# US 2021/0331972 A1 · Cementitious reagents, methods of manufacturing and uses thereof

> Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt

- Number: US 2021/0331972 A1
- Document ID: US20210331972A1
- Status: Published application
- Kind: A1
- Application number: 17/369,509
- Filed: 2021-07-07
- Published: 2021-10-28
- Earliest claimed: 2019-06-27
- Assignees: Terra Co2 Technology Holdings, Inc.
- Applicants: Terra CO2 Technology Holdings, Inc.
- Inventors: Donald John Lake
- Web page: https://patentgrep.com/patent/US20210331972A1

## CPC

- C04B 14/22: Glass {; Devitrified glass}
- B05B 7/20: by flame or combustion
- B22F 3/003: {Apparatus, e.g. furnaces (in general F27B)}
- C03B 5/00: Melting in furnaces; Furnaces so far as specially adapted for glass manufacture
- C03B 19/10: Forming beads
- C04B 7/4453: {using plasmas or radiations}
- C04B 14/30: Oxides other than silica {(ferrites C04B14/363)}
- C04B 20/0036: {Microsized or nanosized}
- C04B 20/026: {Comminuting, e.g. by grinding or breaking; Defibrillating fibres other than asbestos}
- C04B 20/04: Heat treatment
- C04B 35/62665: {Flame, plasma or melting treatment}
- C09K 8/80: Compositions for reinforcing fractures, e.g. compositions of proppants used to keep the fractures open
- F27B 15/00: Fluidised-bed furnaces; Other furnaces using or treating finely-divided materials in dispersion
- F27B 15/10: Arrangements of air or gas supply devices
- F27B 15/14: Arrangements of heating devices
- C04B 7/43: Heat treatment, e.g. precalcining, burning, melting; Cooling {(aspects only relating to the installation F27B)}
- C04B 7/44: Burning; Melting
- C04B 2103/0042: {Amorphous materials}
- C04B 2111/00327: {for obtaining microstructures}
- C04B 2235/528: Spheres
- F27B 15/003: {Cyclones or chain of cyclones}
- Y02P 40/10: Production of cement, e.g. improving or optimising the production methods; Cement grinding
- Y02P 40/121: Energy efficiency measures, e.g. improving or optimising the production methods
- Y02P 40/18: Carbon capture and storage [CCS]
- Y02W 30/91: Use of waste materials as fillers for mortars or concrete
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE
- B05B: SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES (spray-mixers with nozzles B01F25/72; processes for applying liquids or other fluent materials to surfaces by spraying B05D)
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- C03B: MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
- C09K: MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- F27B: FURNACES, KILNS, OVENS OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02W: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT

## 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.

## Claims

### Claim 1

A method comprising:
introducing solid particles of an aluminosilicate feedstock into a melt chamber;
heating the aluminosilicate feedstock particles within the melt chamber to form molten particles; and
cooling the molten particles within a quench chamber to form microspheroidal glassy particles, wherein the microspheroidal glassy particles have a mean roundness (R)>0.7, are at least about 40% x-ray amorphous, and have a molar composition containing Si and Al and optionally one or more of Fe, Ca, Mg, Na, and K, such that:
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
.

### Claim 2 (depends on 1)

The method of claim 1, wherein the aluminosilicate feedstock is substantially free of fly ash.

### Claim 3 (depends on 1)

The method of claim 1, further comprising blending the aluminosilicate feedstock with a composition adjustment material prior to heating the aluminosilicate feedstock particles within the melt chamber.

### Claim 4 (depends on 1)

The method of claim 1, further comprising blending the aluminosilicate feedstock with a composition adjustment material while heating the aluminosilicate feedstock particles within the melt chamber.

### Claim 5 (depends on 1)

The method of claim 1, further comprising milling the solid aluminosilicate feedstock particles prior to heating the aluminosilicate feedstock particles within the melt chamber.

### Claim 6 (depends on 1)

The method of claim 1, further comprising mixing the aluminosilicate feedstock with a fluxing material adapted to lower a melting point of the aluminosilicate feedstock particles prior to heating the aluminosilicate feedstock particles within the melt chamber.

### Claim 7 (depends on 1)

The method of claim 1, further comprising entraining the solid aluminosilicate feedstock particles in a gas stream.

### Claim 8 (depends on 7)

The method of claim 7, wherein the gas stream comprises an oxidant gas and a combustible fuel.

### Claim 9 (depends on 1)

The method of claim 1, wherein the aluminosilicate feedstock particles are suspended in a flame comprising an oxidant gas and a combustible fuel.

### Claim 10 (depends on 9)

The method of claim 9, wherein the flame is stabilized by an annular flow of quench air.

### Claim 11 (depends on 1)

The method of claim 1, wherein the solid aluminosilicate feedstock particles are flown and melted in suspension and the molten particles are cooled in suspension.

### Claim 12 (depends on 1)

The method of claim 1, wherein the molten feedstock particles are cooled at a cooling rate of about 102 Ks-1 to about 106 Ks-1.

### Claim 13 (depends on 1)

The method of claim 1, wherein the cooling comprises contacting the molten particles with a stream containing a fluid selected from the group consisting of air, steam, and water.

### Claim 14 (depends on 1)

The method of claim 1, further comprising milling the microspheroidal glassy particles to a Sauter mean diameter D[3,2] of about 20 micrometers or less.

### Claim 15

(canceled)

### Claim 16 (depends on 1)

The method of claim 1, further comprising collecting the microspheroidal glassy particles using a cyclone separator.

### Claim 17 (depends on 1)

The method of claim 1, further comprising mixing the microspheroidal glassy particles with one or more additives selected from the group consisting of hardeners, ambient cure reagents, admixtures, plasticizers, reinforcement materials, sand, and coarse aggregate.

### Claim 18

(canceled)

### Claim 19

(canceled)

### Claim 20

(canceled)

### Claim 21 (depends on 1)

The method of claim 1, further comprising adding the microspheroidal particles to a cementitious matrix as a reagent.

### Claim 22 (depends on 1)

The method of claim 1, wherein the solid particles of the aluminosilicate feedstock comprise one or more of dredged sediments, demolished concrete, mine wastes, rocks and mineral mixtures, glacial deposits, and fluvial deposits.

### Claim 23 (depends on 1)

The method of claim 1, wherein heating the aluminosilicate feedstock particles within the melt chamber comprises one or more of a plasma torch, an oxy-fuel burner, an air-fuel burner, a biomass burner, electrical resistance heating, electrical inductance heating, and a solar concentrating furnace.

### Claim 24 (depends on 3)

The method of claim 3, wherein blending the aluminosilicate feedstock with the composition adjustment material comprises selecting and adding the composition adjustment material to modify a content of one or more of Ca, Mg, Na, K, Al, Fe, and Si in the microspheroidal glassy particles.