WO2013139961A1 - Composition pour la production de matériaux de construction - Google Patents

Composition pour la production de matériaux de construction Download PDF

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Publication number
WO2013139961A1
WO2013139961A1 PCT/EP2013/056069 EP2013056069W WO2013139961A1 WO 2013139961 A1 WO2013139961 A1 WO 2013139961A1 EP 2013056069 W EP2013056069 W EP 2013056069W WO 2013139961 A1 WO2013139961 A1 WO 2013139961A1
Authority
WO
WIPO (PCT)
Prior art keywords
water
composition according
mgo
composition
uncalcined
Prior art date
Application number
PCT/EP2013/056069
Other languages
English (en)
Inventor
Mohammad Hajmohammadian BAGHBAN
Original Assignee
Institutt For Bygg, Anlegg Og Transport
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Institutt For Bygg, Anlegg Og Transport filed Critical Institutt For Bygg, Anlegg Og Transport
Publication of WO2013139961A1 publication Critical patent/WO2013139961A1/fr
Priority to NO20141145A priority Critical patent/NO20141145A1/no

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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
    • C04B28/34—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 cold phosphate binders
    • 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
    • C04B14/064—Silica aerogel
    • 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
    • C04B14/30—Oxides other than silica
    • C04B14/301—Oxides other than silica porous or hollow
    • C04B14/302—Aerogels
    • 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
    • C04B14/30—Oxides other than silica
    • C04B14/304—Magnesia
    • 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
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00034—Physico-chemical characteristics of the mixtures
    • C04B2111/00068—Mortar or concrete mixtures with an unusual water/cement ratio
    • 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
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00034—Physico-chemical characteristics of the mixtures
    • C04B2111/00215—Mortar or concrete mixtures defined by their oxide composition
    • 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
    • C04B2201/00—Mortars, concrete or artificial stone characterised by specific physical values
    • C04B2201/30—Mortars, concrete or artificial stone characterised by specific physical values for heat transfer properties such as thermal insulation values, e.g. R-values
    • C04B2201/32—Mortars, concrete or artificial stone characterised by specific physical values for heat transfer properties such as thermal insulation values, e.g. R-values for the thermal conductivity, e.g. K-factors
    • 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
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/91—Use of waste materials as fillers for mortars or concrete

