EP4584232A1 - Mousses inorganiques solides - Google Patents

Mousses inorganiques solides

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Publication number
EP4584232A1
EP4584232A1 EP23765525.3A EP23765525A EP4584232A1 EP 4584232 A1 EP4584232 A1 EP 4584232A1 EP 23765525 A EP23765525 A EP 23765525A EP 4584232 A1 EP4584232 A1 EP 4584232A1
Authority
EP
European Patent Office
Prior art keywords
foam
inorganic
suspension
gas
vol
Prior art date
Legal status (The legal status 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 status listed.)
Pending
Application number
EP23765525.3A
Other languages
German (de)
English (en)
Inventor
Michele Zanini
Alex HEUSI
Etienne Jeoffroy
Aybige ÖZTÜRE
Enrico SCOCCIMARRO
Alessandro DUTTO
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Fenx Ag
Original Assignee
Fenx Ag
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Filing date
Publication date
Application filed by Fenx Ag filed Critical Fenx Ag
Publication of EP4584232A1 publication Critical patent/EP4584232A1/fr
Pending legal-status Critical Current

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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
    • C04B28/24—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 alkyl, ammonium or metal silicates; containing silica sols
    • C04B28/26—Silicates of the alkali metals
    • 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
    • C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
    • C04B38/02—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by adding chemical blowing agents
    • 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
    • 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
    • C04B40/02—Selection of the hardening environment
    • C04B40/0231—Carbon dioxide hardening
    • 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
    • C04B2111/00129—Extrudable mixtures
    • 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
    • C04B2111/00181—Mixtures specially adapted for three-dimensional printing (3DP), stereo-lithography or prototyping
    • 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
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00793—Uses not provided for elsewhere in C04B2111/00 as filters or diaphragms
    • 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
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/0081—Uses not provided for elsewhere in C04B2111/00 as catalysts or catalyst carriers
    • 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
    • C04B2111/52—Sound-insulating 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
    • C04B2201/30—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
    • 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
    • C04B2201/50—Mortars, concrete or artificial stone characterised by specific physical values for the mechanical strength

Definitions

  • the present invention relates to the technical field of solid inorganic foams, methods for manufacturing said solid inorganic foams, and uses of said solid inorganic foams.
  • a rather simple and relatively inexpensive production method for lighter density products is achieved by foamed concretes, which typically consist of a slurry of cement, sand and water, which is then further blended with an aqueous foam.
  • the foam is created using a foaming agent, such as proteins.
  • mineral foams or inorganic foams are very advantageous for many applications due among others to their thermal and sound insulation properties.
  • Mineral foam is a material in the form of a foam. This material is more lightweight than the bulk counterpart due to its porosity or empty spaces. These pores or empty spaces are due to the presence of air or other gases in the mineral foam and they may be in the form of bubbles. With 1 m 3 of raw material it is possible to produce approximately 5 m 3 of a finished product if the porous body is composed by 20% of material and 80% of air (this is valid for raw materials with bulk density of 2000 kg/m 3 and a final density of approximately 400 kg/m 3 ).
  • US2017158568 A1 discloses a method for producing an ultra-light mineral foam, wherein a slurry of Portland cement and an aqueous foam comprising water and a foaming agent are mixed. Thereby, a slurry of foamed cement is obtained, which is then subjected to casting, followed by setting for several days and drying at 45 °C. Although the ultra-light mineral foam hardens at temperatures close to the room temperature, the production of the Portland cement, which typically requires firing limestone at temperatures of about 1450 °C, results in high carbon dioxide emissions.
  • W02020007784 describes an alternative method of preparing foams.
  • the method relies upon the provision of a suspension comprising an aqueous liquid, particles, such as fly ash particles and earth particles, and at least one surfactant, wherein the at least one surfactant at least partially hydrophobizes a surface of the particles.
  • the foam can be subjected to sintering or hardening.
  • the sintering process requires exposure of the foam to high temperatures from about 800 °C to about 1800 °C for several hours depending on the samples size and material thermal conductivity. Sintering is per se energy-intensive and associated with high carbon dioxide emissions.
  • Figure 3 shows a comparison of the compressive strength of foams according to the present invention (empty bars) that were obtained by the process according to the present invention versus foams that were not subjected to a curing step (d) as described herein (patterned bars).
