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    • 专利摘要:
    aerated concrete construction materials manufacturing process and construction materials obtained from the same aerated concrete construction materials manufacturing process, which comprises the following steps: a. mixing a composition comprising at least water, a cementitious material, calcium oxide, a compound comprising reactive silicon dioxide, an oxygen source, and a compound selected from sodium carbon, sodium bicarbonate and sodium hydroxide, b. pour the mixture from step (a) into a mold and allow the mixture to consolidate, thereby forming a stiffened body, c. remove the stiffened body from the mold, d. optionally cutting and configuring the stiffened body, e.g. heal the stiffened body.
    公开号:BR112012027612A2
    申请号:R112012027612
    申请日:2011-04-29
    公开日:2020-04-14
    发明作者:Massa Giorgio；Dournel Pierre；Seccombe Rodney
    申请人:Solvay；
    IPC主号:
    专利说明:

    AIRCRAFT CONCRETE CONSTRUCTION MANUFACTURING PROCESS
    This order claims priority for European order EP 10161496.4, registered on April 29, 2010, the entire content of which is incorporated herein by reference for all purposes.
    The present invention relates to a process for the manufacture of aerated concrete construction materials and construction materials obtained therefrom, in particular a process for the manufacture of blocks, and bricks.
    The possibility of producing aerated building materials (either cellular or porous or made light or light) by adding a foaming agent (or gas-generating agent) is well known. The gas generated forms bubbles that remain in the mass of the construction material during consolidation and provide the material's porosity, which remains present after curing.
    At present, the market for lightweight materials is growing. It has been proven that there is a correlation between building materials with incorporated air (either aerated or porous or low density) and improved insulating properties, including thermal insulation, sound insulation and fire resistance. The use of materials with incorporated air also reduces the costs of transporting construction materials to their destination. The use of materials with incorporated air also increases the longevity of the resulting construction. In addition, low density materials were considered suitable for construction in seismic regions.
    In this domain, aerated concrete and especially aerated autoclaved concrete (CAA), also called autoclaved cellular concrete, is well known. CAA was discovered in the early 1900s and is a lightweight construction material, usually precast, that provides structure, insulation, fire and mold resistance in a single material. CAA can be up to five times lighter than concrete. CAA also exhibits excellent thermal efficiency.
    As disclosed in Kirk-Othmer, Encyclopedia of Chemical Technology, Chapter “Lime and Limestone”, page 26 (DOI 10.1002 / 0471238961.
    1209130507212019.a01.pub2, published on May 17, 2002), CAA can typically be prepared by mixing quicklime with an active form of silicon (for example, crushed silica sand or pulverized fuel ashes comprising dioxide reactive silicon), sand, water, powdered aluminum and, depending on the quality of quicklime, cement. The reaction of quicklime with powdered aluminum generates hydrogen bubbles that cause the cake to grow. At the same time, quicklime reacts with water, generating heat and causing the cake to consolidate. The cake is then removed from the mold and cut into blocks before autoclaving at high temperature and pressure.
    2/24
    Also known, for example, from GB 648,280, the production of CAA by mixing Portland cement, pulverized fuel ash, sand, and water and inducing aeration by the action of an alkali, such as caustic soda, in a powder. finely divided metallic, like powdered aluminum.
    However, these methods lead to the production of hydrogen gas, and fine powdered aluminum and hydrogen gas are explosive and dangerous substances that require special safety equipment.
    It is also known to use other aeration agents, such as hydrogen peroxide. The use of hydrogen peroxide has no environmental impact, as the gas formed is oxygen. For example, GB1028243, published in 1966, discloses a process for the production of porous hydraulic materials, such as porous concrete, in which the porosity is at least partly due to the release of oxygen produced through the decomposition of hydrogen peroxide.
    Unfortunately, in the field of aerated concrete and especially CAA, we now find, surprisingly, that the mere replacement of the well-known process with powdered aluminum with an oxygen source, such as hydrogen peroxide, does not allow the manufacture of aerated concrete with the same expansion coefficients for the same formulation.
