CA2821414A1 - Cement binder compositions and their uses and products made therefrom - Google Patents
Cement binder compositions and their uses and products made therefrom Download PDFInfo
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- CA2821414A1 CA2821414A1 CA2821414A CA2821414A CA2821414A1 CA 2821414 A1 CA2821414 A1 CA 2821414A1 CA 2821414 A CA2821414 A CA 2821414A CA 2821414 A CA2821414 A CA 2821414A CA 2821414 A1 CA2821414 A1 CA 2821414A1
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P40/00—Technologies relating to the processing of minerals
- Y02P40/10—Production of cement, e.g. improving or optimising the production methods; Cement grinding
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Abstract
The present application describes a low cost, commercially viable cement binder composition comprising magnesium oxide, fly ash and a liquid potassium phosphate fertilizer and its use in the preparation of low cost MgO concrete composite materials, in particular, glass composite materials or "glasscrete".
Description
TITLE: CEMENT BINDER COMPOSITIONS AND THEIR USES AND
PRODUCTS MADE THEREFROM
FIELD
[0001] The present disclosure relates to cement binder compositions useful for preparing composite materials, such as construction forms made from glass materials. In particular, the binder composition is a magnesium oxide (MgO) cement formulation that is lower in cost than other known MgO cement formulations, and is insulating and odorless.
BACKGROUND
PRODUCTS MADE THEREFROM
FIELD
[0001] The present disclosure relates to cement binder compositions useful for preparing composite materials, such as construction forms made from glass materials. In particular, the binder composition is a magnesium oxide (MgO) cement formulation that is lower in cost than other known MgO cement formulations, and is insulating and odorless.
BACKGROUND
[0002] Despite the many advantages of MgO cements over traditional Portland cements, all available MgO cement binder formulations are used only in special applications because of their high cost. For example, existing and available MgO cement composites cost more than 5 times the same composites made with Portland cement.
[0003] Many alternative low cost binder formulations are prepared with ammonium phosphate solutions (e.g. 11-37-0, 15-15-15) however these formulations emit an ammonia smell which is unpleasant and causes health issues.
SUMMARY
SUMMARY
[0004] In the present application a low cost MgO cement binder has been prepared that does not emit nitrogenous odors. The cement is up to 10 times stronger than Portland cement and is specially formulated to ensure the unique primary insulating properties of MgO cement is not altered or affected.
[0005] Accordingly the present application includes a cement binder composition comprising:
(a) about 30% to about 40% MgO;
(b) about 15% to about 40% fly ash; and (c) about 30% to about 40% of a nitrogen-free liquid potassium phosphate fertilizer.
(a) about 30% to about 40% MgO;
(b) about 15% to about 40% fly ash; and (c) about 30% to about 40% of a nitrogen-free liquid potassium phosphate fertilizer.
[0006] The present application also includes products made with the cement binder compositions disclosed herein. In particular, the cement binder compositions are combined with a construction aggregate, such as glass aggregate, to create a composite material that is useful in construction. The resulting composite material can be made into any shape and size and used, for example, in a wide variety of landscape and building projects. The composite material advantageously does not conduct heat or cold, and therefore is insulating and does not emit odor. The composite material also does not conduct electro-magnetic forces (EWF) and dehydrates at a very high rate (for example, much faster than similar Portland cement-bonded products) thus retaining its insulating properties.
100071 Accordingly, the present application further includes a composite material comprising a cement binder composition disclosed herein and a construction aggregate. In an embodiment, the construction aggregate is glass, such as processed waste glass aggregate (clean glass). In a further embodiment, the construction aggregate is present in the composite material in an amount of about 55% to about 83% and the cement binder composition is present in the composite material in an amount of about 17% to about 45%.
[00081 Also included, is a process for producing the composite materials of the present application. Accordingly the present application includes a process for producing a composite material comprising:
(a) combining MgO and fly ash to provide a first mixture;
(b) combining a construction aggregate and the first mixture to provide a second mixture;
(c) combining a suitable quantity of water and the second mixture to provide a third mixture, the suitable quantity of water being determined by a setting time;
(d) combining a nitrogen-free liquid potassium phosphate fertilizer and the third mixture to provide a final mixture; and (e) allowing the final mixture to set and cure to provide the composite material.
