FOAMED PRODUCT

Abstract: A foamed product for flowing over a distance of at least 30 metres (100 feet) before setting and for providing increased strength and resiliency as well as high water resistance. The foamed product is produced from a mixture to which water is added to form a slurry, and a mineral acid and latex are added to the slurry. The mixture is of hydraulic cement, inert filler, aggregate, stabilizer, and latex. The latex is preferably a nonionic latex, and the hydraulic cement is preferably calcium aluminate cement.

Description: The invention relates to a foamed product. Old murder mystery films frequently show whiffs of steam rising out of the manhole covers from deep within the bowels of the earth in large cities. Such a scene is representative of a substantial energy loss problem which many large cities experience. Hundreds of miles of steam lines may lie buried under the streets and criss-cross larger cities. These steam lines may have been initially installed many years ago. In order to insulate them against heat loss, they were typically provided with a thick block, for example 100 mm (four inches) of calcium silicate refractory which is surrounded by a tubular member leaving perhaps a 50 mm (two inch) dead air space between the refractory block and the tubular member. Over the years the tubular member may become corroded from the elements so that water is able to seep into this dead air space and eat through the refractory block so as to diminish its effectiveness to insulate, which loss of effectiveness is evident in the whiffs of steam rising from the manhole covers. As the years pass, the effectiveness of the original insulation resultingly becomes less and less, and the heat losses become greater and greater. In many large cities, the losses are now becoming sufficiently great that it is becoming urgent to renew the insulation. Conventionally, renewing the insulation would require digging or excavating the ground down to the pipeline. However, such a process is very expensive since it is believed the excavation cost alone would be in the range of £2000 to £3000 per metre. In order to eliminate these huge excavation costs, it is desirable to be able to pump a water resistant insulating material along the dead air space for a distance of perhaps 40 metres (130 feet) in each direction from a single small hole dug in the ground to the steam line or from a position where a steam line passes through a manhole. It is then desirable that the insulating material harden after it has been flowed along the pipeline thereby to renew the insulation. European Patent Specification No. 0073516-A discloses a foamed product produced from a latex to which hydraulic cement and aluminium powder have been added, the aluminium reacting in alkaline environments to produce hydrogen gas. A foamed cellular refractory product produced from a dry mixture of hydraulic cement, fine grain inert filler, and an aggregate mixed with water, and with a mineral acid added to the resulting slurry mixture to induce chemical foaming, such as disclosed in United States patent US-A-4 341 561, while suitable for many applications, is not sufficiently suitable for field applications such as the re-insulating of underground steam lines as described above where ground water and moisture are present where it is desirable that the insulating product have lighter weight, higher strength, and especially water resistance, particularly since a reduction in density of the product of US-A-4 341 561 typically results in lower strength. A foamed waterglass cement to which a natural latex dispersion has been added, such as disclosed in United States patent US-A-4 425 291, releases water to bond and would therefore shrink upon air drying with the result that gaps would form along the steam lines and there would be insufficient insulation for the steam lines. This problem may be solved by increasing the amount of mineral acid to prevent shrinkage. However, if too much mineral acid is added, outgassing and collapsing of the material may occur. Thus, in order for this product to be effective, it is required that very precise proportions of waterglass and mineral acid be provided to form the foamed material. This is of course difficult to control. In addition, there is a greater chance that the sodium, potassium, or lithium in waterglass cement will leach out and combine with chlorine found in river water and degrade the insulating material than if calcium were instead found in the insulating material. Insulating material which is mechanically foamed cannot be controlled easily since it begins foaming as soon as foaming is induced and its foaming action may be lost before it has been pumped 30 metres (100 feet) as desired for underground steam lines. According to one aspect of the invention there is provided a foamed product produced from a mixture to which water has been added to form a slurry and to which slurry a latex and a foaming agent comprising a mineral acid have been added, the mixture comprising, by weight, between 15 percent and 