EP4587403A1 - Procédé de production d'additifs de liant minéral - Google Patents

Procédé de production d'additifs de liant minéral

Info

Publication number
EP4587403A1
EP4587403A1 EP23765513.9A EP23765513A EP4587403A1 EP 4587403 A1 EP4587403 A1 EP 4587403A1 EP 23765513 A EP23765513 A EP 23765513A EP 4587403 A1 EP4587403 A1 EP 4587403A1
Authority
EP
European Patent Office
Prior art keywords
mineral binder
additive
source material
uncured
carbonation
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
EP23765513.9A
Other languages
German (de)
English (en)
Inventor
Arnd Eberhardt
Emmanuel GALLUCCI
Arnaud RIOU
Lukas Frunz
Patrick JUILLAND
Denise Muths-Kern
Luis Pegado
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.)
Sika Technology AG
Original Assignee
Sika Technology AG
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 Sika Technology AG filed Critical Sika Technology AG
Publication of EP4587403A1 publication Critical patent/EP4587403A1/fr
Pending legal-status Critical Current

Links

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
    • C04B7/00—Hydraulic cements
    • C04B7/36—Manufacture of hydraulic cements in general
    • C04B7/48—Clinker treatment

Definitions

  • the invention is concerned with a method to produce a mineral binder additive from uncured mineral binder material. Furthermore, the invention is directed to a mineral binder additive obtainable or obtained with this method and a method for producing a mineral binder composition with such an additive. Additionally, the invention is concerned with the use of a mineral binder additive as an additive in a mineral binder composition.
  • cement in binder compositions can be partly replaced by latent hydraulic and/or pozzolanic cement admixtures, as for example fly ashes, slags, or silica dust. Admixtures of this kind are byproducts of various industrial processes and are therefore advantageous in relation to the carbon dioxide balance. However, setting of cement admixtures of this kind, without additional measures, takes much longer than in the case of hydraulic cement.
  • the invention provides a method to produce a mineral binder additive comprising the steps of: a) Providing a source material comprising uncured mineral binder material, carbonating the source material with carbon dioxide, especially under abrasive conditions, such that the mineral binder material is at least partially, in particular essentially completely, carbonated to produce a carbonated product; b) Retrieving the carbonated product of step a) as the mineral binder additive in dry state.
  • the carbonated product, which is retrieved in step b) of the inventive process can be reused as mineral binder additive.
  • the mineral binder additive can, for example, be used as cement substitute in mineral binder compositions, as accelerating additive, and/or as rheological improver for mineral binder compositions.
  • the term "source material” stands for any material comprising or consisting of uncured mineral binder material.
  • the source material is a granular material, especially a powder.
  • the source material comprises hardened mineral binder. Crushing will increase the surface of the source material, which in turn enhances the carbonation process.
  • a proportion of hardened mineral binder in the source material is below 50 wt.-%, in particular below 5 wt.-%, especially below 1 wt.-%, with respect to the total weight of the source material.
  • the source material does not comprise any hardened mineral binder.
  • a “hydraulic binder” is meant to be a mineral binder that can be hardened with water or even under water, such as especially cement or hydraulic lime.
  • a “non- hydraulic binder” is a mineral binder that can be hardened with water even but not underwater, such as, in particular, gypsum in the form of anhydrite or gypsum hemihydrate.
  • latent hydraulic and/or pozzolanic binder materials stands in particular for type II concrete additives with latent hydraulic and/or pozzolanic character according to standard EN 206-1 .
  • the latent hydraulic or pozzolanic binder material comprises or consists of slag, fly ash, silica fume, clays and/or pozzolanes.
  • the source material or the uncured mineral binder comprises or consists of cement clinker.
  • Cement clinker is a solid material produced in the manufacture of cement as an intermediary product.
  • Cement clinker occurs in particular as lumps and/or nodules.
  • clinker particles have a size of a few millimetres up to 25 millimetres in diameter.
  • Cement clinker is produced by sintering limestone and aluminosilicate materials, especially in a cement kiln.
  • the cement clinker for example is a Portland cement clinker.
  • the uncured mineral binder comprises or consists of cements of type CEM I, II, III, IV or V according to standard EN 197, in particular of type CEM I or II.
  • other types of cements can be used as well.
  • cement When compared to cement clinker, cement is a much finer product. Usually, cement is obtained by grinding cement clinker, optionally with further binder components, in a cement mill. Typically, cements have a Blaine surface of at least 1'000 cm 2 /g, for example from 3'000 - 5'000 cm 2 /g. Nevertheless, cements with other Blaine surfaces are known as well.
  • the uncured mineral binder comprises or consists of uncured hydraulic binder, e.g. uncured cementitious binder.
  • the uncured mineral binder can comprise or consist of uncured hydraulic binder, uncured latent hydraulic binder and/or uncured pozzolanic binder materials as well.
  • the uncured hydraulic binder is uncured cement.
  • the uncured latent hydraulic and/or pozzolanic binder material is uncured slag and/or fly ash.
