Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F265/00—Macromolecular compounds obtained by polymerising monomers on to polymers of unsaturated monocarboxylic acids or derivatives thereof as defined in group C08F20/00
  • C08F265/04—Macromolecular compounds obtained by polymerising monomers on to polymers of unsaturated monocarboxylic acids or derivatives thereof as defined in group C08F20/00 on to polymers of esters
• • 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
  • C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
  • C04B14/02—Granular materials, e.g. microballoons
  • C04B14/04—Silica-rich materials; Silicates
  • C04B14/06—Quartz; Sand
• • 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
  • C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
  • C04B14/02—Granular materials, e.g. microballoons
  • C04B14/04—Silica-rich materials; Silicates
  • C04B14/10—Clay
• • 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
  • C04B20/02—Treatment
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  • 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
  • C04B20/02—Treatment
  • C04B20/023—Chemical treatment
• • 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
  • C04B24/00—Use of organic materials as active ingredients for mortars, concrete or artificial stone, e.g. plasticisers
  • C04B24/02—Alcohols; Phenols; Ethers
  • C04B24/023—Ethers
• • 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
  • C04B24/00—Use of organic materials as active ingredients for mortars, concrete or artificial stone, e.g. plasticisers
  • C04B24/24—Macromolecular compounds
• • 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
  • C04B24/00—Use of organic materials as active ingredients for mortars, concrete or artificial stone, e.g. plasticisers
  • C04B24/24—Macromolecular compounds
  • C04B24/26—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
  • C04B24/2641—Polyacrylates; Polymethacrylates
  • C04B24/2647—Polyacrylates; Polymethacrylates containing polyether side chains
• • 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
  • C04B24/00—Use of organic materials as active ingredients for mortars, concrete or artificial stone, e.g. plasticisers
  • C04B24/24—Macromolecular compounds
  • C04B24/26—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
  • C04B24/2664—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds of ethylenically unsaturated dicarboxylic acid polymers, e.g. maleic anhydride copolymers
  • C04B24/267—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds of ethylenically unsaturated dicarboxylic acid polymers, e.g. maleic anhydride copolymers containing polyether side chains
• • 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
  • C04B24/00—Use of organic materials as active ingredients for mortars, concrete or artificial stone, e.g. plasticisers
  • C04B24/24—Macromolecular compounds
  • C04B24/28—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
  • C04B24/283—Polyesters
• • 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
  • C04B24/00—Use of organic materials as active ingredients for mortars, concrete or artificial stone, e.g. plasticisers
  • C04B24/24—Macromolecular compounds
  • C04B24/28—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
  • C04B24/30—Condensation polymers of aldehydes or ketones
• • 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
  • C04B24/00—Use of organic materials as active ingredients for mortars, concrete or artificial stone, e.g. plasticisers
  • C04B24/24—Macromolecular compounds
  • C04B24/28—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
  • C04B24/30—Condensation polymers of aldehydes or ketones
  • C04B24/305—Melamine-formaldehyde condensation polymers
• • 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
  • C04B40/00—Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability
  • C04B40/0028—Aspects relating to the mixing step of the mortar preparation
  • C04B40/0039—Premixtures of ingredients
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F265/00—Macromolecular compounds obtained by polymerising monomers on to polymers of unsaturated monocarboxylic acids or derivatives thereof as defined in group C08F20/00
  • C08F265/04—Macromolecular compounds obtained by polymerising monomers on to polymers of unsaturated monocarboxylic acids or derivatives thereof as defined in group C08F20/00 on to polymers of esters
  • C08F265/06—Polymerisation of acrylate or methacrylate esters on to polymers thereof
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F290/00—Macromolecular compounds obtained by polymerising monomers on to polymers modified by introduction of aliphatic unsaturated end or side groups
  • C08F290/08—Macromolecular compounds obtained by polymerising monomers on to polymers modified by introduction of aliphatic unsaturated end or side groups on to polymers modified by introduction of unsaturated side groups
  • C08F290/14—Polymers provided for in subclass C08G
  • C08F290/142—Polyethers
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K3/00—Use of inorganic substances as compounding ingredients
  • C08K3/34—Silicon-containing compounds
  • C08K3/346—Clay
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