95 percent hydraulic cement, between 0 percent and 85 percent inert filler, between 0 percent and 85 percent aggregate, and between 0 percent and 20 percent stabilizer. In a further aspect of the invention such a product may be used for filling cavities, such as may surround underground steamlines. Desirably such a foamed product can be flowed over long distances such as 30 metres (100 feet) before bonding in order to insulate or re-insulate underground steam lines. Preferably such a foamed product has a low density, high strength and resiliency and does not degrade easily when combined with chlorine from river water. Advantageously the foamed product will continue foaming as it is being pumped over long distances such as 30 metres (100 feet) but is easy to formulate. One embodiment of a foamed product according to the invention is produced from a mixture comprising, by weight, between 15 percent and 95 percent cement, between 0 percent and 85 percent inert filler, between 0 percent and 85 percent aggregate, between 0 percent and 20 percent stabilizer to which mixture water is added to form a slurry, latex is added to the slurry, and the slurry is foamed as described hereinafter. As used in this specification and in the appended claims, a "foamed" product is one in which porosity has been introduced into the product such as by the introduction of a gas generated by a chemical reaction. Such a foamed product may be characterized as cellular. So that the insulating material does not contain elements such as sodium, potassium, or lithium which would easily combined with chlorine from ground water to degrade the product and in order to provide for easy formulation of the product when chemically foaming it, the cement used is a hydraulic cement such as calcium aluminate or calcium silicate cement. By "hydraulic" cement is meant a cement which hydrates when mixed with water to form a bond. This is in contrast to waterglass cement which releases water to bond thereby shrinking upon air drying whereby gaps form in the bonded material. Since both calcium and aluminate bond with mineral acids, in order to provide increased strength to the final foamed product, it is preferred that the cement be a calcium aluminate cement such as Refcon, available from Lehigh Cement Company. A preferred amount of the cement is about 25 weight percent based on the total weight of the dry ingredients. In addition, a calcium aluminate cement is generally considered to have less contaminants than a calcium silicate cement. About 22 percent by weight of inert fillers are preferably present in the dry mixture. These fillers are preferably fine grained, and may include, for example, a pyrophyllite filler such as RG-200 Pyrophyllite, sold by R.T. Vanderbilt Co., to act as a pore stabilizer, and a wollastonite such as Nyad 400 Wollastonite, supplied by Nyco Corporation, to provide low density in the final product. About 48 percent by weight of an aggregate such as kaolin calcine is preferably present in the dry mixture. The aggregate size is preferably sufficiently coarse for the aggregate particles not to use too much water to dilute the foaming agent (described hereinafter) for the pot life to be increased and for increased strength to be provided to the product. The aggregate size is preferably sufficiently fine for the particles to be suspended in the slurry a long time. Therefore, in order to provide increased strength, longer pot life, and the other qualities described above for the product, the preferred aggregate size ranges between about 0.833mm (-20 mesh) and about 0.043mm (+325 mesh), and more preferably between 0.104mm (-150 mesh) and 0.061mm (+250 mesh). A suitable example of kaolin calcine for providing better flowability, less tendency to settle, and greater dispersion of the material throughout the mixture is 200M Mulcoa 47, sold by Combustion Engineering Company. Examples of other aggregates which may be used include, but are not limited to, trap rock, alumina, and silica sand. A stabilizer such as, for example, anhydrous dibasic calcium phosphate is added to reduce settling, increase the pot life of the mixture, and act as a buffer in maintaining the pH of the mixture. In a preferred embodiment, the anhydrous dibasic calcium phosphate is present in an amount of about 5 percent by weight of the dry mixture. Since water is a good heat conductor, it is desirable to keep water away from insulated steam lines. In order to form webs between the foamed cells to close the cells so that water cannot pass through the webs and thereby provide water-resistant properties to the final product as well as to provide increased resiliency to the final product, latex is added in an amount preferably equal to between about 5 percent and about 50 percent (more preferably, in order to provide reduced costs to the product, about 5 percent) by weight of the dry mixture to the slurry mixture while continuously mixing. For example, if the dry mixture weighs 100 kg, 5 kg of latex, i.e. 5 percent by weight of the dry mixture, may be added to the slurry. Since