[0009] Other features and advantages of the present disclosure will become apparent from the following detailed description. It should be understood, however, that the detailed description and the specific examples while indicating embodiments of the disclosure are given by way of illustration only, since various changes and modifications within the spirit and scope of the disclosure will become apparent to those skilled in the art from this detailed description.
DETAILED DESCRIPTION
I. Definitions [0010] Unless otherwise indicated, all percentages reported herein are by volume (i.e. v/v%).
[0011] The term "cement" as used herein refers to a substance that acts as a binder. Cements set and harden independently, and can bind other materials, such as aggregate, together.
[0012] The term "fly ash" as used herein refers to the ash that is created during the combustion of coal and that is collected in the flue stack. The composition of fly ash varies depending on the type of coal that is burned. All fly ash contains silicon dioxide (Si02) and calcium oxide or lime (CaO).
[0013] The term "Class C fly ash" as used herein is a designation given by the American Society for Testing and Materials (ASTM) under their C618 standard to refer to the fly ash produced when the type of coal that is burned is a younger lignite. Class C
fly ash has a lime content of greater than 10% and is often referred to as "high calcium"
fly ash.
[0014] The term "liquid fertilizer" as used herein refers to a liquid solution that comprises inorganic material that is added to a soil to supply one or more plant nutrients essential to the growth of plants. In the United States and Canada, the labeling scheme for fertilizers presents three numbers separated by dashes (e.g. 10-10-10 or 16-4-8). The first number represents the percentage of nitrogen in the product; the second number, the percentage of phosphorus; and the third, the percentage of potassium. This labeling scheme is generalized as the N-P-K number.
[0015] The term "nitrogen free liquid fertilizer" refers to a liquid fertilizer having a labeling scheme that is 0 (zero)-X-Y, wherein X is the percentage of phosphorus and Y
is the percentage of potassium.
[0016] The term "construction aggregate" as used herein refers to a broad category of coarse particulate material used in construction, and includes glass, sand, gravel, crushed stone, slag, recycled concrete and geosynthetic aggregates.
The aggregate serves as reinforcement to add strength to the overall composite material.
[0017] The term "glass aggregate" as used herein refers to glass, including recycled glass that has been cleaned and processed so that it suitable for combining with a cement binder composition of the present application to make a composite material. In an embodiment, the glass is processed to have rounded edges and graded from 0.01mm ¨ 9 mm.
[0018] The term "setting time" or "set time" as used herein refers to the time it takes for a liquid mixture to solidify, or stop flowing.
[0019] The term "cure" as used herein refers to the process of drying of a set mixture to provide a product that has reached its maximum strength.
[0020] The term "de-molding time" as used herein refers to the time it takes for a mixture to be strong and hard enough to be removed from the mold, for example, without chipping or breaking.
[0021] Unless otherwise indicated, the definitions and embodiments described in this and other sections are intended to be applicable to all embodiments and aspects of the disclosure herein described for which they are suitable as would be understood by a person skilled in the art.
[0022] In understanding the scope of the present disclosure, the term "comprising" and its derivatives, as used herein, are intended to be open ended terms that specify the presence of the stated features, elements, components, groups, integers, and/or steps, but do not exclude the presence of other unstated features, elements, components, groups, integers and/or steps. The foregoing also applies to words having similar meanings such as the terms, "including", "having" and their derivatives. The term "consisting" and its derivatives, as used herein, are intended to be closed terms that specify the presence of the stated features, elements, components, groups, integers, and/or steps, but exclude the presence of other unstated features, elements, components, groups, integers and/or steps. The term "consisting essentially of', as used herein, is intended to specify the presence of the stated features, elements, components, groups, integers, and/or steps as well as those that do not materially affect the basic and novel characteristic(s) of features, elements, components, groups, integers, and/or steps.
[0023] Terms of degree such as "about" and "approximately" as used herein mean a reasonable amount of deviation of the modified term such that the end result is not significantly changed. These terms of degree should be construed as including a deviation of at least 1% of the modified term if this deviation would not negate the meaning of the word it modifies.
