WO2008048617A2 - Compositions et procédés servant à produire des composés du béton - Google Patents

Compositions et procédés servant à produire des composés du béton Download PDF

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WO2008048617A2
WO2008048617A2 PCT/US2007/022106 US2007022106W WO2008048617A2 WO 2008048617 A2 WO2008048617 A2 WO 2008048617A2 US 2007022106 W US2007022106 W US 2007022106W WO 2008048617 A2 WO2008048617 A2 WO 2008048617A2
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alkali
accordance
activated
composition
aggregate
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PCT/US2007/022106
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English (en)
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WO2008048617A3 (fr
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Michel Barsoum
Aaron Sakulich
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Drexel University
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Publication of WO2008048617A3 publication Critical patent/WO2008048617A3/fr

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Classifications

    • 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
    • C04B28/021—Ash cements, e.g. fly ash cements ; Cements based on incineration residues, e.g. alkali-activated slags from waste incineration ; Kiln dust cements
    • 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
    • C04B28/006—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 mineral polymers, e.g. geopolymers of the Davidovits type
    • 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
    • C04B28/08—Slag cements
    • 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

Definitions

  • the technical field is generally related to compositions of concrete and manufacturing concrete.
  • the technical field is more specifically related to alkali-activated concrete and low-greenhouse gas emission earth concrete.
  • Portland cement has long been an industry standard and is the most common type of cement in general usage. Portland cement is manufactured by sintering raw materials, primarily limestone, at 1450° C. The hydraulic mixture of lime and clay hardens and sets with the addition of water. Portland cement compositions are subject to corrosion and require long setting times. In addition, large amounts of lime are required to make such cements, which requires significant infrastructure for production and results in undesirable greenhouse gas emissions.
  • Novel concrete compounds as described herein are inexpensive to produce, exhibit high strength, are corrosion resistant, and minimize environmental harm during formulation.
  • the concrete compounds do not need to undergo high temperature processing and can set at room temperature, thus minimizing or eliminating the consumption of fuel during its manufacture.
  • the composition comprises an alkali-activated material made by reaction of amorphous silica with an alkali.
  • the alkali-activated material is subsequently mixed with an aggregate to form a concrete material labeled Earth Concrete.
  • amorphous silica is reacted with an alkali and mixed with an aggregate and cured to form the concrete composition.
  • This composition has the advantage that it may be manufactured by an environmentally friendly process that uses an alkali initiator and eliminates or minimizes the need for limestone combustion to produce the lime needed to make many current commercial concrete materials.
  • the Earth Concrete sets at room temperature and achieves high early strengths. The Earth Concrete does not adhere to steel, cardboard, plastic, or wood.
  • the Earth Concrete is fluid enough to fill complex molds with ease.
  • the Earth Concrete shrinks slightly during setting, which acts as a natural mold release.
  • Earth Concrete is capable of filling complex molds and providing perfect replicas.
  • a concrete-like substance uses simple, naturally available materials in combination with waste products (e.g., blast furnace slag) from the ore processing industries.
  • This new substance referred to herein as Slag Concrete
  • Slag Concrete is simple to manufacture and results in the emission of 10% or less of the amount of greenhouse gases that would be emitted by a similar quantity of Portland cement-based concrete.
  • Various embodiments of the Slag Concrete formula comprise additives introduced during mixing.
  • Example additives include silica, clay, and aluminum oxide containing powders. The additives change the ratios of silicon or aluminum to other elements. Additionally, salts or acids can be added as plasticizers.
  • the Slag Concrete sets at room temperature and achieves high early strengths.
  • the Slag Concrete does not adhere to steel, cardboard, plastic, or wood.
  • the Slag Concrete is fluid enough to fill complex molds with ease.
  • the Slag Concrete shrinks slightly during setting, which acts as a natural mold release.
  • Slag Concrete is capable of filling complex molds and providing perfect replicas.
