CA2525585A1 - Methods for producing low density products - Google Patents

Methods for producing low density products Download PDF

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Publication number
CA2525585A1
CA2525585A1 CA002525585A CA2525585A CA2525585A1 CA 2525585 A1 CA2525585 A1 CA 2525585A1 CA 002525585 A CA002525585 A CA 002525585A CA 2525585 A CA2525585 A CA 2525585A CA 2525585 A1 CA2525585 A1 CA 2525585A1
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Prior art keywords
precursor
blowing agent
agent
primary component
range
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CA002525585A
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French (fr)
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CA2525585C (en
Inventor
Hamid Hojaji
Huagang Zhang
Shannon Marie Labernik
Thinh Pham
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James Hardie Technology Ltd
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    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B18/00—Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B18/02—Agglomerated materials, e.g. artificial aggregates
    • C04B18/023—Fired or melted materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2/00—Processes or devices for granulating materials, e.g. fertilisers in general; Rendering particulate materials free flowing in general, e.g. making them hydrophobic
    • B01J2/02—Processes or devices for granulating materials, e.g. fertilisers in general; Rendering particulate materials free flowing in general, e.g. making them hydrophobic by dividing the liquid material into drops, e.g. by spraying, and solidifying the drops
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J13/00—Colloid chemistry, e.g. the production of colloidal materials or their solutions, not otherwise provided for; Making microcapsules or microballoons
    • B01J13/02—Making microcapsules or microballoons
    • B01J13/04—Making microcapsules or microballoons by physical processes, e.g. drying, spraying
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C11/00—Multi-cellular glass ; Porous or hollow glass or glass particles
    • C03C11/002—Hollow glass particles
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B18/00—Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B18/02—Agglomerated materials, e.g. artificial aggregates
    • C04B18/027—Lightweight materials
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B20/00—Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups C04B14/00 - C04B18/00 and characterised by shape or grain distribution; Treatment of materials according to more than one of the groups C04B14/00 - C04B18/00 specially adapted to enhance their filling properties in mortars, concrete or artificial stone; Expanding or defibrillating materials
    • C04B20/0016—Granular materials, e.g. microballoons
    • C04B20/002—Hollow or porous granular materials
    • C04B20/0036—Microsized or nanosized
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
    • C04B38/009—Porous or hollow ceramic granular materials, e.g. microballoons
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
    • C04B38/02—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by adding chemical blowing agents

Abstract

The method of preparing a low-density material and precursor for forming a low-density material. An aqueous mixture of inorganic primary component and a blowing agent is formed, the mixture is dried and optionally ground to form an expandable precursor. Such a precursor is then fired with activation of the blowing agent being controlled such that it is activated within a predetermined optimal temperature range. Control of the blowing agent can be accomplished via a variety of means including appropriate distribution throughout the precursor, addition of a control agent into the precursor, or modification of the firing conditions i.e. oxygen deficient or fuel rich environment, plasma heating etc.

Claims (111)

1. A method of producing a low density material comprising providing a precursor by forming an aqueous mixture of inorganic primary component and a blowing agent, drying the mixture and optionally grinding to a predetermined particle size and firing the precursor to activate the blowing agent to expand the precursor and form a low density material wherein activation of the blowing agent is controlled such that the blowing agent is activated within a predetermined optimal temperature range.
2. A method as claimed in claim 1 wherein the low density material is a microparticle with a diameter of up to 1,000 microns.
3. A method as claimed in any one of claims 1-3 wherein the blowing agent is activated within a temperature range in which the inorganic primary component has melted and is within an optimal viscosity range.
4. A method as claimed in any one of the preceding claims wherein the blowing agent is controlled by addition of a control agent.
5. A method as claimed in any one of the preceding claims wherein the blowing agent is provided as a primary blowing agent, and the control agent is provided as a secondary blowing agent.
6. A method as claimed in any one of the preceding claims wherein the primary blowing agent has a first activation temperature and the secondary blowing agent has a second activation temperature which is less than the first activation temperature.
