阅读说明：本技术 制备用于生成建筑材料的钙矾石粘合剂的方法 (Method for preparing ettringite binder for forming building materials ) 是由 大卫·霍夫曼 于 2018-11-07 设计创作，主要内容包括：本发明涉及建筑材料领域。本发明尤其涉及由铝硅酸盐源、硫酸钙源和氢氧化钙(或熟石灰,CH)源制备钙矾石粘合剂的方法,所述粘合剂包含催化剂和/或活化剂。本发明还涉及通过根据本发明的方法生产的钙矾石粘合剂用于生产水泥、砌筑水泥、砂浆、混凝土、道路粘合剂和/或配制型石灰的用途。(The invention relates to the field of building materials. The invention relates in particular to a process for preparing an ettringite binder from an aluminosilicate source, a calcium sulphate source and a calcium hydroxide (or hydrated lime, CH) source, said binder comprising a catalyst and/or an activator. The invention also relates to the use of the ettringite binder produced by the method according to the invention for producing cement, masonry cement, mortar, concrete, road binders and/or formulated lime.)

1. An ettringite binder comprising:

-at least one source of aluminosilicate;

-at least one source of calcium sulphate;

-at least one source of calcium hydroxide; and

-at least one activator chosen from compounds suitable for complexing cations, preferably compounds suitable for complexing calcium, aluminium and/or silicon.

2. The ettringite binder according to claim 1, wherein the activator is selected from sucrose, alpha hydroxy acids or salts thereof, ethanolamine or salts thereof, and/or catechol and derivatives thereof.

3. The ettringite binder of claim 1 or claim 2, further comprising an alkali catalyst, preferably an alkali catalyst selected from sodium fluoride, sodium aluminate, trisodium phosphate, sodium orthosilicate, sodium metasilicate, sodium hexafluorosilicate, sodium fluorophosphate, sodium hexametaphosphate, sodium carbonate, sodium borate, sodium hexafluoroaluminate, potassium tetrafluoroaluminate, or mixtures thereof.

4. The ettringite binder of claim 3, wherein the amount by mass of the catalyst is in the range of greater than 0% to 20% relative to the total amount of binder.

5. The ettringite binder according to any one of claims 1 to 4, wherein the source of aluminosilicate is a pozzolan, a fine powder of ash derived from fireclay production or paper sludge, preferably metakaolin.

6. The ettringite binder of any one of claims 1-5, wherein the source of calcium hydroxide is hydrated lime, hydraulic lime, quicklime, delayed effect quicklime, air lime, regular hydrated lime or any commercially available lime.

7. The ettringite binder according to any of claims 1 to 6, wherein the source of calcium sulphate is selected from anhydrous gypsum, natural gypsum or gypsum obtained as a by-product of industrial reactions, such as desulphated gypsum, titanium gypsum, fluorgypsum or phosphogypsum.

8. The ettringite binder according to any one of claims 1 to 7, further comprising an additive, preferably slag, more preferably blast furnace slag or amorphous aluminate slag.

9. The ettringite binder of any one of claims 1 to 8, wherein the source of aluminosilicate is characterized by a pozzolanic activity Index (IPZ) as determined by the Chapelle test method of from 200 to 2200 mg/g.

10. Method for preparing an ettringite binder according to any one of claims 1 to 9, comprising mixing at least the following:

-a source of aluminosilicate;

-a source of calcium sulphate;

-a source of calcium hydroxide; and

-at least one activator chosen from compounds suitable for complexing cations, preferably compounds suitable for complexing calcium, aluminium and/or silicon.

11. The method of claim 10, wherein the mixing is carried out at a temperature of from greater than 0 ℃ to 50 ℃, preferably from 10 ℃ to 40 ℃, more preferably about 25 ℃.

12. Use of the ettringite binder according to any one of claims 1 to 9 for the preparation of cement, masonry cement, mortar, concrete, road binder and/or formulated lime.

Technical Field

The invention relates to the field of building materials. The invention particularly relates to a process for the preparation of an ettringite binder from an aluminosilicate source, a calcium sulphate source and a calcium hydroxide (or hydrated lime, CH) source, said binder comprising a catalyst and/or an activator.

The invention also relates to the use of the ettringite binder produced by the method according to the invention for producing cement, masonry cement, mortar, concrete, road binders and/or formulated lime.

Background

In response to the needs in this field, the preparation of building materials such as, for example, concrete or cement requires the availability of innovative binders.

Among the known and used binders, ettringite binders have the advantage of hardening rapidly when mixed with water, while providing materials with low shrinkage and good chemical resistance.

These adhesives are prepared mainly according to two methods: by hydrated canasite (Ye' elemite) -based clinker (WO88/04285) or by formulation from high alumina cement (WO 03/091179).

The first method, through hydration, requires clinker production at high temperatures (1200-. The second method, by formulation, requires the use of multiple additives and expensive raw materials.

Therefore, there is a need to provide a method for preparing ettringite binders that is easy to implement and that is less energy-costly. In particular, it would be desirable to provide a method for preparing ettringite binders without the need for heating. Furthermore, there is a need to provide a more economical process that can be carried out using readily available and inexpensive raw materials and that has a smaller carbon footprint than prior art processes. For this purpose, the applicant has in particular sought to provide a process for preparing an ettringite binder obtainable without using portland cement. In fact, its production also requires many resources and produces a non-negligible amount of contaminants, making it unsuitable for use in the preparation of adhesives with a reduced carbon footprint.

Surprisingly, the applicant has shown that a mixture comprising at least a source of aluminosilicate, a source of calcium sulphate and a source of lime, characterized in that the stoichiometric ratio of the available calcium sulphate (RMK) in the mixture is in the range of 0.05 to 1.25, and the saturation level of calcium hydroxide sat (ch) is in the range of 0.75 to 8, makes it possible to prepare a stable ettringite binder.