  • C09K8/00—Compositions for drilling of boreholes or wells; Compositions for treating boreholes or wells, e.g. for completion or for remedial operations
  • C09K8/42—Compositions for cementing, e.g. for cementing casings into boreholes; Compositions for plugging, e.g. for killing wells
  • C09K8/46—Compositions for cementing, e.g. for cementing casings into boreholes; Compositions for plugging, e.g. for killing wells containing inorganic binders, e.g. Portland cement
  • C09K8/467—Compositions for cementing, e.g. for cementing casings into boreholes; Compositions for plugging, e.g. for killing wells containing inorganic binders, e.g. Portland cement containing additives for specific purposes
• • 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
  • C04B2103/00—Function or property of ingredients for mortars, concrete or artificial stone
  • C04B2103/0045—Polymers chosen for their physico-chemical characteristics
  • C04B2103/0059—Graft (co-)polymers
• • 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
  • C04B2103/00—Function or property of ingredients for mortars, concrete or artificial stone
  • C04B2103/30—Water reducers, plasticisers, air-entrainers, flow improvers
• • 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
  • C04B2103/00—Function or property of ingredients for mortars, concrete or artificial stone
  • C04B2103/30—Water reducers, plasticisers, air-entrainers, flow improvers
  • C04B2103/32—Superplasticisers

Definitions

• This invention relates to the treatment of clay-bearing aggregates used for construction, and more particularly to the use of a carboxylate graft polymer having high molecular weight and low ratio of carboxylic acid to polyoxyalkylene groups.
• clays that are carried in the sand, rock, gravel, or other aggregates that are used for making these construction materials or that are often intermingled into these construction materials. Clays can adversely affect the properties and/or performance of construction materials because they absorb water and chemical agents used for treating these materials.
• a method for mitigating the deleterious effects of clays is to wash the clay from the aggregates.
• excessive washing can remove a portion of fines (i.e., small aggregates) that otherwise benefits the performance or enhances a desired property of the construction material.
• An objective of the present invention is to mitigate the deleterious effects of clays carried in aggregates while improving one or more properties of the construction materials.
• the present invention can lead to improvements in the properties of mortars and concretes (e.g., workability, strength), asphalts (e.g., binder demand), and road base materials (e.g., improved flowability). Reducing or eliminating washing steps can lead to greater beneficial fines content in construction materials.
• the present invention relates to clay-mitigating compositions and methods for modifying clays that are carried (or “born” or conveyed) or otherwise mixed within inorganic particulates such as sand aggregates, crushed stone (gravel, rocks, etc.), granulated slag, and other inorganic particles that are used in construction applications and in construction materials.
• inorganic particulates such as sand aggregates, crushed stone (gravel, rocks, etc.), granulated slag, and other inorganic particles that are used in construction applications and in construction materials.
• the clay-mitigation agents of the present invention may be incorporated into clay-bearing construction aggregates and materials such as mortar, concrete, asphalt, road base, and well bore drilling fluids and muds.
• the clay mitigation agents may be introduced into dry or wet aggregates.
• the clay-mitigation methods and compositions of the present invention can provide improved workability without increasing water demand of cementitious binder systems.
• the inventive compositions can reduce the effort required for washing and/or removing of clay contained in the aggregates.
• an exemplary carboxylate graft polymer composition of the present invention for treating clay or clay-bearing aggregates comprises:
• R 1 , R 2 , and R 3 each independently represent hydrogen, C 1 -C 3 alkyl, —COOH, —CH 2 COOH, or mixtures thereof;
• X represents hydrogen or an alkali metal;
• R 4 , R 5 , R 6 , R 7 , and R 8 each independently represent hydrogen, C 1 -C 3 alkyl, —COOH, or mixtures thereof;
• Y represents —O—, —COO—, —OOC—, —COHN—, or —NHCO—;
• Z represents (CH 2 ) n wherein “n” represents a whole number of 0 to 6; and “m” represents an integer of 25 to 200;
• (C) optionally a third component comprising a repeating unit of polymerized (meth)acrylamide, N-alkyl (meth)acrylamide, N,N-dialkyl (meth)acrylamide, 3-acrylamido-2-methylpropane sulfonic acid or its salts, and styrene sulfonic acid or its salt, or mixtures thereof; and
• the molar ratio of said first component A to said second component B is in the range of 50:100 to 100:40 and the weight-average molecular weight of the carboxylate graft polymer is in the range of 22,000 to 250,000;
• the weight-average molecular weight of the carboxylate graft polymer is in the range of 70,000 to 250,000.
