Narrow PSD hydraulic cement, cement-SCM blends, and methods for making same
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
C04B-007/00
C04B-014/00
C04B-024/00
C04B-024/10
C04B-014/40
C04B-007/32
C04B-007/36
C04B-009/11
C04B-011/28
C04B-028/06
C04B-018/06
C04B-009/12
C04B-028/00
C04B-028/04
C04B-007/14
C04B-007/19
C04B-011/00
C04B-028/14
출원번호
US-0315089
(2011-12-08)
등록번호
US-8377201
(2013-02-19)
발명자
/ 주소
Guynn, John M.
Hansen, Andrew S.
출원인 / 주소
Roman Cement, LLC
인용정보
피인용 횟수 :
6인용 특허 :
29
초록▼
Hydraulic cements, such as Portland cements and other cements that include substantial quantities of tricalcium silicate (C3S), dicalcium silicate (C2S), tricalcium aluminate (C3A), and/or tetracalcalcium alumino-ferrite (C4AF), are particle size optimized to have increased reactivity compared to ce
Hydraulic cements, such as Portland cements and other cements that include substantial quantities of tricalcium silicate (C3S), dicalcium silicate (C2S), tricalcium aluminate (C3A), and/or tetracalcalcium alumino-ferrite (C4AF), are particle size optimized to have increased reactivity compared to cements of similar chemistry and/or decreased water demand compared to cements of similar fineness. Increasing hydraulic cement reactivity increases early strength development and release of reactive calcium hydroxide, both of which enhance SCM replacement and 1-28 day strengths compared to blends of conventional Portland cement and one or more SCMs, such as coal ash, slag or natural pozzolan. Decreasing the water demand can improve strength by decreasing the water-to-cement ratio for a given workability. The narrow PSD cements are well suited for making blended cements, including binary, ternary and quaternary blends.
대표청구항▼
1. A cement-SCM composition, comprising: a narrow PSD hydraulic cement fraction comprising: a plurality of hydraulic cement particles comprising one or more minerals that, when mixed with water, react to form a cementitious binder comprised of at least one of calcium silicate hydrates or calcium alu
1. A cement-SCM composition, comprising: a narrow PSD hydraulic cement fraction comprising: a plurality of hydraulic cement particles comprising one or more minerals that, when mixed with water, react to form a cementitious binder comprised of at least one of calcium silicate hydrates or calcium aluminum hydrates,the hydraulic cement particles in the narrow PSD hydraulic cement fraction having a particle size distribution (PSD) defined by a lower endpoint d10, an average particle size, and an upper endpoint d90,wherein the upper endpoint d90 of the PSD of the hydraulic cement particles is in a range of 11 μm to 30 μm and the lower endpoint d10 of the PSD of the hydraulic cement particles is equal to or greater than 2 μm,wherein the d90 and d10 are selected so that the PSD of the hydraulic cement particles has a ratio d90/d10 of less than or equal to 14.5; andone more types of supplementary cementitious material (SCM) particles selected from the group consisting of pozzolans, fly ash, slag, ground granulated blast-furnace slag, natural pozzolans, artificial pozzolans, limestone, ground limestone, ground quartz, ground filler materials, and pulverized fuel ash, the one or more types of SCM particles comprising: a coarse SCM fraction comprising coarse SCM particles having an average particle size greater than the average particle size of the hydraulic cement particles so that greater than 50% of particles larger than 20 μm provided by the coarse SCM fraction and hydraulic cement fraction comprise the coarse SCM particles and the average particle size of the coarse SCM fraction is in a range of about 1.25 times to about 25 times the average particle size of the hydraulic cement fraction, andan ultrafine SCM fraction comprising SCM particles having a particle size so that at least 50% of particles smaller than 3 μm provided by the ultrafine SCM fraction and the hydraulic cement fraction comprise the ultrafine SCM particles. 2. A cement-SCM composition as in claim 1, wherein the ratio d90/d10 of the hydraulic cement particles in the hydraulic cement fraction is less than or equal to 13. 3. A cement-SCM composition as in claim 1, wherein the ratio d90/d10 of the hydraulic cement particles in the hydraulic cement fraction is less than or equal to 11.5. 4. A cement-SCM composition as in claim 1, wherein the ratio d90/d10 of the hydraulic cement particles in the hydraulic cement fraction is less than or equal to 9. 5. A cement-SCM composition as in claim 4, wherein the ratio d90/d10 of the hydraulic cement particles in the hydraulic cement fraction is less than or equal to 7. 6. A cement-SCM composition as in claim 1, wherein the hydraulic cement particles in the hydraulic cement fraction consist essentially of Portland cement and/or hydraulic cement having a tricalcium silicate content of at least about 50% by weight. 