Furthermore, the applicant has shown that a mixture comprising at least a source of aluminosilicate, a source of calcium sulphate and a source of calcium hydroxide, in the presence of an activator chosen from compounds capable of complexing with cations such as calcium, aluminium and/or silicon, allows to obtain materials having a higher compressive strength and an optimal yield than conventional ettringite binders.

Advantageously, the method according to the invention enables the production of ettringite binder and/or stabilized ettringite. In addition, during the use of the ettringite binder and/or ettringite of the invention in the production of building materials, this does not lead to any swelling of the final material over time, while exhibiting better mechanical properties than conventional pozzolanic binders.

Disclosure of Invention

Accordingly, the present invention relates to an ettringite binder comprising:

-at least one source of aluminosilicate;

-at least one source of calcium sulphate;

-at least one source of calcium hydroxide; and

-at least one activator chosen from compounds suitable for complexing cations, preferably compounds suitable for complexing calcium, aluminium and/or silicon.

According to one embodiment, the activator is selected from sucrose, alpha-hydroxy acids or salts thereof, ethanolamine or salts thereof, and/or catechol and derivatives thereof.

According to one embodiment, the binder further comprises an alkaline catalyst, preferably an alkaline catalyst selected from sodium fluoride, sodium aluminate, trisodium phosphate, sodium orthosilicate, sodium metasilicate, sodium hexafluorosilicate, sodium fluorophosphate, sodium hexametaphosphate, sodium carbonate, sodium borate, sodium hexafluoroaluminate, potassium tetrafluoroaluminate, or mixtures thereof.

According to one embodiment, the amount by mass of the catalyst is in the range of more than 0% to 20% relative to the total amount of the binder.

According to one embodiment, the aluminosilicate source is a pozzolan, a fine powder of ash derived from fireclay production or paper sludge, preferably metakaolin.

According to one embodiment, the calcium hydroxide source is hydrated lime, hydraulic lime, quicklime, delayed effect quicklime, air lime, regular hydrated lime or any commercially available lime.

According to one embodiment, the calcium sulphate source is selected from anhydrous gypsum, natural gypsum or gypsum obtained as a by-product of an industrial reaction, such as desulphated gypsum, titanium gypsum, fluorgypsum or phosphogypsum.

According to one embodiment, the binder further comprises an additive, preferably slag, more preferably blast furnace slag or amorphous aluminate slag.

According to one embodiment, the aluminosilicate source is characterized by a pozzolanic activity Index (IPZ) of 200mg/g to 2200mg/g as determined by the Chapelle test method.

According to one embodiment, the mixture (aluminosilicate source/calcium sulfate source/calcium hydroxide source) comprises or consists of: with respect to the total mass of the mixture,

-50% by mass of flash metakaolinIts IPZ is equal to about 800 mg/g;

-25% by mass of lime; and

-25% by mass of gypsum.

According to one embodiment, the mixture (aluminosilicate source/calcium sulfate source/calcium hydroxide source) comprises or consists of: with respect to the total mass of the mixture,

-60% by mass of flash metakaolinIts IPZ is equal to about 800 mg/g;

-30% by mass of lime; and

-10% by mass of gypsum.

The invention also relates to a process for preparing an adhesive as described above, comprising mixing at least the following:

-a source of aluminosilicate;

-a source of calcium sulphate;

-a source of calcium hydroxide; and

-at least one activator chosen from compounds suitable for complexing cations, preferably compounds suitable for complexing calcium, aluminium and/or silicon.

According to one embodiment, the mixing is carried out at a temperature of from greater than 0 ℃ to 50 ℃, preferably from 10 ℃ to 40 ℃, more preferably about 25 ℃.

As mentioned above, the invention also relates to the use of the ettringite binder according to the invention for the preparation of cement, masonry cement, mortar, concrete, road binder and/or formulated lime.

Definition of

In the present invention, the following terms are defined in the following manner:

"alpha-hydroxy acid" relates to a carboxylic acid comprising a hydroxyl group (-OH) on the carbon adjacent to the carboxylic acid function.

"activator" relates to any product capable of increasing the reaction yield during the formation of ettringite.

"aluminosilicates" relate to mineral compounds of the silicate family in which some of the silicon (Si) atoms have been replaced by aluminium atoms.

"Anhydrous gypsum" relates to anhydrous calcium sulphate, empirical formula CaSO₄A mineral or chemical compound of (a).

"concrete" means a mortar in which the aggregates have a size greater than 4 mm.

"catalyst" refers to any chemical substance that participates in a chemical reaction to increase the rate but is regenerated or removed during or at the end of the reaction. According to one embodiment, "catalyst" refers to any chemical substance capable of accelerating the rate of reaction between a source of aluminosilicate (e.g., metakaolin) and a source of calcium hydroxide (e.g., hydrated lime); preferably in order to obtain calcium aluminate.

- "base catalyst": to catalysts comprising at least one alkali element, i.e. at least one metal of the alkali metal family, preferably lithium (Li), sodium (Na), potassium (K), rubidium (Rb), cesium (Cs) or francium (Fr).

- "catechol" or "o-benzeneDiphenol "or" 1, 2-benzenediol ": involving an empirical formula of C₆H₄(OH)₂The organic compound of (1).

- "sludge ash": relates to ash derived from the combustion of sludge obtained from pulp manufacture.

- "lime" or "air lime" or "hydrated lime": relates to calcium hydroxide of empirical formula Ca (OH)₂The mineral compound of (1). These terms refer to lime obtained by hydration of quicklime. According to one embodiment, these terms also refer to compounds having calcium hydroxide as the main component and containing solid impurities as minority compounds.

"natural hydraulic lime": relates to lime extracted with water and then with air, the lime being formed from calcareous deposits containing small amounts of clay.

- "quick lime": representing the anhydrous lime obtained from the lime kiln after pyrolysis at 900 c. The main compound of quicklime is calcium oxide (CaO).