• the present invention also provides aggregate, cementitious, and admixture compositions containing the described carboxylate graft polymer composition.
• the above-described carboxylate graft polymer can be combined with a plurality of clay-bearing sand (natural or manufactured), crushed rock or gravel, drilling mud, or other clay-bearing aggregates used in construction to provide exemplary aggregate compositions of the invention.
• the above-described carboxylate graft polymer can be combined with a cementitious binder (e.g., Ordinary Portland Cement, argillaceous materials) to provide an exemplary cementitious composition of the invention.
• a cementitious binder e.g., Ordinary Portland Cement, argillaceous materials
• the above-described carboxylate graft polymer can be combined with at least one chemical admixture selected from the group consisting of water-reducing agent, set retarders, set accelerators, air entraining agents, air detraining agents, and mixtures thereof, to provide an exemplary admixture composition of the invention.
• the present invention thus also provides methods for treating clay-bearing aggregates as well as construction materials and cementitious compositions containing clay and aggregates.
• Exemplary methods for treating clay or clay-bearing aggregates comprises introducing the above-described carboxylate graft polymer to clay or clay-bearing aggregates, or into construction materials containing aggregates and clay (which may have been borne by the aggregates).
• Exemplary clay-mitigating carboxylate graft polymer compositions of the invention may be introduced to clay-bearing aggregates at the mine or quarry where aggregates are obtained and/or manufactured. They may also be introduced at the concrete mix plant wherein the aggregates are combined with cement to provide mortar or concrete compositions. They may also be added at any point before, during, or after these operations.
• the clay-mitigation compositions may also be introduced into crushed stone or rock which is contaminated with clay, such as crushed gravel or rocks from quarries which are prepared for road base or other construction use (e.g., foundations) and other construction applications.
• clay-mitigation compositions can also be used, in other construction methods, such as in wellbore drilling applications, such as servicing wellbores using a wellbore servicing fluid, e.g., wellbore drilling (mud) fluid, mud displacement fluid, and/or wellbore cementing composition, to inhibit the swelling of argillaceous (shale or clay) material-containing subterranean formation penetrated by the wellbore.
• a wellbore servicing fluid e.g., wellbore drilling (mud) fluid, mud displacement fluid, and/or wellbore cementing composition
• the present invention thus relates to construction materials which comprise a plurality of aggregates, clay, and the carboxylate graft polymer described above.
• the present invention relates to clay-mitigation compositions and methods for treating clays contained in aggregates such as sand, crushed rock, crushed gravel, drilling mud (or other fluids pumped into well bore operations for recovering oil or gas), and other clay-bearing aggregates which are used in or as part of construction materials or operations.
• aggregates such as sand, crushed rock, crushed gravel, drilling mud (or other fluids pumped into well bore operations for recovering oil or gas), and other clay-bearing aggregates which are used in or as part of construction materials or operations.
• the present invention also provides aggregate compositions (e.g., road base, asphalts), cementitious compositions containing aggregates (e.g., mortars, concretes), and well-bore drilling muds or fluids (some of which may or may not contain cementitious materials and/or aggregates; and/or which are flowed through clay-bearing rock or shale).
• aggregate compositions e.g., road base, asphalts
• cementitious compositions containing aggregates e.g., mortars, concretes
• well-bore drilling muds or fluids some of which may or may not contain cementitious materials and/or aggregates; and/or which are flowed through clay-bearing rock or shale.
• the present invention relates to treatment of all types of clays.
• the clays may include but are not limited to swelling clays of the 2:1 type (such as smectite type clays) or also of type 1:1 (such as kaolinite) or of the 2:1:1 type (such as chlorite).
• the term “clays” has referred to aluminum and/or magnesium silicates, including phyllosilicates having a lamellar structure; but the term “clay” as used herein may also refer to clays not having such structures, such as amorphous clays.
• the present invention is also not limited to clays which absorb polyoxyalkylene superplasticizers (such as ones containing ethylene oxide (“EO”) and/or propylene oxide (“PO”) groups); but also includes clays that directly affect the properties of construction materials, whether in their wet or hardened state.
• Clays which are commonly found in sands include, for example, montmorillonite, illite, kaolinite, muscovite, and chlorite. These are included in the methods and compositions of the present invention.