latex has a natural tendency to coagulate, a surfactant such as an organic salt or a salt of a fatty acid is added to the latex in order to disperse it. This results in the latex becoming ionic, i.e., its particles becoming positively or negatively charged. However, the surfactant itself may react with the foaming agent (hereinafter described) to cause coagulation and resulting clogging of the application nozzle used to carry the foaming material and thereby adversely affect flowability. Although anionic latexes may clog the application nozzles during pumping of the product along underground steam lines, in applications where quick setting is desirable, such as for spraying, such anionic latexes as 2671 Latex, produced by B.F. Goodrich Co., may be desirable. In order to remove the charges on the latex particles, they may be coated with a coating such as polyvinyl alcohol, paraffin wax, or other suitable inert coating to provide what is called herein a "nonionic" latex. By "nonionic" latex is thus meant a latex which has been treated to disperse and in which the particles thereof are not charged. In accordance with a preferred embodiment, in order to reduce clogging of the nozzle carrying the foamed material, to provide increased flowability of the foamed material, and to inhibit settling during foaming of the material, the latex added to the mixture is a nonionic latex such as, for example, 115 Neoprene Latex, sold by E.I. duPont deNemours and Co., or 26120 Latex, produced by B.F. Goodrich Co. A neoprene latex also exhibits a high temperature use limit when compared with, for example, acrylic latexes. The dry mixture and latex are mixed with water to form a stable slurry with preferably about 55 to 70 percent solids content after which it is foamed as hereinafter described. The latex dispersion is preferably added last to the slurry mixture while continuously mixing. After the product has been pumped or otherwise placed in position where it is to be used, it is then allowed to set. Since mechanical foaming begins immediately when the foaming is initiated and may not last long enough for the product to be pumped over a desired distance of perhaps 30 metres (100 feet) or more, in order better to control the foaming action so that there is a delayed reaction whereby the foaming may not begin until the material is being pumped and may last a longer period of time to allow pumping of the material over long distances, a mineral acid such as, for example, phosphoric acid, sulfuric acid, hydrochloric acid, or hydrofluoric acid is added to the slurry chemically to foam it. If too much mineral acid is added to the slurry, outgassing which may cause the mixture to collapse may occur. On the other hand, if too little mineral acid is added to the slurry, the strength thereof is reduced and less foaming will occur resulting in a denser product. Therefore, in order to provide increased strength to the product and to prevent collapsing thereof during bonding, the mineral acid is preferably added to the slurry in a range of slurry to acid ratio of 2:1 to 7:1. Since phosphate bonds such as calcium phosphate or aiuminium phosphate are more insoluble and thus are not as easily washed out and are more refractory and since phosphoric acid is considered safer to use, it is preferred that the mineral acid be phosphoric acid. Referring to Table 1, there are shown several examples of foamed materials and test results showing the density, cold crushing strength (CCS), water absorption (which is a measure of water resistance), the set time, rise time, and volume increase. Values for density are shown in kg/m³ taken at 65.5 o C (pounds per cubic foot at 150 o F) after the foamed material has set overnight. The cold crushing strength (CCS) is given in kPa taken at 65.5 o C (pounds per square inch at 150 o F) after the product has set overnight. Experimental values obtained before and after submersion and redrying are shown. The viscosity shown is that obtained where the mineral acid is mixed with the slurry mixture at the nozzle of the application apparatus used to apply the foamed material to the situs to be insulated. The percent of water absorption was determined after soaking of each sample in water for two days. The water absorption refers to the percent of original weight added. Table 1 shows that the density of the final product is in the range of about 352 to 880 kg/m³ (22 to 55 pounds per cubic foot) which is less than the density of the products of US-A-4 341 561. It is normally expected by those of ordinary skill in the art to which this invention pertains that as the density is decreased, the cold crushing strength is also decreased. However, contrary to such expected results, the tests of Table 1 show generally an increased cold crushing strength (after submersion and redrying two days) to the range of 145 to 1730 kPa (21 to 251 psi). This is generally greater than the cold crushing strength of typically 137 kPa (20 psi) and usually no more than 214 kPa (30 psi) of the products of US-A-4 341 561. Although the reasons