II. Cement Binder Compositions [0024] The present application includes a cement binder composition comprising:
(a) about 30% to about 40% MgO;
(b) about 15% to about 40% fly ash; and (c) about 30% to about 40% of a nitrogen-free liquid potassium phosphate fertilizer.
[0025] In an embodiment, the magnesium oxide (MgO) is a dry magnesium powder. MgO is available commercially [0026] In another embodiment, the fly ash is Type C fly ash. In another embodiment, the fly ash is used in dry form. In a further embodiment, the Type C fly ash is from a cement plant.
[0027] In another embodiment, the nitrogen-free liquid potassium phosphate fertilizer is any potassium phosphate fertilizer that does not comprise a source of nitrogen.
In a further embodiment, the nitrogen-free liquid potassium phosphate fertilizer has a N-P-K composition of 0 (zero)-X-Y, wherein X is about 10 to about 30 and B is about 10 to about 30. In a further embodiment, the nitrogen-free liquid potassium phosphate fertilizer has a N-P-K composition of 0-20-20. Nitrogen-free liquid potassium phosphate fertilizer are commercially available.
III. Methods of Using the Cement Binder Compositions and Products Made Therefrom [0028] The cement binder compositions of the present application can be used in any product or process where a cement is needed. In an embodiment the cement binder compositions are used to prepare composite materials for use in construction.
For example, the cement binder compositions are combined with a construction aggregate to prepare a composite material with high mechanical strength (for example up to 10 times stronger than corresponding products made with Portland cement), good insulating properties and low odor. The composite materials are commercially viable as they are of lower cost compared with similar materials prepared with other available alternative MgO cement formulations, which are only used for special applications because of their high cost.
Accordingly, the present application also includes products made with the cement binder compositions disclosed herein. In particular, the cement binder compositions are combined with a construction aggregate, to create a composite material that is useful in construction. The resulting composite materials can be made into any shape and size and used, for example, in a wide variety of landscape and building projects.
[0030]
Therefore, the present application further includes a composite material for use in construction comprising a cement binder composition disclosed herein and a construction aggregate.
100311 In an embodiment, the construction aggregate is glass, such as processed waste or recycled glass aggregate. . In further embodiment, the glass is free from other contaminants. In a further embodiment the glass is a graded glass aggregate having a size of 0.01 mm to about 9 mm. In a further embodiment, the glass aggregate is present in the composite material in an amount of about 55% to about 83% and the cement binder composition is present in the composite material in an amount of about 17% to about 45%.
The quantity of the cement binder in the composite material is increased or decreased within the range, depending on the size composition (distribution) of the aggregate used, as would be known to those skilled in the art. The composite material prepared from glass aggregate and the cement binder compositions of the present application, advantageously has a stone-like appearance, the colour of which is altered by the addition of liquid or powdered pigments. The cement binder formulation reacts together to form a gel-like paste that does not conduct heat or cold, and therefore is insulating, and does not emit odor.
[0032] Also included, is a process for producing the composite materials of the present application. Accordingly the present application includes a process for producing a composite material comprising:
(a) combining MgO and fly ash to provide a first mixture;
(b) combining a construction aggregate and the first mixture to provide a second mixture;
(c) combining a suitable quantity of water and the second mixture to provide a third mixture, the suitable quantity of water being determined by a setting time;
(d) combining a nitrogen-free liquid potassium phosphate fertilizer and the third mixture to provide a final mixture; and (e) allowing the final mixture to set and cure to provide the composite material..
[0033] In an embodiment, the construction aggregate is glass and the composite material is a glass concrete. In another embodiment, the glass is a glass aggregate obtained from waste glass. In further embodiment, the glass is free from other contaminants.
[0034] In an embodiment, the MgO is a dry MgO powder and is present in the final composite material in an amount (not including water) of about 10% to about 15%; the fly ash is Type C fly ash used as a dry powder and is present in the final composite material in an amount (not including water) of about 5% to about 15%; the glass is present in the final composite material in an amount (not including water) of about 60% to about 85%; and the nitrogen-free liquid potassium phosphate fertilizer is present in the final composite material in an amount (not including water) of about 5% to about 8%. In a further embodiment, the nitrogen-free liquid potassium phosphate fertilizer has a N-P-K composition of 0 (zero)-X-Y, wherein X is about 10 to about 30 and B is about 10 to about 30. In a further embodiment, the nitrogen-free liquid potassium phosphate fertilizer has a N-P-K
composition of 0-20-20.