7. The method of any one of the preceding claims, wherein the primary blowing agent is selected from powdered coal, carbon black, activated carbon, graphite, carbonaceous polymeric organics, oils, carbohydrates such as sugar, corn syrup or starch, PVA, carbonates, carbides, sulfates, sulfides, nitrides, nitrates, amines, polyols, glycols or glycerine.
8. The method of any one of the preceding claims, wherein the secondary blowing agent is selected from powdered coal, carbon black, activated carbon, graphite, carbonaceous polymeric organics, oils, carbohydrates such as sugar, corn syrup or starch, PVA, carbonates, carbides, sulfates, sulfides, nitrides, nitrates, amines, polyols, glycols or glycerine.
9. The method of any one of the preceding claims, wherein the precursor further comprises a tertiary blowing agent having a third activation temperature, wherein the third activation temperature is less than the first activation temperature.
10. The method as claimed in claim 9, wherein the tertiary blowing agent is selected from powdered coal, carbon black, activated carbon, graphite, carbonaceous polymeric organics, oils, carbohydrates, PVA, carbonates, sulfates, sulfides, nitrates, amines, polyols, glycols or glycerine.
11. A method according to any one of the preceding claims wherein firing of the precursor is conducted under such conditions as to control activation of the blowing agent.
12. A method according to any one of the preceding claims wherein firing of the precursor is conducted in an oxygen deficient environment.
13. A method as claimed in claim 12 wherein firing of the precursor is conducted in a fuel rich/less oxidising environment.
14. A method according to any one of the preceding claims wherein activation of the blowing agent is controlled by appropriate dosing with O2 depleting or O2 enriching gases during firing of the precursor.
15. A method according to any one of the preceding claims wherein the precursor is formed with a predetermined distribution of blowing agent there through, said distribution providing a controlled activation of the blowing agent during firing of the precursor.
16. The method of claim 1, wherein the drying step is performed using a spray dryer having an aqueous slurry feed.
17. The method of claim 16, wherein the spray dryer has an inlet temperature in the range of 300 to 600°C.
18. The method of claims 16 or 17, wherein the spray dryer has an outlet temperature in the range of 90 to 220°C.
19. The method of any one of the preceding claims, wherein the amount of inorganic primary component is at least 50 wt.%, based on the total dry weight of the agglomerate precursor.
20. The method of any one of the preceding claims, wherein the amount of blowing component is in the range of 0.05 to 10 wt.%, based on the total dry weight of the agglomerate precursor.
21. The method of any one of the preceding claims wherein the ratio of inorganic primary component to blowing component is in the range of 1000:1 to 10:1.
22. The method of any one of the preceding claims, wherein the mixture is dried such that the water content of the precursor is less than about 14 wt.%.
23. The method of any one of the preceding claims, wherein the resultant agglomerate precursors have an average agglomerate particle size in the range of 10 to 1000 microns.
24. The method of any one of the preceding claims, wherein the resultant agglomerate precursors have a total alkali metal oxide content of about 10 wt.% or less, based on the total dry weight of the agglomerate precursor.
25. The method of any one of the preceding claims, wherein the inorganic primary component comprises at least one material selected from inorganic oxides, non-oxides, salts or combinations thereof.
26. The method of any one of the preceding claims, wherein the inorganic primary component comprises at least one material selected from industrial and/or residential by-products, minerals, rocks, clays, technical grade chemicals or combinations thereof.
27. The method of any one of the preceding claims, wherein the inorganic primary component comprises at least one silicate material.
28. The method of claim 27, wherein the at least one silicate material is selected from fly ash, bottom ash, blast-furnace slag, paper ash, basaltic rock, andesitic rock, feldspars, aluminosilicate clays, bauxite, volcanic ash, volcanic rocks, volcanic glasses, geopolymers, or combinations thereof.
29. The method of any one of the preceding claims, wherein the inorganic primary component is capable of forming a viscoelastic liquid.
30. The method of any one of the preceding claims, wherein the inorganic primary component has an average primary particle size in the range of 0.01 to 100 microns.
31. The method of any one of the preceding claims, wherein the primary blowing agent is relatively less water-soluble than the secondary blowing agent.