  • the compressive strength was measured on foams prepared as described in example 2.
  • the objective is achieved by the method for manufacturing a solid, inorganic foam according to claim 1 , a solid, inorganic foam comprising an inorganic material entrapping pores according to claim 13, a use of the solid, inorganic foam according to claim 16, and a use of an industrial grade carbon dioxide gas and/or of an exhaust gas comprising at least 4 vol% CO2 according to claim 17.
  • Preferred embodiments are disclosed in the specification and the dependent claims.
  • the term “and/or” means that either all or only one of the elements of said group may be present.
  • a and/or B means “only A, or only B, or both A and B”. In the case of “only A”, the term also covers the possibility that B is absent, i.e. “only A, but not B”.
  • ⁇ at least one surfactant, which at least partially hydrophobizes a surface of the inorganic particles
  • step (d) curing the inorganic foam of step (b) or (c) by exposing it to a CO2 containing gas with a CO2 concentration of at least 4 vol-%, and a relative humidity from about 5% to about 95 %, provides a solid, inorganic foam with a low embodied carbon footprint, very low density, and improved mechanical properties, in particular improved mechanical strength.
  • the solid inorganic foam presents a marked closed-cell morphology.
  • the method comprises the steps of:
  • ⁇ optionally one or more additives
  • step (d) curing the dry or partially dry inorganic foam of step (c) by exposing it to a CO2 containing gas having a CO2 concentration of at least 4 vol% and a relative humidity from 5% to 95% to thereby obtain a cured, inorganic foam.
  • the aqueous suspension may consist of inorganic particles, at least one surfactant, which at least partially hydrophobizes a surface of the inorganic particles, water soluble silicates, optionally one or more additives, and water.
  • solid, inorganic foam refers to a hardened or cured foam made of a solid inorganic material surrounding gas-filled voids or cells.
  • the solid, inorganic foam is a closed-cell foam i.e. a foam wherein the gas forms discrete cells, each completely surrounded by the solid material.
  • Open-cell foams are porous foams having a large number of interconnected pockets or voids or cells within their solid material.
  • the solid, inorganic foam claimed and described herein has preferably a water content lower than 50 wt-%, more preferably lower than 20 wt-% e.g. lower than 10 wt-% based on the total weight of the solid, inorganic foam.
  • the inorganic material contained by the solid, inorganic foam may contain up to about 10 wt-%, preferably up to about 5 wt-% of organic compounds.
  • the inorganic particles are selected from the group consisting of secondary raw material particles, naturally occurring mineral particles, and mixtures thereof; and/or
  • the at least one surfactant has a backbone chain comprising at least nine carbon atoms, preferably the at least one surfactant is an amphiphilic molecule consisting of a tail coupled to a head group, wherein the tail comprises the backbone chain comprising at least nine carbon atoms; and/or • the water soluble silicates are selected from the group consisting of sodium silicates, potassium silicates, calcium silicates and combinations thereof, in particular sodium silicates, potassium silicates and combinations thereof; and/or
  • the inorganic particles used herein comprise an amorphous part containing Al 3+ cations (e.g. amorphous aluminum oxide; amorphous aluminum silicate).
  • the water-soluble silicates react with the amorphous parts of the inorganic particles leading to aluminosilicate gel network, including tetrahedral Al 3+ sites charge balanced by alkali metal cations.
  • second raw material includes, but is not limited to, excavated materials, filter cakes from excavated materials, expanded perlite, fly ash, metakaolin, mineral processing tailings, catalyst residues, coal bottom ash, rice husk ash, palm oil ash, waste glass, paper sludge ash, paper ash, sludge from water treatments, ground granulated blast-furnace slags (GGBS), microsilica (silica fume) calcium carbonate and ceramic waste material and combination thereof, in particular excavated materials, filter cakes from excavated materials, fly ash, mineral processing tailings, catalyst residues, coal bottom ash, rice husk ash, palm oil ash, waste glass, paper sludge ash, paper ash, sludge from water treatments, ground granulated blast-furnace slags (GGBS), calcium carbonate, ceramic waste material and combinations thereof.