Definitions

  • Field of invention concerns novel construction material compositions, and the use of such compositions in the production of building elements.
  • WO 201 166209 discloses the use of aerogel granules as aggregates in concrete to improve the material properties. Since aerogel granules have low thermal conductivity, relatively high strength and are resistant to fire; they can be a good option for this purpose. A special type of surfactant is usually used in this type of product for dispersing aerogel granules in concrete. However since thermal conduction of the solid part of hardened portland cement paste in the composite is much higher than of conventional aerogels, the matrix acts like thermal bridge in the composite system and results in a concrete with much higher thermal conductivity than the thermal conductivity of typical aerogel granules.
  • MgO is calcined at 1300 °C prior to mixing in order to reduce its solubility for practical applications. See for instance US patent no. 6,776,837 and 6,204,214, wherein the desired use of calcined MgO in the production of phosphate ceramics is disclosed.
  • the present invention provides a composition for producing construction materials having improved properties compared to prior art materials.
  • the composition is mixed with water to provide the desired construction material.
  • the present invention provides a composition for the production of construction materials, comprising:
  • the composition comprises 20-80 wt% hydrophobic aerogel granules based on the total weight of the composition, preferably 30-80 wt%.
  • the composition comprises 5-25 wt% uncalcined MgO.
  • the composition comprises 15-65 wt% of alkali phosphate salt.
  • the composition comprises a alkali phosphate salt selected from a group consisting of mono-potassium phosphate, dipotassium phosphate, mono-sodium phosphate and disodium phosphate, and any combination thereof, preferably the alkali phosphate salt is mono-potassium phosphate.
  • the mono-potassium phosphate has a water- solubility of at least 15 g/1, at least 100 g/1, or preferably at least 200 g/1 at 25 °C.
  • the composition is able to form a homogenous slurry which cure without separation when mixed with water in the range of 50-600 wt% based on the combined weight of uncalcined MgO and alkali phosphate salt, preferably in the range of 100-600 wt% or 150-600 wt%, and even more preferred 200-600 wt%.
  • homogenous slurry is in this application intended to define a slurry being overall homogenous, or uniform, in the sense that it does not separate into phases of different viscosity.
  • the amount of water is in the range of 15-70 wt% based on the total weight of the composition.
  • the homogenous, or uniform, slurry would comprise 5-65% wt% of hydrophobic aerogel granules based on the total weight of the slurry.
  • the composition comprises at least one additive selected from fly ash, silicate materials, foaming agents, surfactants, fibers and aggregates.
  • the invention provides a construction material produced by mixing a composition according to the invention and water, wherein the amount of water is in the range of 50-600 wt%, 100-600 wt%, 150-600 wt%, or 200-600 wt% based on the combined weight of uncalcined MgO and alkali phosphate salt.
  • the construction material has a thermal conductivity of less than 0.040 W/mK, less than 0.030 W/mK, less than 0.025 W/mK or even more preferred less than 0.020 W/mK.
  • the construction material has a compressive strength higher than 0.3 MPa, 1 MPa, 3 MPa, 10 MPa or 20 MPa, and even more preferred higher than 60 MPa.
  • the construction material comprises 5-65 wt% of hydrophobic aerogel granules based on the total weight of the construction material.
  • the invention provides the use of a composition according to the invention, for preparing a construction material, preferably a self-supporting concrete type construction material.
  • the invention provides a process for the production of a construction material comprising the step of mixing a composition according to the invention and water, wherein the amount of water is in the range of 50-600 wt%, 100-600 wt%, 150-600 wt%, or 200-600 wt% based on the combined weight of uncalcined MgO and alkali phosphate salt.
  • the amount of water is more than 100 wt% based on the combined weight of uncalcined MgO and alkali phosphate salt, preferably more than 150 wt%, more than 200 wt%, and even more preferred more than 300 wt%.
  • the composition of the invention is able to form a homogenous slurry which cure without separation when mixed with water in an amount of more than 100 wt% based on the combined weight of uncalcined MgO and alkali phosphate salt, preferably more than 150 wt%, more than 200 wt%, and even more preferred more than 300 wt%.
  • the invention provides a construction material produced by mixing a composition according to the invention and water, wherein the amount of water is more than 100 wt% based on the combined weight of uncalcined MgO and alkali phosphate salt, preferably more than 150 wt%, more than 200 wt%, and even more preferred more than 300 wt%.
  • the present invention provides a composite, or composition, containing aerogel granules, magnesium oxide and an alkali phosphate salt.
  • the phosphate and the magnesium oxide form a chemically bonded phosphate ceramic when mixed with water.
  • the construction material obtained after mixing the composition according to the invention with water will have a much lower thermal conductivity than the prior art concretes. Nevertheless, it is noteworthy that although replacing Portland cement with chemically bonded phosphate ceramics results in a matrix with lower thermal conductivity, the thermal conduction of the matrix will still be much higher than the aerogel granules. Thus, a method is proposed to further reduce the thermal conductivity of the matrix which leads to an even more environmentally friendly construction material and a more cost effective composition as well.
  • the porosity of a concrete-type construction material is, among many factors, dependent on the water-cement ratio.