    Thus, an objective of the present invention is to provide a process for the manufacture of aerated concrete and especially CAA with improved expansion coefficients compared to the use of only hydrogen peroxide. It is also an objective of the present invention to provide a process for the manufacture of aerated concrete and especially CAA that is safe and environmentally friendly compared to the classical technology based on the generation of hydrogen gas from powdered aluminum. Since the process of the invention is safer, the equipment can also be simplified and is also advantageous in terms of process control. The process of the present invention is also advantageous in terms of energy savings.
    For this purpose, the present invention relates to a process for the manufacture of aerated concrete construction materials, which comprises the following steps:
    The. preparing a composition comprising at least water, a cementitious material, calcium oxide, a compound comprising reactive silicon dioxide, an oxygen source, and a compound selected from sodium carbonate (Na 2 CO 3 ), sodium bicarbonate (NaHCO 3 ) and sodium hydroxide (NaOH),
    B. pour the mixture from step (a) into a mold and let the mixture consolidate, thereby forming a stiffened body,
    ç. remove the stiffened body from the mold,
    d. optionally cut and configure the stiffened body, and
    3/24
    and. heal the stiffened body.
    The term aerated concrete designates a material expanded to the point of including the presence of small bubbles in the concrete mixture during its consolidation, which will give porosity to the final cured material. Due to the presence of these bubbles, this type of material is made light or is light or has air incorporated or is porous in comparison to classic concrete materials, that is, the resulting aerated concrete material has a lower density compared to a concrete material classic. For example, aerated concrete with a density from 0.2 to 1.2 kg / dm 3 , in particular from 0.3 to 0.8 kg / dm 3 , for example, about 0.5, 0.6 or 0 , 7 kg / dm 3 , can be obtained according to the process of the present invention. The density was determined as follows: the dry weight of a rectangular block (kg) was divided by its volume (dm 3 ). This type of material exhibits a highly porous volume, which is generally at least 15%, in particular at least 20% and, in the most advantageous cases, at least 55%. The porous volume is measured according to the following method:
    • Measurement of the weight of a dry material, such as a brick, obtained by heating for 24 hours at 100 ° C and subsequent cooling, • Filling the entire porous volume with water by immersing it for 24 hours in water, and • Measurement of the weight of wet material, such as a brick.
    Pre-molded building materials prepared by the process of the invention are typically bricks, lintels, planks, beams, roof tiles, blocks, including, for example, blocks for inner sheets, blocks for partition walls, blocks for partitions, blocks for foundations , floor blocks, paneled bricks, the most common being bricks and blocks.
    The cementitious material used as one of the raw materials in the process of the invention can be chosen from hydraulic binders, pozzolanic materials and mixtures thereof.
    Hydraulic binders are finely crushed inorganic materials that, when mixed with water, form a paste that consolidates and hardens through hydration reactions and processes and that, after hardening, retains its strength and stability even under water. Typical examples of hydraulic binders are Portland cement; calcium aluminate cements, such as monocalcium aluminate (CaAI 2 O 4 ), usually formed from the mixture of limestone and bauxite, and Mayenite (Ca 12 AI 14 O3 3 ); calcium sulfoaluminate cements, such as ye'elimita (Ca 4 (AIO 2 ) 6 SO 4 ); pulverized (fuel) fly ash of type C (PFA-C), also called limestone fly ash; hydraulic lime; and mixtures of these.