7. A cement-SCM composition as in claim 6, wherein the upper endpoint d90 is in a range of 12.5 μm to 30 μm, the lower endpoint d10 is equal to or greater than 3 μm, and the range d90/d10 is less than or equal to 10. 8. A cementitious composition formed according to the following method: obtaining or forming the cement-SCM composition as in claim 1, wherein the cement-SCM composition is either a preblended composition comprising the narrow PSD hydraulic cement fraction preblended with the coarse and ultrafine SCM fractions so as to form the cement-SCM composition prior to mixing the cement-SCM composition with water and aggregate or the cement-SCM composition is formed in situ within a freshly mixed cementitious composition; andforming a fresh cementitious mixture comprising mixture products of the narrow PSD hydraulic cement fraction, the coarse and ultrafine SCM fractions, water, and aggregate. 9. A method of manufacturing the cement-SCM composition of claim 1, comprising: obtaining cement clinker comprising one or more cement minerals that, when mixed with water, react to form a cementitious binder;initially comminuting the cement clinker to form an initially ground cement material;separating the initially ground cement material into a coarse cement fraction and a first fine cement fraction;further comminuting the coarse cement fraction to form a second fine cement fraction;blending the first and second fine cement fractions together to form the narrow PSD hydraulic cement fraction of the cement-SCM composition; andcombining the narrow PSD hydraulic cement fraction with the coarse and ultrafine SCM fractions to form the cement-SCM composition. 10. A method as in claim 9, wherein at least one of the steps of initially comminuting or further comminuting is performed in a roll press, and wherein the steps of initially comminuting, separating, further comminuting, and blending are performed in a continuous grinding-classification circuit that continuously grinds, classifies, and regrinds. 11. A method of manufacturing a cementitious composition, comprising: obtaining or forming the cement-SCM composition as in claim 1, wherein the cement-SCM composition is either a preblended composition comprising the narrow PSD hydraulic cement fraction preblended with the coarse and ultrafine SCM fractions so as to form the cement-SCM composition prior to mixing the cement-SCM composition with water and aggregate or the cement-SCM composition is formed in situ within a freshly mixed cementitious composition; andforming a fresh cementitious mixture comprising mixture products of the narrow PSD hydraulic cement fraction, the coarse and ultrafine SCM fractions, water, and aggregate. 12. A method as in claim 11, further comprising: placing the fresh cementitious mixture into a desired configuration; andallowing the fresh cementitious mixture to harden into a hardened cementitious composition. 13. A cement-SCM blend, comprising: a narrow PSD hydraulic cement fraction comprised of: a plurality of hydraulic cement particles comprising one or more minerals that, when mixed with water, react to form a cementitious binder comprised of at least one of calcium silicate hydrates or calcium aluminum hydrates,the hydraulic cement particles in the hydraulic cement composition having a particle size distribution (PSD) defined by a lower endpoint d10, an average particle size, a median particle size d50, and an upper endpoint d90,wherein the upper endpoint d90 of the PSD of the hydraulic cement particles is greater than 10 μm,wherein the median particle size d50 is equal to or greater than 6.5 μm,wherein the lower endpoint d10 of the PSD of the hydraulic cement particles is equal to or greater than 3 μm,wherein the PSD of the hydraulic cement particles has a ratio d90/d10 of less than or equal to 10, andwherein the d50/d10 is less than or equal to 6.85;a first supplementary cementitious material (SCM) fraction that provides coarse SCM particles having an average particle size greater than the average particle size of the hydraulic cement particles so that greater than 50% of particles larger than 20 μm provided by the first SCM fraction and the hydraulic cement fraction comprise the coarse SCM particles, the first SCM fraction being selected from the group consisting of natural pozzolans, artificial pozzolans, pulverized fuel ash, fly ash, slag, ground granulated blast-furnace slag, ground filler materials, and mixtures thereof; anda second supplementary cementitious material (SCM) fraction that provides ultrafine SCM particles having a particle size so that at least 50% of particles smaller than 3 μm provided by the second SCM fraction and the hydraulic cement fraction comprise the ultrafine SCM particles. 