• Clay-bearing sands and/or crushed rock or gravel which are treated by the method of the present invention may be used in cementitious materials, whether hydratable or not, and such cementitious materials include mortar, concrete, and asphalt, which may be used in structural building and construction applications, roadways, foundations, civil engineering applications, as well as in precast and prefabrication applications.
• Sand as used herein shall mean and refer to aggregate particles usually used for construction materials such as concrete, mortar, and asphalt, and this typically involves granular particles of average size between 0 and 8 mm (e.g., not including zero), and, more preferably, between 2 and 6 mm.
• Sand aggregates may comprise calciferous, siliceous or siliceous limestone minerals.
• Such sands may be natural sand (e.g., derived from glacial, alluvial, or marine deposits which are typically weathered such that the particles have smooth surfaces) or may be of the “manufactured” type, which are made using mechanical crushers or grinding devices.
• cement as used herein includes hydratable cement and Portland cement which is produced by pulverizing clinker consisting of hydraulic calcium silicates and one or more forms of calcium sulfate (e.g., gypsum) as an interground additive.
• Portland cement is blended with one or more supplemental cementitious materials, such as fly ash, granulated blast furnace slag, limestone, natural pozzolans, or mixtures thereof, and provided as a blend.
• supplemental cementitious refers to materials that comprise Portland cement or which otherwise function as a binder to hold together fine aggregates (e.g., sand), coarse aggregates (e.g., crushed stone, rock, gravel), or mixtures thereof.
• hydratable is intended to refer to cement or cementitious materials that are hardened by chemical interaction with water.
• Portland cement clinker is a partially fused mass primarily composed of hydratable calcium silicates.
• the calcium silicates are essentially a mixture of tricalcium silicate (3CaO.SiO 2 “C 3 S” in cement chemists notation) and dicalcium silicate (2CaO.SiO 2 , “C 2 S”) in which the former is the dominant form, with lesser amounts of tricalcium aluminate (3CaO.Al 2 O 3 , “C 3 A”) and tetracalcium aluminoferrite (4CaO.Al 2 O 3 .Fe 2 O 3 , “C 4 AF”).
• CaO.Al 2 O 3 .Fe 2 O 3 tetracalcium aluminoferrite
• the term “mortar” usually refers to a hydratable cementitious mixture comprising a cementitious binder and a fine aggregate that is typically sand, and water is added to initiate hydration of the cement and hardening of the mixture.
• a “concrete” comprises the cementitious binder, sand, and further comprises a coarse aggregate such as crushed stone, rock, or gravel. Both mortars and concrete may additionally contain one or more chemical admixtures. As clays may be contained in the sand used for making the mortar or concrete, such mortars and concretes may in a sense to describe as both clay-bearing aggregate compositions as well as hydratable cementitious compositions which contain aggregates and clay.
• an exemplary carboxylate graft polymer composition of the present invention for treating clay or clay-bearing aggregates comprises:
• R 1 , R 2 , and R 3 each independently represent hydrogen, C 1 -C 3 alkyl, —COOH, —CH 2 COOH, or mixtures thereof;
• X represents hydrogen or an alkali metal;
• R 4 , R 5 , R 6 , R 7 , and R 8 each independently represent hydrogen, C 1 -C 3 alkyl, —COOH, or mixtures thereof;
• Y represents —O—, —COO—, —OOC—, —COHN—, or —NHCO—;
• Z represents (CH 2 ) n wherein “n” represents a whole number of 0 to 6; and “m” represents an integer of 25 to 200;
• (C) optionally a third component comprising a repeating unit of polymerized (meth)acrylamide, N-alkyl (meth)acrylamide, N,N-dialkyl (meth)acrylamide, 3-acrylamido-2-methylpropane sulfonic acid or its salts, and styrene sulfonic acid or its salt, or mixtures thereof; and
• the molar ratio of said first component A to said second component B is in the range of 50:100 to 100:40 and the weight-average molecular weight of the carboxylate graft polymer is in the range of 22,000 to 250,000;
• the weight-average molecular weight of the carboxylate graft polymer is in the range of 70,000 to 250,000.
• the above-described carboxylate graft polymer composition further comprises at least one repeating unit of the identified component “C” compounds selected from repeating unit of polymerized (meth)acrylamide, N-alkyl (meth)acrylamide, N,N-dialkyl (meth)acrylamide, 3-acrylamido-2-methylpropane sulfonic acid or its salts, and styrene sulfonic acid or its salt, or mixtures thereof.