[0035] In an embodiment, the final mixture is poured into molds forming shapes for use in building or landscape construction and the final mixture is allowed to set and eufe in the mold, until it is ready to be de-molded and stacked in plates to cure at room temperature. The shape will be determined by the final end use of the composite material and includes, but is not limited to, brick-like shapes for building walls, flatter shapes (e.g.
100071 Accordingly, the present application further includes a composite material comprising a cement binder composition disclosed herein and a construction aggregate. In an embodiment, the construction aggregate is glass, such as processed waste glass aggregate (clean glass). In a further embodiment, the construction aggregate is present in the composite material in an amount of about 55% to about 83% and the cement binder composition is present in the composite material in an amount of about 17% to about 45%.
[00081 Also included, is a process for producing the composite materials of the present application. Accordingly the present application includes a process for producing a composite material comprising:
(a) combining MgO and fly ash to provide a first mixture;
(b) combining a construction aggregate and the first mixture to provide a second mixture;
(c) combining a suitable quantity of water and the second mixture to provide a third mixture, the suitable quantity of water being determined by a setting time;
(d) combining a nitrogen-free liquid potassium phosphate fertilizer and the third mixture to provide a final mixture; and (e) allowing the final mixture to set and cure to provide the composite material.
[0009] Other features and advantages of the present disclosure will become apparent from the following detailed description. It should be understood, however, that the detailed description and the specific examples while indicating embodiments of the disclosure are given by way of illustration only, since various changes and modifications within the spirit and scope of the disclosure will become apparent to those skilled in the art from this detailed description.
DETAILED DESCRIPTION
I. Definitions [0010] Unless otherwise indicated, all percentages reported herein are by volume (i.e. v/v%).
[0011] The term "cement" as used herein refers to a substance that acts as a binder. Cements set and harden independently, and can bind other materials, such as aggregate, together.
[0012] The term "fly ash" as used herein refers to the ash that is created during the combustion of coal and that is collected in the flue stack. The composition of fly ash varies depending on the type of coal that is burned. All fly ash contains silicon dioxide (Si02) and calcium oxide or lime (CaO).
[0013] The term "Class C fly ash" as used herein is a designation given by the American Society for Testing and Materials (ASTM) under their C618 standard to refer to the fly ash produced when the type of coal that is burned is a younger lignite. Class C
fly ash has a lime content of greater than 10% and is often referred to as "high calcium"
fly ash.
[0014] The term "liquid fertilizer" as used herein refers to a liquid solution that comprises inorganic material that is added to a soil to supply one or more plant nutrients essential to the growth of plants. In the United States and Canada, the labeling scheme for fertilizers presents three numbers separated by dashes (e.g. 10-10-10 or 16-4-8). The first number represents the percentage of nitrogen in the product; the second number, the percentage of phosphorus; and the third, the percentage of potassium. This labeling scheme is generalized as the N-P-K number.
[0015] The term "nitrogen free liquid fertilizer" refers to a liquid fertilizer having a labeling scheme that is 0 (zero)-X-Y, wherein X is the percentage of phosphorus and Y
is the percentage of potassium.
[0016] The term "construction aggregate" as used herein refers to a broad category of coarse particulate material used in construction, and includes glass, sand, gravel, crushed stone, slag, recycled concrete and geosynthetic aggregates.
The aggregate serves as reinforcement to add strength to the overall composite material.
[0017] The term "glass aggregate" as used herein refers to glass, including recycled glass that has been cleaned and processed so that it suitable for combining with a cement binder composition of the present application to make a composite material. In an embodiment, the glass is processed to have rounded edges and graded from 0.01mm ¨ 9 mm.
[0018] The term "setting time" or "set time" as used herein refers to the time it takes for a liquid mixture to solidify, or stop flowing.
[0019] The term "cure" as used herein refers to the process of drying of a set mixture to provide a product that has reached its maximum strength.
