Patent EA-001799-B1 (EA)
Title: A settable composition and uses therefor
Inventor: RECHICHI DINO
IPC: C04B2/10
Filed: 1996-12-03
Abstract: 1. A method for manufacturing a settable binder composition, consisting essentially of a mixture of a calcium carbonate and a caustic magnesium oxide, wherein the dolomite is heated at a temperature within the range of 500 to 800 degree C to cause preferential decarbonization of the magnesium carbonate by liberating carbon dioxide, whereby between 2% to 50% of the carbon dioxide is retained within the magnesium carbonate without substantially decarbonizing the calcium carbonate resulting in a mixture of magnesium oxide, magnesium carbonate, and calcium carbonate (MgO, MgCO3, and CaCO3). 2. The method of claim 1, wherein the dolomite is a magnesium deficient dolomite and to which is added additional caustic magnesium oxide. 3. The method of claim 1, wherein 0.1%-5% of a suitable inorganic salt is added to enhance the preferential decarbonization of the magnesium carbonate. 4. The method of claim 1, wherein 2% to 20% of the carbon dioxide is retained within the magnesium carbonate. 5. The method of claim 4, wherein the composition has a particle size of 50-80 micron with 90% passing through a 160 micron sieve. 6. The method of claim 1, wherein further including a sulfate additive present between 0.01% up to 10%. 7. The method of claim 6, wherein the sulfate additive is selected from the group consisting of sulfuric acid, magnesium sulfate and aluminum sulfate. 8. The method of claim 1, wherein including a carbonate additive which produces a source of carbonation during the setting process. 9. The method of claim 8, wherein the carbonate additive is selected from the group consisting of sodium carbonate, citric acid, lemon acid, acetic acid, glycolic acid, oxalic acid; acids being able to react to liberate carbon dioxide. 10. The method of claim 9, wherein the carbonate additive is present between 0.01%-5%. 11. The method of claim 1, wherein including aluminum sulfate and carboxylic acid, the additives comprising about 3% to about 15% of the composition. 12. The method of claim 11, wherein further including salt, and aluminum sulfate is present between 40%-80%, is present between 10%-60% and salt is present between 1%-20% of the additives. 13. The method of claim 6, wherein further including at least one filler. 14. The system of claim 13, wherein the filler comprises between 3-90% of the total composition. 15. The system of claim 14, wherein the at least one filler is selected from the group consisting of power station ash, volcanic ash, alumina, red mud, crushed rock, sand coral, pumice, glass, cenospheres, perlite, vermiculate, styrene bead, sawdust, shredded rubber, straw, rice husk, coconut fiber, wood chip, wood bark, paper, cardboard, plastic, concrete rubble, soil, lead concentrate, litharge, lead wood, boron, lithium, cadmium, metal dusts and chemically precipitated gypsum, steel, glass fiber, carbon straw and mixtures thereof. 16. A system for manufacturing a settable binder composition, the composition consisting of a mixture of a calcium carbonate and a caustic magnesium oxide, wherein a synthetic blend formed by mixing calcium carbonate with preformed caustic magnesium oxide, the preformed caustic magnesium oxide being prepared by heating magnesium carbonate to partially drive off carbon dioxide whereby between 2% to 50% of the carbon dioxide is retained within the magnesium carbonate, and wherein the calcium carbonate retains substantially all of its carbon dioxide resulting in a mixture of magnesium oxide, magnesium carbonate and calcium carbonate (MgO, MgCO3 and CaCO3). 17. The system of claim 16, wherein 0.1%-5% of a suitable inorganic salt is added to enhance the preferential decarbonization of the magnesium carbonate. 18. The system of claim 16, wherein further including a sulfate additive present between 0.01% up to 10%. 19. The system of claim 18, wherein the sulfate additive is selected from the group consisting of sulfuric acid, magnesium sulfate and aluminum sulfate. 20. The system of claim 16, wherein including a carbonate additive which produces a source of carbonation during the setting process. 21. The system of claim 20, wherein the carbonate additive is selected from the group consisting of sodium carbonate, citric acid, lemon acid, acetic acid, glycolic acid, oxalic acid; acids being able to react to liberate carbon dioxide. 22. The system of claim 16, wherein including aluminum sulfate and carboxylic acid, the additives comprising about 3% to about 15% of the composition. 23. The system of claim 22, wherein further including salt, and aluminum sulfate is present between 40%-80%, is present between 10%-60% and salt is present between 1%-20% of the additives. 24. The system of claim 18, wherein further including at least one filler. 25. An article of manufacture comprising a set composition of claims 1 to15. 26. An article of manufacture comprising a set composition of claims 16 to24. 27. The article of claim 25, wherein the article is selected from the group consisting of a brick, block, paver, tile, mortar, pipe, board, panel, cladding, paving, structure, statue, monument, sleeper, post, pole, storage tank, boat, pile, wharf and marina. 28. The article of claim 26, wherein the article is selected from the group consisting of a brick, block, paver, tile, mortar, pipe, board, panel, cladding, paving, structure, statue, monument, sleeper, post, pole, storage tank, boat, pile, wharf and marina.