• the molar ratio of component A to component B is between 0.6 and 1.8, and more preferably between 0.7 and 1.5; and the weight-average molecular weight of said carboxylate graft polymer composition is preferably in the range of 70,000 to 150,000.
• the number-average molecular weight of said component B is in the range of 1,000 to 10,000; preferably in the range of 2,000 to 5,000 and most preferably, it is in the range of 1,500 to 7,500.
• the carboxylate graft polymer of the invention can be formed either by direct polymerization of a carboxylate monomer of component A with a polyoxyalkylene macromonomer of component B, optionally with an unsatured monomer of component C; or by grafting of polyoxyalkylene groups onto a carboxylic polymer.
• Carboxylate monomers of component A can be selected, for example, from a list including acrylic acid, methacrylic acid, crotonic acid, maleic acid, fumaric acid, itaconic acid, anhydride or salt of these acids, or mixtures thereof.
• polyoxyalkylene macromonomer of component B examples include, without limitation, polyoxyalkylene acrylate ester, polyoxyalkylene methacrylate ester, polyoxyalkylene maleate ester, polyoxyalkylene fumarate ester, polyoxyalkylated C 2 to C 7 unsaturated alcohol, N-polyoxyalkylene acrylamide, N-polyoxyalkylene methacrylamide, or mixtures thereof.
• unsatured monomer of component C examples include, without limitation, acrylamide, methacrylamide, N-alkyl acrylamide, N-alkyl methacrylamide, N,N-dialkyl acrylamide, N,N-dialkyl methacrylamide, vinylsulfonic acid, allylsulfonic acid, methallylsulfonic acid, 3-acrylamido-2-methylpropane sulfonic acid, styrene sulfonic acid, salts of these acids, or mixtures thereof.
• the carboxylate graft polymer of the invention can be prepared by grafting of the polyoxyalkylene groups onto a carboxylic acid or anhydride polymer.
• the carboxylic polymer includes homo- or copolymer of acrylic acid, methacrylic acid, crotonic acid, maleic acid, fumaric acid, itaconic acid, anhydride or salt of these acids, or mixtures thereof.
• the chemical linkage of the polyoxyalkylene and the carboxylic polymer can be an ester, amide, imide, or mixtures thereof.
• carboxylate graft polymers of the present invention have little or no water reducing ability when used in hydratable cementitious compositions such as concrete, mortar, and cements.
• carboxylate graft polymers of the invention should not be superplasticizers, and most preferably they should not have the ability to confer significant slump increase either initially or over time.
• any increase slump in plastic hydratable cementitious compositions such as cement, mortar, or concrete should be 0-4 inches (using standard inverted slump cone measurement); more preferably, less than 3 inches; and, most preferably, less than 2 inches, at normal dosage range (i.e., 0.08 to 0.15% dry polymer weight to dry cement weight), as compared to a control concrete mix that does not contain a water-reducing admixture.
• it is preferred that the slump of plastic concrete containing the carboxylate graft polymers of the invention does not exhibit an increase in slump over time.
• exemplary clay-mitigating compositions, cementitious compositions, and aggregate compositions of the invention contain the carboxylate graft polymer which increases slump 0-4 inches, more preferably 0-3 inches, and most preferably 0-2 inches (using slump cone standard, e.g., ASTM C143 (which the inventors believed was last updated in 2010 but which has used the same cone for many years).
• ASTM C143 which the inventors believed was last updated in 2010 but which has used the same cone for many years.
• Exemplary aggregate compositions of the present invention comprise a plurality of clay-bearing aggregates and the above-described carboxylate graft polymer composition.
• the aggregates may comprise, for example, clay-bearing aggregates including natural or manufactured sand, crushed stone, crushed gravel, crushed rock, crushed shale, or mixtures thereof.
• Such aggregate compositions may further comprise a cementitious binder.
• the carboxylate graft polymer can be used in the plurality of clay-bearing aggregates in an amount of 0.1% to 100% by weight based on dry weight of clay contained in the plurality of aggregates, and more preferably in an amount of 1% to 50% by weight based on dry weight of clay contained in said plurality of aggregates.