[0020] The term "de-molding time" as used herein refers to the time it takes for a mixture to be strong and hard enough to be removed from the mold, for example, without chipping or breaking.
[0021] Unless otherwise indicated, the definitions and embodiments described in this and other sections are intended to be applicable to all embodiments and aspects of the disclosure herein described for which they are suitable as would be understood by a person skilled in the art.
[0022] In understanding the scope of the present disclosure, the term "comprising" and its derivatives, as used herein, are intended to be open ended terms that specify the presence of the stated features, elements, components, groups, integers, and/or steps, but do not exclude the presence of other unstated features, elements, components, groups, integers and/or steps. The foregoing also applies to words having similar meanings such as the terms, "including", "having" and their derivatives. The term "consisting" and its derivatives, as used herein, are intended to be closed terms that specify the presence of the stated features, elements, components, groups, integers, and/or steps, but exclude the presence of other unstated features, elements, components, groups, integers and/or steps. The term "consisting essentially of', as used herein, is intended to specify the presence of the stated features, elements, components, groups, integers, and/or steps as well as those that do not materially affect the basic and novel characteristic(s) of features, elements, components, groups, integers, and/or steps.
[0023] Terms of degree such as "about" and "approximately" as used herein mean a reasonable amount of deviation of the modified term such that the end result is not significantly changed. These terms of degree should be construed as including a deviation of at least 1% of the modified term if this deviation would not negate the meaning of the word it modifies.
II. Cement Binder Compositions [0024] The present application includes a cement binder composition comprising:
(a) about 30% to about 40% MgO;
(b) about 15% to about 40% fly ash; and (c) about 30% to about 40% of a nitrogen-free liquid potassium phosphate fertilizer.
[0025] In an embodiment, the magnesium oxide (MgO) is a dry magnesium powder. MgO is available commercially [0026] In another embodiment, the fly ash is Type C fly ash. In another embodiment, the fly ash is used in dry form. In a further embodiment, the Type C fly ash is from a cement plant.
[0027] In another embodiment, the nitrogen-free liquid potassium phosphate fertilizer is any potassium phosphate fertilizer that does not comprise a source of nitrogen.
In a further embodiment, the nitrogen-free liquid potassium phosphate fertilizer has a N-P-K composition of 0 (zero)-X-Y, wherein X is about 10 to about 30 and B is about 10 to about 30. In a further embodiment, the nitrogen-free liquid potassium phosphate fertilizer has a N-P-K composition of 0-20-20. Nitrogen-free liquid potassium phosphate fertilizer are commercially available.
III. Methods of Using the Cement Binder Compositions and Products Made Therefrom [0028] The cement binder compositions of the present application can be used in any product or process where a cement is needed. In an embodiment the cement binder compositions are used to prepare composite materials for use in construction.
For example, the cement binder compositions are combined with a construction aggregate to prepare a composite material with high mechanical strength (for example up to 10 times stronger than corresponding products made with Portland cement), good insulating properties and low odor. The composite materials are commercially viable as they are of lower cost compared with similar materials prepared with other available alternative MgO cement formulations, which are only used for special applications because of their high cost.
Accordingly, the present application also includes products made with the cement binder compositions disclosed herein. In particular, the cement binder compositions are combined with a construction aggregate, to create a composite material that is useful in construction. The resulting composite materials can be made into any shape and size and used, for example, in a wide variety of landscape and building projects.
[0030]
Therefore, the present application further includes a composite material for use in construction comprising a cement binder composition disclosed herein and a construction aggregate.
100311 In an embodiment, the construction aggregate is glass, such as processed waste or recycled glass aggregate. . In further embodiment, the glass is free from other contaminants. In a further embodiment the glass is a graded glass aggregate having a size of 0.01 mm to about 9 mm. In a further embodiment, the glass aggregate is present in the composite material in an amount of about 55% to about 83% and the cement binder composition is present in the composite material in an amount of about 17% to about 45%.
The quantity of the cement binder in the composite material is increased or decreased within the range, depending on the size composition (distribution) of the aggregate used, as would be known to those skilled in the art. The composite material prepared from glass aggregate and the cement binder compositions of the present application, advantageously has a stone-like appearance, the colour of which is altered by the addition of liquid or powdered pigments. The cement binder formulation reacts together to form a gel-like paste that does not conduct heat or cold, and therefore is insulating, and does not emit odor.