    Pozzolanic materials, also called cement extenders, do not
    4/24 harden on their own when mixed with water, but when finely ground and in the presence of water, they react at normal room temperature with dissolved calcium hydroxide to form calcium silicate and calcium aluminate compounds, which develop resistance, which are similar to those formed in the hardening of hydraulic binders. Thus, when combined with calcium hydroxide, pozzolanic materials exhibit cement properties (of hydraulic bonding). Calcium hydroxide is usually formed by mixing lime or calcium oxide (CaO) with water. Examples of suitable pozzolanic materials are fly ash (or fuel ash), in particular pulverized fuel ash type F (PFA-F), also called siliceous fly ash, crushed granulated blast slag, smoke silica, metakaolin high reactivity, crushed baked clay brick residues, natural pozzolans, including diatomaceous earth, metakaolin, crushed bagacine, ashes from rice husks (or skins), volcanic ash, pumicite, calcined clay or calcined shale, and mixtures thereof.
    Examples of cementitious materials comprising a hydraulic binder and a pozzolanic material are blast furnace Portland cement (ie, a mixture of Portland cement and crushed granulated blast furnace slag), Portland fly ash cement (ie, a mixture of Portland cement and fly ash), Portland pozzolanic cement (ie a mixture of Portland cement and fly ash and / or other natural or artificial pozzolans) and Portland silica smoke cement (ie, a mixture of Portland cement and silica from smoke).
    Examples of cementitious materials comprising a pozzolanic material but without hydraulic binder as defined above are pozzolan-lime cements (that is, a mixture of crushed natural or artificial pozzolans and lime), slag-lime cements (that is, a mixture of slag crushed granulated blast furnace and lime) and supersulfated cements (ie a mixture of crushed granulated blast furnace slag, plaster and lime).
    In the following, the expression “Dry Material (MS)” (or Dry Mix) will be used to designate the mixture consisting of the following compounds, provided that they are used in the composition of step (a), selected from cementitious materials (including binders) hydraulic and pozzolanic materials), the compound comprising reactive silicon dioxide, limestone, calcium carbonate, lime or quicklime (CaO), plaster (CaSO 4 .2H 2 O) (and / or hemihydrated calcium sulfate (CaSO 4 . 1/2 H 2 O) and / or anhydrite (CaSO 4)), and aggregates. As a first example, if, from this list, only a cementitious material and a compound comprising reactive silicon dioxide are used in the composition of step (a), the term Dry Material will designate the mixture comprising the cementitious material and the compound comprising silicon dioxide reactive. As a second example, if all compounds in this list are used in the composition of step (a), the expression Material
    5/24
    Dry will designate the mixture comprising the cementitious material, the compound comprising reactive silicon dioxide, limestone, calcium carbonate, lime or quick lime, gypsum (and / or sulfate hemihydrate calcium (CaSO4. 1/2 H 2 O) and / or anhydrite), and the aggregates.
    In general, the cementitious material is present in the composition of step (a) in an amount from 5 to 99% by weight of the Dry Material, preferably in an amount from 10 to 80%.
    In the present invention, calcium oxide (or lime) is usually added to the composition of step (a) in an amount from 1 to 50% by weight of the Dry Material, in particular from 2 to 35%, for example, from 3 to 15%.
    In the process of the present invention, the term compound comprising reactive silicon dioxide means that the compound comprises at least a fraction of silicon dioxide that is soluble after treatment with hydrochloric acid and boiling potassium hydroxide solution, as defined in the British Standard BS EN 197-1: 2000. In the present invention, the compound comprising reactive silicon dioxide can be selected, for example, from sodium silicates, for example, sodium silicates with a Na 2 O / SiO 2 ratio from 1 to 3, for example, from sodium metasilicate (Na 2 SiO 3 ), also called water glass or soluble glass, sodium orthosilicate (Na4SiO4), sodium pyrosilicate (NaeSfeO ) And mixtures thereof; aluminum silicate (AI 2 SiO 5 ), including minerals composed of aluminum silicate, such as andalusite, silimanite (or bucholzite) and kyanite; calcium silicates, such as CaSiO 3 or CaO.SiO 2 (also called wollastonite), Ca 2 SiO 4 or 2CaO.SiO 2 (also called calcium orthosilicate), Ca 3 SiO 5 or 3CaO.SiO 2 (also called alita), Ga 3 Si 2 O 7 or 3CaO.2SiO 2 (also called ranquinite); precipitated silica; smoke silica; silicate sand, preferably crushed silicate sand or pure quartz sand, in particular crushed silica sand; diatomaceous earth; fly ash (fuel), in particular pulverized fly ash, in particular type F sprayed fly ash (PFA-F), also called siliceous fly ash; crushed granulated blast furnace slag and mixtures thereof. In the present invention, depending on its nature, the compound comprising reactive silicon dioxide can comprise reactive silicon dioxide in various amounts. For example, pure quartz sand can comprise from about 80 to about 100% by weight of reactive silicon dioxide. Another example is type F sprayed fly ash that comprises a large amount of reactive silicon dioxide. For example, depending on their composition, pulverized fly ash of type F can comprise from 40 to 55% by weight of reactive silicon dioxide, or even more than 55% by weight. Preferably, the compound comprising silicon dioxide comprises it in an amount of at least 35% by weight, preferably at least 40% by weight, more preferably at least 45% by weight.
