WO2015057978A2 - High temperature lightweight thermal insulating cement and silica based materials - Google Patents

High temperature lightweight thermal insulating cement and silica based materials Download PDF

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Publication number
WO2015057978A2
WO2015057978A2 PCT/US2014/060924 US2014060924W WO2015057978A2 WO 2015057978 A2 WO2015057978 A2 WO 2015057978A2 US 2014060924 W US2014060924 W US 2014060924W WO 2015057978 A2 WO2015057978 A2 WO 2015057978A2
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Prior art keywords
recited
insulating material
cement
range
weight
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PCT/US2014/060924
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English (en)
French (fr)
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WO2015057978A3 (en
Inventor
Evan R. Daniels
Per Just ANDERSON
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INTELLECTUAL GORILLA BV
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INTELLECTUAL GORILLA BV
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Priority to EP14854429.9A priority Critical patent/EP3057916A4/en
Priority to US15/029,416 priority patent/US10196309B2/en
Priority to BR112016008293-1A priority patent/BR112016008293B1/pt
Priority to AU2014337246A priority patent/AU2014337246A1/en
Priority to CN201480068683.2A priority patent/CN105873878B/zh
Priority to CA2927354A priority patent/CA2927354C/en
Publication of WO2015057978A2 publication Critical patent/WO2015057978A2/en
Publication of WO2015057978A3 publication Critical patent/WO2015057978A3/en
Anticipated expiration legal-status Critical
Priority to AU2018203986A priority patent/AU2018203986B2/en
Ceased legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • 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
    • C04B28/06—Aluminous 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
    • 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
    • C04B14/38—Fibrous materials; Whiskers
    • C04B14/42—Glass
    • 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
    • C04B16/00—Use of organic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of organic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B16/02—Cellulosic materials
    • C—CHEMISTRY; METALLURGY
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    • C04B16/00—Use of organic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of organic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B16/04—Macromolecular compounds
    • C04B16/06—Macromolecular compounds fibrous
    • C04B16/0616—Macromolecular compounds fibrous from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • C04B16/0625—Polyalkenes, e.g. polyethylene
    • C04B16/0633—Polypropylene
    • 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
    • C04B16/00—Use of organic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of organic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B16/04—Macromolecular compounds
    • C04B16/06—Macromolecular compounds fibrous
    • C04B16/0616—Macromolecular compounds fibrous from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • C04B16/0641—Polyvinylalcohols; Polyvinylacetates
    • C—CHEMISTRY; METALLURGY
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    • C04B22/00—Use of inorganic materials as active ingredients for mortars, concrete or artificial stone, e.g. accelerators or shrinkage compensating agents
    • C04B22/02—Elements
    • C04B22/04—Metals, e.g. aluminium used as blowing agent
    • 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
    • C04B28/04—Portland 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
    • C04B28/18—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 mixtures of the silica-lime 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
    • C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
    • C04B38/10—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by using foaming agents or by using mechanical means, e.g. adding preformed foam
    • 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
    • C04B2103/0068—Ingredients with a function or property not provided for elsewhere in C04B2103/00
    • C04B2103/0079—Rheology influencing agents
    • 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
    • C04B2103/40—Surface-active agents, dispersants
    • C04B2103/408—Dispersants
    • 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
    • C04B2103/48—Foam stabilisers
    • 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
    • C04B2111/00431—Refractory materials
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/20—Resistance against chemical, physical or biological attack
    • C04B2111/28—Fire resistance, i.e. materials resistant to accidental fires or high temperatures
    • 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
    • C04B2111/40—Porous or lightweight materials
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2201/00—Mortars, concrete or artificial stone characterised by specific physical values
    • C04B2201/20—Mortars, concrete or artificial stone characterised by specific physical values for the density
    • 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
    • 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

  • the present invention relates generally to the field of composite materials and, more particularly, to high temperature lightweight thermal insulating cement and silica based materials.
  • the present invention provides a high temperature lightweight thermal insulating cement or silica based material ("insulating material") formed from a mixture that includes cement or silica sand, water and a foaming agent.