- "delayed effect lime": to quicklime, which is prepared by a special solidification method and exhibits rehydration when contacted with water.

- "cement": relates to a hydraulic binder (i.e. mineral powder) which sets and hardens on contact with water or salt solutions.

- "masonry cement": to a cement whose properties have been modified so that it can be used directly in masonry.

- "complex-forming agent": to any product capable of complexing ions; the ion is preferably a cation; more preferably an alkaline earth metal cation. According to one embodiment, the complex forming agent is a compound capable of complexing the elements calcium (Ca), aluminum (Al) and silicon (Si).

- "desulfurized gypsum": it means gypsum obtained in the desulfurization process of combustion gases of coal and fuel oil, particularly in the case of thermal power plants and nuclear power plants. According to one embodiment, desulfurized gypsum is a manufacturing by-product (waste from thermal power plants).

- "calcium rock": denotes a mineral species consisting of calcium sulfate and aluminum hydrate,molecular formula is Ca₆Al₂(SO₄)₃(OH)₁₂26H₂O。

- "ethanolamine": relates to the formula HO- (CH)₂)₂-NH₂(monoethanolamine) of formula HO- (CH)₂)₂-NH-(CH₂)₂-OH (diethanolamine) or formula N [ (CH)₂)₂-OH]₂(triethanolamine).

- "fluorogypsum": representing the gypsum obtained during the hydrofluoric acid production. According to one embodiment, fluorogypsum is a byproduct (waste) of hydrofluoric acid manufacture.

- "Gypsum": relates to a dihydrate of calcium sulfate, the molecular formula of which is CaSO₄.2H₂O。

- "IPZ" or "pozzolanic index" or "pozzolanic activity index": represents the active part of an aluminosilicate (e.g. metakaolin), in other words calcium hydroxide Ca (OH) which can be immobilized in one gram of aluminosilicate₂The amount of (c). This index (expressed in mg/g) can be determined by methods known to the person skilled in the art, such as the Chapelle test (m.cyr and g.escadeilalas, http:// dspace.univ-tlement.dz/bitstream/112/624/1/Normalisation-du-metakolin-poirquoi-comment.pdf).

- "slag": slag is meant to be formed when metal is melted or processed by liquid means. The slag consists of a mixture of silicates, aluminates and lime, and optionally metal oxides (excluding iron oxides).

- "blast furnace slag": relates to any by-product of the steel industry formed during the production of cast iron from iron ore.

- "amorphous aluminate slag": to iron industry slags having a high aluminum content, which are cooled to make the structure amorphous.

- "hydraulic binder": to any powder mixture which, during its hydration, has the properties of curing and then hardening, obtaining mechanical properties such as compressive strength, tensile strength or adhesion.

- "calcium rock stone binder": relates to a hydraulic binder, the composition of whichThe component (3) CaO, Al, should be converted during hydration and provided as the main hydrate₂O₃.3CaSO₄.32H₂Ettringite of O.

- "metakaolin": to calcined and/or milled powders derived from clays. According to one embodiment, metakaolin is a calcined and ground powder derived from a clay consisting primarily of kaolinite. According to one embodiment, metakaolin is a powder consisting essentially of amorphous aluminosilicate particles consisting essentially of reactive Silica (SiO)₂) And alumina (Al)₂O₃) And (4) forming.

- "mortar": to formulations comprising or consisting of a binder, sand, water and optionally additives.

- "phosphogypsum": which represents gypsum formed during the manufacture of phosphoric acid from natural phosphates. According to one embodiment, phosphogypsum is a by-product (waste) of phosphoric acid manufacture.

- "pozzolan": to a natural or artificial siliceous aluminum material capable of being combined with lime at ambient temperature and in the presence of water.

- "RMK" is defined by the following equation:

wherein:

IPZ represents the pozzolan index of the aluminosilicate source;

q (MK) represents the mass of aluminosilicate present in the ettringite binder, preferably in grams; and

qm (C $) represents the molar amount of calcium sulfate present in the ettringite binder.

- "sucrose": represents a glucose molecule and a fructose molecule linked by a reducing group thereof and having the formula C₁₂H₂₂O₁₁The compound of (1).

- "Sat (CH)" denotes calcium hydroxide Ca (OH) in a given composition₂Mass saturation level of (2). Determined according to the following equation (e 1):

wherein:

q (CH) represents calcium hydroxide (Ca (OH) in the mixture according to the invention₂) In grams; and

qst (ch) represents the stoichiometric amount in grams of calcium hydroxide required for the reaction to form ettringite. The parameter qst (ch) may be determined according to the following equation (e 2):

wherein:

IPZ represents the pozzolan index described above;

q (MK) represents the amount in grams of metakaolin or aluminosilicate in the mixture; and

p (ch) represents the purity of the calcium hydroxide source, e.g. lime, e.g. in terms of calcium hydroxide.

- "calcium sulfate": relates to the formula CaSO₄The anhydrous mineral compound of (1).

- "titanium Gypsum": denotes gypsum formed during titanium manufacture, according to one embodiment titanium gypsum is a by-product (waste) during titanium manufacture.

"gypsum from demolition": denotes gypsum obtained by grinding gypsum board or all forms of building gypsum.

Drawings

Figure 1 is a graph showing the percentage increase in mechanical properties after 28 days, as a function of the value of the parameter RMK, with respect to a conventional pozzolanic composition, for an ettringite binder obtained from a mixture according to the invention.

Figure 2 is a graph showing the percentage increase in mechanical properties after 3 days (solid line) or 7 days (dashed line) as a function of the value of the parameter RMK, with respect to a conventional pozzolanic composition, for an ettringite binder obtained from a mixture of the invention.