  • Figure 1 is an illustration of an example alkali-activated concrete compound.
  • Figure 2 is a flow diagram of an example process for making a alkali-activated concrete composition.
  • Figure 3 is a graph illustrating the compressive strengths of various alkali- activated concrete samples having different amounts of aggregate.
  • Figure 4 is a graph illustrating the compressive strengths of various alkali- activated concrete samples prepared using different curing times.
  • Figure 5 is a graph illustrating compressive strengths of various alkali-activated concrete samples having varying amounts of sodium hydroxide.
  • Figure 6 is a graph illustrating compressive strengths of various alkali-activated concrete samples that were cured at 90° C, prior to, and after soaking in water.
  • Figure 7 is another graph illustrating compressive strengths of various alkali- activated concrete samples that were cured at 90° C, prior to, and after soaking in water.
  • Figure 8 is yet another graph illustrating compressive strengths of various alkali- activated concrete samples that were cured at 90° C, prior to, and after soaking in water.
  • Figure 9 too is a graph illustrating compressive strengths of various alkali- activated concrete samples that were cured at 90° C, prior to, and after soaking in water.
  • Figure 10 illustrates compressive strength versus strain for various alkali- activated concrete samples.
  • Figure 11 an illustration of an example slag-based concrete compound.
  • Figure 12 is a flow diagram of an example process for making a slag-based concrete compound.
  • a concrete compound comprises a alkali- activated concrete composition that exhibits high strength, corrosion resistance, thermal resistance and durability.
  • the concrete compositions include at least one aggregate and at least one alkali-activated component. These compositions have properties that are at least comparable to standard concrete compositions based on Portland concrete that are typically used for residential and commercial construction projects.
  • the alkali-activated concrete compound comprises three components: an alkali-activated component, an aggregate component, and a liquid component, such as water.
  • the aggregate component can comprise any inert granular material including sand, granite, limestone, other minerals such as carbonates, including barium and magnesium carbonates, and mixtures thereof, for example.
  • the aggregate can be fine or coarse granular material or any combination thereof.
  • Example particle sizes of aggregate can range from approximately 50 ⁇ m to 10 cm in size. In an example configuration, larger particle sizes are utilized in order to minimize the surface area of the aggregate material.
  • the compressive strength of the concrete compound generally increases with the particle size of the aggregate. In example configuration, the aggregate has particle sizes on the order of 1-8 mm to 1-8 cm.
  • the aggregate can constitute any appropriate portion of the concrete compound.
  • the aggregate constitutes about 40-95% by volume of the concrete compound.
  • the aggregate constitutes 50-85% by volume of the concrete compound.
  • the aggregate constitutes 60-80% by volume of the concrete compound.
  • the aggregate comprises limestone and constitutes about 60-80% by volume of the concrete material.
  • the alkali-activated composition contains, in an example composition, amorphous silica, alkali, and water.
  • the amorphous silica can be obtained in the form of, for example, amorphous diatomaceous earth and/or fumed silica.
  • the amorphous silica makes up about 20 to about 50 weight percent of the components of the alkali-activated composition. In another example configuration, the amorphous silica makes up about 25 - 45 weight percent of the components of the alkali-activated composition, In yet another example configuration, the amorphous silica makes up about 30 - 40 weight percent of the components of the alkali- activated composition.
  • the herein described alkali- activated concrete compound contains significantly more amorphous silica.
  • FIG. 2 is a flow diagram of an example process for making a alkali-activated concrete composition.
  • a high pH alkali solution is prepared.
  • the alkali solution is composed of at least one alkali material in an aqueous solution.
  • the high-pH solution can comprise any appropriate material.
  • a high-pH material that can be used for the high-pH solution is Natron.
  • Various configurations of Natron comprise Soda Ash (Na 2 CO 3 ) or Sodium Carbonate-Soda Ash and Water (Na 2 CO 3 10 H 2 O).