  • the foaming agent can be an aluminum powder or a surfactant.
  • the insulating material has a maximum use temperature greater than about 600 degrees Celsius.
  • the maximum use temperature can be up to about 900 degrees Celsius when Ordinary Portland cement (OPC) is used.
  • OPC Ordinary Portland cement
  • the maximum use temperature can be up to about 1000 degrees Celsius when silica sand is used.
  • the maximum use temperature can be up to about 1800 degrees Celsius when calcium aluminate cement (CAC) is used.
  • the present invention provides an insulating material formed from a mixture that includes cement or silica sand in an amount of about 25 to 90% of weight wet, water in an amount of about 10 to 70% of weight wet, and a foaming agent.
  • the foaming agent can be an aluminum powder in an amount of about 0.5 to 3.0% by weight of the cement or silica sand, or a surfactant in an amount of about 0.05 to 2.0% by weight of the water.
  • the insulating material has a maximum use temperature greater than about 600 degrees Celsius, a density in the range of about 0.1 to 1.0 g/cm 3 , a thermal conductivity in the range of about 0.05 to 0.30 W/(m-K), and a compressive strength in the range of about 30 to 3000 PSI (2.068 to 206.8 Bar).
  • the present invention provides a method for manufacturing an insulating material by mixing cement or silica sand with water, foaming the mixture using a foaming agent, pouring the foamed mixture into a mold and allowing the foamed mixture to rise to form the insulating material, and removing the insulating material from the mold.
  • the insulating material can be cured or heat treated.
  • the insulating material has a maximum use temperature greater than about 600 degrees Celsius.
  • the present invention provides a method for manufacturing an insulating material by mixing cement or silica sand in an amount of about 25 to 90% of weight wet with water in an amount of about 10 to 70% of weight wet, foaming the mixture using a foaming agent (an aluminum powder in an amount of about 0.5 to 3.0% by weight of the cement or silica sand, or a surfactant in an amount of about 0.05 to 2.0% by weight of the water), pouring the foamed mixture into a mold and allowing the foamed mixture to rise to form the insulating material, and removing the insulating material from the mold.
  • the insulating material can be cured or heat treated.
  • the insulating material has a maximum use temperature greater than about 600 degrees Celsius, a density in the range of about 0.1 to 1.0 g/cm 3 , a thermal conductivity in the range of about 0.05 to 0.30 W/(m-K), and a compressive strength in the range of about 30 to 3000 PSI (2.068 to 206.8 Bar).
  • OPC Ordinary Portland cement
  • CAC calcium aluminate cement
  • the insulating material will have a maximum use temperature up to approximately 900 Celsius
  • CAC calcium aluminate cement
  • Silica sand in a mixture with water and calcium oxide can be foamed with reacting aluminum powder or by the use of a surfactant.
  • the insulating material will have a maximum use temperature up to approximately 1000 Celsius.
  • the cement or silica sand binder can be used in combination with a multitude of additive materials such as sand, gypsum, silica fume, fumed silica, plaster of Paris, fly ash, slag, rock, fiber (e.g., glass fibers, cellulose fibers polyvinyl alcohol fibers, polypropylene fibers, or a combination thereof), etc.
  • additive materials such as sand, gypsum, silica fume, fumed silica, plaster of Paris, fly ash, slag, rock, fiber (e.g., glass fibers, cellulose fibers polyvinyl alcohol fibers, polypropylene fibers, or a combination thereof), etc.
  • the silica sand is initially ground as a wet slurry in a ball mill to a fineness less than 100 microns.
  • the water to solids ratio by weight is typically in the range of 0.2 to 2.0.
  • these mixtures can be made more fluid by adding a conventional high range water reducer (HRWR) in an amount of 0.25-4.0% of the cement or silica sand weight.
  • HRWR high range water reducer
  • the foamed mixture (cement-water or silica-water) is sometimes stabilized by the addition of a rheology modifying agent.
  • the rheology modifying agent will typically be added in an amount of 0.1 to 5% of the cement or silica sand weight.