[0032] Also included, is a process for producing the composite materials of the present application. Accordingly the present application includes a process for producing a composite material comprising:
(a) combining MgO and fly ash to provide a first mixture;
(b) combining a construction aggregate and the first mixture to provide a second mixture;
(c) combining a suitable quantity of water and the second mixture to provide a third mixture, the suitable quantity of water being determined by a setting time;
(d) combining a nitrogen-free liquid potassium phosphate fertilizer and the third mixture to provide a final mixture; and (e) allowing the final mixture to set and cure to provide the composite material..
[0033] In an embodiment, the construction aggregate is glass and the composite material is a glass concrete. In another embodiment, the glass is a glass aggregate obtained from waste glass. In further embodiment, the glass is free from other contaminants.
[0034] In an embodiment, the MgO is a dry MgO powder and is present in the final composite material in an amount (not including water) of about 10% to about 15%; the fly ash is Type C fly ash used as a dry powder and is present in the final composite material in an amount (not including water) of about 5% to about 15%; the glass is present in the final composite material in an amount (not including water) of about 60% to about 85%; and the nitrogen-free liquid potassium phosphate fertilizer is present in the final composite material in an amount (not including water) of about 5% to about 8%. In a further embodiment, the nitrogen-free liquid potassium phosphate fertilizer has a N-P-K composition of 0 (zero)-X-Y, wherein X is about 10 to about 30 and B is about 10 to about 30. In a further embodiment, the nitrogen-free liquid potassium phosphate fertilizer has a N-P-K
composition of 0-20-20.
[0035] In an embodiment, the final mixture is poured into molds forming shapes for use in building or landscape construction and the final mixture is allowed to set and eufe in the mold, until it is ready to be de-molded and stacked in plates to cure at room temperature. The shape will be determined by the final end use of the composite material and includes, but is not limited to, brick-like shapes for building walls, flatter shapes (e.g.
7 tiles, flagstones, cobble stones, keystones, edge stones) for building pathways or for use to cover wall surfaces, and irregular shapes for making decorative features such as imitation stones and rocks, and other landscaping stone products. It is an embodiment that, when the final mixture is poured into molds, it is vibrated before it sets.
[0036] In an embodiment, the setting time of the final mixture is determined by the amount of water that is added during the process. Generally, the greater the amount of water that is used, the longer the setting time. A person skilled in the art can adjust the amount of water that is used in the process to obtain the desired setting time. A larger amount of water (i.e. longer set times) is typically used for batch mixing processes. In an embodiment, the quantity of water added is about 5% and about 20% by volume.
However water in excess of 10% by volume weakens the chemical reaction of the formulation and the resulting product will lose a part of its insulating property.
Advantageously, the present process is also amenable to continuous process techniques, for example, for use in continuous casting machines. The use of smaller amounts of, which helps maintain the insulating properties of the final product, results in shorter setting times, which can only be accommodated if continuous casting machines are used.
Under continuous casting conditions, the ingredients for the composite material are mixed together in a continuous fashion and poured continuously into molds, or directly onto a construction site or location. It is an embodiment that the final mixture sets in about 30 seconds to about 1 minute and is ready to be removed from a mold (de-molded) in about 20 minutes to about 30 minutes.
[0037] The following non-limiting examples are illustrative of the present disclosure:
EXAMPLES
Example 1: Preparation of Glass-Cement Composite (a) Materials [0038] 15% MgO by volume, 15% Type C Fly Ash by volume with 15% liquid potassium phosphate solution 0-20-20 by volume with 55% by volume of glass 10% by volume of water is added to delay set time
[0036] In an embodiment, the setting time of the final mixture is determined by the amount of water that is added during the process. Generally, the greater the amount of water that is used, the longer the setting time. A person skilled in the art can adjust the amount of water that is used in the process to obtain the desired setting time. A larger amount of water (i.e. longer set times) is typically used for batch mixing processes. In an embodiment, the quantity of water added is about 5% and about 20% by volume.