Detailed description of the preferred embodiments

Method of producing a composite material

The invention therefore relates to a process for preparing a hydraulic binder, preferably an ettringite binder. According to one embodiment, the process of the invention relates to the preparation of a hydraulic binder for obtaining ettringite, preferably raw ettringite, as the main hydrate.

In particular, the present invention relates to a process for preparing a hydraulic binder or an ettringite binder, comprising the step of mixing at least:

-a source of aluminosilicate;

-a source of calcium sulphate; and

a source of calcium hydroxide (or lime).

According to one embodiment, the aluminosilicate source comprises or consists of an aluminosilicate. According to one embodiment, the aluminosilicate source comprises or consists of metakaolin, calcined clay, or fines derived from fireclay production. According to one embodiment, the method for preparing an ettringite binder does not comprise the use of portland cement. According to one embodiment, the source of aluminosilicate is a pozzolan derived from a fine powder of a fireclay production or paper sludge (stationery slurry) ash, preferably metakaolin.

According to one embodiment, the metakaolin is a commercial product, preferably the metakaolin is metakaolinMetakaolin clayArgicalM501.SokaOr an equivalent thereof. According to one embodiment, the aluminosilicate source is a fine powder from the fireclay industry.

According to one embodiment, the calcium sulphate is selected from anhydrite, natural gypsum or gypsum obtained as a by-product of an industrial reaction, such as desulphated gypsum, titanium gypsum, fluorgypsum or phosphogypsum. According to one embodiment, the calcium sulfate source comprises or consists of gypsum, anhydrite and/or stucco. According to one embodiment, the calcium sulfate source is alpha and/or beta stucco. According to one embodiment, the calcium sulphate source comprises or consists of anhydrite, preferably natural anhydrite.

According to one embodiment, the calcium hydroxide source is hydrated lime. According to one embodiment, the calcium hydroxide source is air lime. According to one embodiment, the calcium hydroxide source is hydraulic lime. According to one embodiment, the calcium hydroxide source is air lime. According to one embodiment, the calcium hydroxide source is obtained from slaked lime.

According to one embodiment, the calcium hydroxide source is selected from commercially available limes, for exampleCL80 lime,CL90 lime, LHOISTLime orCL90 slaked air lime.

According to one embodiment, the mixture (aluminosilicate source/calcium sulphate source/lime) may further comprise at least (i) a catalyst, preferably a base catalyst; (ii) a reaction activator; and/or (iii) a second additive, such as a filler, preferably a calcareous filler. According to one embodiment, the adhesive of the present invention may further comprise at least (i) a catalyst, preferably a basic catalyst; and (ii) an activator of the reaction, and/or (iii) a second additive, for example a supported, preferably limestone filler.

According to one embodiment, the second additive is a mineral filler, preferably selected from a calcareous filler, a siliceous filler or a granulated slag.

According to one embodiment, the invention relates to a process for preparing a hydraulic binder or an ettringite binder, comprising the step of mixing at least:

-a source of aluminosilicate;

-a source of calcium sulphate;

-a source of calcium hydroxide (or lime);

-and optionally a catalyst and/or an activator.

According to one embodiment, the invention relates to a process for preparing a hydraulic binder or an ettringite binder, comprising the step of mixing at least:

-a source of aluminosilicate;

-a source of calcium sulphate;

-a source of calcium hydroxide (or lime);

and optionally a catalyst and/or activator selected from the group consisting of basic aluminates and compounds suitable for complexing cations, especially calcium, such as sucrose, tartaric acid, citric acid, gluconic acid, mandelic acid, lactic acid or ethanolamines such as Triethanolamine (TEA).

According to one embodiment, the invention relates to a process for preparing a hydraulic binder or an ettringite binder, comprising the step of mixing at least:

-a source of aluminosilicate;

-a source of calcium sulphate;

-a source of calcium hydroxide (or lime);

and a mixture for accelerating curing, comprising a catalyst and/or an activator.

Advantageously, the addition of at least one catalyst and at least one activator to the binder allows to accelerate the curing of said binder during its hydration, obtaining a building material.

According to one embodiment, the invention relates to a process for preparing a hydraulic binder or an ettringite binder, comprising the step of mixing at least:

-a source of aluminosilicate;

-a source of calcium sulphate;

-a source of calcium hydroxide (or lime);

-sucrose;

-tartaric acid; and

alkaline aluminates, preferably sodium aluminate.

According to one embodiment, the mixture or binder of the present invention does not comprise oxalic acid, triethanolamine and/or potassium aluminate. According to one embodiment, the mixture or binder of the invention does not comprise tartaric acid and/or sucrose. According to one embodiment, the mixture or adhesive of the invention does not comprise mucic acid, malic acid, tartaric acid, citric acid, sucrose and/or hydroxypolycarboxylic acids.

According to one embodiment, the mixture or binder of the invention comprises:

flash metakaolin having an IPZ of 700 to 800mg/g

-hydrated lime of the CL90 type having a LEDUC lime content of about 90%; and

-gypsum.

According to one embodiment, the mixture or binder of the invention comprises:

argical of metakaolin

-quarry calcium sulfate;

-lime CL 90;

-a catalyst; and

-an activator.