  • the rheology-modifying agents fall into the following categories: (1) polysaccharides and derivatives thereof, (2) proteins and derivatives thereof, and (3) synthetic organic materials. Polysaccharide rheology-modifying agents can be further subdivided into (a) cellulose-based materials and derivatives thereof, (b) starch based materials and derivatives thereof, and (c) other polysaccharides.
  • Suitable cellulose-based rheology-modifying agents include, for example, methylhydroxyethylcellulose (MHEC), hydroxymethylethylcellulose (HMEC), carboxymethylcellulose (CMC), methylcellulose (MC), ethylcellulose (EC), hydroxyethylcellulose (HEC), hydroxyethylpropylcellulose (HEPC) and hydroxypropoylmethylcelluose (HPMC), etc.
  • MHEC methylhydroxyethylcellulose
  • HMEC carboxymethylcellulose
  • MC methylcellulose
  • EC ethylcellulose
  • HEC hydroxyethylcellulose
  • HEC hydroxyethylpropylcellulose
  • HPMC hydroxypropoylmethylcelluose
  • Suitable starch based materials include, for example, wheat starch, pre-gelled wheat starch, potato starch, pre-gelled potato starch, amylopectin, amylose, seagel, starch acetates, starch hydroxyethyl ethers, ionic starches, long-chain alkylstarches, dextrins, amine starches, phosphate starches, and dialdehyde starches.
  • the currently preferred rheology-modifying agent is hydroxypropylmethylcellulose, examples of which are Methocel 240 and Methocel 240S.
  • the aluminum When using aluminum as a foaming agent, the aluminum is typically in a particle size below 100 microns.
  • the aluminum can be added as a dry powder, or as a paste in a mixture with water or diethyleneglycol and for some applications can also be used in a retarded version.
  • the preferred aluminum is purchased from the company Eckart (a German company).
  • Eckart a German company
  • the aluminum is added in an amount of 0.05-3% by weight of the cement or silica sand weight.
  • the water and cement are typically mixed first for 1-5 minutes where after the aluminum is added and mixed for 5 seconds to 1 minute.
  • foaming CAC cement based mixes the water, cement and rheology modifying agent are typically mixed first for 1-5 minutes, where after calcium oxide, calcium hydroxide, sodium hydroxide or similar pH increasing material is added in an amount of 0.5 to 10% of the water weight and mixed for 5 seconds to 1 minute, and finally the aluminum is added and mixed for 5 seconds to 1 minute.
  • the water, sand and rheology modifying agent are typically mixed first for 1-5 minutes where after the calcium oxide, calcium hydroxide, sodium hydroxide or similar pH increasing material is added in an amount of 0.5 to 40% of the water weight and mixed for 1-5 minutes, and finally the aluminum is added and mixed for 5 seconds to 1 minute.
  • the mixture is poured into the mold system, which can be in the shape of a pipe, half-pipe or block and is allowed to rise (due to the formation of hydrogen bubbles as the aluminum reacts with the hydroxyl ions) and fill the mold over the next 0.5 to 2 hours.
  • the mold system can be in the shape of a pipe, half-pipe or block and is allowed to rise (due to the formation of hydrogen bubbles as the aluminum reacts with the hydroxyl ions) and fill the mold over the next 0.5 to 2 hours.
  • the surfactant When using a surfactant as the foaming agent, the surfactant is specially chosen to have a high degree of foam stability and to generate the right bubble size.
  • One such air entraining agent is sold by the company Sika.
  • the surfactant is typically added in an amount of 0.05 to 2.0% of the weight of water.
  • foaming OPC or CAC cement based mixtures the water, cement, surfactant and rheology modifying agent are typically mixed for 1 to 10 minutes to foam up the mixture.
  • the water, sand and rheology modifying agent are typically mixed first for 1-5 minutes, where after calcium oxide, calcium hydroxide, sodium hydroxide or similar pH increasing material is added in an amount of 0.5 to 40% of the water weight and mixed for 1-5 minutes, and finally the surfactant is added and mixed for 1 to 10 minutes to foam up the mixture.