    6/24 weight, for example, at least 50 or 55% by weight. The compound comprising reactive silicon dioxide can comprise an amount of reactive silicon dioxide as high as 100% by weight, in particular as high as 90% by weight, for example, as high as 80% by weight.
    The amount of compound comprising reactive silicon dioxide in composition (a) will depend on its nature (including its proportion of reactive silicon dioxide) and the nature and proportions of the other compounds. Depending on its nature and the nature and proportions of the other compounds present in composition (a), that compound can, for example, be added to the composition of step (a) in an amount of at least 35% by weight of the Dry Material, preferably at least 40% by weight, more preferably at least 45% by weight, for example, at least 50% by weight. The compound comprising reactive silicon dioxide is typically present in the composition of step (a) in an amount of up to 95% by weight, in particular up to 90% by weight, for example, in an amount of up to 80% by weight .
    The oxygen source used in the process of the invention can be selected, among others, from hydrogen peroxide, sodium percarbonate, sodium perborate, calcium peroxide, magnesium peroxide, zinc peroxide, mixed calcium / magnesium peroxide and mixtures thereof , preferably hydrogen peroxide. These products, when introduced in the process, result in the formation of gaseous oxygen that forms bubbles and creates porosity in the material. In the process of the invention, the oxygen source is usually present in the composition of step (a) in an amount X from 0.01 to 10% of the corresponding hydrogen peroxide by weight of the Dry Material used in the composition of step (a), in from 0.05 to 4%, the oxygen source can be added to the composition of step (a) in the form of a solid or in the form of a solution or in the form of a suspension, preferably in the form of a solution or suspension , in particular in the form of an aqueous solution or suspension. If the oxygen source compound is hydrogen peroxide, it is typically added in the form of an aqueous solution, which usually contains from 1 to 70% weight / weight of hydrogen peroxide, preferably from 2 to 50% weight / weight, in from 3 to 30% weight / weight, for example, about 5.10, 15 or 20% weight / weight.
    In the process of the invention, at least one compound selected from sodium carbonate, sodium bicarbonate and sodium hydroxide is generally present in the composition of step (a) in a total amount Y from 0.1 to 10% by weight of the Dry Material used in the composition of step (a), preferably from 0.2 to 9%, more preferably from 0.5 to 8%, most preferably from 1 to 7%.
    In the process of the invention, at least one compound selected from sodium carbonate, sodium bicarbonate and sodium hydroxide is generally present in the composition
    7/24 of step (a) in a total amount Y from 0.1 to 2% by weight of the Dry Material used in the composition of step (a), preferably from 0.2 to 1%, for example, 0.5 %.