  • the cement is here considered as the total amount of MgO and phosphate salt.
  • the maximum water-cement ratio may for example be limited to less than 60 % of the cement weight for ordinary Portland cement pastes. Special techniques and methods, such as rotating curing or chemical stabilizers, are needed to avoid separation if increased water content is desired.
  • the amount of water normally used in the magnesium potassium phosphate ceramic mixes is about 50 % of the cement weight (weight of MgO and KH 2 P0 4 ).
  • the porosity of the matrix around the aerogel aggregates is increased by substantially increasing the water-cement ratio without causing separation.
  • uncalcined MgO has finer and more porous particles compared to the calcined MgO, and is also much more reactive towards water and phosphate.
  • the use of uncalcined MgO also leads to a more environmentally friendly product due to elimination of the calcination process which has a high energy demand. Using uncalcined MgO may not be feasible for practical applications in the prior art mixes comprising magnesium potassium phosphate ceramic, since the attempt of making the ceramic in large scale may fail due to a very high exothermic heat production.
  • hydrophobic aerogel granules in the mix as aggregates reduces the total exothermic heat production in the volume compared to the plain magnesium potassium phosphate ceramic mixes. Furthermore, the demand for water will further increase by using the hydrophobic aerogel granules, and the increased amount of water in the mix helps cooling the mixture during the mixing process. In fact, using uncalcined MgO with finer particles and hydrophobic aerogel granules helps to increase the water content of the mix, and increasing the water content together with using hydrophobic aerogel granules as aggregate make it practical to use uncalcined MgO with fine particles instead of calcined MgO.
  • the particle size of the uncalcined MgO is normally in the range of 5 nm - 400 ⁇ , wherein a finer particle size increases the water demand.
  • MgO powder with particle size of less than 5 nm is also possible, but such powders are usually very expensive. Therefore, from an economic aspect it is sufficient to use powder with a particle size not impairing the adhesion force during cement setting.
  • Aerogels in the sense of the present invention include colloidal substances which are gelled and dried. They have low density and high porosity. The solid substance is only about 1 to 15 volume %, of the aerogel. The rest of its volume is gas, or even vacuum, which means that they have a high surface area (up to 1000 m 2 /g). Inorganic aerogels are usually hydrophilic by themselves and are considered one of the lightest materials and one of the best heat insulators. Aerogel granulates may be obtained by grinding of aerogel monoliths. Hydrophobic in the sense of the present invention is water-repellent, is that the used aerogel shows a marked interaction with polar solvents like water. The used hydrophobic aerogel granulates have a water contact angle > 90 °.
  • Hydrophobic aerogel granulates are often obtained from hydrophilic aerogel granulates by a hydrophobizing treatment.
  • a hydrophobizing treatment such as an etherification using trimethylsilyl chloride (TMSC1), can thus convert a hydrophilic aerogel into a hydrophobic aerogel.
  • TMSC1 trimethylsilyl chloride
  • hydrophobic aerogel is prepared using hydrophobizing agents during the formation of the aerogel.
  • Alkali phosphate salts include all such salts suitable for use in a composition for the production of construction materials. These include water soluble phosphates like the various sodium and potassium salts, and especially mono-potassium phosphate.
  • the phosphate salt for instance mono-potassium phosphate salt, has an initial solubility in water of more than 15 g/1 at 25 °C, and even more preferred about 220 g/1 at 25 °C. The initial solubility of mono-potassium phosphate is adjusted by the size and consistency of the particles used. Use of mono-potassium phosphate with high water solubility in the mixture will result in an even higher demand for water, faster setting, and finally even lower thermal conductivity.
  • fly ash or other materials containing silicate can also be used in the mixture to further increase the total water demand and also increase the strength.
  • foaming agents can be added to the mix to introduce macro air pores to the composite and still further increase the porosity of the material.
  • Other types of admixtures such as surfactants can also be used to improve the mechanical and thermal properties.
  • hydrophobic agents during the mixing process or after mixing can also be beneficial in order to increase the durability and decrease the thermal conductivity of the material in moist condition such as in building envelopes in contact with rain, or for construction elements in contact with underground water or sea water.
  • using different types of fibers can enhance mechanical or even thermal properties of the material. Phase change materials in either encapsulated form or without encapsulation as well as other materials with high specific heat capacity can also be introduced to the mixture to improve the thermal properties of the material.
  • different types of aggregates may be used in the mixture to modify the material properties.
  • compositions as disclosed in the present application provides composite construction materials having advantageous properties such as light weight, versatility, quick production and installation, high thermal insulation, fire resistance and sound insulation.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Structural Engineering (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Civil Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Dispersion Chemistry (AREA)
  • Addition Polymer Or Copolymer, Post-Treatments, Or Chemical Modifications (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
  • Polyurethanes Or Polyureas (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)

