CA2556584A1 - Process and apparatus for manufacturing set cellular cement - Google Patents

Process and apparatus for manufacturing set cellular cement Download PDF

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Publication number
CA2556584A1
CA2556584A1 CA002556584A CA2556584A CA2556584A1 CA 2556584 A1 CA2556584 A1 CA 2556584A1 CA 002556584 A CA002556584 A CA 002556584A CA 2556584 A CA2556584 A CA 2556584A CA 2556584 A1 CA2556584 A1 CA 2556584A1
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CA
Canada
Prior art keywords
slurry
mixing device
cement
mixer
shear
Prior art date
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Granted
Application number
CA002556584A
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French (fr)
Other versions
CA2556584C (en
Inventor
Michel Rigaudon
Joerg Bold
Steven Roy Butler
Eric Millamon
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Etex Building Performance International SAS
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Individual
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Publication of CA2556584A1 publication Critical patent/CA2556584A1/en
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Publication of CA2556584C publication Critical patent/CA2556584C/en
Expired - Fee Related legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28C—PREPARING CLAY; PRODUCING MIXTURES CONTAINING CLAY OR CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28C5/00—Apparatus or methods for producing mixtures of cement with other substances, e.g. slurries, mortars, porous or fibrous compositions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
    • B01F27/00—Mixers with rotary stirring devices in fixed receptacles; Kneaders
    • B01F27/05—Stirrers
    • B01F27/09—Stirrers characterised by the mounting of the stirrers with respect to the receptacle
    • B01F27/091—Stirrers characterised by the mounting of the stirrers with respect to the receptacle with elements co-operating with receptacle wall or bottom, e.g. for scraping the receptacle wall
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
    • B01F27/00—Mixers with rotary stirring devices in fixed receptacles; Kneaders
    • B01F27/60—Mixers with rotary stirring devices in fixed receptacles; Kneaders with stirrers rotating about a horizontal or inclined axis
    • B01F27/73—Mixers with rotary stirring devices in fixed receptacles; Kneaders with stirrers rotating about a horizontal or inclined axis with rotary discs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
    • B01F33/00—Other mixers; Mixing plants; Combinations of mixers
    • B01F33/80—Mixing plants; Combinations of mixers
    • B01F33/82—Combinations of dissimilar mixers
    • B01F33/821—Combinations of dissimilar mixers with consecutive receptacles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
    • B01F35/00—Accessories for mixers; Auxiliary operations or auxiliary devices; Parts or details of general application
    • B01F35/71—Feed mechanisms
    • B01F35/717—Feed mechanisms characterised by the means for feeding the components to the mixer
    • B01F35/71775—Feed mechanisms characterised by the means for feeding the components to the mixer using helical screws
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28C—PREPARING CLAY; PRODUCING MIXTURES CONTAINING CLAY OR CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28C5/00—Apparatus or methods for producing mixtures of cement with other substances, e.g. slurries, mortars, porous or fibrous compositions
    • B28C5/08—Apparatus or methods for producing mixtures of cement with other substances, e.g. slurries, mortars, porous or fibrous compositions using driven mechanical means affecting the mixing
    • B28C5/10—Mixing in containers not actuated to effect the mixing
    • B28C5/12—Mixing in containers not actuated to effect the mixing with stirrers sweeping through the materials, e.g. with incorporated feeding or discharging means or with oscillating stirrers
    • B28C5/1238—Mixing in containers not actuated to effect the mixing with stirrers sweeping through the materials, e.g. with incorporated feeding or discharging means or with oscillating stirrers for materials flowing continuously through the mixing device and with incorporated feeding or discharging devices
    • B28C5/1269—Mixing in containers not actuated to effect the mixing with stirrers sweeping through the materials, e.g. with incorporated feeding or discharging means or with oscillating stirrers for materials flowing continuously through the mixing device and with incorporated feeding or discharging devices for making cellular concrete
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28C—PREPARING CLAY; PRODUCING MIXTURES CONTAINING CLAY OR CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28C5/00—Apparatus or methods for producing mixtures of cement with other substances, e.g. slurries, mortars, porous or fibrous compositions
    • B28C5/38—Apparatus or methods for producing mixtures of cement with other substances, e.g. slurries, mortars, porous or fibrous compositions wherein the mixing is effected both by the action of a fluid and by directly-acting driven mechanical means, e.g. stirring means ; Producing cellular concrete
    • B28C5/381—Producing cellular concrete
    • B28C5/383—Producing cellular concrete comprising stirrers to effect the mixing
    • 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
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/14—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements
    • 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
    • C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
    • 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
    • C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
    • C04B38/007—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof characterised by the pore distribution, e.g. inhomogeneous distribution of pores
    • C04B38/0074—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof characterised by the pore distribution, e.g. inhomogeneous distribution of pores expressed as porosity percentage
    • 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
    • C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
    • C04B38/007—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof characterised by the pore distribution, e.g. inhomogeneous distribution of pores
    • C04B38/0077—Materials with a non-porous skin
    • 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
    • C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
    • C04B38/10—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by using foaming agents or by using mechanical means, e.g. adding preformed foam
    • 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
    • C04B40/00—Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability
    • 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
    • C04B40/00—Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability
    • C04B40/0028—Aspects relating to the mixing step of the mortar preparation
    • 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
    • C04B40/00—Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability
    • C04B40/0028—Aspects relating to the mixing step of the mortar preparation
    • C04B40/005—High shear mixing; Obtaining macro-defect free materials
    • 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
    • C04B40/00—Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability
    • C04B40/06—Inhibiting the setting, e.g. mortars of the deferred action type containing water in breakable containers ; Inhibiting the action of active ingredients
    • C04B40/0658—Retarder inhibited mortars activated by the addition of accelerators or retarder-neutralising agents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
    • B01F27/00—Mixers with rotary stirring devices in fixed receptacles; Kneaders
    • B01F27/60—Mixers with rotary stirring devices in fixed receptacles; Kneaders with stirrers rotating about a horizontal or inclined axis
    • B01F27/61—Mixers with rotary stirring devices in fixed receptacles; Kneaders with stirrers rotating about a horizontal or inclined axis about an inclined axis
    • 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
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00612—Uses not provided for elsewhere in C04B2111/00 as one or more layers of a layered structure
    • C04B2111/0062—Gypsum-paper board like materials