• Exemplary admixture compositions of the present invention comprise the above described clay-mitigating carboxylate graft polymer and one or more conventional chemical admixtures.
• the admixtures include, without limitation, water reducing agents (such as lignin sulfonate, naphthalene sulfonate formaldehyde condensate (NSFC), melamine sulfonate formaldehyde condensate (MSFC), polycarboxylate comb polymers (containing alkylene oxide groups such as ethylene oxide (“EO”) and/or propylene oxide (“PO”) groups), gluconic acid and/or gluconate, and the like); set retarders; set accelerators; defoamers; air entraining agents; surface active agents; and mixtures thereof.
• water reducing agents such as lignin sulfonate, naphthalene sulfonate formaldehyde condensate (NSFC), melamine sulfonate formalde
• Admixtures that include EO-PO type polymers, e.g., which have EO and/or PO groups, and polycarboxylic acid and/or salt groups, are preferred.
• Exemplary cement dispersants (admixtures) contemplated for use in methods and compositions of the invention include EO-PO polymers and EO-PO comb polymers, as described for example in U.S. Pat. Nos. 6,352,952 B1 and 6,670,415 B2 of Jardine et al., which mentioned the polymers taught in U.S. Pat. No. 5,393,343 (assigned to W. R. Grace & Co.-Conn.).
• Another exemplary cement dispersant polymer, also containing EO/PO groups is obtained by polymerization of maleic anhydride and an ethylenically-polymerizable polyalkylene, as taught in U.S. Pat. No. 4,471,100.
• EO/PO-group-containing cement dispersant polymers are taught in U.S. Pat. No. 5,661,206 and U.S. Pat. No. 6,569,234.
• the amount of such polycarboxylate cement dispersants used within concrete may be in accordance with conventional use (e.g., 0.05% to 0.25% based on weight of active polymer to weight of cementitious material).
• compositions of the invention will depend on application, nature and quality of the cement, water/cement ratio, temperature, application objectives, other admixtures employed, and other factors typically considered by the construction worker/artisan.
• Suitable water-reducing admixtures suitable for use with the carboxylate graft polymers of the present invention, are available from Grace Construction Products, Cambridge, Mass., under the trade name “ADVA.”
• an exemplary admixture composition for modifying a cementitious composition comprises:
• At least one chemical admixture selected from the group consisting of water-reducing agent, set retarders, set accelerators, air entraining agents, air detraining agents, and mixtures thereof;
• a carboxylate graft polymer composition for treating clay or clay-bearing aggregates comprising:
• An exemplary method of the present invention for treating clay or clay-bearing aggregates comprises introducing to clay or to clay-bearing aggregates (such as mortar or concrete aggregates, asphalt aggregates, road base aggregates) in an amount of 0.1% to 100% by weight based on dry weight of the clay being treated, the carboxylate graft polymer as described above.
• clay-bearing aggregates such as mortar or concrete aggregates, asphalt aggregates, road base aggregates
• the carboxylate graft polymer also preferably has a weight-average molecular weight of 22,000 to 250,000, and more preferably more than 70,000, as measured by aqueous gel permeation chromatography (GPC) using poly(ethylene glycol) as calibration standard.
• GPC aqueous gel permeation chromatography
• the GPC processing conditions are as follows: 0.1M aqueous potassium nitrate as elution solvent, flow rate of 0.8 mL/min, injection volume of 10 ⁇ L, and column temperature at 30° C.
• carboxylate graft polymers are introduced to clay contained in aggregates (e.g., mortar or concrete aggregates, asphalt aggregates, road base aggregates), in the amount of 0.1% to 100% (as previously mentioned), more preferably in an amount of 1% to 50%, and most preferably in an amount of 2% to 25% by weight based on dry weight of the clay contained in said aggregates.
• aggregates e.g., mortar or concrete aggregates, asphalt aggregates, road base aggregates
• an aggregate composition applies to a clay-bearing plurality of aggregates which may be in a dry pile state (e.g., located in supply piles at the mine or quarry or concrete plant, located at a preparation site for installation as road base, etc.) or may be within a wet cementitious slurry (e.g., concrete, mortar).
• a dry pile state e.g., located in supply piles at the mine or quarry or concrete plant, located at a preparation site for installation as road base, etc.
• a wet cementitious slurry e.g., concrete, mortar
• the admixture compositions comprise at least one chemical admixture selected from the group of oxyalkylene-containing water-reducing admixture, shrinkage reducing admixture, or mixture thereof, in combination with said carboxylate graft polymer.