for this unexpected result are not definitely known, it is believed that the latex acts as an organic binder which substitutes for cement thus providing added strength as well as resiliency. It is also noted, again unexpectedly, from Table 1 that as the amount of latex is increased from 25 percent to 30 percent, there is a very sharp increase in cold crushing strength thus to provide good shock absorbing capacity to the product. In addition, the water absorption rate advantageously drops off substantially as the amount of latex is increased from 25 percent to 30 percent. Thus, in order to provide a low water absorption as well as good shock absorbing capacity to the product, it is preferred that latex be added in an amount equal to at least about 30 percent by weight of the dry mixture to the slurry mixture. The test results as shown in Table 1 indicate that the water absorption (percent of original weight added) of a product embodying the invention ranges between about 37 percent and 103 percent, which is substantially less than a typical water absorption rate of 128 percent for the product of US-A-4 341 561 and 400 percent for calcium silicate insulation. Although foamed borosilicate glass insulation may have a typical water absorption rate of 21 percent, foamed borosilicate glass insulations as well as calcium silicate insulations are rigid pre-formed insulating materials typically used in insulating and water proofing applications which pre-formed insulations, unlike the new water-resistance inorganic foamed product embodying the invention, may not be flowed into place before setting. As previously stated, the ability to flow the foamed product of the invention into place before setting is advantageous for use in areas such as with "buried" steam lines where excavation would otherwise be required to re-insulate and waterproof the lines with such conventional materials as foamed borosilicate glass insulations.

Claims: A foamed product produced from a mixture to which water has been added to form a slurry and to which slurry a latex and a foaming agent comprising a mineral acid have been added, the mixture comprising, by weight, between 15 percent and 95 percent hydraulic cement, between 0 percent and 85 percent inert filler, between 0 percent and 85 percent aggregate, and between 0 percent and 20 percent stabilizer. A foamed produced according to claim 1, wherein the product is a cellular refractory product. A foamed product as claimed in claim 1 or claim 2 which is water resistant and insulating and which, before setting, is capable of flowing over a distance of at least 30 metres. A foamed product as claimed in any preceding claim wherein the hydraulic cement is calcium aluminate cement. A foamed product as claimed in any preceding claim wherein the inert filler includes pyrophyllite and wollastonite. A foamed product as claimed in any preceding claim wherein the aggregate includes kaolin calcine. A foamed product as claimed in any preceding claim wherein the aggregate size is between 0.833mm (-20 mesh) and 0.043mm (+325 mesh). A foamed product as claimed in any preceding claim wherein the stabilizer is anhydrous dibasic calcium phosphate. A foamed product as claimed in any preceding claim wherein the water is present in the slurry after the addition of latex in an amount sufficient to provide a solids content of between 55 percent and 70 percent. A foamed product as claimed in any preceding claim wherein the latex is a nonionic latex. A foamed product as claimed in any preceding claim wherein the amount of latex added to the slurry is equal to between 5 percent and 50 percent by weight of the mixture. A foamed product according to claim 11 wherein the amount of latex added to the slurry is equal to at least 30 percent by weight of the mixture. A foamed product as claimed in any preceding claim wherein the mineral acid is phosphoric acid. A foamed product as claimed in any preceding claim wherein the ratio by weight of the slurry, after the addition of the latex, to the mineral acid is between 2:1 to 7:1. A foamed product as claimed in claim 3 or any preceding claim dependent thereon wherein the mixture consists essentially by weight of 25 percent calcium aluminate cement, 22 percent inert filler, 48 percent aggregate, and 5 percent stabilizer, and the amount of latex is equal to 5 percent by weight of the mixture. A foamed product according to claim 15 wherein the inert filler consists essentially by weight of the dry mixture of about 13 percent pyrophyllite and about 9 percent wollastonite, the aggregate consists essentially of kaolin calcine, the water is present in the slurry, after the addition of latex, in an amount sufficient to provide a solids content of about 67 percent, and the mineral acid is phosphoric acid. Use of a foamed product as claimed in any preceding claim for filling cavities, such as may surround underground steam lines.

Inventors: MALONE, RUSSELL M., WIDENER, JOSEPH
Applicants: THERMAL CERAMICS, INC.
Application year: 1986
Main classification: C04B38
IPC codes: C04B38, C04B28