32. The method of any one of the preceding claims, wherein the blowing agent has an average particle size in the range of 0.01 to 10 microns.
33. The method of any one of the preceding claims, further comprising mixing a binding agent with the inorganic primary component and the blowing agent.
34. The method of claim 33, wherein the binding agent is selected from alkali metal silicates, alkali metal aluminosilicates, alkali metal borates, alkali or alkaline earth metal carbonates, alkali or alkaline earth metal nitrates, alkali or alkaline earth metal nitrites, boric acid, alkali or alkaline earth metal sulfates, alkali or alkaline earth metal phosphates, alkali or alkaline earth metal hydroxides, carbohydrates, colloidal silica, ultrafine fly ash, Type C fly ash, Type F fly ash, inorganic silicate cements, Portland cement, alumina cement, lime-based cement, phosphate-based cement, organic polymers or combinations thereof.
35. The method of claims 33 or 34, wherein the binding agent has a melting point which is lower than the melting point of the resultant agglomerate precursor as a whole.
36. The method of any one of claims 32 to 34, wherein the binding agent has a melting point in the range of 700 to 1000°C.
37. The method of claim 35 or 36, wherein the binding agent is a silicate.
38. The method of claim 35 or 36, wherein the binding agent is an alkali metal silicate generated by in situ reaction of an alkali metal hydroxide and an silicate primary component.
39. The method of any one of claims 35 to 38, wherein the amount of binding agent is in the range of 0.1 to 50 wt.%, based on the total dry weight of the agglomerate precursor.
40. The method of any of claims 35 to 39, wherein the binding agent is relatively more water-soluble than the primary blowing agent.
41. The method of any one of the preceding claims, wherein the primary component, the blowing component and, optionally, the binding agent are co-ground together.
42. A method of forming a precursor for a low density material comprising the steps of:
(g) providing an inorganic primary component;
(h) forming an aqueous mixture of the inorganic primary component, a blowing agent and a control agent, and;
(i) drying the mixture to provide an expandable precursor for forming a low density material wherein said blowing agent and control agent are selected to control activation of the blowing agent such that the blowing agent is activated within a predetermined optimal temperature range.
43. A method as claimed in claim 42, wherein the blowing agent is provided as a primary blowing agent, and the control agent is provided as a secondary blowing agent.
44. A method as claimed in claims 42 or 43, wherein the primary blowing agent has a first activation temperature and the secondary blowing agent has a second activation temperature which is less than the first activation temperature.
45. The method of any one of claims 42 to 43, wherein the primary blowing agent is selected from powdered coal, carbon black, activated carbon, graphite, carbonaceous polymeric organics, oils, carbohydrates such as sugar, corn syrup or starch, PVA, carbonates, carbides, sulfates, sulfides, nitrides, nitrates, amines, polyols, glycols or glycerine.
46. The method of any one of claims 42 to 45, wherein the secondary blowing agent is selected from powdered coal, carbon black, activated carbon, graphite, carbonaceous polymeric organics, oils, carbohydrates such as sugar, corn syrup or starch, PVA, carbonates, carbides, sulfates, sulfides, nitrides, nitrates, amines, polyols, glycols or glycerine.
47. The method of any one of claims 42 to 46, wherein the precursor further comprises a tertiary blowing agent having a third activation temperature, wherein the third activation temperature is less than the first activation temperature.
48. The method as claimed in claim 47, wherein the tertiary blowing agent is selected from powdered coal, carbon black, activated carbon, graphite, carbonaceous polymeric organics, oils, carbohydrates, PVA, carbonates, sulfates, sulfides, nitrates, amines, polyols, glycols or glycerine.
49. A method according to any one of claims 42 to 48 wherein activation of the blowing agent is controlled by appropriate dosing with O2 depleting or O2 enriching gases during firing of the precursor.
50. A method according to any one of claims 42 to 49 wherein the precursor is formed with a predetermined distribution of blowing agent there through, said distribution providing a controlled activation of the blowing agent during firing of the precursor.