• Exemplary methods of the invention comprise combining said admixture compositions with a hydratable cementitious binder, either before, during, or after combining said cementitious binder with clay-bearing aggregates to create a mortar or concrete material.
• the carboxylate graft polymers of the present invention may be introduced to aggregates (e.g., sand) by application to the clay-bearing aggregates at the quarry or mine; by application at the concrete mix plant where the aggregates are combined with cement to form hydratable mortar or concrete; or by application at an asphalt plant wherein clay-bearing aggregates are combined with bituminous binder.
• the carboxylate graft polymers of the present invention may also be incorporated into the aggregates at the concrete mix plant before the cement binder is added or into dry or wet mortar or concrete containing the aggregates.
• the polymer may be used together with conventional concrete admixtures such as water reducers (such as superplasticizers), set retarders, set accelerators, air detraining agents, air entraining agent, shrinkage reducing agents, crack control agents, strength enhancing agents, fibers, and the like.
• water reducers such as superplasticizers
• set retarders such as superplasticizers
• set accelerators such as superplasticizers
• air detraining agents such as air entraining agent
• shrinkage reducing agents such as crack control agents
• strength enhancing agents such as fibers, and the like.
• the functionalized water-soluble polyamines of the present invention may be introduced into the aqueous well bore cement slurry or drilling fluid or mud, which in turn stabilizes subterranean clay-bearing formations.
• carboxylate graft polymer can also be used in wellbore drilling applications, such as wellbore mud drilling fluid and/or wellbore cementing compositions and methods for servicing wellbores.
• Natural resources such as gas, oil, and water residing in subterranean formations or zones are usually recovered by drilling a wellbore down to the subterranean formation while circulating a drilling fluid (also known as a drilling mud) through the drill pipe and the drill bit and upwardly through the wellbore to the surface.
• the drilling fluid serves to lubricate the drill bit and carry drill cuttings back to the surface.
• the drill pipe and drill bit are typically withdrawn from the wellbore while the drilling fluid is left in the wellbore while the drilling fluid is left in the wellbore to provide hydrostatic pressure on the formation penetrated by the wellbore and thereby prevent formation fluids from flowing into the wellbore.
• the wellbore drilling operation involves running a string of pipe, e.g., casing, in the wellbore.
• Primary cementing is then typically performed whereby a cement slurry is pumped down through the string of pipe and into the annulus between the string of pipe and the walls of the wellbore, whereby the drilling mud is displaced, and the cement slurry sets into a hardened mass (i.e., sheath) and thereby seals the annulus.
• a cement slurry is pumped down through the string of pipe and into the annulus between the string of pipe and the walls of the wellbore, whereby the drilling mud is displaced, and the cement slurry sets into a hardened mass (i.e., sheath) and thereby seals the annulus.
• carboxylate graft polymer is suitable for use as a clay mitigating agent in aqueous wellbore drilling fluid (mud) compositions and/or wellbore cementing compositions.
• mud wellbore drilling fluid
• advantages or purposes of doing this is to stabilize argillaceous formations like shales and/or clays in the wellbore which could otherwise be weakened and displaced by water in the aqueous wellbore mud.
• penetration of a small volume of wellbore fluid into the formation can result in a considerable increase in pore fluid pressure near the wellbore wall, which, in turn, can reduce the effective cement support, which leads to a less stable wellbore condition.
• the present invention also concerns a method for servicing a wellbore comprising: introducing to a wellbore formation an aqueous wellbore servicing fluid (e.g., drilling mud, spacer fluid, mud displacement fluid, cementing composition, or combination thereof) comprising the above-described carboxylate graft polymer.
• an aqueous wellbore servicing fluid e.g., drilling mud, spacer fluid, mud displacement fluid, cementing composition, or combination thereof
• the exemplary drilling mud or cementing composition can further contain conventional cementitious compositions, surfactants, or combinations thereof.
• the cementitious composition may comprise a cement such as a hydraulic cement (as previously defined above), and this cement may include calcium, aluminum, silicon, oxygen, and/or sulfur and which sets and hardens by reaction with water.
• hydraulic cements include but are not limited to Portland cements (e.g., classes A, C, G, and H Portland cements), pozzolan cements, high alumina cements, silica cements, high alkalinity cements, and combinations thereof.