  • a highly preferred uncured latent hydraulic binder material is uncured slag.
  • the uncured mineral binder comprises or consists of 5 - 100 wt.-%, especially 50 - 100 wt.-%, more preferably, 65 - 100 wt.-%, of uncured hydraulic binder.
  • the uncured mineral binder comprises or consists of 5 - 95 wt.-% of uncured hydraulic binder and 95 - 5 wt.-% of uncured latent hydraulic and/or pozzolanic binder material. More preferably, the uncured mineral binder can comprise or consist of 30 - 90 wt.-% of uncured hydraulic binder and 70 - 10 wt.- % of uncured latent hydraulic and/or pozzolanic binder material.
  • the uncured mineral binder comprises or consists of production waste of cement production.
  • This is for example cement clinker and/or cement that, e.g. due to temporary processing issues, does not fulfil certain desired specifications.
  • carbonation of the source material in step a) takes place under a gas atmosphere containing or consisting of carbon dioxide.
  • the source material is in direct contact with the gas atmosphere.
  • the source material during step a) in not immersed in a liquid, especially water, and/or does not form a suspension with a liquid, especially water.
  • the concentration of carbon dioxide in the gas atmosphere is in particular above the carbon dioxide concentration of normal air.
  • a content of carbon dioxide in the gas atmosphere preferably is > 500 ppm carbon dioxide, in particular > 1'000 ppm, especially > 1'500 ppm.
  • mixtures of carbon dioxide with other gaseous substances can be used as gas atmosphere for carbonation in step a).
  • Such mixtures in particular comprise carbon dioxide in an amount > 1 wt.-%, for example > 8 wt.-%, preferably > 10 wt.-%, especially preferred > 50 wt.-%, in particular > 95 wt.-%, especially > 99 wt.-%.
  • exhaust gas from industrial processes is used as the gas atmosphere for carbonation in step a).
  • exhaust gas from a cement plant is used as the gas atmosphere for carbonation in step a).
  • the carbon dioxide comprised in the exhaust gas is captured and used for carbonation in step a) before it enters the atmosphere.
  • the exhaust gas comprises CO2.
  • the exhaust gas comprises about 5 - 25 wt.-% CO2, preferably 8 - 20 wt.-% CO2 or 10 - 15 wt.-% CO2.
  • the gas atmosphere in step a) consists of essentially pure carbon dioxide.
  • a purity of the carbon dioxide preferably is > 50 wt.-%, for example > 75 wt.-%, preferably > 90 wt.-%, in particular > 95 wt.-%, especially > 99 wt.-%.
  • essentially pure carbon dioxide is highly favourable.
  • the carbonation in step a) can take place under dry conditions or under humid conditions, especially with a relative humidity of 40 - 100%. Dry conditions are beneficial because the mineral binder additive can directly be obtained in dry state without further measures. However, the humidity in the gas atmosphere still is acceptable since the drying effort is rather low and the humidity might even improve the carbonation efficiency.
  • a pressure of the gas atmosphere used for carbonation of the source material in step a) might be in the range of atmospheric pressure to an overpressure of for example 10 bar.
  • an overpressure of 0.1 - 2 bar is applied.
  • the source material may be provided in dry from or wetted with a liquid, especially water.
  • a source material in dry from is beneficial because the carbonated granular product will have a low water content, which in turn makes it easier to obtain the mineral binder additive in dry state.
  • the presence of some water on the source material still is acceptable since the drying effort is rather low and the liquid, especially water, even can improve the carbonation efficiency.
  • the carbonation of the source material takes place in a liquid, and, preferably, the carbon dioxide is added in gaseous form into the liquid.
  • the source material is at least partially, in particular fully, immersed in the liquid.
  • the liquid is in particular an aqueous liquid, preferably water. This causes the carbon dioxide to dissolve in the aqueous liquid or water.
  • drying of the carbonated product is required if a dry mineral binder additive is desired.
  • a weight ratio of water in the liquid to source material in particular is from 0.1 - 0.3, especially 0.1 - 0.25, for example 0.12 - 0.2. Further preferred, in this case carbonation takes place under abrasive conditions as described above.
  • step a) takes place at a temperature between -10 - 100°C, especially between -5 - 75°C or 5 - 40°C.
  • the treatment may take place above 100°C.
  • a density of solid material, in particular source material and/or carbonated product, in a processing volume during step a) is about 10 - 80 vol.-%, especially 15 - 75 vol.-%, in particular 20 - 70 vol.-%, more preferably 30 - 65 vol.-% or 40 - 60 vol.-%.
  • processing volume stands for the volume where the carbonation is effectively carried out. In other words, the processing volume is defined to be the space in which the source material is exposed to carbonation and optionally abrasive conditions.
  • the carbonating of the source material in step a) can be done in a batch process or in a continuous process.
  • a further aspect of the present invention is directed to a mineral binder additive obtainable or obtained by the method as described above.
  • the mineral binder additive comprises or consists of calcium carbonate.
  • the mineral binder additive comprises or consists of calcium carbonate, silica, and aluminium hydroxide.
  • the mineral binder additive comprises or consists of carbonated cement, for example carbonate cement of type CEM I, II, III, IV or V according to standard EN 197.