According to one embodiment, the mixture or binder of the invention comprises:

flash metakaolin having an IPZ equal to about 700mg/g

-hydrated lime of the CL90 type having a LEDUC lime content of about 90%; and

-desulfurized gypsum; and

NaAl0 as catalyst₂(1.3％)。

According to one embodiment, the mixture comprises, by mass relative to the total mass of the mixture, from 0% to 20%, preferably from 0% to 15%, more preferably from 1% to 10% of catalyst. According to one embodiment, the mixture comprises, by mass relative to the total mass of the mixture, from 1% to 20%, preferably from 2% to 20%, from 3% to 20%, from 4% to 20%, from 5% to 20%, from 6% to 20%, from 7% to 20%, from 8% to 20%, from 9% to 20%, from 10% to 20%, from 11% to 20%, from 12% to 20%, from 13% to 20%, from 14% to 20%, from 15% to 20%, from 16% to 20%, from 17% to 20%, from 18% to 20%, from 19% to 20% of catalyst. According to one embodiment, the mixture comprises, by mass relative to the total mass of the mixture, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19 or 20% of catalyst. According to one embodiment, the binder comprises, by mass relative to the total mass of the binder, from 0% to 20%, preferably from 0% to 15%, more preferably from 1% to 10% of catalyst. According to one embodiment, the binder comprises, by mass relative to the total mass of the binder, from 1% to 20%, preferably from 2% to 20%, from 3% to 20%, from 4% to 20%, from 5% to 20%, from 6% to 20%, from 7% to 20%, from 8% to 20%, from 9% to 20%, from 10% to 20%, from 11% to 20%, from 12% to 20%, from 13% to 20%, from 14% to 20%, from 15% to 20%, from 16% to 20%, from 17% to 20%, from 18% to 20%, from 19% to 20% of catalyst. According to one embodiment, the binder comprises, by mass relative to the total mass of the binder, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19 or 20% of catalyst.

According to one embodiment, the mixture comprises, by mass relative to the total mass of the mixture, from 0% to 20%, preferably from 0% to 15%, more preferably from 1% to 10% of activator. According to one embodiment, the mixture comprises, by mass relative to the total mass of the mixture or the binder, from 1% to 20%, preferably from 2% to 20%, from 3% to 20%, from 4% to 20%, from 5% to 20%, from 6% to 20%, from 7% to 20%, from 8% to 20%, from 9% to 20%, from 10% to 20%, from 11% to 20%, from 12% to 20%, from 13% to 20%, from 14% to 20%, from 15% to 20%, from 16% to 20%, from 17% to 20%, from 18% to 20%, from 19% to 20% of activator. According to one embodiment, the mixture comprises, by mass relative to the total mass of the mixture, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19 or 20% of an activator. According to one embodiment, the adhesive comprises, by mass relative to the total mass of the adhesive, from 0% to 20%, preferably from 0% to 15%, more preferably from 1% to 10% of an activator. According to one embodiment, the mixture comprises, by mass relative to the total mass of the binder, preferably from 1% to 20%, preferably from 2% to 20%, from 3% to 20%, from 4% to 20%, from 5% to 20%, from 6% to 20%, from 7% to 20%, from 8% to 20%, from 9% to 20%, from 10% to 20%, from 11% to 20%, from 12% to 20%, from 13% to 20%, from 14% to 20%, from 15% to 20%, from 16% to 20%, from 17% to 20%, from 18% to 20%, from 19% to 20% of activator. According to one embodiment, the adhesive comprises, by mass relative to the total mass of the adhesive, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19 or 20% of an activator.

According to one embodiment, the binder comprises, by mass, more than 0% to 2%, preferably more than 0%; 0.1; 0.2; 0.3; 0.4; 0.5; 0.6; 0.7; 0.8; 0.9; 1.0; 1.1; 1.2; 1.3; 1.4; 1.5; 1.6; 1.7; 1.8; 1.9 or 2%; an activator and/or a catalyst.

According to one embodiment, the mixture comprises, in molar amount with respect to the total amount of the mixture, from 0% to 20%, preferably from 0% to 15%, more preferably from 1% to 10% of the activator. According to one embodiment, the mixture comprises, in molar amount with respect to the total amount of the mixture, from 1% to 20%, preferably from 2% to 20%, from 3% to 20%, from 4% to 20%, from 5% to 20%, from 6% to 20%, from 7% to 20%, from 8% to 20%, from 9% to 20%, from 10% to 20%, from 11% to 20%, from 12% to 20%, from 13% to 20%, from 14% to 20%, from 15% to 20%, from 16% to 20%, from 17% to 20%, from 18% to 20%, from 19% to 20% of the activator. According to one embodiment, the mixture comprises, in molar amount relative to the total amount of the mixture, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19 or 20% of an activating agent. According to one embodiment, the binder comprises, in molar amount with respect to the total amount of the binder, from 0% to 20%, preferably from 0% to 15%, more preferably from 1% to 10% of an activator. According to one embodiment, the adhesive comprises, in molar amount relative to the total amount of the adhesive, from 1% to 20%, preferably from 2% to 20%, from 3% to 20%, from 4% to 20%, from 5% to 20%, from 6% to 20%, from 7% to 20%, from 8% to 20%, from 9% to 20%, from 10% to 20%, from 11% to 20%, from 12% to 20%, from 13% to 20%, from 14% to 20%, from 15% to 20%, from 16% to 20%, from 17% to 20%, from 18% to 20%, from 19% to 20% of an activator. According to one embodiment, the binder comprises, by moles with respect to the total amount of binder, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19 or 20% of an activator.

According to one embodiment, the mixture comprises, by mass relative to the total mass of the mixture or the binder, from 1% to 30%, preferably from 5% to 20%, of a second additive. According to one embodiment, the mixture comprises, by mass relative to the total mass of the mixture or binder, from 1% to 30%, preferably from 2% to 30%, from 3% to 30%, from 4% to 30%, from 5% to 30%, from 6% to 30%, from 7% to 30%, from 8% to 30%, from 9% to 30%, from 10% to 30%, from 12% to 30%, from 13% to 30%, from 14% to 30%, from 15% to 30%, from 16% to 30%, from 17% to 30%, from 18% to 30%, from 19% to 30%, from 20% to 30%, from 21% to 30%, from 22% to 30%, from 23% to 30%, from 24% to 30%, from 25% to 30%, from 26% to 30%, from 27% to 30%, from 28% to 30% or from 29% to 30% of the second additive. According to one embodiment, the mixture comprises, by mass, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29 or 30% of additives with respect to the total mass of the mixture or the binder.