14. A method of manufacturing the cement-SCM blend of claim 13, comprising: forming the hydraulic cement fraction by: obtaining cement clinker comprising one or more cement minerals that, when mixed with water, react to form a cementitious binder comprised of at least one of calcium silicate hydrates or calcium aluminum hydrates;initially comminuting the cement clinker to form an initially ground cement material;separating the initially ground cement material into a coarse cement fraction and a first fine cement fraction;further comminuting the coarse cement fraction to form a second fine cement fraction; andblending the first and second fine cement fractions together to form the narrow PSD hydraulic cement fraction,wherein at least one of the steps of initially comminuting or further comminuting is performed in a roll press, and wherein the steps of initially comminuting, separating, further comminuting, and blending are performed in a continuous grinding-classification circuit that continuously grinds, classifies, and regrinds; andblending the narrow PSD hydraulic cement fraction with the first and second SCM fractions to form the cement-SCM blend. 15. A method as in claim 14, wherein the cement-SCM blend is formed prior to use in preparing a fresh cementitious composition comprising the cement-SCM blend, water, and aggregate. 16. A method as in claim 14, wherein the cement-SCM blend is formed in situ during preparation of a fresh cementitious composition comprising the narrow PSD hydraulic cement fraction, the first and second SCM fractions, water, and aggregate. 17. A cement-SCM blend, comprising: a narrow PSD hydraulic cement fraction comprised of: a plurality of hydraulic cement particles comprising one or more minerals that, when mixed with water, react to form a cementitious binder comprised of at least one of calcium silicate hydrates or calcium aluminum hydrates,the hydraulic cement particles in the hydraulic cement composition having a particle size distribution (PSD) defined by a d10, d50, d90, average particle size, and a ratio d90/d10 of less than or equal to 20,wherein the d10 is greater than or equal to 1.75 μm, the d50 is greater than or equal to 6.5 μm, and the d90 is greater than 10 μm;wherein the hydraulic cement particles are formed by obtaining a cement clinker and then grinding and classifying the cement clinker to within the PSD defined by the d10, d50, d90 and ratio d90/d10;a first supplementary cementitious material (SCM) fraction that provides coarse SCM particles having an average particle size that is about 1.25 times to about 25 times greater than the an average particle size of the hydraulic cement particles of the hydraulic cement fraction so that greater than 50% of particles larger than 20 μm provided by the first SCM fraction and the hydraulic cement fraction comprise the coarse SCM particles, wherein the first SCM fraction comprises at least one member selected from the group consisting of natural pozzolans, artificial pozzolans, pulverized fuel ash, fly ash, slag, ground granulated blast-furnace slag, inert filler materials, and mixtures thereof; anda second supplementary cementitious material (SCM) fraction that provides ultrafine SCM particles having a particle size so that at least 50% of particles smaller than 3 μm provided by the second SCM fraction and the hydraulic cement fraction comprise the ultrafine SCM particles. 18. A cement-SCM blend as in claim 17, wherein the narrow PSD hydraulic cement fraction is formed by a process comprising the steps of: initially comminuting the cement clinker to form an initially ground cement material;separating the initially ground cement material into a coarse cement fraction and a first fine cement fraction;further comminuting the coarse cement fraction to form a second fine cement fraction; andblending the first and second fine cement fractions together to form the narrow PSD hydraulic cement fraction,wherein the steps of initially comminuting or further comminuting are performed by a roll press, and wherein the steps of initially comminuting, separating, further comminuting, and blending are performed in a continuous grinding-classification circuit that continuously grinds, classifies, and regrinds. 19. A cement-SCM blend as in claim 18, wherein the narrow PSD hydraulic cement fraction comprises Portland cement. 20. A cement-SCM blend as in claim 19, wherein the ultrafine SCM particles comprises an inert filler material that provides nucleation sites that promote formation of hydration products during hydration of the cement-SCM blend and a reactive SCM that reacts with excess calcium liberated from the hydraulic cement fraction during hydration of the cement-SCM blend, andwherein the coarse SCM particles comprises at least one of a non-reactive SCM or a reactive SCM.
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