51. The method of claim 42, wherein the drying step is performed using a spray dryer having an aqueous slurry feed.
52. The method of claim 51, wherein the spray dryer has an inlet temperature in the range of 300 to 600°C.
53. The method of claims 51 or 52, wherein the spray dryer has an outlet temperature in the range of 90 to 220°C.
54. The method of any one of claims 42 to 53, wherein the amount of inorganic primary component is at least 50 wt.%, based on the total dry weight of the agglomerate precursor.
55. The method of any one of claims 42 to 54, wherein the amount of blowing component is in the range of 0.05 to 10 wt.%, based on the total dry weight of the agglomerate precursor.
56. The method of any one of claims 42 to 55wherein the ratio of inorganic primary component to blowing component is in the range of 1000:1 to 10:1.
57. The method of any one of claims 42 to 56, wherein the mixture is dried such that the water content of the precursor is less than about 14 wt.%.
58. The method of any one of claims 42 to 57, wherein the resultant agglomerate precursors have an average agglomerate particle size in the range of 10 to 1000 microns.
59. The method of any one of claims 42 to 58, wherein the resultant agglomerate precursors have a total alkali metal oxide content of about 10 wt.% or less, based on the total dry weight of the agglomerate precursor.
60. The method of any one of claims 42 to 59, wherein the inorganic primary component comprises at least one material selected from inorganic oxides, non-oxides, salts or combinations thereof.
61. The method of any one of claims 42 to 60, wherein the inorganic primary component comprises at least one material selected from industrial and/or residential by-products, minerals, rocks, clays, technical grade chemicals or combinations thereof.
62. The method of any one of claims 42 to 61, wherein the inorganic primary component comprises at least one silicate material.
63. The method of claim 62, wherein the at least one silicate material is selected from fly ash, bottom ash, blast-furnace slag, paper ash, basaltic rock, andesitic rock, feldspars, aluminosilicate clays, bauxite, volcanic ash, volcanic rocks, volcanic glasses, geopolymers, or combinations thereof.
64. The method of any one of claims 42 to 63, wherein the inorganic primary component is capable of forming a viscoelastic liquid.
65. The method of any one of claims 42 to 64, wherein the inorganic primary component has an average primary particle size in the range of 0.01 to 100 microns.
66. The method of any one of claims 42 to 65, wherein the primary blowing agent is relatively less water-soluble than the secondary blowing agent.
67. The method of any one of claims 42 to 66, wherein the blowing agent has an average particle size in the range of 0.01 to 10 microns.
68. The method of any one of 42 to 67 claims, further comprising mixing a binding agent with the inorganic primary component and the blowing agent.
69. The method of claim 68, wherein the binding agent is selected from alkali metal silicates, alkali metal aluminosilicates, alkali metal borates, alkali or alkaline earth metal carbonates, alkali or alkaline earth metal nitrates, alkali or alkaline earth metal nitrites, boric acid, alkali or alkaline earth metal sulfates, alkali or alkaline earth metal phosphates, alkali or alkaline earth metal hydroxides, carbohydrates, colloidal silica, ultrafine fly ash, Type C fly ash, Type F fly ash, inorganic silicate cements, Portland cement, alumina cement, lime-based cement, phosphate-based cement, organic polymers or combinations thereof.
70. The method of claims 68 or 69, wherein the binding agent has a melting point which is lower than the melting point of the resultant agglomerate precursor as a whole.
71. The method of any one of claims 68 to 70, wherein the binding agent has a melting point in the range of 700 to 1000°C.
72. The method of claim 70 or 71, wherein the binding agent is a silicate.
73. The method of any one of claims 70 or 71, wherein the binding agent is an alkali metal silicate generated by in situ reaction of an alkali metal hydroxide and an silicate primary component.
74. The method of any one of claims 70 to 73, wherein the amount of binding agent is in the range of 0.1 to 50 wt.%, based on the total dry weight of the agglomerate precursor.
75. The method of any of claims 70 to 74, wherein the binding agent is relatively more water-soluble than the primary blowing agent.
76. The method of any one of claims 42 to 75, wherein the primary component, the blowing component and, optionally, the binding agent are co-ground together.
