Cementitious reagents, methods of manufacturing and uses thereof
AssigneeTerra Co2 Technology Holdings, Inc.
InventorDonald John Lake
Life of this patent
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Abstract
Described are cementitious reagent materials produced from globally abundant inorganic feedstocks. Also described are methods for the manufacture of such cementitious reagent materials and forming the reagent materials as microspheroidal glassy particles. Also described are apparatuses, systems and methods for the thermochemical production of glassy cementitious reagents with spheroidal morphology. The apparatuses, systems and methods make use of an in-flight melting/quenching technology such that solid particles are flown in suspension, melted in suspension, and then quenched in suspension. The cementitious reagents can be used in concrete to substantially reduce the CO2 emission associated with cement production.
Claims27
A cementitious material comprising:
- glassy particles having a mean roundness (R)>0.7, and a molar composition containing Si and Al and optionally one or more of Fe, Ca, Mg, Na, and K, wherein:
- about
-
-
- 0.3
- <
- Si
- Si
- +
- Al
- +
- Fe
- +
- Ca
- +
- Mg
- +
- Na
- +
- K
- <
- about
-
-
- 0.6
- ;
- about
-
-
- 0.2
- <
- Al
- Si
- +
- Al
- +
- Fe
- +
- Ca
- +
- Mg
- +
- Na
- +
- K
- <
- about
-
-
- 0.35
- ;
- and comprising at least one of:
- (i) a mullite content of less than about 1 wt. %;
- (ii) a phosphorus (P2O5) content of less than about 0.5 wt. %;
- (iii) a sulfur (SO3) content of less than about 0.2 wt. %;
- and
- (iv) a total heavy metal content of less than about 3000 ppm.
A method comprising:
- entraining solid particles of an aluminosilicate feedstock in a conveying gas stream;
- optionally pre-heating the aluminosilicate feedstock particles to a temperature insufficient to substantially melt the solid particles;
- flowing the aluminosilicate feedstock particles through a burner or combustion zone;
- heating the aluminosilicate feedstock particles to a temperature sufficient to melt the solid particles and form molten particles;
- and
- cooling the molten particles to form microspheroidal glassy particles having a mean roundness (R)>0.7, and a molar composition containing Si and Al and optionally one or more of Fe, Ca, Mg, Na, and K, wherein:
- about
-
-
-
- 0.3
- <
- Si
- Si
- +
- Al
- +
- Fe
- +
- Ca
- +
- Mg
- +
- Na
- +
- K
- <
- about
-
-
- 0.6
- ;
-
- and
-
- about
-
-
- 0.2
- <
- Al
- Si
- +
- Al
- +
- Fe
- +
- Ca
- +
- Mg
- +
- Na
- +
- K
- <
- about
-
-
- 0.35
- .
A concrete batch mixture comprising:
- 5-45 wt. % solid aggregate;
- 15-25 wt. % ambient cure reagent;
- and
- 40-70 wt. % cementitious reagent, wherein the cementitious reagent comprises:
- microspheroidal glassy particles having a mean roundness (R)>0.7, and a molar composition containing Si and Al and optionally one or more of Fe, Ca, Mg, Na, and K, where:
- about
-
-
- 0.3
- <
- Si
- Si
- +
- Al
- +
- Fe
- +
- Ca
- +
- Mg
- +
- Na
- +
- K
- <
- about
-
-
- 0.6
- ;
-
- and
- about
-
-
- 0.2
- <
- Al
- Si
- +
- Al
- +
- Fe
- +
- Ca
- +
- Mg
- +
- Na
- +
- K
- <
- about
-
-
- 0.35
- .
A cementitious material comprising:
- glassy particles having a mean roundness (R)>0.7, and a molar composition containing Si and Al and optionally one or more of Fe, Ca, Mg, Na, and K, wherein:
- about
-
-
- 0.067
- <
- Si
- Si
- +
- Al
- +
- Fe
- +
- Ca
- +
- Mg
- +
- Na
- +
- K
- <
- about
-
-
- 0.95
- ;
- about
-
-
- 0.03
- <
- Al
- Si
- +
- Al
- +
- Fe
- +
- Ca
- +
- Mg
- +
- Na
- +
- K
- <
- about
-
-
- 0.49
- ;
- and comprising at least one of:
- (i) a mullite content of less than about 1 wt. %;
- (ii) a phosphorus (P2O5) content of less than about 0.5 wt. %;
- (iii) a sulfur (SO3) content of less than about 0.2 wt. %;
- and
- (iv) a total heavy metal content of less than about 3000 ppm.
Dependencies are inferred from the claim text.