  • Natron also can comprise various amounts of sodium chloride and/or sodium sulfate.
  • the pH of the aqueous solution is at least 11.5. The pH can be slightly decreased if the amount of heat used in the reaction to form the alkali-activated component is increased.
  • the alkali solution has a pH of at least about 12.
  • the alkali material can be selected from alkali metal salts, alkaline earth metal salts, or mixtures thereof.
  • the cation is selected from sodium, potassium, calcium, and ammonium.
  • the alkali material is sodium hydroxide.
  • Sodium hydroxide is inexpensive, has low volatility, and is a strong base.
  • the mole ratio of monovalent alkali metal cation to amorphous silica is from about 0.5 - 2.0, from about 0.7 - 1.4, or, from about 0.8 - 1.1.
  • the alkali material additionally includes one or more alkaline earth metal salts, such as calcium salts, for example, calcium oxide (lime). It has been found that the addition of alkaline earth metal ions to the alkali-activated component minimizes the tendency of the concrete material to dissolve in water.
  • alkaline earth metal ions such as calcium salts, for example, calcium oxide (lime).
  • about one mole of divalent alkaline earth metal cation can be used for every 2 - 8 total moles of silica and alumina used to make the alkali- activated component, hi an example configuration, about one mole of divalent alkaline earth metal cation is employed for each 3 - 6 total moles of silica and alumina.
  • the alkali-activated concrete composition contains at least 90 percent by weight of calcium, oxygen, silicon, carbon, and hydrogen.
  • the alkali-activated material contains both monovalent and divalent cationic materials
  • an aqueous solution of the monovalent cation-containing salts is first made, and this aqueous solution is reacted with the amorphous silica.
  • a second aqueous solution of the divalent cation-containing salts is prepared and added to the resultant alkali-activated material after the reaction between the monovalent alkali material and the amorphous silica, but prior to addition of the aggregate.
  • the aggregate is added to the composition with thorough mixing and the composition is cured to form a concrete composition.
  • the alkali-activated component of the concrete compound advantageously has a high tolerance for the inclusion of other materials therein.
  • the alkali-activated component can be combined with optional additives such as aluminosilicate clays, such as metakaolinite (Al 2 O 3 (SiO 2 ) 2 ).
  • aluminosilicate clays such as metakaolinite (Al 2 O 3 (SiO 2 ) 2 ).
  • the aluminosilicate clays have been found to be useful to prevent dissolution of alkali-activated components in the aqueous solutions.
  • sufficient aluminosilicate is employed to provide sufficient alumina to prevent dissolution of alkali-activated components in the aqueous solution.
  • aluminosilicate clays constitute no more than about 15 weight percent of the alkali-activated components, no more than about 10 weight percent of the alkali-activated components, or, no more than about 8 weight percent of the alkali-activated components.
  • the amount of aluminosilicate clay employed will depend upon the amount of alumina present in the particular clay employed.
  • the alkali-activated concrete composition has a good compressive strength and superior corrosion resistance and thermal stability in comparison to Portland cement-based concretes.
  • the alkali-activated concrete compositions exhibit compressive strengths of about 15- 43 MPa.
  • the physical properties of the alkali-activated concrete composition are comparable to medium strength Portland cement-based concretes. In all other respects, the alkali-activated concrete composition is mechanically comparable to commercially available cement-based concretes. Because of the alkali-activated concrete composition's superior corrosion resistance and thermal stability, the alkali-activated concrete composition may require less maintenance, repair, and/or less frequent replacement than currently available Portland cement-based concretes.
  • the resultant alkali-activated concrete compositions can be used for various applications including, but not limited to, roadways, bridges, sidewalks, walls, docks, and building foundations; ancillary products, including but not limited to blast barriers, bollards, and highway dividers; objects of art, including but not limited to statutes, sculptures, monuments, and tombstones; consumer products, including but not limited to garden and landscaping products, countertops, and large-gauge jewelry; and/or any application for which Portland cement is used.