77. A method of forming a precursor for a low density material comprising the steps of:
(j) providing an inorganic primary component;
(k) forming an aqueous mixture of the inorganic primary component and a blowing agent; and (l) drying the mixture to provide an expandable precursor for forming a low density material wherein said blowing agent is selected and/or distributed in the precursor to control activation of the blowing agent upon firing of the precursor such that the blowing agent is activated within a predetermined optimal temperature range.
78. A precursor suitable for producing expanded micro particles, said precursor comprising an expandable inorganic primary component, a blowing agent adapted to be activated and thereby expand said primary component, and a control agent selected to control activation of the blowing agent such that the blowing agent is activated within a predetermined optimal temperature range.
79. A precursor according to claim 78 wherein the blowing agent is provided as a primary blowing agent, and the control agent is provided as a secondary blowing agent.
80. A precursor as claimed in claim 78 or 79 wherein the primary blowing agent has a first activation temperature and the secondary blowing agent has a second activation temperature which is less than the first activation temperature.
81. A precursor as claimed in any one of claims 78 to 80, wherein the primary blowing agent is selected from powdered coal, carbon black, activated carbon, graphite, carbonaceous polymeric organics, oils, carbohydrates such as sugar, corn syrup or starch, PVA, carbonates, carbides, sulfates, sulfides, nitrides, nitrates, amines, polyols, glycols or glycerine.
82. A precursor as claimed in any one of claims 78 to 81, wherein the secondary blowing agent is selected from powdered coal, carbon black, activated carbon, graphite, carbonaceous polymeric organics, oils, carbohydrates such as sugar, corn syrup or starch, PVA, carbonates, carbides, sulfates, sulfides, nitrides, nitrates, amines, polyols, glycols or glycerine.
83. A precursor as claimed in any one of claims 78 to 82, wherein the precursor further comprises a tertiary blowing agent having a third activation temperature, wherein the third activation temperature is less than the first activation temperature.
84. A precursor as claimed in claim 83, wherein the tertiary blowing agent is selected from powdered coal, carbon black, activated carbon, graphite, carbonaceous polymeric organics, oils, carbohydrates, PVA, carbonates, sulfates, sulfides, nitrates, amines, polyols, glycols or glycerine.
85. A precursor as claimed in any one of claims 78 to 84 wherein activation of the blowing agent is controlled by appropriate dosing with O2 depleting or O2 enriching gases during firing of the precursor.
86. A precursor as claimed in any one of claims 78 to 85 wherein the precursor is formed with a predetermined distribution of blowing agent there through, said distribution providing a controlled activation of the blowing agent during firing of the precursor.
87. A precursor as claimed in any one of claims 78 to 86, wherein the amount of inorganic primary component is at least 50 wt.%, based on the total dry weight of the agglomerate precursor.
88. A precursor as claimed in any one of claims 78 to 87, wherein the amount of blowing component is in the range of 0.05 to 10 wt.%, based on the total dry weight of the agglomerate precursor.
89. A precursor as claimed in any one of claims 78 to 88, wherein the ratio of inorganic primary component to blowing component is in the range of 1000:1 to 10:1.
90. A precursor as claimed in any one of claims 78 to 89, wherein the mixture is dried such that the water content of the precursor is less than about 14 wt.%.
91. A precursor as claimed in any one of claims 78 to 90, wherein the resultant agglomerate precursors have an average agglomerate particle size in the range of 10 to 1000 microns.
92. A precursor as claimed in any one of claims 78 to 91, wherein the resultant agglomerate precursors have a total alkali metal oxide content of about 10 wt.% or less, based on the total dry weight of the agglomerate precursor.
93. A precursor as claimed in any one of claims 78 to 92, wherein the inorganic primary component comprises at least one material selected from inorganic oxides, non-oxides, salts or combinations thereof.
94. A precursor as claimed in any one of claims 78 to 93, wherein the inorganic primary component comprises at least one material selected from industrial and/or residential by-products, minerals, rocks, clays, technical grade chemicals or combinations thereof.