However water in excess of 10% by volume weakens the chemical reaction of the formulation and the resulting product will lose a part of its insulating property.
Advantageously, the present process is also amenable to continuous process techniques, for example, for use in continuous casting machines. The use of smaller amounts of, which helps maintain the insulating properties of the final product, results in shorter setting times, which can only be accommodated if continuous casting machines are used.
Under continuous casting conditions, the ingredients for the composite material are mixed together in a continuous fashion and poured continuously into molds, or directly onto a construction site or location. It is an embodiment that the final mixture sets in about 30 seconds to about 1 minute and is ready to be removed from a mold (de-molded) in about 20 minutes to about 30 minutes.
[0037] The following non-limiting examples are illustrative of the present disclosure:
EXAMPLES
Example 1: Preparation of Glass-Cement Composite (a) Materials [0038] 15% MgO by volume, 15% Type C Fly Ash by volume with 15% liquid potassium phosphate solution 0-20-20 by volume with 55% by volume of glass 10% by volume of water is added to delay set time
8 . .
(b) Process [0039] Dry magnesium oxide powder (0.15 m3, MgO) was thoroughly blended with dry Fly Ash (0.15 m3). Graded glass aggregate (0.55 m3) was added to the MgO/Fly Ash mixture and this combination mixed thoroughly. Water (10% by volume) was then added. The liquid phosphate fertilizer (0.15 m3) was then added with fast mixing and the final composite mixture was quickly poured into forms. The forms were vibrated prior to setting (approximately 30 seconds from adding the fertilizer). The product was ready for removal from the forms within 25 minutes. The chemical reaction between the cement binder composition produces a closed cell gel like paste which binds the aggregates together and sets rapidly within 1 minute.
[0040] All publications, patents and patent applications are herein incorporated by reference in their entirety to the same extent as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated by reference in its entirety. Where a term in the present disclosure is found to be defined differently in a document incorporated herein by reference, the definition provided herein is to serve as the definition for the term.
(b) Process [0039] Dry magnesium oxide powder (0.15 m3, MgO) was thoroughly blended with dry Fly Ash (0.15 m3). Graded glass aggregate (0.55 m3) was added to the MgO/Fly Ash mixture and this combination mixed thoroughly. Water (10% by volume) was then added. The liquid phosphate fertilizer (0.15 m3) was then added with fast mixing and the final composite mixture was quickly poured into forms. The forms were vibrated prior to setting (approximately 30 seconds from adding the fertilizer). The product was ready for removal from the forms within 25 minutes. The chemical reaction between the cement binder composition produces a closed cell gel like paste which binds the aggregates together and sets rapidly within 1 minute.
[0040] All publications, patents and patent applications are herein incorporated by reference in their entirety to the same extent as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated by reference in its entirety. Where a term in the present disclosure is found to be defined differently in a document incorporated herein by reference, the definition provided herein is to serve as the definition for the term.
9
Claims (19)
1. A cement binder composition comprising:
(a) about 30% to about 40% magnesium oxide (MO);
(b) about 15% to about 40% fly ash; and (c) about 30% to about 40% of a nitrogen-free liquid potassium phosphate fertilizer.
(a) about 30% to about 40% magnesium oxide (MO);
(b) about 15% to about 40% fly ash; and (c) about 30% to about 40% of a nitrogen-free liquid potassium phosphate fertilizer.
2. The cement binder composition of claim 1, wherein the MgO is a dry magnesium powder.
3. The cement binder composition of claim 1 or 2, wherein the fly ash is Type C fly ash.
4. The cement binder composition of any one of claims 1 to 3, wherein the nitrogen-free liquid potassium phosphate fertilizer has a N-P-K composition of 0 (zero)-X-Y, wherein X is about 10 to about 30 and B is about 10 to about 30.
5. The cement binder composition of claim 4, wherein the nitrogen-free liquid potassium phosphate fertilizer has a N-P-K composition of 0-20-20.
6. A composite material for use in construction comprising the cement binder composition of any one of claims 1 to 5 and a construction aggregate.