Abstract

The invention provides a process for manufacturing set cellular cement, comprising the steps of: (i) mixing cementitious material, water, foaming agent and optionally additives into a free flowing slurry having a slump of at least 100mm; subsequently (ii) injecting and distributing air into the slurr y of step (i) to form a cellular slurry; subsequently (iii) casting said cellular slurry of step (ii); and finally allowing said cellular slurry to set. The invention also provides apparatus for carrying out the process of t he invention.

Claims (54)

1. A continuous process for manufacturing set cellular cement, comprising the steps of:
(i) mixing cementitious material, water, foaming agent and optionally additives into a free flowing slurry having a slump of at least 100mm; subsequently (ii) injecting and distributing air into the slurry of step (i) to form a cellular slurry; subsequently (iii) casting said cellular slurry of step (ii); and finally (iv) allowing said cellular slurry to set.
2. The process of claim 1, in which step (i) is performed in the absence of fiber.
3. The process of claim 1, in which step (i) is performed in the presence of fibers.
4. The process of any one of claims 1 to 3, in which step (i) is performed under high-shear mixing conditions.
5. The process of any one of claims 1 to 4, in which step (ii) is performed under controlled-shear mixing conditions.
6. The process of claim 5, in Which step (ii) is performed under low-shear mixing conditions.
7. The process of any one of claims 1 to 6, in which step (i) is earned out in the absence of added prefabricated foam.
8. The process of any one of claims 1 to 6, in which step (i) is carried out in the presence of added prefabricated foam.
9. The process of any one of claims 1 to 8, in which the slump of the slurry obtained at step (i), is at least 150mm.
10. The process of any one of claims 1 to 9, in which the slump of the slurry obtained at step (i), is from 200 to 250mm.
11. The process of any one of claims 1 to 10, in which, in the final set product, the pores volume created by water voids ranges from 20 to 65%vol and the cell volume created by injected air ranges from 3 to 50%vol.
12. The process of any one of claims 1 to 11, in which, in the final set product, the total pore volume ranges is between 47 and 95%vol.
13. The process of any one of claims 1 to 11, in which, in the final set product, the total pore volume ranges from 53 to 75%vol.
14. The process of any one of claims 1 to 13, in which the water to cement ratio is comprised from 0,25 to 1,1, preferably from 0,45 to 0,85.
15. The process of any one of claims 1 to 14, in which the cement is calcium sulfate .alpha.-hemi-hydrate, calcium sulfate .beta.-Hemi-hydrate or a blend thereof.
16. The process of any one of claims 1 to 15, in which the cement further comprises at least one aggregate and/or at least one filler.
17. The process of any one of claims 1 to 16, which comprises adding a retarder and an accelerator for the setting of the cement in step (i).
18. The process of any one of claims 1 to 16, in which step (i) further comprises the step of retarding the setting of cement while step (ii) further comprises the step of accelerating the setting of cement.
19. The process of claim 17 or 18, in which the cement is plaster and retarding the setting of plaster is obtained by adding a conventional plaster retarder prior to or concurrently with step (i) and accelerating the setting of the plaster is obtained by adding BMA prior to or concurrently with step (ii).
20. The process of claim 17 or 18, in which the cement is plaster and retarding the setting of plaster is obtained by adding sodium palyacrylate prior to or concurrently with step (i) and accelerating the setting of plaster is obtained by adding aluminum sulfate prior to or concurrently with step (ii).