    In the present invention, sodium carbonate can be added in the form of anhydrous sodium carbonate (Na 2 CO 3 ), hydrated sodium carbonate, such as sodium carbonate monohydrate (Na 2 CO 3 .H 2 O), sodium carbonate heptahydrate (Na 2 CO 3 .7H 2 O), sodium carbonate decahydrate (Na 2 CO3.10H 2 O), and mixtures thereof. Sodium bicarbonate (NaHCO 3 ) can be added in the form of synthetic sodium bicarbonate, natural salts, such as nahcolite, and mixtures of these. Sodium carbonate and sodium bicarbonate can also be added in the form of mixed salts, such as sodium sesquicarbonate (Na 2 CO 3 .NaHCO 3 .2H 2 O), trona (Na 2 CO 3 .NaHCO 3 .2H 2 O ), wegscheiderite (Na 2 CO 3 .3NaHCO 3 ), and mixtures of these. In the process of the invention, at least one compound selected from sodium carbonate, sodium bicarbonate and sodium hydroxide can be added to the composition of step (a) in the form of a solid or in the form of a solution or in the form of a suspension , preferably in the form of a solution or suspension, in particular in the form of an aqueous solution or suspension. If that compound is added in the form of a solution or suspension, the solution or suspension typically has a concentration from 1 to 70% weight / weight, preferably from 2 to 50% weight / weight, in particular from 5 to 30% weight / weight, for example, about 10, 15 or 20% weight / weight.
    The water present in the composition of step (a) is usually present in an amount such that the ratio of water to Dry Material (A / MS) is at least 0.1, preferably at least 0.2, more preferably at least 0.3, for example, at least 0.4. This ratio of water to dry mix is usually at most 1, in particular at most 0.8, in particular at most 0.6, for example, at most 0.5.
    The composition of step (a) can also comprise at least one aggregate, preferably a fine aggregate. This aggregate can be selected, for example, from sand, including crushed silica sand, quartz sand, bagacina, dry or finely crushed clay, crushed aerated autoclaved concrete, and mixtures thereof. Aggregates are often added in an amount of 0 to 90% by weight of the Dry Material, for example, from 10 to 80%. If an aggregate is added that does not act as a pozzolanic material or as a compound comprising reactive silicon dioxide, it will usually be added in an amount from 0 to 50% by weight of the Dry Material, for example, from 0 to 30%.
    The composition of step (a) may also include limestone, calcium carbonate, gypsum (CaSO 4 .2H 2 O), calcium sulfate hemihydrate (CaSO4. 1/2 H2O), anhydrite (CaSO4) , and mixtures thereof . It is recognized that anhydrite (or gypsum or calcium sulfate hemihydrate) helps to regulate consolidation, since, in the hydration process, it releases heat and
    8/24 hardens quite quickly. Anhydrite (or gypsum or calcium sulfate hemihydrate) is typically added in an amount from 0 to 10% by weight of the Dry Material.
    The composition of step (a) can also comprise at least one catalyst used to activate or accelerate the release of gaseous oxygen by the oxygen source compound. The catalyst can be selected from metals and metal derivatives, preferably from transition metals and transition metal derivatives, more preferably from oxides and salts of transition metals, especially from Mn, Fe, Cu, Co, Pd and their derivatives, for example, of MnO 2 , MnSO 4 , CuO, FeSO 4 , FeO, Fe 2 Oa, FeCI 3 or KMnO 4 , which will release MnO 2 in alkaline medium. Most preferred are manganese based catalysts, especially MnO 2 and KMnO 4 . The catalyst is typically added to the composition of step (a) in an amount from 1 to 1000 ppm by weight of Dry Material, in particular from 10 to 500 ppm, for example, in an amount of about 50 to 200 ppm. If a compound naturally containing these metals, metal oxides and / or metal salts, in a sufficient amount, is added to the composition of step (a), that compound will also act as a catalyst. For example, pulverized fly ash of type F (PFA-F) and granulated blast furnace slag (GBFS) naturally comprise salts of transition metals and transition metal oxides, such as Fe 2 O3. Thus, PFA-F and GBFS will act as natural catalysts. The catalyst can also be selected from enzymes, for example, catalase.
