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EP-4735398-A1 - CEMENTITIOUS PRODUCTS INCLUDING ADMIXTURES, AND ASSOCIATED SYSTEMS AND METHODS

EP4735398A1EP 4735398 A1EP4735398 A1EP 4735398A1EP-4735398-A1

Abstract

A lime-based cement extender composition and associated systems and methods are disclosed herein. A lime-based binder or cement extender includes lime particles comprising calcium hydroxide and/or calcium oxide, pozzolan particles including silicon dioxide and/or aluminum dioxide; and an admixture. The admixture is configured to promote reactions between the lime particles and the pozzolan particles. When the composition is mixed with cement to form a cement blend, calcium aluminum sulfate forms within 28 days of blending. Additionally or alternatively, the cement blend can have a Strength Activity Index (SAI) of at least 90%.

Inventors

  • MCFARLANE, Lucas
  • ROMANIUK, NIKOLAS ANDREI
  • HARIHARAN, NARAIN

Assignees

  • Graymont Western Canada Inc.

Dates

Publication Date
20260506
Application Date
20240620

Claims (20)

  1. 1. A lime-based composition, comprising: lime particles comprising calcium hydroxide and/or calcium oxide; pozzolan particles comprising silicon dioxide and/or aluminum dioxide, wherein at least 90% of the lime particles and pozzolan particles are less than 75 microns; and an admixture, wherein, when the composition is mixed with cement to form a cement blend, calcium aluminum sulfate forms within 28 days.
  2. 2. The composition of claim 1, wherein the cement blend has a Strength Activity Index (SAI) of at least 80% within 7 days.
  3. 3. The composition of claim 2, wherein the cement blend has a Strength Activity Index (SAI) of at least 90% within 28 days.
  4. 4. The composition of claim 1, wherein the calcium aluminum sulfate comprises at least one of ettringite or calcium aluminate monosulfate hydrate.
  5. 5. The composition of claim 1 , wherein, when the composition is mixed with cement to form the cement blend, the calcium aluminum sulfate forms within 14 days.
  6. 6. The composition of claim 1, wherein the admixture comprises a mid-range water reducer and lignosulphonates.
  7. 7. The composition of claim 1, wherein the admixture comprises an accelerant including at least one of chloride, calcium chloride, sodium thiocyanate, calcium formate, calcium nitrate, or calcium nitrite.
  8. 8. The composition of claim 1, wherein the admixture comprises a retardant including at least one of calcium salts, magnesium salts, sodium salts, ammonium salts, oxides of lead and zinc, phosphates, fluorates, borates, or carbohydrates.
  9. 9. The composition of claim 1, wherein the admixture comprises an air entrainer including at least one of fatty acid salts, abietic and pimelic acid salts, alkyl acryl sulphonates, alkyl sulphonates, phenol ethoxylates, rosin resins, aliphatic alcohol sulfonates, protein salts, or petroleum sulfonates.
  10. 10. The composition of claim 1, wherein the admixture comprises less than 1% by weight of the composition.
  11. 11. The composition of claim 1, wherein the admixture comprises two or more of an accelerant, a retardant, a water reducer, or an air entrainer.
  12. 12. The composition of claim 1, further comprising calcium carbonate particles.
  13. 13. The composition of claim 12, wherein: the lime particles comprise 10-35% by weight of the composition, the calcium carbonate particles comprise 5-10% by weight of the composition, and the pozzolan particles comprise 55-85% by weight of the composition.
  14. 14. A lime-based composition, comprising: lime particles comprising calcium hydroxide and/or calcium oxide; pozzolan particles comprising silicon dioxide and/or aluminum dioxide, wherein at least 90% of the lime particles and pozzolan particles are less than 75 microns; and an admixture, wherein, when the composition is mixed with cement to form a cement blend, the cement blend has a Strength Activity Index (SAI) of at least 90% within 7 days of mixing.
  15. 15. The composition of claim 14, wherein the cement blend has a Strength Activity Index (SAI) of at least 95% within 28 days of mixing.
  16. 16. The composition of claim 14, wherein, when the composition is mixed with cement to form the cement blend, ettringite forms within 28 days.
  17. 17. The composition of claim 14, wherein, when the composition is mixed with cement to form the cement blend, calcium aluminate monosulfate hydrate forms within 28 days.
  18. 18. The composition of claim 14, wherein the admixture comprises a high-range water reducer configured to achieve at least 12% in water reduction and at least 8 inches of slump increase, and wherein the admixture comprises at least one of polycarboxylates, sulfonated melamines, vinyl copolymers, or lignosulphonates.
  19. 19. The composition of claim 14, wherein the admixture comprises an accelerant including at least one of chloride, calcium chloride, sodium thiocyanate, calcium formate, calcium nitrate, or calcium nitrite.
  20. 20. The composition of claim 14, wherein the admixture comprises a retardant including at least one of calcium salts, magnesium salts, sodium salts, ammonium salts, oxides of lead and zinc, phosphates, fluorates, borates, or carbohydrates.