  • An aspect of the herein described alkali-activated concrete composition is utilizing an effective amount of alkali initiator to activate the amorphous silica, hi comparison to standard means for concrete production which require heat-treatment, high purities of reactants, or long reaction periods that may persist for days, the present method eliminates any need for large batch curing in excess water or curing in general by utilizing an alkali initiator. For some applications, however, a modest curing regime for short periods of time may be employed to initiate the reaction to form the alkali-activated component. [0034] In one example embodiment, only naturally occurring reactants are utilized to prepare the alkali-activated concrete composition, simplifying manufacturing and minimizing environmental greenhouse emissions.
  • Standard methods for producing cement often employ large amounts of lime, produced by burning limestone (CaCO 3 ), which releases carbon dioxide (CO 2 ) into the atmosphere in addition to other gases created by the consumption of fuel during the burning process itself.
  • lime (CaO) and metakaolinite are not major components of the alkali-activated concrete compositions, the attendant release of harmful greenhouse gases is minimized. Additionally, the above described method of preparing the alkali-activated concrete composition is inexpensive and does not involve specialized or complex processing.
  • the alkali- activated concrete composition can be formed using a simple mixer and may optionally be cured at relatively low temperatures of room temperature (20° C) to about 90° C.
  • the alkali- activated concrete composition is composed of naturally abundant materials available worldwide, that are substantially less expensive than other materials frequently used to make geopolymers. This simple manufacturing process facilitates inexpensive, large-scale production and may be particularly practical for rural or developing areas lacking the facilities and infrastructure required for the calcination of limestone required in standard concrete production.
  • the alkali-activated concrete composition comprises 105 g of diatomaceous earth, 14O g of water (2 batches of 70 g each for preparing separate aqueous solutions of NaOH and CaO), 23.5 g of lime (CaO), 60 g of sodium hydroxide (NaOH), 25 g of metakaolinite, and 800 grams of limestone aggregate.
  • the alkali- activated concrete composition provides a compressive strength, after soaking in water, as high as 29.8 MPa.
  • Figure 3 is a graph illustrating the compressive strengths of various alkali- activated concrete samples having different amounts of aggregate.
  • the samples depicted in Figure 2 comprised a 1 : 1 molar ratio of sodium hydroxide and water amorphous diatomaceous earth and sand.
  • a sample comprising 20% sand by volume exhibited a compressive strength of slightly above 10 MPa.
  • a sample comprising 40% sand by volume exhibited a compressive strength of approximately 24 MPa.
  • a sample comprising 60% sand by volume exhibited a compressive strength of approximately 15 MPa.
  • a sample comprising 80% sand by volume exhibited a compressive strength of approximately 12 MPa.
  • Figure 4 is a graph illustrating the compressive strengths of various alkali- activated concrete samples prepared using different curing times.
  • the samples comprise a 1 : 1 molar ratio of sodium hydroxide and water, amorphous diatomaceous earth and about 40% by volume of sand.
  • a sample cured for two hours exhibited a compressive strength of abut 13.5 MPa.
  • a sample cured for three hours exhibited a compressive strength of about 19 MPa.
  • a sample cured for four hours exhibited a compressive strength of about 30 MPa.
  • a sample cured for five hours exhibited a compressive strength of about 32 MPa.
  • a sample cured for six hours exhibited a compressive strength of about 34 MPa.
  • Figure 5 is a graph illustrating compressive strengths of various alkali-activated concrete samples having varying amounts of sodium hydroxide. They samples comprise sodium hydroxide, water, amorphous diatomaceous earth, and about 40% by volume of sand. A sample comprising 0.9 moles of sodium hydroxide exhibited the compressive strength of approximately 42 MPa. A sample comprising 1.0 moles of sodium hydroxide exhibited a compressive strength of approximately 37 MPa. A sample comprising 1.1 moles of sodium hydroxide exhibited a compressive strength of approximately 29 MPa.