  • GGBS ground granulated blast-furnace slags
  • the secondary raw materials include expanded perlite, fly ash, metakaolin, mineral processing tailings, catalyst residues, coal bottom ash, rice husk ash, palm oil ash, paper sludge ash, paper ash, sludge from water treatments, ground granulated blast-furnace slags (GGBS), microsilica (silica fume) and combinations thereof.
  • fly ash, or flue ash, or coal ash, or pulverized coal ash is a heterogeneous material with silicon dioxide (SiO2), aluminum oxide (AI2O3), iron oxide (Fe2Oa) and occasionally calcium oxide (CaO) being the main chemical components.
  • clay is a fine-grained natural soil material containing one or more clay minerals (hydrous aluminum phyllosilicates) with possible traces of quartz (SiO2) and metal oxides, such as aluminum oxide (AI2O3) and magnesium oxide (MgO).
  • the clay mineral is selected from kaolin, montmorillonite-smectite, illite, chlorite, vermiculite, talc, pyrophyllite, halloysite, sepiolite, palygorskite and mixtures thereof.
  • the inorganic particles include phyllosilicates, such as serpentine, clay, and mica, feldspar, silica, calcium carbonate, fly ash, metakaolin, microsilica (silica fume), and combinations thereof.
  • the inorganic particles used in the aqueous suspension described herein are selected from the group consisting of fly ash particles, clay particles, metakaolin particles, perlite particles, including expanded perlite particles, and combinations thereof.
  • the inorganic particles have preferably a particle size from about 1 nm to about 500 pm, more preferably from about 50 nm to about 200 pm, and even more preferably from about 200 nm to about 65 pm as determined by scattering methods and/or image analysis.
  • the particle size corresponds to the mean particle size measured for the largest dimension and depends on the origin of the particles.
  • the fly ash particles are generally spherical in shape and range in size from about 0.5 pm to about 300 pm. If desired, the particle size can be adjusted by sieving or ball milling techniques as commonly known in the present field of technology.
  • the suspension described herein contains preferably from about 10 wt-% to about 70 wt-%, more preferably from about 10 wt-% to about 50 wt-%, much preferably from about 15 wt-% to about 40 wt-% inorganic particles, the wt-% being based on the total weight of the suspension.
  • the suspension provided at step (a) contains at least one surfactant, which at least partially hydrophobizes a surface of the inorganic particles.
  • the use of inorganic particles in combination with at least one surfactant, which at least partially hydrophobizes a surface of the inorganic particles leads to a significant increase in the stability from a few minutes to months of the resulting wet, inorganic foam.
  • the stability of the wet, inorganic foams results from i) the adsorption of the particles having the at least partially hydrophobized surface at the liquid-gas interface, i.e. interface stabilization due to the adsorption of the surface- modified particles on the surface of the bubbles and from ii) bulk stabilization due to the formation of a percolating network of particles throughout the aqueous liquid.
  • the term “backbone chain” refers to the longest series of covalently bonded atoms that together create a continuous chain of the molecular structure of the surfactant.
  • the backbone chain of a surfactant having a backbone chain comprising at least nine carbon atoms can comprise at least nine carbon atoms being covalently connected with each other (linear backbone chain) or at least nine carbon atoms some of which being covalently connected to other atoms (branched backbone chain), or at least nine carbon atoms part of them forming a cyclic ring. Due to the fact that the surfactants have a backbone chain of at least nine carbon atoms, the particles will be hydrophobized upon adsorption of the surfactant.
  • the at least one surfactant is preferably an amphiphilic molecule consisting of a tail coupled to a head group, wherein the tail comprises the backbone chain comprising at least nine carbon atoms.
  • the at least one surfactant is preferably selected from the group consisting of polyelectrolytes, proteins, polysaccharides, glycerols, glycerides such as monoglycerides, diglycerides and triglycerides, fatty acids such as oleic acid or linoleic acid, ammonium compounds, alkyl compounds, or combinations thereof.
  • a suitable polysaccharide surfactant is chitosan.
  • a suitable triglyceride surfactant is Miglyol® 812.
  • Imwitor® 988 is an example of a conceivable monoglyceride surfactant and diglyceride surfactant, respectively.
  • suitable polyelectrolyte surfactants include polyacrylic acid, polystyrene sulfonate and polyallylamine hydrochloride.
  • the water soluble silicates are selected from the group consisting of sodium silicates, potassium silicates calcium silicates, and combinations thereof, in particular from the group consisting of sodium silicates, potassium silicates, and combinations thereof.