    The composition of step (a) can also comprise at least one hypochlorite, preferably at least one hypochlorite selected from calcium hypochlorite (Ca (CIO) 2 ), sodium hypochlorite (NaOCI) and mixtures thereof. In fact, the hypochlorite can activate the release of oxygen through a redox reaction with the oxygen source compound. In the present invention, if a hypochlorite is used, it is typically added in a stoichiometric amount relative to the oxygen source compound, especially in a stoichiometric amount relative to the corresponding hydrogen peroxide.
    The composition of step (a) can also comprise several different additives, including surfactants, sodium silicates, cellulosic derivatives, such as carboxymethylcellulose, natural or synthetic protein derivatives, and / or starch and starch derivatives, such as modified starches. Sodium silicate is usually added as a viscosity modifier and / or as a consolidation accelerator, and can be selected from any sodium silicate compound, especially sodium silicate compounds with a Na 2 O / SiO 2 ratio from 1 to 3, preferably from 1.2 to 2, more preferably from 1.6 to 1.8, for example, sodium metasilicate (Na 2 SiO 3 ), also called water glass or soluble glass, sodium orthosilicate sodium (Na 4 SiO 4 ), sodium pyrosilicate (Na 6 Si 2 O 7 ) and mixtures thereof. Natural or synthetic protein derivatives are
    9/24 commonly used to create porous cellular structures. Starch and starch derivatives are usually added to control the rheology of the mixture prior to consolidation.
    In the process of the present invention, a compound can have two or more functions. For example, pulverized fly ash of type F (PFA-F) and crushed granulated blast furnace slag can be used as a cementitious material (pozzolanic material) and as a compound comprising reactive silicon dioxide, also providing metals and metal derivatives, in particular metal salts and metal oxides, which will act as a catalyst for the release of gaseous oxygen by the oxygen source. Another example is smoke silica, which is a pozzolanic material known as well as a source of silicon dioxide. Yet another example is finely ground silica sand or quartz sand, which can be used as a compound comprising reactive silicon dioxide and a fine aggregate.
    In a first preferred embodiment of the process of the invention, the composition of step (a) is prepared according to the following steps:
    i. mixing, optionally in the presence of part of the water, the at least one cementitious material with the at least one compound comprising reactive silicon dioxide and with the other components optionally used in the Dry Material, ii. add at least one selected compound of sodium carbonate, sodium bicarbonate and sodium hydroxide, optionally in a premix with part of the water, to the mixture of step (i) and homogenize the mixture, preferably by mixing for 1 at 600 seconds, more preferably from 5 to 300 seconds, and iii. add the oxygen source, optionally pre-mixed with part of the water, and the remaining part of the water, to the mixture from step (ii), and homogenize the mixture, preferably by mixing for a period of 1 second to 120 seconds , more preferably from 5 to 60 seconds.
    In a second preferred embodiment of the present invention, the composition of step (a) is prepared according to the following steps:
    i. mixing at least one compound comprising reactive silicon dioxide with part of the water, to produce a paste, ii. add the at least one cementitious material and the other components optionally used in the Dry Material to the paste of step (i), especially sequentially, and homogenize the mixture, preferably by mixing for 1 to 300 seconds, more preferably 5 to 180 seconds, iii. add at least one selected compound of sodium carbonate, sodium bicarbonate and sodium hydroxide, optionally in premix with an additional part of the water, to the mixture of step (i) and homogenize the mixture, preferably by means of
    10/24 mixing for 1 to 180 seconds, more preferably from 5 to 120 seconds, and iv. add the oxygen source, optionally pre-mixed with part of the water, and the remaining part of the water to the mixture from step (iii), and homogenize the mixture, preferably by mixing for 1 to 120 seconds, more preferably from 5 to 60 seconds.
    In this second preferred embodiment, in the first step (i), the compound comprising reactive silicon dioxide is mixed with a first part of the water, to form a paste. Such a paste can, for example, have a dry matter content of 50 to 90% by weight, for example, about 70% by weight. In an especially preferred embodiment, that paste is preheated to a temperature from 20 to 70 ° C, preferably from 25 to 60 ° C, for example, about 30 to 50 ° C, before adding the other components .