  • Figure 6 is a graph illustrating compressive strengths of various alkali-activated concrete samples that were cured at 90° C, prior to, and after soaking in water. As depicted in Figure 6, samples that were not soaked in water are labeled as pre-soaked, and samples that were soaked in water are labeled a post-soaked. The samples were made using the above example composition, i.e., 105 g of diatomaceous earth, 140 g of water (2 batches of 7Og each for preparing separate aqueous solutions of NaOH and CaO), 23.5 g of lime (CaO), 63.5 g of sodium hydroxide (NaOH), and 800 grams of limestone aggregate. No metakaolinite was used.
  • the darker shaded bars on the graph are indicative of samples that were post-soaked, and the lighter shaded bars on the graph indicate samples that were pre-soaked.
  • Pre-soaked samples that were cured for two hours exhibited a compressive strength of approximately 14 MPa
  • post soaked samples that were cure for two hours exhibited a compressive strength of approximately 3 MPa.
  • Pre-soaked samples that were cured for six hours exhibited a compressive strength of approximately 17 MPa
  • post soaked samples that were cure for six hours exhibited a compressive strength of approximately 22 MPa.
  • Pre-soaked samples that were cured for 24 hours exhibited a compressive strength of approximately 21 MPa
  • post soaked samples that were cure for 24 hours exhibited a compressive strength of approximately 19 MPa.
  • Pre-soaked samples that were cured for 48 hours exhibited a compressive strength of approximately 25 MPa
  • post soaked samples that were cure for 48 hours exhibited a compressive strength of approximately 17 MPa.
  • Figure 7 is a graph illustrating compressive strengths of various alkali-activated concrete samples that were cured at 90° C, prior to, and after soaking in water. As depicted in Figure 7, samples that were not soaked in water are labeled as pre-soaked, and samples that were soaked in water are labeled a post-soaked. The samples were made using the example composition of Figure 6, with the exception that 53 grams of sodium hydroxide was used instead of 60 grams of sodium hydroxide.
  • the composition used for Figure 7 was 105 g of diatomaceous earth, 14O g of water (2 batches of 7Og each for preparing separate aqueous solutions of NaOH and CaO), 23.5 g of lime (CaO), 50 g of sodium hydroxide (NaOH), 25 g of metakaolinite, and 800 grams of limestone aggregate.
  • the darker shaded bars on the graph are indicative of samples that were post-soaked, and the lighter shaded bars on the graph indicate samples that were pre-soaked.
  • Pre-soaked samples that were cured for two hours exhibited a compressive strength of approximately 10 MPa
  • post soaked samples that were cure for two hours exhibited a compressive strength of approximately 14 MPa.
  • FIG. 8 is a graph illustrating compressive strengths of various alkali-activated concrete samples that were cured at 90° C, prior to, and after soaking in water.
  • samples that were not soaked in water are labeled as pre-soaked, and samples that were soaked in water are labeled a post-soaked.
  • the samples were made using the example composition of Figure 6 with the exception that Metakaolin was used.
  • the composition used for Figure 8 was 105 g of diatomaceous earth, 14O g of water (2 batches of 7Og each for preparing separate aqueous solutions of NaOH and CaO), 23.5 g of lime (CaO), 63 g of sodium hydroxide (NaOH), 25 g of metakaolinite, and 800 grams of limestone aggregate.
  • the darker shaded bars on the graph are indicative of samples that were post-soaked, and the lighter shaded bars on the graph indicate samples that were pre-soaked.
  • Pre-soaked samples that were cured for two hours exhibited a compressive strength of approximately 7.5 MPa
  • post soaked samples that were cure for two hours exhibited a compressive strength of approximately 7 MPa.
  • Pre-soaked samples that were cured for six hours exhibited a compressive strength of approximately 10 MPa
  • post soaked samples that were cured for six hours exhibited a compressive strength of approximately 11.5 MPa.