  • the foamed mixture is poured into the mold system.
  • the wet material will be de- molded and can be cut to size, trimmed, sanded or routed into a specified shape (e.g., pipe, half-pipe, block, panel, etc.).
  • a specified shape e.g., pipe, half-pipe, block, panel, etc.
  • the wet material is de-molded and can be cut to size, trimmed, sanded or routed into a specified shape (e.g., pipe, half-pipe, block, panel, etc.).
  • the product is either allowed to sit around for 28 days in a humid environment, or the strength development can be accelerated within 24-48 hours by heating either by its own internal heat development or by steam curing such as is conventional in the State-of-the-Art.
  • Products made from CAC cement will achieve its final strength in 24 hours and does not require additional curing.
  • the product is dried to generate the finished lightweight insulating composite material.
  • the hardened composite material can be cut to size, trimmed, sanded or routed into a specified shape (e.g., pipe, half-pipe, block, panel, etc.).
  • the finished product can be made water repellent by spraying the product with water or solvent based silane.
  • Such product is typically sold by BASF.
  • the finished lightweight cement or silica based insulating composite will have a density in the range of 0.1-1.0 g/cm 3 , a compressive strength in the range of 30-3000 PSI (2.068 to 206.8 Bar) and a heat conductance in the range of 0.05-0.3 W/(m-K).
  • the water can be 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%,
  • the secondary material can be 0%, 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%,
  • the reinforcement fiber can be 0%, 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%,
  • the rheology modifying agent can be 0%, 0.1%, 0.2%, 0.3%, 0.4%, 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1.0%, 1.1%, 1.2%, 1.3%, 1.4%, 1.5%, 1.6%, 1.7%, 1.8%, 1.9%, 2.0%, 2.1%, 2.2%, 2.3%, 2.4%, 2.5%, 2.6%, 2.7%, 2.8%, 2.9%, 3.0%, 3.1%, 3.2%, 3.3%, 3.4%, 3.5%, 3.6%, 3.7%, 3.8%, 3.9% or 4.0% by weight or other incremental percentage between.
  • the aluminum powder can be 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1.0%, 1.1%, 1.2%, 1.3%, 1.4%, 1.5%, 1.6%, 1.7%, 1.8%, 1.9%, 2.0%, 2.1%, 2.2%, 2.3%, 2.4%, 2.5%, 2.6%, 2.7%, 2.8%, 2.9% or 3.0% by weight or other incremental percentage between.
  • the surfactant can be 0.05%, 0.1%, 0.2%, 0.3%, 0.4%, 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1.0%, 1.1%, 1.2%, 1.3%, 1.4%, 1.5%, 1.6%, 1.7%, 1.8%, 1.9% or 2.0% by weight or other incremental percentage between.
  • the pH increasing agent can be 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1.0%, 1.1%, 1.2%, 1.3%, 1.4%, 1.5%, 1.6%, 1.7%, 1.8%, 1.9%, 2.0%, 2.1%, 2.2%, 2.3%, 2.4%, 2.5%, 2.6%, 2.7%, 2.8%, 2.9%, 3.0%, 3.1%, 3.2%, 3.3%, 3.4%, 3.5%, 3.6%, 3.7%, 3.8%, 3.9%, 4.0%, 4.1%, 4.2%, 4.3%, 4.4%, 4.5%, 4.6%, 4.7%, 4.8%, 4.9%, 5.0%, 5.1%, 5.2%, 5.3%, 5.4%, 5.5%, 5.6%, 5.7%, 5.8%, 5.9%, 6.0%, 6.1%, 6.2%, 6.3%, 6.4%, 6.5%, 6.6%, 6.7%, 6.8%, 6.9%, 7.0%, 7.1%, 7.2%, 7.3%, 7.4%, 7.5%, 7.6%, 7.7%, 7.8%, 7.9%, 8.0%, 8.1%, 8.2%, 8.3%, 8.4%, 8.5%, 8.6%, 8.7%
  • the present invention provides a high temperature lightweight thermal insulating cement or silica based material ("insulating material") formed from a mixture that includes cement or silica sand, water and a foaming agent.