  • the water soluble silicates may be solubilized in hydroxide (e.g. NaOH, KOH, LiOH) prior to addition to the suspension.
  • hydroxide e.g. NaOH, KOH, LiOH
  • the water-soluble silicates react with the amorphous parts of inorganic particles leading to aluminosilicate gel network, including tetrahedral Al 3+ sites charge balanced by alkali metal cations.
  • the water-soluble silicates react with the carbon dioxide in presence of water to form the corresponding carbonate forms.
  • Water soluble silicates are preferably present in the suspension described herein in an amount from about 10 wt-% to about 30 wt-%, more preferably from about 15 wt-% to about 30 wt-%, much preferably from about 20 wt-% to about 30 wt-%, the wt-% being based on the total weight of the suspension.
  • the sodium silicates are of general formula (Na2O) (SiC>2)x, with x being from 1 to 3.5. More preferably, the sodium silicates are selected from Na2SiOs (sodium metasilicate), Na2SiOs, Na4SiC>4 (sodium orthosilicate), NaeSi2O? (sodium pyrosilicate), and mixtures thereof.
  • the potassium silicates are of general formula (K2O) (SiO2) y , with y being from 1 to 3. More preferably, the potassium silicates are selected from K2SiOa (potassium metasilicate), K 2 SiC>5, K4SiO4 (potassium orthosilicate), KeSi2O? (potassium pyrosilicate), and mixtures thereof.
  • the calcium silicates are of general formula (CaO) (SiC>2)z, with z being from 0.33 to 2.
  • the calcium silicates are selected from CaSiCh (wollastanite), Ca2SiC>4 (calcium orthosilicate), CasSiOs (alite), CasSiO?, and mixtures thereof.
  • Calcium silicates can originate from precipitation of dissolved silicates in solution in presence of calcium cations and/or from dissolution of solid silica in highly alkaline solutions in presence of calcium ions.
  • the water-soluble silicates are sodium silicates as described herein.
  • the stabilizers may be present in an amount of up to about 10 wt-% per total weight of the inorganic particles, preferably up to about 4 wt-% by weight per total weight of the inorganic particles, more preferably up to about 2 wt-% per total weight of the inorganic particles, particularly preferably up to about 0.1 wt-% per total weight of the inorganic particles.
  • both organic and inorganic plasticizers and/or superplasticizers can be used.
  • the former comprises lignosulfonates, naphthalene, melamine or polycarboxylate compounds, for example sulfonate-based naphthalene or sulfonate-based melamine or polycarboxylate ether, can be used.
  • the latter comprises sodium compounds as sodium hexametaphosphates.
  • Wetting agents such as alcohols, oils, silicones, silanes, siloxanes or glycols, in particular alcohols, oils, silicones, or glycols, can be used for modifying a contact angle and serve the purpose of tuning the water adsorption behavior of the foam.
  • gas generating agents such as aluminum powder or hydrogen peroxide can be added to the suspension described herein.
  • the gas generating agent may be present in the suspension described herein for example in an amount from about 0.1 wt-% to about 5 wt-%, in particular from about 1 wt-% to about 5 wt-%, such as about 3 wt-% or about 2 wt-% , with the wt-% being based on the total weight of the suspension.
  • the gas generating agent may be used in combination with a catalyst.
  • catalysts include iron oxides, iron hydroxides, iron(lll) oxide hydroxide (geothite), iron chlorides, copper (I) oxide, manganese dioxide, titanium (IV) dioxide, iron (II) carbonate, potassium permanganate, potassium iodide, and nickel (II) oxide.
  • the aqueous suspension may further contain a hardening agent. If present, the amount of the hardening agent shall not exceed 20 wt-% based on the total weight of the suspension.
  • the term hardening agent refers to a hydraulic binder, such as cements, quicklime (CaO), stucco, calcium sulfate, calcium sulfate hemi-hydrated, calcium aluminate, portlandite (Ca(OH)2), Mg(OH)2, MgO and combinations thereof, in particular cements, quicklime (CaO), stucco, calcium sulfate, calcium sulfate hemi-hydrated, calcium aluminate, and combinations thereof.
  • cements include cements CEM l-V, calciumsulfoaluminates (CSA), calciumaluminate cements (CaC).