  • Pre-soaked samples that were cured for 24 hours exhibited a compressive strength of approximately 24 MPa
  • post soaked samples that were cure for 24 hours exhibited a compressive strength of approximately 12.5 MPa.
  • Pre-soaked samples that were cured for 48 hours exhibited a compressive strength of approximately 17.5 MPa
  • post soaked samples that were cure for 48 hours exhibited a compressive strength of approximately 15 MPa.
  • Figure 9 is a graph illustrating compressive strengths of various alkali-activated concrete samples that were cured at 90° C, prior to, and after soaking in water. As depicted in Figure 9, samples that were not soaked in water are labeled as pre-soaked, and samples that were soaked in water are labeled a post-soaked.
  • the samples were made using the example composition of Figure 8, with the exception that metakaolinite also was used, i.e., 105 g of diatomaceous earth, 140 g of water (2 batches of 7Og each for preparing separate aqueous solutions of NaOH and CaO), 23.5 g of lime (CaO), 50 g of sodium hydroxide (NaOH), 25 g of metakaolinite, and 800 grams of limestone aggregate.
  • metakaolinite also was used, i.e., 105 g of diatomaceous earth, 140 g of water (2 batches of 7Og each for preparing separate aqueous solutions of NaOH and CaO), 23.5 g of lime (CaO), 50 g of sodium hydroxide (NaOH), 25 g of metakaolinite, and 800 grams of limestone aggregate.
  • metakaolinite also was used, i.e., 105 g of diatomaceous earth, 140 g of water (2 batches of 7Og each for preparing separate aqueous solutions of NaOH
  • Pre-soaked samples that were cured for two hours exhibited a compressive strength of approximately 17 MPa, and post soaked samples that were cure for two hours exhibited a compressive strength of approximately 18 MPa.
  • Pre-soaked samples that were cured for six hours exhibited a compressive strength of approximately 18 MPa, and post soaked samples that were cure for six hours exhibited a compressive strength of approximately 28 MPa.
  • Pre-soaked samples that were cured for 24 hours exhibited a compressive strength of approximately 18 MPa, and post soaked samples that were cure for 24 hours exhibited a compressive strength of approximately 22 MPa.
  • Pre-soaked samples that were cured for 48 hours exhibited a compressive strength of approximately 24.5 MPa, and post soaked samples that were cure for 48 hours exhibited a compressive strength of approximately 20 MPa.
  • Figure 10 illustrates compressive strength versus strain for various alkali- activated concrete samples.
  • Graph 20 and graph 22 shows compressive strength versus strain for an example composition comprising 1.00 moles Silicon Dioxide (SiO 2 ), 1.10 moles Sodium Hydroxide (NaOH), 1.65 moles Water (H 2 O), 0.20 moles Calcium Carbonate (CaCO 3 ), and 40% by volume sand.
  • Graph 20 illustrates compressive strength versus strain for a sample cured for 4 hours and 70° C.
  • Graph 22 illustrates compressive strength versus strain for a sample cured for 24 hours and 24° C.
  • a concrete compound comprises a waste product (e.g., slag) from any of the ore processing industries, an aggregate and a liquid.
  • This slag-based concrete compound referred to herein as Slag Concrete, is also alkali-activated. It is simple to manufacture and results in the emission of 10% or less of the amount of greenhouse gases that would be emitted by a similar quantity of Portland cement- based concrete.
  • Various embodiments of the slag-based concrete compound comprise additives introduced during mixing.
  • Example additives include silica, clay, and aluminum containing powders. The additives change the ratios of silicon or aluminum to other elements. Additionally, salts or acids can be added as plasticizers.
  • the slag-based concrete compound sets at room temperature and achieves high early strengths. The slag-based concrete compound does not adhere to steel, cardboard, plastic, or wood. The slag-based concrete compound shrinks slightly during setting, which acts as a natural mold release.