  • the foaming agent can be an aluminum powder or a surfactant.
  • the insulating material has a maximum use temperature greater than about 600 degrees Celsius.
  • the maximum use temperature can be up to about 900 degrees Celsius when Ordinary Portland cement (OPC) is used.
  • OPC Ordinary Portland cement
  • the maximum use temperature can be up to about 1000 degrees Celsius when silica sand is used.
  • the maximum use temperature can be up to about 1800 degrees Celsius when calcium aluminate cement (CAC) is used.
  • the present invention provides an insulating material formed from a mixture that includes cement or silica in an amount of about 25 to 90% of weight wet, water in an amount of about 10 to 70% of weight wet, and a foaming agent.
  • the foaming agent can be an aluminum powder in an amount of about 0.5 to 3.0% by weight of the cement or silica sand, or a surfactant in an amount of about 0.05 to 2.0% by weight of the water.
  • the insulating material has a maximum use temperature greater than about 600 degrees Celsius, a density in the range of about 0.1 to 1.0 g/cm 3 , a thermal conductivity in the range of about 0.05 to 0.30 W/(m-K), and a compressive strength in the range of about 30 to 3000 PSI (2.068 to 206.8 Bar).
  • the present invention provides a method for manufacturing an insulating material by mixing cement or silica sand with water, foaming the mixture using a foaming agent, pouring the foamed mixture into a mold and allowing the foamed mixture to rise to form the insulating material, and removing the insulating material from the mold.
  • the insulating material can be cured or heat treated.
  • the insulating material has a maximum use temperature greater than about 600 degrees Celsius.
  • the present invention provides a method for manufacturing an insulating material by mixing cement or silica sand in an amount of about 25 to 90% of weight wet with water in an amount of about 10 to 70% of weight wet, foaming the mixture using a foaming agent (an aluminum powder in an amount of about 0.5 to 3.0% by weight of the cement or silica sand, or a surfactant in an amount of about 0.05 to 2.0% by weight of the water), pouring the foamed mixture into a mold and allowing the foamed mixture to rise to form the insulating material, and removing the insulating material from the mold.
  • the insulating material can be cured or heat treated.
  • the insulating material has a maximum use temperature greater than about 600 degrees Celsius, a density in the range of about 0.1 to 1.0 g/cm 3 , a thermal conductivity in the range of about 0.05 to 0.30 W/(m-K), and a compressive strength in the range of about 30 to 3000 PSI (2.068 to 206.8 Bar).

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Structural Engineering (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Civil Engineering (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)
  • Porous Artificial Stone Or Porous Ceramic Products (AREA)
  • Environmental & Geological Engineering (AREA)
  • General Chemical & Material Sciences (AREA)
PCT/US2014/060924 2013-10-17 2014-10-16 High temperature lightweight thermal insulating cement and silica based materials Ceased WO2015057978A2 (en)

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EP14854429.9A EP3057916A4 (en) 2013-10-17 2014-10-16 High temperature lightweight thermal insulating cement and silica based materials
US15/029,416 US10196309B2 (en) 2013-10-17 2014-10-16 High temperature lightweight thermal insulating cement and silica based materials
BR112016008293-1A BR112016008293B1 (pt) 2013-10-17 2014-10-16 Material isolante formado a partir de uma mistura e método para produção de um material isolante
AU2014337246A AU2014337246A1 (en) 2013-10-17 2014-10-16 High temperature lightweight thermal insulating cement and silica based materials
CN201480068683.2A CN105873878B (zh) 2013-10-17 2014-10-16 高温轻质热绝缘水泥和二氧化硅基材料
CA2927354A CA2927354C (en) 2013-10-17 2014-10-16 High temperature lightweight thermal insulating cement and silica based materials
AU2018203986A AU2018203986B2 (en) 2013-10-17 2018-06-05 High temperature lightweight thermal insulating cement and silica based materials

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US201361892239P 2013-10-17 2013-10-17
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