According to one embodiment, the addition of the second additive increases the mechanical properties, in particular the compressive strength, of the material obtained from the ettringite binder according to the invention by 1% to 100%, preferably by 5% to 60%, with respect to the same mixture according to the invention without the second additive.

Advantageously, the addition of the second additive in the mixture according to the invention results in a synergistic effect of the mechanical properties of the material obtained with the ettringite binder according to the invention. Advantageously, the addition of the second additive in the mixture according to the invention reduces the water requirement and changes the dimensional shrinkage during the use of the ettringite binder according to the invention.

According to one embodiment, the mixture according to the invention further comprises an adjuvant, preferably selected from water-reducing and/or superplasticizers, water-repellents, defoamers, air-entraining agents and/or fibers.

According to one embodiment, the water reducing agent and/or superplasticizer is a polymer; preferably selected from poly (meth) acrylates, polycarboxylates and/or polyolefins, such as Polyethylene (PE), or copolymers thereof; more preferably, the water reducing agent is selected from the products sold by the company SIKA: tempoTempoViscocreteViscocreteViscocreteViscocreteViscocreteViscocreteOr Viscocrete

According to one embodiment, the water reducing agent is not a lignosulfonate.

According to one embodiment, the waterproofing agent is selected from the group consisting of a polysiloxane and/or a carboxylate; preferably silicone and/or stearate. According to one embodiment, the water repellent is selected from the commercial product SIKA HydrofugeSIKADow Coming SHPDow Corning SHPAnd Dow Coming IEAccording to one embodiment, the water repellent is selected from magnesium stearate, calcium stearate and aluminium stearate.

According to one embodiment, the antifoaming agent is a siloxane, preferably poly (siloxane), more preferably Polydimethylsiloxane (PDMS).

According to one embodiment, the air entraining agent is selected from the commercial product SIKAPreferably SIKAAnd SIKAIn the present invention, the term "air entraining agent" refers to any compound or chemical formulation that allows fine bubbles to be entrained into the mixture, said air entraining agent providing bubbles having an average diameter of 10 to 500 microns according to one embodiment.

According to one embodiment, the fibers are selected from metal fibers, polymer fibers, such as polyethylene fibers, plant fibers and/or glass fibers.

According to one embodiment, the curing agent is selected from the commercial product Pieri Cure&Andin the present invention, a "cured product" refers to any compound capable of limiting the evaporation of water during the hardening of the concrete or mortar produced from the ettringite binder according to the invention.

According to one embodiment, the mould release oil is selected from natural or synthetic vegetable or mineral oils; preferably vegetable oil; more preferably, the Decoffre emulsion sold by SIKA oil sold by Deltapro

According to one embodiment, the ettringite binder is anhydrous. According to one embodiment, the ettringite binder does not comprise any amount of water sufficient to hydrate the compounds of the mixture and/or to achieve hardening of the ettringite binder. According to one embodiment, the ettringite binder further comprises water.

According to one embodiment, the ettringite binder or the mixture of the invention is characterized in that:

-calcium hydroxide saturation level, expressed as sat (ch), in the range of 0.75 to 8; and/or

-the stoichiometric ratio of calcium sulphate, expressed as RMK, ranging from 0.05 to 1.25; the parameter RMK is defined by the following equation:

wherein:

IPZ represents the pozzolan index of the aluminosilicate source;

q (mk) represents the amount in grams of aluminosilicate present in the ettringite binder; and

qm (C $) represents the molar amount of calcium sulfate present in the ettringite binder.

According to one embodiment, the pozzolanic index IPZ ranges from 200 to 2200mg/g, preferably from 400 to 2000mg/g, more preferably from 600 to 1800 mg/g. According to one embodiment, the pozzolanic index IPZ ranges from 200 to 2200mg/g, preferably 550 to 2200mg/g, 600 to 2200mg/g, 700 to 2200mg/g, 800 to 2200mg/g, 900 to 2200mg/g, 1000 to 2200mg/g, 1100 to 2200mg/g, 1200 to 2200mg/g, 1300 to 2200mg/g, 1400 to 2200mg/g, 1500 to 2200mg/g, 200 to 1900mg/g, 200 to 1800mg/g, 200 to 1700mg/g, 200 to 1600mg/g, 200 to 1500mg/g, 200 to 1400mg/g, 200 to 1300mg/g, 200 to 1200mg/g, 200 to 1100mg/g, 200 to 1000mg/g, 200 to 900 mg/g. According to one embodiment, the pozzolanic index IPZ is 600, 700, 800, 900, 1000, 1100, 1200, 1300 or 1400 mg/g.

According to one embodiment, the parameter RMK as defined above ranges from 0.05 to 1.25; preferably 0.1 to 1; more preferably 0.2 to 0.8. According to one embodiment, the parameter RMK as defined above is comprised between 0.1 and 1.25; 0.2 to 1.25; 0.3 to 1.25; 0.4 to 1.25; 0.5 to 1.25; 0.6 to 1.25; 0.7 to 1.25; 0.8 to 1.25; 0.9 to 1.25; 1 to 1.25. According to one embodiment, the parameter RMK as defined above is comprised between 0.1 and 1.25; 0.1 to 1.2; 0.1 to 1.25; 0.1 to 1.1; 0.1 to 1; 0.1 to 0.9; 0.1 to 0.8; 0.1 to 0.7; 0.1 to 0.6; 0.1 to 0.5; 0.1 to 0.4; 0.1 to 0.3; or 0.1 to 0.2. According to one embodiment, the parameter RMK as defined above ranges from 0.20 to 0.80; preferably 0.25 to 0.80; 0.30 to 0.80; 0.35 to 0.80; 0.40 to 0.80; 0.45 to 0.80; 0.50 to 0.80; 0.55 to 0.80; 0.60 to 0.80; 0.65 to 0.80; or 0.70 to 0.80. According to one embodiment, the parameter RMK as defined above ranges from 0.20 to 0.80; preferably 0.20 to 0.75; 0.20 to 0.70; 0.20 to 0.65; 0.20 to 0.60; 0.20 to 0.55; 0.20 to 0.50; 0.20 to 0.45; 0.20 to 0.40; 0.20 to 0.35; 0.20 to 0.30; or 0.20 to 0.25.