  • formulation of the slag-based concrete compound comprises activating aluminosilicate minerals with a high-pH solution.
  • the slag-based concrete compound comprises slag, a by-product of the pre refining process, and crushed limestone aggregate.
  • the slag component can comprise any appropriate slag compound.
  • the slag component can comprise slag resulting from ferrous and/or non-ferrous smelting processes.
  • the slag component can comprise calcium, magnesium, aluminum, or a combination thereof.
  • the aggregate component can comprise any appropriate aggregate.
  • the aggregate component comprises limestone, granite (e.g., powdered granite), sand, or a combination thereof.
  • the liquid component can comprise any appropriate liquid component, such as water for example.
  • the liquid component can have combined therewith a high-pH activator to form a high-pH solution, hi an example embodiment, high-pH is a pH greater than or equal to 14. In another example embodiment, high-pH is a pH greater than or equal to 10.
  • the high-pH solution can comprise any appropriate material.
  • Example materials that can be used for the high- pH solution include a waterglass (Sodium Silicate) and Sodium Hydroxide (NaOH) solution, and a waterglass and Potassium Hydroxide (KOH) solution, hi another example embodiment, the high-pH material comprises Natron.
  • Natron Various configurations of Natron comprise Soda Ash (Na 2 CO 3 ) or Sodium Carbonate-Soda Ash and Water (Na 2 CO 3 10 H 2 O). Natron also can comprise various amounts of sodium chloride and/or sodium sulfate.
  • FIG 12 is a flow diagram of an example process for making a slag-based alkali-activated concrete compound.
  • Slag is mixed with aggregate at step 24.
  • the slag can comprise any appropriate slag, such as slag resulting from ferrous and/or non- ferrous smelting processes.
  • the aggregate can comprise any appropriate aggregate, such as limestone, granite, sand, or a combination thereof.
  • Liquid is added to the mixture of slag and aggregate at step 24.
  • the liquid comprises a high-pH activator such as, waterglass or Natron solution.
  • the compound comprising the combination of the mixture and liquid is cured at room temperature at step 28. The reaction will occur at any temperature above the freezing temperature of water.
  • room temperature comprises a temperature ranging from about 0° C (32° F) to about 23° C (73° F).
  • the slag-based concrete composition comprises 480 g of limestone, 400 g of slag, and 144 g of waterglass. This formulation has exhibits a compressive strength of 70 MPa.
  • the slag-based concrete composition comprises 480 g of limestone, 400 g of slag, 124.8 g of water, 144 g of waterglass, and 41.6 g of Sodium Hydroxide (NaOH).
  • the slag-based concrete composition comprises 480 g of limestone, 400 g of slag, 32 g of Natron, and 124.8 g of water.
  • the slag-based concrete composition comprises 480 g of limestone, 400 g of slag, 32 g of Natron, 100 g of water, and 35 g of diatomaceous earth.
  • alkali-activated Earth or Slag concrete compositions should not be limited to any single embodiment, but rather should be construed in breadth and scope in accordance with the appended claims.

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Abstract

Selon l'invention, des compositions de béton à faible émission de gaz à effet de serre, résistantes à la corrosion et de résistance élevée comprennent un composé du béton à base de géopolymère et un composé du béton à base de laitier. Le composant géopolymère comprend une quantité relativement importante de silice amorphe et il est mélangé avec un composé agrégat tel que du granit, du calcaire ou du sable. Le composé du béton à base de géopolymère peut être fabriqué par un procédé respectueux de l'environnement qui consiste à activer la silice amorphe par un alcali et qui minimise donc le besoin de chaux, ce qui implique typiquement la combustion de calcaire. Le composé du béton à base de laitier comprend du laitier et un agrégat comprenant du calcaire, du granit et/ou du sable. Le composé du béton à base de laitier peut également comprendre un activateur servant à augmenter le pH du composé. Les exemples d'activateurs comprennent le verre soluble (silicate de sodium) et le natron.
