximately 0.8 reactions with MgO (Sorel cement type reactions). CaCO tonnes of carbon dioxide for every tonne of cement produced acts as a “moderating substance' to enable NaCl and the MgO and is responsible for approximately 5% of all anthropogenic to perform the necessary chemical reactions (see GB CO2 emissions. 116.0029 above). 0005 Apart from the intrinsic benefit of reducing CO (0011 U.S. Pat. No. 1,867,180 describes a cement compo emissions, it is likely that CO emissions by the cement indus sition based on slaked lime (Ca(OH)) that contains less than try will be regulated in an attempt to reduce environmental 1% MgO and NaCl. damage. Therefore, there is a real need to develop a new range 0012 U.S. Pat. No. 1,561,473 discloses that, when a wet of cementitious binders that are associated with minimal or mixture of aggregates and magnesium oxide is treated with even negative CO2 emissions. gaseous or dissolved CO, its tensile strength is improved. 0006 Binders based on systems other than calcium oxide The composition must be exposed to CO when wet and the and silicates are known. For example, Sorel cement (magne patent discloses the exposure of the wet mixture to a special sium oxychloride cement or magnesia cement) is an example atmosphere of moist CO. of a cement binder that comprises a mixture of magnesium (0013 WO 01/55049 discloses a dry powdered cement oxide (burnt magnesia, MgO) and magnesium chloride composition containing MgO, a hydraulic cement compo together with filler materials like sand or crushed stone. It sets nent, such as Portland cement, Sorel cements or calcium to a very hard abrasive-resistant material and so is used for aluminate cements, and optionally various poZZolanic mate grindstones, tiles, artificial stone (cast Stone) and cast floors, rials. The cement composition taught can also contain various in which application it has a high wear resistance. Howeverits additives such as ferrous Sulphate (FeSO4), Sodium or potas chief drawback is its poor resistance to water, making it sium silicates or aluminates, phosphoric acid (HPO) or unsuitable for external construction applications. phosphoric acid salts, copper Sulphate (CuSO4), and various 0007. Other magnesium based cements include magne other organic polymers and resins, such as polyvinyl acetate sium oxysulfate cement and magnesium phosphate cements (PVA), vinyl acetate-ethylene, styrene-butyl acrylate, butyl but both these have drawbacks, the former having a poor acrylate-methylacrylate, and styrene-butadiene. The magne water resistance and the latter sets very fast so that it is sium oxide is obtained by low temperature calcining. difficult to work with. 0014 GB529128 discloses the use of magnesium carbon 0008 GB 116.0029 discloses cements based on mixing ate as an insulating material; it is made from concentrated sea magnesium oxide (MgO), sodium chloride (NaCl) or sodium water containing magnesium salts by precipitating the salts nitrate (NaNO) and calcium carbonate (CaCO). CaCO is with alkali metal carbonates, which forms needle-like crys US 2014/0290535 A1 Oct. 2, 2014 tals that can set. A slurry of Such crystals, when paced in a cement. However there is no explicit disclosure of the mould, will set to provide a slab or block that is useful as improved binder compositions claimed herein or the benefits insulation. If there are any bicarbonate ions in the alkali metal thereof. carbonate, magnesium bicarbonate will form in the above 0022 WO 2010/039903 and WO 2010/048457 disclose reaction, which slows down the setting reaction. In order to reduced carbon footprint concrete compositions for use in a counteract this, 1-5% magnesium oxide may be added, which variety of building materials and building applications. These will precipitate the bicarbonate as magnesium carbonate. compositions appear to be a blend of a carbon dioxide seques tering component comprising a carbonate, bicarbonate or 0.015 U.S. Pat.
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