  • the aqueous suspension is free of hardening agent.
  • the CO2 containing gas used at step (d) of the inventive manufacturing method is preferably selected from an industrial grade CO2, an exhaust gas comprising at least 4 vol% CO2 and a gas containing at least 4 vol% captured CO2.
  • the CO2 containing gas contains at least 10 vol% CO2, more preferably at least 20 vol% CO2, most preferably at least 50 vol% CO2.
  • the gas contains at least 80 vol% CO2, preferably at least 90 vol% CO2, more preferably at least 95 vol% CO2.
  • the exhaust gas comprising at least 4 vol% CO2 may originate from a combustion engine, a coal- or gas- or petroleum- or wood-fired power plant, a kiln or a volcanic activity.
  • the gas containing at least 4 vol-% captured CO2 may be obtained by direct CO2 capture from the air using the known adsorption/desorption technologies, or by CO2 capture using the known adsorption/desorption technologies from large point sources, such as large fossil fuel or biomass electricity power plants, industries with major CO2 emissions, natural gas processing, synthetic fuel plants and fossil fuel-based hydrogen production plants.
  • the CO2 containing gas used at step (d) of the inventive manufacturing method is an exhaust gas comprising at least 4 vol-% CO2 as described herein, preferably an exhaust gas from a combustion engine, or a coal- or gas- or petroleum- or wood-fired power plant or a kiln.
  • the CO2 containing gas used at step (d) of the inventive manufacturing method is an industrial grade CO2 gas.
  • the solid, inorganic foam obtained by the manufacturing process claimed herein is characterized by one or more of the following properties:
  • a porosity from about 80 vol% to about 99 vol%, preferably from about 80 vol-% to about 98 vol-% as determined by the complement to one of the porous material’s specific density;
  • the manufacturing method claimed and described herein enables the production of ultra-light, solid, inorganic foams, and in particular having a density from about 20 kg/m 3 to about 300 kg/m 3 , preferably from about 20 kg/m 3 to about 100 kg/m 3 .
  • foams can be advantageously used as construction or building materials.
  • Thermal conductivity (also called lambda N) is a physical value characterizing the behaviour of materials during the transfer of heat by conduction. Thermal conductivity represents the quantity of heat transferred per unit of surface and per unit of time submitted to a gradient of temperature. In the international system of units, thermal conductivity is expressed in watts per metre Kelvin, (W/mK).
  • the manufacturing method claimed and described herein enables the production of solid, inorganic foams having good mechanical properties, in particular good mechanical strength from about 1 kPa to about 4 MPa.
  • the manufacturing method claimed and described herein enables the production of solid, inorganic foams having a surface area as measured by Brunauer- Emmett-Teller (BET) method of at least about 1 m 2 /g and/or a bubble size for the macro-size pores lower than 1.5 mm.
  • BET Brunauer- Emmett-Teller
  • foams having a surface area as measured by BET method of at least about 1 m 2 /g present lower thermal conductivities for similar mechanical strength compared to foams with lower surface area (less than 1 m 2 /g).
  • the suspension provided at step (a) preferably contains ⁇ up to 70 wt-% water,
  • the suspension provided at step (a) preferably contains
  • the inorganic material contains on a surface facing the meso-size and macro-size pores at least one of a crystalline sodium sesquicarbonate, a crystalline potassium sesquicarbonate, and a crystalline calcium carbonate, and
  • the foam claimed and described herein is characterized by one or more of the following properties:
  • nano-size pores refers to pores having a size of between 1 nm and 80 nm as determined Brunauer-Emmett-Teller (BET) method using a density functional theory (DFT) analysis based on a Non Local DFT (NLDFT) calculation model for nitrogen at 77 K on cylindrical pores in silica.
  • DFT density functional theory
  • NLDFT Non Local DFT
  • meo-size pores refers to pores having a size from 80 nm to 1 mm as determined by scanning electron microscopy i.e. includes both submicron-size (80 nm - 1 pm) pores and micro-size (1 pm - 1 mm) pores.
  • micro-size pores refers to pores having a size greater than 1 mm as determined by light microscopy using an inverted digital microscope in reflection mode (VHX 6000 with VH-K20 attachment, Keyence. SEM analysis was conducted using LEO 1530, instrument from Zeiss GmbH, Germany using a working distance of 4 mm and an acceleration voltage of 5 kV.