PCT/US2007/022106 2006-10-16 2007-10-16 Compositions et procédés servant à produire des composés du béton WO2008048617A2 (fr)

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WO2010079414A2 (fr) 2009-01-09 2010-07-15 Stephen Alter Compositions de géopolymères
CZ302237B6 (cs) * 2008-10-21 2011-01-05 Cs-Beton S.R.O. Zarízení pro vzájemné spojení dvou dílcu silnicního svodidla a zpusob vzájemného spojování techto dílcu
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EP2514727A2 (fr) 2011-04-20 2012-10-24 Consolis Technology Oy Ab Composition de béton de calcaire activé par un alcali et utilisation de la composition dans le coulage de béton
FR3026739A1 (fr) * 2014-10-07 2016-04-08 Centre D'etudes Et De Rech De L'industrie Du Beton Procede ameliore pour la realisation d'un beton ecologique et composition d'un beton ecologique.
WO2019110134A1 (fr) * 2017-12-08 2019-06-13 Ecocem Materials Limited Liant à base de laitier de haut fourneau granulé broyé, formulations sèches et humides fabriquées à partir de celui-ci, et leurs procédés de préparation
CN113387620A (zh) * 2021-06-16 2021-09-14 河海大学 一种基于碱激发胶凝材料的固化疏浚淤泥块体及其制备方法
CN113429134A (zh) * 2021-07-21 2021-09-24 西安建筑科技大学 一种调整化学激发胶凝材料体系流动性与凝结时间的方法
EP4129950A1 (fr) 2021-08-02 2023-02-08 Parma OY Composition de béton

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CZ302237B6 (cs) * 2008-10-21 2011-01-05 Cs-Beton S.R.O. Zarízení pro vzájemné spojení dvou dílcu silnicního svodidla a zpusob vzájemného spojování techto dílcu
WO2010079414A2 (fr) 2009-01-09 2010-07-15 Stephen Alter Compositions de géopolymères
US20110271876A1 (en) * 2009-01-09 2011-11-10 Stephen Alter Geopolymer compositions
FR2962125A1 (fr) * 2010-06-30 2012-01-06 Patrick Cebe Produit se presentant sous forme de poudre de pierre utilisable dans le cadre de materiaux mineraux de parement ou de decoration
EP2514727A2 (fr) 2011-04-20 2012-10-24 Consolis Technology Oy Ab Composition de béton de calcaire activé par un alcali et utilisation de la composition dans le coulage de béton
FR3026739A1 (fr) * 2014-10-07 2016-04-08 Centre D'etudes Et De Rech De L'industrie Du Beton Procede ameliore pour la realisation d'un beton ecologique et composition d'un beton ecologique.
EP3006416A1 (fr) 2014-10-07 2016-04-13 Centre d'Etudes et de Recherches de l'Industrie du Béton Procede ameliore pour la realisation d'un beton ecologique et composition d'un beton ecologique
WO2019110134A1 (fr) * 2017-12-08 2019-06-13 Ecocem Materials Limited Liant à base de laitier de haut fourneau granulé broyé, formulations sèches et humides fabriquées à partir de celui-ci, et leurs procédés de préparation
CN113387620A (zh) * 2021-06-16 2021-09-14 河海大学 一种基于碱激发胶凝材料的固化疏浚淤泥块体及其制备方法
CN113429134A (zh) * 2021-07-21 2021-09-24 西安建筑科技大学 一种调整化学激发胶凝材料体系流动性与凝结时间的方法
CN113429134B (zh) * 2021-07-21 2023-03-17 西安建筑科技大学 一种调整化学激发胶凝材料体系流动性与凝结时间的方法
EP4129950A1 (fr) 2021-08-02 2023-02-08 Parma OY Composition de béton

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