21. The process of claim 17 or 18, in which the cement is plaster and retarding the setting of plaster is obtained by adding sodium phosphonate prior to or concurrently with step (i) and accelerating the setting of cement is obtained by adding zinc sulfate prior to or concurrently with step (ii).
22. The process of any one of claims 1 to 21, in which step (i) and/or step (ii) further comprises the step of adding a strength enhancing resin into the slurry.
23. The process of claim 22, in which the strength enhancing resin is a styrene-butadiene copolymer.
24. The process of any one of claims 1 to 23, in which step (i) and/or step (ii) further comprises the step of adding a bubble stabilizing agent into the slurry.
25. The process of any one of claims 1 to 24, in which step (i) and/or step (ii) further comprises the step of adding a water-soluble viscosity modifier into the slurry.
26. The process of any one of claims 1 to 25, in which step (i) comprises two sub-steps (a) and (b), where sub-step (a) comprises the step of mixing cementitious material, water and optionally additives and sub-step (b) comprises the step of adding the foaming agent to the slurry of sub-step (a).
27. The process of claim 26, in which sub-step (a) further comprises the step of adding a retarder while sub-step (b) further comprises the step of adding an accelerator.
28. The process of claim 26 or 27, in which sub-step (a) is performed under high-shear mixing conditions.
29. The process of claim 26 or 27, in which sub-step (b) is performed under low or controlled-shear mixing conditions.
30. The process of any one of claims 1 to 29, which comprises, between step (i) and step (ii), a step of spreading the slurry of step (i) prior to the introduction of air.
31. The process of any one of claims 1 to 30, in which step (iii) comprises the step of depositing said slurry on at least one moving facer to form a cellular core.
32. The process of any one of claims 1 to 31, in which step (iii) comprises the step of depositing said slurry on at least one moving facer to form a cellular core and which further comprises diverting part of the slurry obtained in step (i) as a stream which is deposited contiguously to the cellular core.
33. The process of any one of claims 1 to 31, in which step (iii) comprises the step of depositing said slurry on at least one moving facer to form a cellular core and which further comprises diverting part of the slurry obtained in step (i) as a stream which is deposited onto and/or beneath the cellular core.
34. The process of any one of claims 31 to 33, in which the moving facer is paper.
35. The process of any one of claims 31 to 34, further comprising the step of removing the facer after the cement has set.
36. The process of any one of claims 31 to 33, in which the moving facer is a non-woven mat, preferably a glass mat.
37. The process of any one of claims 1 to 36, in which step (ii) comprises the sub step of expanding air between injecting and distributing.
38. A mixing device for manufacturing a cellular cement slurry, comprising (i) at least one first mixing device comprising a cement inlet and a water and foaming agent inlet, said first mixer being a high-shear mixer operated under conditions to prepare a fluid slurry;
and (ii) at least one second mixing device comprising air injection means, said second mixer being operated under controlled-shear conditions.
39. A mixing device for manufacturing a cellular cement slurry, comprising (i) at least one first mixing device comprising a cement inlet and a water inlet, said first mixer being a high-shear mixer operated under conditions to prepare a fluid slurry;