  • the solid, inorganic foam claimed and described herein is obtained by the manufacturing method claimed and described herein.
  • Also claimed and described herein is a solid, inorganic foam having a density from 20 kg/m 3 to about 300 kg/m 3 , preferably from about 20 kg/m 3 to about 100 kg/m 3 , obtained by the manufacturing method claimed and described herein.
  • a third aspect according to the present invention relates to a use of the foam claimed and described herein as a thermal insulating material, a construction or building material, a filtering material, a catalyst support material, a sound insulation material or a fire-resistant material.
  • a fourth aspect according to the present invention is directed to a use of an industrial grade CO2 gas and/or an exhaust gas comprising at least 4 vol% CO2 for manufacturing a solid, inorganic foam, particularly the solid, inorganic foam claimed and described herein.
  • the exhaust gas is an exhaust gas from a combustion engine, a coal- , gas-, petroleum- or wood- fired power plant, a kiln, or a volcanic activity, in particular from a combustion engine, a coal- , gas-, or petroleum- fired power plant, or a kiln.
  • a method for manufacturing a solid, inorganic foam comprising the steps of:
  • ⁇ at least one surfactant, which at least partially hydrophobizes a surface of the inorganic particles
  • ⁇ optionally one or more additives
  • step (b) foaming the suspension of step (a) to thereby obtain a wet, inorganic foam
  • step (c) drying or partially drying the foam of step (b) to thereby obtain a dry or partially dry inorganic foam
  • step (d) curing the dry or partially dry inorganic foam of step (c) by exposing it to a CO2 containing gas having a CO2 concentration of at least 4 vol% and a relative humidity from 5% to 95% to thereby obtain a cured, inorganic foam.
  • step (a) ⁇ in situ-foaming the suspension of step (a) by adding a gas generating agent to the suspension, and/or
  • step (a) injecting and/or bubbling a gas in the suspension of step (a).
  • step (c) is performed at a temperature lower than 80 °C and I or the dry or partially dry inorganic foam obtained at step (c) has a water content lower than about 50 wt-%.
  • step (d) The method according to any one of #1 to #7, wherein at step (d) the dry or partially dry inorganic foam of step (c) is exposed to the CO2 containing gas for a time period from 15 minutes to 100 hours, preferably for less than 50 hours, more preferably for less than 40 hours and/or step (d) is conducted at a temperature lower than 80°C, preferably without applying additional heat, more preferably at room temperature.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Organic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Toxicology (AREA)
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  • Inorganic Chemistry (AREA)
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  • Environmental & Geological Engineering (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Geochemistry & Mineralogy (AREA)
  • Geology (AREA)
  • General Chemical & Material Sciences (AREA)
  • Catalysts (AREA)

Abstract

La présente invention concerne un procédé de fabrication d'une mousse inorganique solide ultralégère, le procédé comprenant les étapes consistant à : utiliser une suspension aqueuse; procéder au moussage de la suspension afin d'obtenir une mousse inorganique humide; éventuellement sécher ou sécher partiellement la mousse; et faire durcir la mousse en l'exposant à un gaz contenant du CO2 présentant une concentration en CO2 au moins égale à 4 % en volume et une humidité relative variant de 5 à 95 %.
EP23765525.3A 2022-09-08 2023-09-07 Mousses inorganiques solides Pending EP4584232A1 (fr)

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EP22194606 2022-09-08
PCT/EP2023/074634 WO2024052487A1 (fr) 2022-09-08 2023-09-07 Mousses inorganiques solides

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WO2026003374A1 (fr) * 2024-06-28 2026-01-02 Fenx Ag Article poreux minéral

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WO2014165252A1 (fr) * 2013-03-13 2014-10-09 Solidia Technologies, Inc. Matériaux composites aérés, leurs procédés de production et utilisations
FR3021969B1 (fr) 2014-06-06 2016-10-28 Lafarge Sa Mousse minerale ultra-legere et son procede de fabrication
EP3590905A1 (fr) 2018-07-03 2020-01-08 ETH Zurich Mousses stabilisée par des particules utilisant des matériaux renouvelables
CN114656225B (zh) * 2022-02-24 2022-09-23 东南大学 一种制备3d打印混凝土的方法
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