• Solution A contained 105.5 g of distilled water, 2.65 g of ammonium persulfate and 8.84 g of 35% hydrogen peroxide.
• Aqueous Gel Permeation Chromatography (GPC) measurement of the resulting carboxylate graft polymer indicated a weight-average molecular weight of 139,000 for the polymer peak using polyethylene glycol (PEG) as standard for calibration.
• the GPC columns used were obtained from Waters Corporation, Massachusetts, USA, and had the trade names ULTRAHYDROGELTM 120, ULTRAHYDROGELTM 250 and ULTRAHYDROGELTM 500.
• the GPC processing conditions were as follows: 0.1M aqueous potassium nitrate as elution solvent, flow rate of 0.8 mL/min, injection volume of 10 ⁇ L, column temperature at 30° C., and refractive index detection for a Waters 1500 series system.
• non-clay-bearing sand was used to make concrete samples.
• the concrete samples included a control which contained no carboxylate graft polymer, a commercial polycarboxylate polymer (prior art used as a reference), and a synthesized carboxylate graft polymer of the present invention.
• Synthesized carboxylate graft polymers in this example were in the lower range of main peak molecular weights for commercially available polycarboxylate polymers.
• the concrete mix design included the following components: Cement—391 kg/m 3 with an alkali equivalent of 0.49% and a free calcium oxide content of 1.39%; Sand—800 kg/m 3 ; Stone—1068 kg/m 3 ; Water—157 kg/m 3 for a water-to-cement ratio of 0.40.
• the dosage for the polymers was 0.11% actives/cement wt.
• Each concrete mix was treated with air detraining agent.
• the mixing procedure was as follows: (1) mix sand, stone, and water for one minute; (2) add cement and mix for two minutes; (3) add polymer and mix for two minutes; (4) stop mixer and rest for three minutes; and (5) re-mix for 2 minutes. After mixing, the slump, air content and the 1-, 7-, and 28-day compressive strength of the concrete samples were measured. Results are shown in Table 2.
• the present inventors discovered that the A/B molar ratio must be decreased below 2.0 (P-2 compared to P-3) or the molecular weight of component B must be increased above 2000 (P-2 compared to P-4).
• the present inventors discovered that the carboxylate graft polymer with the lowest A/B molar ratio and greatest molecular weight of component B exhibited the lowest slump (P-5).
• the present inventors conducted a second set of experiments using the same mix design and protocol of Example 2.
• the synthesized carboxylate graft polymers were either in the high range of main peak molecular weights for commercially available polycarboxylates or higher. The results are shown in Table 3.
• the present inventors discovered that the A/B molar ratio must be decreased below 2.0 (P-6 and P-7 compared to P-8) or the molecular weight of component B must be increased above 2000 (P-6 compared to P-9). Increasing the main peak molecular weight was also seen to minimize slump (P-9 compared to P-1).
• carboxylate graft polymers of the present invention to function as clay mitigation agents
• the present inventors tested concrete using sand doped with clay and compared performance against known clay-mitigating agent involving the polycondensates of epichlorohydrin and dimethylamine (hereinafter “EPI-DMA”).
• the carboxylate graft polymers used as potential clay mitigating agents were chosen to have low ability in increasing slump and a range of main peak molecular weights.
• the concrete mix design included the following components: Cement—445 kg/m 3 with an alkali equivalent of 0.49% and a free calcium oxide content of 1.39%; Sand—884 kg/m 3 ; Clay—sodium montmorillinite, 1.15 g/m 3 (0.13% solids/sand); Stone—886 kg/m 3 ; Water—184 kg/m 3 for a water-to-cement ratio of 0.41; Polycarboxylate superplasticizer formulated with a defoamer—0.145 wt % solids/cement.
• the dosage for the clay mitigation agents was 10% solids/clay.
• the mixing procedure was as follows: (1) mix sand, clay, 1/3 of mixing water and clay mitigating agent together for five minutes; (2) add stone and mix for one minute; (3) add cement and mix for two minutes; (4) add polymer and mix for two minutes; (5) stop mixer and rest for three minutes; (6) re-mix for 2 minutes. After mixing, the slump flow (diameter of the spread), air content and the 1-, 7-, and 28-day compressive strength of the concrete were determined. The results are shown in Table 4.

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