According to one embodiment, the parameter sat (ch) as defined above ranges from 0.75 to 20, preferably from 1 to 15. According to one embodiment, the parameter sat (ch) as defined above is 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19 or 20. According to one embodiment, the parameter sat (ch) as defined above ranges from 0.75 to 8, preferably from 1 to 8; 2 to 8; 3 to 8; 4 to 8; 5 to 8; 6 to 8; or 7 to 8. According to one embodiment, the parameter sat (ch) is equal to 1, 2, 3, 4, 5, 6, 7 or 8. According to one embodiment, the parameter sat (ch), as defined above, ranges from 0.75 to 8; 0.75 to 7; 0.75 to 6; 0.75 to 5; 0.75 to 4; 0.75 to 3; 0.75 to 2; or 0.75 to 1.

According to one embodiment, the rate of sodium hydroxide in these limes can be determined by all methods well known to the person skilled in the art, such as the Leduc method (Hornain, 1995).

Ettringite adhesive

The invention also relates to hydraulic binders, preferably ettringite binders. In particular, the invention relates to an ettringite binder obtainable by the process according to the invention as described above.

According to one embodiment, the ettringite binder is obtained from a mixture of at least:

-a source of aluminosilicate as described previously;

-a source of calcium sulphate as described previously; and

a source of calcium hydroxide as previously described.

According to one embodiment, the ettringite binder is obtained from a mixture of at least:

-a source of aluminosilicate as described previously;

-a source of calcium sulphate as described previously;

-a source of calcium hydroxide as previously described; and

-at least one activator as described previously, preferably chosen from compounds suitable for complexing cations, preferably compounds suitable for complexing calcium, aluminium and/or silicon.

According to one embodiment, the ettringite binder has a parameter RMK as defined above, ranging from 0.05 to 1.25; preferably 0.1 to 1; more preferably 0.2 to 0.8. According to one embodiment, the parameter RMK as defined above is comprised between 0.1 and 1.25; 0.2 to 1.25; 0.3 to 1.25; 0.4 to 1.25; 0.5 to 1.25; 0.6 to 1.25; 0.7 to 1.25; 0.8 to 1.25; 0.9 to 1.25; 1 to 1.25. According to one embodiment, the parameter RMK as defined above is comprised between 0.1 and 1.25; 0.1 to 1.2; 0.1 to 1.25; 0.1 to 1.1; 0.1 to 1; 0.1 to 0.9; 0.1 to 0.8; 0.1 to 0.7; 0.1 to 0.6; 0.1 to 0.5; 0.1 to 0.4; 0.1 to 0.3; or 0.1 to 0.2. According to one embodiment, the parameter RMK as defined above ranges from 0.20 to 0.80; preferably 0.25 to 0.80; 0.30 to 0.80; 0.35 to 0.80; 0.40 to 0.80; 0.45 to 0.80; 0.50 to 0.80; 0.55 to 0.80; 0.60 to 0.80; 0.65 to 0.80; or 0.70 to 0.80. According to one embodiment, the parameter RMK as defined above ranges from 0.20 to 0.80; preferably 0.20 to 0.75; 0.20 to 0.70; 0.20 to 0.65; 0.20 to 0.60; 0.20 to 0.55; 0.20 to 0.50; 0.20 to 0.45; 0.20 to 0.40; 0.20 to 0.35; 0.20 to 0.30; or 0.20 to 0.25.

According to one embodiment, the parameter sat (ch) as defined above ranges from 0.75 to 20, preferably from 1 to 15. According to one embodiment, the parameter sat (ch) as defined above is 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19 or 20. According to one embodiment, the ettringite binder has the parameter sat (ch), as defined above, ranging from 0.75 to 8; preferably 1 to 8; 2 to 8; 3 to 8; 4 to 8; 5 to 8; 6 to 8; or from 7 to 8. According to one embodiment, the parameter sat (ch) is equal to 1, 2, 3, 4, 5, 6, 7 or 8. According to one embodiment, the parameter sat (ch), as defined above, ranges from 0.75 to 8; 0.75 to 7; 0.75 to 6; 0.75 to 5; 0.75 to 4; 0.75 to 3; 0.75 to 2; or 0.75 to 1.

Use of

The invention also relates to the use of a binder according to the invention, preferably an ettringite binder, as described above, for the preparation of building materials.

According to one embodiment, the ettringite binder according to the invention is used for the preparation of cement, masonry cement, road cement, concrete, mortar and/or formulated lime.

Building material

According to one embodiment, the invention also relates to a material obtained from a hydraulic binder according to the invention as described above, preferably from an ettringite binder.

According to one embodiment, the material is obtained by hydrating a hydraulic binder according to the invention. According to one embodiment, the material is obtained by hydrating an ettringite binder according to the invention.

During hydration of the ettringite binder, two chemical reactions are carried out, whereby ettringite can be obtained:

(1) the reaction between lime and aluminosilicate leads to the formation of calcium aluminate (C4 AH13 in the Cement chemist notation)

AS2+4CH→C4AH13+2S

(2) The reaction of the calcium aluminate formed in (1) with calcium sulphate leads to the formation of ettringite.

C4AH13+3C$→C6A$3H32+CH

The chemical equation for the hydration reaction of an ettringite binder is:

AS2+5CH+3C$→C6A$3H32+2CSH

in the present invention, hydration of the ettringite binder according to the invention results in a material whose density depends on the intended application. According to one embodiment, the material according to the invention has a density of more than 0 to 2.1kg/L, preferably 1 to 2kg/L, more preferably, the density is about 1.9 kg/L. Advantageously, the density of the material according to the invention is lower than the density of the material obtained using portland cement.