Abstract

La présente invention porte sur une composition pour la production de matériaux de construction, comprenant 15-80 % en poids de granulés d'aérogel hydrophobe sur la base du poids total de la composition et du MgO non calciné, et un sel de phosphate de métal alcalin, le rapport moléculaire entre le MgO non calciné et le phosphate étant dans la plage de 0,75 à 1,25.
PCT/EP2013/056069 2012-03-23 2013-03-22 Composition pour la production de matériaux de construction WO2013139961A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
NO20141145A NO20141145A1 (no) 2012-03-23 2014-09-21 En sammensetning for produksjon av byggematerialer

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
NO20120355 2012-03-23
NO20120355 2012-03-23

Publications (1)

Publication Number Publication Date
WO2013139961A1 true WO2013139961A1 (fr) 2013-09-26

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN110028300A (zh) * 2019-04-18 2019-07-19 北京碧海舟腐蚀防护工业股份有限公司 水性陶瓷保温隔热涂料及其应用、防腐涂层
CN112430018A (zh) * 2020-11-27 2021-03-02 山东鲁阳节能材料股份有限公司 一种增韧型无机纸复合的气凝胶产品及其制备方法
CN115849858A (zh) * 2022-12-26 2023-03-28 中发创新(安徽)新材料有限公司 一种气凝胶前驱体复合镁基胶凝剂的保温浆料

Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2465247A (en) * 1946-10-24 1949-03-22 Westinghouse Electric Corp Composition for and method of producing phosphate films on metals
US5645518A (en) 1995-01-31 1997-07-08 The University Of Chicago Method for stabilizing low-level mixed wastes at room temperature
US5830815A (en) 1996-03-18 1998-11-03 The University Of Chicago Method of waste stabilization via chemically bonded phosphate ceramics
US6204214B1 (en) 1996-03-18 2001-03-20 University Of Chicago Pumpable/injectable phosphate-bonded ceramics
US6518212B1 (en) 2000-09-18 2003-02-11 The University Of Chicago Chemically bonded phospho-silicate ceramics
US6776837B2 (en) 2001-11-30 2004-08-17 The University Of Chicago Formation of chemically bonded ceramics with magnesium dihydrogen phosphate binder
WO2010096827A1 (fr) * 2009-02-23 2010-08-26 Arun Wagh Compositions de protection contre l'incendie, procédés et articles associés
WO2011066209A2 (fr) 2009-11-25 2011-06-03 Cabot Corporation Composites à base d'aérogel et procédés de fabrication et d'utilisation associés
WO2011100288A2 (fr) * 2010-02-09 2011-08-18 Latitude 18, Inc. Composites liés à un phosphate et procédés

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US7914914B2 (en) * 2007-06-30 2011-03-29 Serious Materials, Inc. Low embodied energy sheathing panels with optimal water vapor permeance and methods of making same

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2465247A (en) * 1946-10-24 1949-03-22 Westinghouse Electric Corp Composition for and method of producing phosphate films on metals
US5645518A (en) 1995-01-31 1997-07-08 The University Of Chicago Method for stabilizing low-level mixed wastes at room temperature
US5830815A (en) 1996-03-18 1998-11-03 The University Of Chicago Method of waste stabilization via chemically bonded phosphate ceramics
US6204214B1 (en) 1996-03-18 2001-03-20 University Of Chicago Pumpable/injectable phosphate-bonded ceramics
US6518212B1 (en) 2000-09-18 2003-02-11 The University Of Chicago Chemically bonded phospho-silicate ceramics
US6776837B2 (en) 2001-11-30 2004-08-17 The University Of Chicago Formation of chemically bonded ceramics with magnesium dihydrogen phosphate binder
WO2010096827A1 (fr) * 2009-02-23 2010-08-26 Arun Wagh Compositions de protection contre l'incendie, procédés et articles associés
WO2011066209A2 (fr) 2009-11-25 2011-06-03 Cabot Corporation Composites à base d'aérogel et procédés de fabrication et d'utilisation associés
WO2011100288A2 (fr) * 2010-02-09 2011-08-18 Latitude 18, Inc. Composites liés à un phosphate et procédés

Non-Patent Citations (2)

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Title
WAGH A S ET AL: "Chemically Bonded Phosphate Ceramics: I, A Dissolution Model of Formation", JOURNAL OF THE AMERICAN CERAMIC SOCIETY NOVEMBER 2003 AMERICAN CERAMIC SOCIETY US, vol. 86, no. 11, November 2003 (2003-11-01), pages 1838 - 1844, XP002697965 *
WAGH ET AL., OIL & GAS JOURNAL, 9 May 2005 (2005-05-09), pages 53 - 55

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN110028300A (zh) * 2019-04-18 2019-07-19 北京碧海舟腐蚀防护工业股份有限公司 水性陶瓷保温隔热涂料及其应用、防腐涂层
CN112430018A (zh) * 2020-11-27 2021-03-02 山东鲁阳节能材料股份有限公司 一种增韧型无机纸复合的气凝胶产品及其制备方法
CN115849858A (zh) * 2022-12-26 2023-03-28 中发创新(安徽)新材料有限公司 一种气凝胶前驱体复合镁基胶凝剂的保温浆料
CN115849858B (zh) * 2022-12-26 2023-11-28 中发创新(安徽)新材料有限公司 一种气凝胶前驱体复合镁基胶凝剂的保温浆料

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