  • a Blaine surface of the mineral binder additive is 0.5 - 8'000 cm 2 /g, in particular 1 - 5'000 cm 2 /g, especially 1 - 1'000 cm 2 /g, particularly 1 - 150 cm 2 /g, for example 20 - 100 cm 2 /g.
  • the mineral binder additive in particular is in the form of a granular product, especially in the form of a powder.
  • the mineral binder additive is a dry solid granular material.
  • the mineral binder additive is not present in the form of a suspension.
  • a content of water in the mineral binder additive is below 5 wt.%, especially below 1 wt.-%, in particular below 0.1 wt.-%, with respect to the weight of the mineral binder additive.
  • the mineral binder additive does not comprise any water.
  • a still further aspect of the present invention is related to a method to produce a mineral binder composition, especially a mortar and/or concrete composition, comprising the steps of:
  • Crude clays are clay minerals extracted from e.g. a quarry, optionally purified and optionally dried.
  • Low-temperature calcined clays are clays that have been thermally treated at temperatures between 500 - 1200°C.
  • low- temperature calcined clay minerals may be produced in a rotary kiln or in a flash calciner.
  • High-temperature calcined clays are clay minerals that have been thermally treated at temperatures above 1200°C and typically between 1300 - 1400°C.
  • High-temperature calcined clays typically are crystalline or contain high amounts of crystalline phases, especially of mullite.
  • clay minerals of the present invention are crude clays, especially phyllosilicates.
  • the clay mineral comprises or consists of kaolinite, montmorillonite, and/or illite, in particular kaolinite. These are clays that can be calcined and have proven to be suitable as components of mineral binders. However, other clay minerals might be suitable as well.
  • Clay minerals of the present invention may be pure clays or may contain other materials as impurities.
  • the content of clay in clay minerals, especially in crude clay is at least 30 w%, preferably at least 50 w%, more preferably at least 70 w%, especially at least 85 w%, relative to the dry weight of the crude clay.
  • clay minerals within the present context are low-temperature calcined clays, especially low-temperature calcined kaolinite.
  • a suitable flash calcination process is for example described in WO 2014/085538.
  • the calcined clay is metakaolin.
  • other clay mineral might be suitable as well.
  • a clay mineral may be added in the form of excavation material from quarries and/or mining or it can be added in pure form.
  • a weight ratio of clay mineral to carbonated product is from 5:1 - 1 :1 , especially 2.5:1 - 1.5:1 , in particular 2:1 .
  • the weight of the clay mineral is with respect to the pure mineral without any impurities possibly present. This allows for example for producing cements of type “LC 3 ” comprising metakaolin, lime, cement and gypsum.
  • Aggregates are for example selected from gravel, sand and/or rock aggregates.
  • Corresponding compositions can be formulated for example as mortar or concrete compositions.
  • a proportion of aggregates is for example 50 - 85 wt.-%, especially 60 - 75 wt.%, with respect to the overall dry weight of the mineral binder composition.
  • a proportion the mineral binder additive and the further mineral binder together is for example 15 - 50 wt.%, especially 20 - 35 wt.-%, with respect to the overall dry weight of the mineral binder composition.
  • the mineral binder composition may comprise at least one admixture, for example, a concrete admixture and/or a mortar admixture.
  • the at least one admixture comprises, for example, a defoaming agent, a dye, a preservative, a plasticizer, a retarding agent, an air pore forming agent, a shrinkage reducing agent and/or a corrosion inhibitor or combinations thereof.
  • a defoaming agent for example, a dye, a preservative, a plasticizer, a retarding agent, an air pore forming agent, a shrinkage reducing agent and/or a corrosion inhibitor or combinations thereof.
  • a defoaming agent for example, a defoaming agent, a dye, a preservative, a plasticizer, a retarding agent, an air pore forming agent, a shrinkage reducing agent and/or a corrosion inhibitor or combinations thereof.
  • such admixtures are used with proportions of 0.0001 - 10 wt.%, with respect to the total dry weight of the mineral binder composition.
  • a further aspect of the present invention is directed to the use of the mineral binder additive as described above as an additive for a mineral binder composition, in particular for accelerating the setting and/or hardening of the mineral binder composition, as a rheology improver in the mineral binder composition and/or as a cement substitute in the mineral binder composition.
  • uncured off-spec Portland cement clinker was treated in a mixing device (concrete mixer) under continuous mixing resulting in abrasive conditions under a gas atmosphere comprising 5'000 ppm CO2 and at a relative humidity of 60 wt.-% under atmospheric pressure at a temperature of 20°C.
  • the progress of the carbonation treatment was controlled by measuring the CO2 partial pressure. During the treatment, the CO2 partial pressure dropped due to the carbonation reaction. As soon as the CO2 partial pressure did not decrease further, the process treatment was stopped and the carbonated powdery product was retrieved.
  • X-ray analysis revealed that the carbonated product mainly consisted of calcium carbonate, silica, and aluminium hydroxide.
  • a Blaine surface was about 100 cm 2 /g.
  • the so-obtained product was used as a mineral binder additive as follows:

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)

Abstract

L'invention concerne un procédé de production d'un additif de liant minéral comprenant les étapes consistant à : a) fournir une matière source comprenant un matériau liant minéral non durci, carbonater la matière source à l'aide de dioxyde de carbone, en particulier dans des conditions abrasives, de telle sorte que le matériau liant minéral soit au moins partiellement, en particulier complètement, carbonaté pour produire un produit granulaire carbonaté, en particulier une poudre carbonatée ; b) récupérer le produit granulaire carbonaté de l'étape a) en tant qu'additif liant minéral.
EP23765513.9A 2022-09-13 2023-09-06 Procédé de production d'additifs de liant minéral Pending EP4587403A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP22195383.9A EP4339172A1 (fr) 2022-09-13 2022-09-13 Procédé de production d'additifs de liant minéral
PCT/EP2023/074484 WO2024056490A1 (fr) 2022-09-13 2023-09-06 Procédé de production d'additifs de liant minéral

Publications (1)

Publication Number Publication Date
EP4587403A1 true EP4587403A1 (fr) 2025-07-23

Family

ID=83319279

Family Applications (2)

Application Number Title Priority Date Filing Date
EP22195383.9A Withdrawn EP4339172A1 (fr) 2022-09-13 2022-09-13 Procédé de production d'additifs de liant minéral
EP23765513.9A Pending EP4587403A1 (fr) 2022-09-13 2023-09-06 Procédé de production d'additifs de liant minéral

Family Applications Before (1)

Application Number Title Priority Date Filing Date
EP22195383.9A Withdrawn EP4339172A1 (fr) 2022-09-13 2022-09-13 Procédé de production d'additifs de liant minéral

Country Status (3)

Country Link
EP (2) EP4339172A1 (fr)
CN (1) CN119654299A (fr)
WO (1) WO2024056490A1 (fr)

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2020239683A1 (fr) 2019-05-28 2020-12-03 Heidelbergcement Ag Procédé et dispositif améliorés de carbonatation de déchets de béton et/ou de séquestration de co2
EP4508020A1 (fr) 2022-04-12 2025-02-19 CarbonBuilt Procédé pour la production de systèmes liants hydrauliques-par carbonatation par activation mécanochimique de matières minérales

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9573847B2 (en) 2012-11-30 2017-02-21 Flsmidth A/S System for the production of fine lime
EP2980036B1 (fr) * 2014-07-28 2018-04-25 HeidelbergCement AG Procédé de broyage de clinker de ciment
WO2017041176A1 (fr) 2015-09-08 2017-03-16 Carboncure Technologies Inc. Pré-carbonatation de mélanges de ciment

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2020239683A1 (fr) 2019-05-28 2020-12-03 Heidelbergcement Ag Procédé et dispositif améliorés de carbonatation de déchets de béton et/ou de séquestration de co2
EP4508020A1 (fr) 2022-04-12 2025-02-19 CarbonBuilt Procédé pour la production de systèmes liants hydrauliques-par carbonatation par activation mécanochimique de matières minérales

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See also references of WO2024056490A1

Also Published As

Publication number Publication date
EP4339172A1 (fr) 2024-03-20
WO2024056490A1 (fr) 2024-03-21
CN119654299A (zh) 2025-03-18

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