95. A precursor as claimed in any one of claims 79 to 94, wherein the inorganic primary component comprises at least one silicate material.
96. A precursor as claimed in claim 95, wherein the at least one silicate material is selected from fly ash, bottom ash, blast-furnace slag, paper ash, basaltic rock, andesitic rock, feldspars, aluminosilicate clays, bauxite, volcanic ash, volcanic rocks, volcanic glasses, geopolymers, or combinations thereof.
97. A precursor as claimed in any one of claims 78 to 96, wherein the inorganic primary component is capable of forming a viscoelastic liquid.
98. A precursor as claimed in any one of claims 78 to 97, wherein the inorganic primary component has an average primary particle size in the range of 0.01 to microns.
99. A precursor as claimed in any one 78 to 98, of the preceding claims, wherein the primary blowing agent is relatively less water-soluble than the secondary blowing agent.
100. A precursor as claimed in any one of claims 78 to 99, wherein the blowing agent has an average particle size in the range of 0.01 to 10 microns.
101. A precursor as claimed in any one of claims 78 to 100, further comprising mixing a binding agent with the inorganic primary component and the blowing agent.
102. A precursor as claimed in claim 101, wherein the binding agent is selected from alkali metal silicates, alkali metal aluminosilicates, alkali metal borates, alkali or alkaline earth metal carbonates, alkali or alkaline earth metal nitrates, alkali or alkaline earth metal nitrites, boric acid, alkali or alkaline earth metal sulfates, alkali or alkaline earth metal phosphates, alkali or alkaline earth metal hydroxides, carbohydrates, colloidal silica, ultrafine fly ash, Type C fly ash, Type F fly ash, inorganic silicate cements, Portland cement, alumina cement, lime-based cement, phosphate-based cement, organic polymers or combinations thereof.
103. A precursor as claimed in claim 101 or 102, wherein the binding agent has a melting point which is lower than the melting point of the resultant agglomerate precursor as a whole.
104. A precursor as claimed in any one of claims 101 to 103, wherein the binding agent has a melting point in the range of 700 to 1000°C.
105. A precursor as claimed in claim 103 or 104, wherein the binding agent is a silicate.
106. A precursor as claimed in claim 103 or 104, wherein the binding agent is an alkali metal silicate generated by in situ reaction of an alkali metal hydroxide and an silicate primary component.
107. A precursor as claimed in any one of claims 103 to 106, wherein the amount of binding agent is in the range of 0.1 to 50 wt.%, based on the total dry weight of the agglomerate precursor.
108. A precursor as claimed in any of claims 103 to 107, wherein the binding agent is relatively more water-soluble than the primary blowing agent.
109. A precursor suitable for producing expanded micro particles, said precursor comprising an expandable inorganic primary component and a blowing agent selected and/or distributed within the precursor to control activation of the blowing agent whereby upon firing of the precursor to produce the expanded micro particles, the blowing agent is activated within a predetermined optimal temperature range.
110. A method of controlling activation of the blowing agent in an inorganic mixture to produce expanded micro particles, said method comprising:
providing at least one blowing agent which is activated under predetermined conditions to release a blowing gas and produce expanded micro particles and controlling such conditions whereby said activation takes place within a predetermined optimal viscosity range of the inorganic mixture.
111. A blowing component for producing expanded micro particles, said blowing component comprising a primary blowing agent and a predetermined quantity of compatible control agent wherein upon inclusion of such a blowing component within an expandable mixture, the control agent may be activated prior or simultaneously with the blowing agent to control and conserve the blowing agent.
CA2525585A 2003-05-16 2004-02-25 Methods for producing low density products Expired - Fee Related CA2525585C (en)

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US47140003P 2003-05-16 2003-05-16
US60/471,400 2003-05-16
PCT/AU2004/000241 WO2004101137A1 (en) 2003-05-16 2004-02-25 Methods for producing low density products

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JP (2) JP2007503997A (en)
KR (1) KR20060024378A (en)
CN (1) CN1805783A (en)
AU (1) AU2004238392B2 (en)
CA (1) CA2525585C (en)
NO (1) NO20055982L (en)
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