US-12623963-B2 - Use of a hydraulic binder containing calcium aluminate for the production of a construction material

Abstract

The invention relates to the use of a hydraulic binder containing calcium aluminate, obtainable by a method in which a) prepared amorphous residual material rich in aluminium oxide and/or aluminium hydroxide is heated after the addition of a b) calcium ion-containing binder component and c) water, for the production of a constructing material.

Inventors

• Stephen Alan Brooks
• Rüdiger Oberste-Padtberg
• Jörg Sieksmeier
• Hubert MOTZET
• Michael Pomberg

Assignees

• ARDEX GROUP GMBH

Dates

Publication Date

20260512

Application Date

20200612

Priority Date

20190612

Claims (17)

1. 1 . A method for producing a hydraulic binder containing calcium aluminate and not containing Portland cement, comprising heating a processed amorphous alumina-rich or alumina-hydroxide-rich residue after addition of a calcium ion-containing binder component and water wherein the processed amorphous alumina-rich or alumina-hydroxide-rich residue is formed in the form of a drinking water treatment residue, wherein the amount of the sum of alumina and alumina-hydroxide of the residue in relation to the dry content is >50 wt.-%.
2. 2 . The method according to claim 1 , wherein the processed amorphous alumina-rich or alumina-hydroxide-rich residue has a degree of crystallization of less than 25%.
3. 3 . The method according to claim 1 , wherein in that the hydraulic binder containing calcium aluminate has a residual proportion of organic material.
4. 4 . The method according to claim 1 , wherein the hydraulic binder containing calcium aluminate is substantially anhydrous.
5. 5 . The method according to claim 1 , wherein the hydraulic binder containing calcium aluminate has a particle size of less than 100 μm.
6. 6 . The method according to claim 1 , wherein the hydraulic binder containing calcium aluminate is formed in the form of a constructing material.
7. 7 . The method according to claim 6 , wherein the constructing material further comprises an ettringite former.
8. 8 . The method according to claim 6 , wherein the constructing material further comprises a filler.
9. 9 . The method according to claim 8 , wherein the filler is formed in the form of limestone powder, quartz sand, marble, chalk, clay, marl, or talc filler.
10. 10 . The method according to claim 6 , wherein the constructing material further comprises additives.
11. 11 . The method according to claim 10 , wherein the additives are in the form of liquefiers, retarders, accelerators, actuators, stabilizers, defoamers or sealants.
12. 12 . The method according to claim 6 , wherein the constructing material further comprises an epoxy resin and an epoxy hardener.
13. 13 . The method according to claim 6 , wherein the constructing material further comprises plastic dispersion powder.
14. 14 . The method according to claim 13 , wherein the plastic dispersion powder is formed on the basis of vinyl or acrylate polymers.
15. 15 . The method according to claim 6 , wherein the constructing material further comprises a fibrous material.
16. 16 . The method according to claim 15 , wherein the fibrous material has fibres of a length of up to 2 mm.
17. 17 . The method according to claim 6 , wherein the constructing material is formed in the form of a screed, mortar, filler or tile adhesive.

Description

The present invention relates to the use of a binder containing calcium aluminate for the production of a construction material. Driven by government investments, the construction industry has seen a steady increase in incoming orders in recent years and now accounts for a significant share of the manufacturing sector. With regard to the achievement of climate policy goals, which have recently come increasingly into focus, the construction industry is therefore also increasingly required to pursue environmentally friendly and sustainable concepts. For this reason, the concept of sustainable construction has been established for some time, which pursues various approaches to carrying out construction measures while preserving the ecosystem and the environment. With regard to possible starting points, the factors that drive climate change most strongly are of particular interest. In addition to the necessarily high demand for fossil fuels in the construction industry, it is above all the high demand for constructing materials that significantly promotes climate change. In contrast to methods for reducing the demand for fossil fuels, the development of sustainable constructing materials still needs to be developed. For example, the production of currently known hydraulic binders or constructing materials is often still associated with a considerable use of natural resources and a high energy input. The durability of known hydraulic binders or of constructing materials produced from known hydraulic binders is also often in need of optimisation. It is therefore the object of the present invention to at least partially overcome the aforementioned disadvantages of known products and systems used for the production of a constructing material. In particular, it is the object of the invention to provide a sustainable and environmentally friendly way of producing a versatile constructing material which can be produced simply and inexpensively. The foregoing object is solved by a use having the features of the independent claim for use. Further features and details of the invention result from the respective dependent claims and the description. Use of a hydraulic binder containing calcium aluminate for the production of a constructing material is provided according to the invention, wherein the hydraulic binder containing calcium aluminate is obtainable by a method in which a) a prepared amorphous residual material rich in aluminium oxide and/or aluminium hydroxide is heated after addition of a b) calcium ion-containing binder component and c) water. In the context of the invention, a hydraulic binder is preferably understood to be a material which, after being mixed with water, independently solidifies and hardens as a result of chemical reactions with the mixing water and, after hardening, also remains solid and dimensionally stable under water. According to the invention, a residual material is understood to mean in particular a residue produced in a method for which no reuse is intended and which therefore has to be disposed of, sometimes in a time-consuming and cost-intensive manner. In the context of the invention, processing can be understood in particular as a form of treatment comprising, for example, collection, filtering, drying, comminution or the like. In the context of the invention, an alumina-rich and/or alumina-hydroxide-rich residual material is understood in particular as a material having an alumina content or an alumina-hydroxide content (the sum of the alumina or alumina-hydroxide) of at least 5 wt. %, preferably of at least 30 wt. %, in-particular of at least 50 wt. %-relative to the dry content of the material. It is understood here that the material may also be formed substantially in the form of only one of the two components. It should be noted at this point in advance of the following explanations that, with respect to the indication of preferred proportions by weight of the components within a mixture, the person skilled in the art is quite capable of combining the ranges in such a way that the total proportion of all components of the mixture is 100 wt. %. In the context of the present invention, it has been recognized that, in particular, by using a processed amorphous residual material rich in aluminum oxide and/or aluminum hydroxide, it is possible to produce in a simple and inexpensive manner a hydraulic binder which can be used in a variety of ways and at the same time makes a contribution to sustainable construction, the contribution in the present case being made in particular by conserving natural resources by using residual or waste materials for the production of the hydraulic binder, which would otherwise have to be disposed of in an elaborate and cost-intensive manner. With regard to a simple processability as well as a high water retention capacity of the hydraulic binder, it can be provided in an objectively advantageous manner that the prepared amorphous residual material r