(ii) at least one further first mixing device comprising a fluid slurry inlet and a foaming agent inlet; and (iii) at least one second mixing device comprising air injection means, said second mixer being operated under controlled-shear conditions.
40. The mixing device of claim 39 in which the at least one further first mixing device of (ii) is incorporated into the high-shear mixer of (i).
41. The mixing device of claim 39 in which the at least one further first mixing device of (ii) is incorporated into the controlled-shear mixer of (iii).
42. The mixing device of any one of claims 38 to 41, in which the second mixer is operated under low-shear conditions.
43. The mixing device of claim 42, in which the controlled-shear conditions comprise shear conditions adapted to create the desired cellular structure.
44. The mixing device of any one of claims 38 to 43, in which the first mixer comprises metering and feeding means, connected to a high-shear rotating mixing means.
45. The mixing device of any one of claims 38 to 44, in which the first mixer comprises a concentrically or eccentrically rotating disc in a circular housing.
46. The mixing device of any one of claims 38 to 44, in which the first mixer comprises a turbine.
47. The mixing device of any one of claims 38 to 46, in which the air is injected into the second mixer by means of porous, fritted parts.
48. The mixing device of any one of claims 38 to 46, in which the air is injected into the second mixer by means of one or several nozzles.
49. The mixing device of any one of claims 38 to 46, in which the slurry and the air are feed through a tee, said tee being equipped with one or several nozzles.
50. The mixing device of any one of claims 38 to 49, in which the second controlled-shear mixer comprises an elongated body, air injection means located at the bottom part of said elongated body, and blending means along the axis of said elongated body.
51. The mixing device of claim 50, in which the blending means comprises an axis and rigid or flexible wires disposed at spaced intervals and linked to said axis.
52. The mixing device of any one of claims 38 to 51, in which the second mixer comprises means for spreading the slurry coming from said first high-shear mixer.
53. The mixing device of claim S2, further comprising means for spreading the cellular slurry coming from said second controlled-shear mixer onto a moving facing material.
54. An apparatus for manufacturing a set foamed cement body, comprising (a) at least one mixer according to any one of claims 38 to 53, (b) means for casting a cellular slurry and (c) means for moving a facer.
CA2556584A 2004-02-24 2005-02-22 Process and apparatus for manufacturing set cellular cement Expired - Fee Related CA2556584C (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
EP04290494A EP1568671B9 (en) 2004-02-24 2004-02-24 Process and apparatus for manufacturing a set cellular cementitious body
EP04290494.6 2004-02-24
PCT/EP2005/002576 WO2005080294A1 (en) 2004-02-24 2005-02-22 Process and apparatus for manufacturing set cellular cement

Publications (2)

Publication Number Publication Date
CA2556584A1 true CA2556584A1 (en) 2005-09-01
CA2556584C CA2556584C (en) 2013-04-09

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CA2556584A Expired - Fee Related CA2556584C (en) 2004-02-24 2005-02-22 Process and apparatus for manufacturing set cellular cement

Country Status (18)

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US (2) US8119207B2 (en)
EP (1) EP1568671B9 (en)
KR (1) KR101183916B1 (en)
CN (1) CN1922120B (en)
AR (1) AR050763A1 (en)
AT (1) ATE463471T1 (en)
AU (1) AU2005213907B2 (en)
BR (1) BRPI0507231A (en)
CA (1) CA2556584C (en)
DE (1) DE602004026400D1 (en)
DK (1) DK1568671T3 (en)
ES (1) ES2343958T3 (en)
PL (1) PL209099B1 (en)
PT (1) PT1568671E (en)
RU (1) RU2006130465A (en)
SI (1) SI1568671T1 (en)
WO (1) WO2005080294A1 (en)
ZA (1) ZA200606856B (en)

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