According to one embodiment, the material is cement, masonry cement, road cement, concrete, mortar and/or formulated lime.

According to one embodiment, the mechanical properties, such as the compressive strength, of the material obtained from the ettringite binder according to the invention are increased by 1% to 100%, preferably by 5% to 80%, more preferably by 40% to 70%, with respect to materials derived from conventional pozzolan compositions, such as materials obtained from mixtures of aluminosilicates and lime.

According to one embodiment, the material further comprises an adjuvant, preferably selected from a solidifying agent and/or a mould release oil. The term "release oil" refers to oil spread over the surface of a formwork to facilitate the release of the concrete or mortar hardened in the formwork.

According to one embodiment, the material obtained from the ettringite binder according to the invention does not have any shrinkage or only a small degree of shrinkage during its molding.

According to one embodiment, the material obtained from the ettringite binder according to the invention does not comprise any portland cement.

According to one embodiment, the compressive strength of the material obtained from the ettringite binder according to the invention at 3 days ranges from more than 0 to 60MPa, preferably from 2 to 45MPa, more preferably from 10 to 40 MPa. According to one embodiment, the compressive strength of the material obtained from the ettringite binder according to the invention at 3 days is in the range of more than 1 to 60MPa, preferably 2 to 50MPa, preferably 10 to 50MPa, preferably 15 to 50MPa, preferably 20 to 50MPa, preferably 25 to 50MPa, preferably 30 to 50MPa, preferably 35 to 50MPa, preferably 40 to 50MPa, or preferably 45 to 50 MPa. According to one embodiment, the material obtained from the ettringite binder according to the invention has a compressive strength at 3 days of about 14MPa, 21MPa, 23MPa or 26 MPa.

According to one embodiment, the compressive strength of the material obtained from the ettringite binder according to the invention at 7 days ranges from more than 0 to 60MPa, preferably from 2 to 45MPa, more preferably from 10 to 40 MPa. According to one embodiment, the compressive strength of the material obtained from the ettringite binder according to the invention at 7 days is in the range of more than 1 to 60MPa, preferably 2 to 50MPa, preferably 10 to 50MPa, preferably 15 to 50MPa, preferably 20 to 50MPa, preferably 25 to 50MPa, preferably 30 to 50MPa, preferably 35 to 50MPa, preferably 40 to 50MPa, or preferably 45 to 50 MPa. According to one embodiment, the material obtained from the ettringite binder according to the invention has a compressive strength of about 11MPa, 17MPa, 18MPa, 21MPa, 27MPa, 30MPa, 31MPa, 32MPa, 33MPa, 35MPa, 42MPa or 46MPa at 7 days.

According to one embodiment, the compressive strength at 28 days of the material obtained from the ettringite binder according to the invention ranges from more than 0 to 150MPa, preferably from 2 to 100MPa, more preferably from 20 to 90 MPa. According to one embodiment, the material obtained from the ettringite binder according to the invention has a compressive strength at 28 days of more than 2 to 150MPa, preferably 20 to 150MPa, preferably 30 to 150MPa, preferably 40 to 150MPa, preferably 50 to 150MPa, preferably 60 to 150MPa, preferably 70 to 150MPa, preferably 80 to 150MPa, preferably 90 to 150MPa, preferably 100 to 150MPa, preferably 110 to 150MPa, preferably 120 to 150MPa, preferably 130 to 150MPa, preferably 140 to 150 MPa. According to one embodiment, the compressive strength at 28 days of the material obtained from the ettringite binder according to the invention ranges from more than 2 to 150MPa, preferably from 2 to 140MPa, preferably from 2 to 130MPa, preferably from 2 to 120MPa, preferably from 2 to 110MPa, preferably from 2 to 100MPa, preferably from 2 to 90MPa, preferably from 2 to 80MPa, preferably from 2 to 70MPa, preferably from 2 to 60MPa, preferably from 2 to 50MPa, preferably from 2 to 40MPa, preferably from 2 to 30MPa, preferably from 2 to 20 MPa. According to one embodiment, the material obtained from the ettringite binder according to the invention has a compressive strength of about 44MPa, 52MPa or 54MPa at 28 days.

According to one embodiment, the flexural strength of the material obtained from the ettringite binder according to the invention at 28 days ranges from more than 0 to 15MPa, preferably from 1 to 10MPa, more preferably from 2 to 9 MPa. According to one embodiment, the flexural strength at 28 days of the material obtained from the ettringite binder according to the invention is from more than 0 to 15MPa, preferably from 1 to 10MPa, more preferably from 2 to 6 MPa. According to one embodiment, the flexural strength at 28 days of the material obtained from the ettringite binder according to the invention ranges from more than 0 to 10MPa, preferably from 1, 2, 3, 4, 5, 6, 7, 8, 9 or 10 MPa.

In the present invention, the compression strength test has been carried out on the preformed composition (cubic mold, 40mm × 40mm or 10cm × 10cm) using a Controlab E0250/15KN class A instrument or using a cylindrical sample (16cm × 32 cm). Compressive strength measurements were also made on the wall using a Controlab durometer instrument.

Method for producing building material

According to one embodiment, the invention also relates to a method for preparing a building material, comprising the preparation and/or use of an ettringite binder as described above.

According to one embodiment, the method for preparing a building material further comprises the step of mixing the above ettringite binder with water.

According to one embodiment, the method for preparing a building material further comprises the step of molding said material.

According to one embodiment, the method for preparing a building material from an ettringite binder according to the invention does not comprise the use of portland cement. According to one embodiment, the method for preparing a building material from an ettringite binder according to the invention does not comprise the use of calcium sulphoaluminate.