Description

CEMENTITIOUS PRODUCTS INCLUDING ADMIXTURES, AND ASSOCIATED SYSTEMS AND METHODS CROSS-REFERENCE TO RELATED APPLICATIONS [0001] The present application claims the benefit of U.S. Provisional Patent Application No. 63/510,592, filed June 27, 2023, the disclosure of which is incorporated herein by reference in its entirety. The present application is related to (i) U.S. Patent Application No. 18/087,728, filed December 22, 2022, titled LIME-BASED CEMENT EXTENDER COMPOSITIONS, AND ASSOCIATED SYSTEMS AND METHODS, and (ii) U.S. Patent Application No. 18/390,399, filed December 20, 2023, titled SYSTEMS AND METHODS FOR STORING AND MINERALIZING CARBON DIOXIDE WITH LIME, the disclosures of which are incorporated herein by reference in their entireties. TECHNICAL FIELD [0002] This present technology relates to lime-based binders, compositions, and/or cementitious products including admixtures, and associated systems and methods. Particular embodiments of the present technology relate to combining a lime-based composition, cement, and admixtures to produce products for use in the mining, cement, construction, and other industries. BACKGROUND [0003] Conventional mine backfill solutions generally include a combination of cement and fly ash, which is used as a cement extender or supplementary cementitious material. However, using fly ash for mine backfill has certain disadvantages, including that significant amounts of fly ash are needed and that the unconfined compressive strength (UCS) of fly ash varies, e.g., depending on the quality of the fly ash. Additionally, the availability of fly ash is diminishing over time, in part because fly ash is produced as a by-product at coal facilities which are being decommissioned or turned down due to issues associated with the environment and greenhouse gas emissions. The diminishing supply of fly ash has caused its cost (e.g., relative to the cost of cement) to increase, making the economics for producing mine backfill with fly ash unpredictable and less desirable. As such, a need exists to develop alternatives to fly ash and/or improve mine backfill solutions. BRIEF DESCRIPTION OF THE DRAWINGS [0004] Features, aspects, and advantages of the presently disclosed technology may be better understood with regard to the following drawings. [0005] FIG. 1 is a schematic block diagram of a system for manufacturing lime-based compositions, in accordance with embodiments of the present technology. [0006] FIG. 2 is a flow diagram of a method for producing lime-based compositions, in accordance with embodiments of the present technology. [0007] FIG. 3A illustrates the relationship between UCS and varying amounts of quicklime, in accordance with embodiments of the present technology. [0008] FIG. 3B illustrates the relationship between UCS and varying amounts of limestone, in accordance with embodiments of the present technology. [0009] FIG. 3C illustrates the relationship between UCS and varying amounts of pozzolan, in accordance with embodiments of the present technology. [0010] FIG. 4 A illustrates the UCS of various concrete cylinders without admixtures over time, in accordance with embodiments of the present technology. [0011] FIG. 4B illustrates the UCS of various concrete cylinders with admixtures over time, in accordance with embodiments of the present technology. [0012] FIGS. 4C-4E illustrate the Strength Activity Index (SAI) of various types of concrete cylinder over time, in accordance with embodiments of the present technology. [0013] FIG. 5 illustrates how concrete wet densities of various types of cement blend pastes vary with different water-to-cement blend ratios, in accordance with embodiments of the present technology. [0014] A person skilled in the relevant art will understand that the features shown in the drawings are for purposes of illustration, and variations, including different and/or additional features and arrangements thereof, are possible. DETAILED DESCRIPTION I. Overview [0015] Embodiments of the present technology relate to combining lime, calcium carbonate, pozzolans, and/or an admixture to produce a lime-based binder or cement extender composition. The binder can be combined (e.g., mixed) with cement to form a cement blend. Water can be added to the cement blend to form a cement blend paste. The cement blend paste can be combined (e.g., mixed) with aggregates (e.g., sand, stone, gravel, etc.) to form a product mixture. In some embodiments, such product mixtures can be used in the mining or other industries (e.g., as mine backfill) or act as a replacement (or partial replacement) for cement in concrete and soil treatment applications. As noted above, mine backfill solutions can generally include a combination of cement and fly ash, which is used as a cement extender or supplementary cementitious material. However, because the availability of fly ash is diminishing over time, significant amounts of fly ash are needed, and the unconfined compressive strength (U