7. The composite material of claim 6, wherein the construction aggregate is glass aggregate.
8. The composite material of claim 7, wherein the glass aggregate is waste or recycled glass aggregate.
9. The composite material of claim 8, wherein the waste glass aggregate is free from other contaminants.
10. The composite material of any one of claims 7 to 9, wherein the glass aggregate size of 0.01 mm to about 9 mm.
11. The composite material of any one of claims 7 to 10, wherein the glass aggregate is present in the composite material in an amount of about 55% to about 83%
and the cement binder composition is present in the composite material in an amount of about 17% to about 45%.
and the cement binder composition is present in the composite material in an amount of about 17% to about 45%.
12. A process for producing a composite material comprising:
(a) combining MgO and fly ash to provide a first mixture;
(b) combining a construction aggregate and the first mixture to provide a second mixture;
(c) combining a suitable quantity of water and the second mixture to provide a third mixture, the suitable quantity of water being determined by a setting time;
(d) combining a nitrogen-free liquid potassium phosphate fertilizer and the third mixture to provide a final mixture; and (e) allowing the final mixture to set and cure to provide the composite material.
(a) combining MgO and fly ash to provide a first mixture;
(b) combining a construction aggregate and the first mixture to provide a second mixture;
(c) combining a suitable quantity of water and the second mixture to provide a third mixture, the suitable quantity of water being determined by a setting time;
(d) combining a nitrogen-free liquid potassium phosphate fertilizer and the third mixture to provide a final mixture; and (e) allowing the final mixture to set and cure to provide the composite material.
13. The process of claim 12, wherein the construction aggregate is glass and the composite material is a glass concrete.
14. The process of claim 12 or 14, wherein the final mixture is poured into molds forming shapes for use in building or landscape construction.
15. The process of claim 14, wherein when the final mixture is poured into molds, it is vibrated before it sets.
16. The process of any one of claims 13 to 15, wherein the MgO is a dry powder and is present in the composite material in an amount (not including water) of about 10% to about 15%; the fly ash is a dry powder and is present in the composite material in an amount (not including water) of about 5% to about 15%; the glass is present in the composite material in an amount (not including water) of about 55% to about 85%; and the nitrogen-free liquid potassium phosphate fertilizer is present in the composite material in an amount (not including water) of about 10% to about 15%.
17. The process of any one of claims 13 to 16, wherein nitrogen-free liquid potassium phosphate fertilizer has a N-P-K composition of 0 (zero)-X-Y, wherein X is about 10 to about 30 and Y is about 10 to about 30.
18. The process of any one claims 12 to 17, performed as a continuous process in a continuous casting machine.
19. The process of any one of claims 12 to 18, wherein the amount of water is selected to provide a setting time of about 30 seconds to about 1 minute and a de-molding time of about 20 minutes to about 30 minutes.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US201361814581P | 2013-04-22 | 2013-04-22 | |
| US61/814,581 | 2013-04-22 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2821414A1 true CA2821414A1 (en) | 2014-10-22 |
Family
ID=51787249
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA2821414A Abandoned CA2821414A1 (en) | 2013-04-22 | 2013-07-16 | Cement binder compositions and their uses and products made therefrom |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2821414A1 (en) |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN105314907A (en) * | 2015-11-30 | 2016-02-10 | 李乾 | Composite potassium magnesium phosphate cement |
| CZ307107B6 (en) * | 2013-08-21 | 2018-01-17 | Ústav Anorganické Chemie Av Čr, V.V.I. | A binder based on hydrated magnesium oxides |
| CN114031345A (en) * | 2021-11-11 | 2022-02-11 | 科之杰新材料集团福建有限公司 | Mechanical spraying plastering mortar and application thereof |
-
2013
- 2013-07-16 CA CA2821414A patent/CA2821414A1/en not_active Abandoned
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CZ307107B6 (en) * | 2013-08-21 | 2018-01-17 | Ústav Anorganické Chemie Av Čr, V.V.I. | A binder based on hydrated magnesium oxides |
| CN105314907A (en) * | 2015-11-30 | 2016-02-10 | 李乾 | Composite potassium magnesium phosphate cement |
| CN114031345A (en) * | 2021-11-11 | 2022-02-11 | 科之杰新材料集团福建有限公司 | Mechanical spraying plastering mortar and application thereof |
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