    According to these two preferred embodiments, any type of mixer can be used, in which kneader-type or screw-type mixers give especially good results.
    In a third preferred embodiment of the present process, the composition of step (a) is prepared according to the following steps:
    i. mixing the cementitious material, the compound comprising reactive silicon dioxide and the other components optionally used in the Dry Material in a dry type mixer for a period sufficient to achieve homogeneity, usually from 1 to 600 seconds, ii. add at least one selected compound of sodium carbonate, sodium bicarbonate and sodium hydroxide, optionally in a premix with part of the water, to the mixture of step (i) and homogenize the mixture, preferably by mixing for 1 at 120 seconds, and iii. add the oxygen source, optionally pre-mixed with part of the water, and the remaining part of the water to the mixture from step (ii), and homogenize the mixture, preferably by mixing for 1 second to 120 seconds, more preferably from 5 to 60 seconds.
    In the process of the present invention, including these three preferred embodiments, if it is desired to add a catalyst, it is advantageously added after the addition of at least one compound selected from sodium carbonate, sodium bicarbonate and sodium hydroxide, and before the addition oxygen source. After the addition of the catalyst, the mixture is usually homogenized, preferably by mixing for 5 to 120 seconds, preferably from 10 to 60 seconds.
    According to that invention, including these three preferred embodiments, if it is desired to add to the composition of step (a) any additional compound, such as
    11/24 a hypochlorite, a surfactant, a sodium silicate, a cellulosic derivative, a protein derivative and / or a starch or a starch derivative, are typically added at the same time, before, or after the selected sodium carbonate compound, sodium bicarbonate and sodium hydroxide, and preferably before the oxygen source.
    In a fourth embodiment of the present invention, which can also be combined with the three previous preferred embodiments described above, the water added at various points in the process, including the water used to prepare pastes and / or intermediate solutions, has a temperature from 20 to 90 ° C as the initial temperature, preferably from 25 to 60 ° C, for example, approximately from 30 to 50 ° C.
    In the process of the present invention, in step (b), after pouring the mixture from step (a) into a mold, the mixture is allowed to form a stiffened body, usually at atmospheric pressure and especially for 1 minute to 24 hours, preferably from 5 minutes to 12 hours, more preferably from 15 minutes to 6 hours, for example, from 20 minutes to 4 hours. The stiffened body is typically formed at a temperature from 10 to 90 ° C. This temperature can be obtained only by the increased temperature generated by the exothermic chemical reactions, after pouring the mixture from step (a) into a mold at room temperature. This stiffening can also be carried out at a temperature from 30 to 90 ° C, especially from 30 to 80 ° C, after pouring the mixture from step (a) into a mold heated to a temperature from 30 to 90 ° C.
    In the present process, after step (c), that is, removal of the stiffened body from step (b) from its mold, the stiffened body can optionally be cut to a defined dimension and / or a defined configuration in a step (d) , for example, in the form of smaller blocks or bricks, or a preferred shape according to the needs of the production, for example, using pliers or any other type of cutters.
    In the present process, curing in step (e) can be carried out under ambient conditions, in a climatic division, in a classic oven or in an autoclave, preferably in an autoclave. If curing is carried out in a climatic division (usually a drying division), it is usually conducted at atmospheric pressure and at a temperature from room temperature to 80 ° C, especially under specific humidity conditions and following a specific thermal profile. . If curing is conducted in an oven, it is typically conducted at atmospheric pressure and a temperature up to 120 ° C, optionally in the presence of a steam source. If curing is carried out in an autoclave, the conditions of pressure, temperature, duration and relative humidity will depend on the equipment available, where the pressure, humidity and temperature are defined by the saturated water-steam diagram. For example, for a specific autoclave, the curing of step (d) can be carried out for a period from 1 to 24 hours, preferably from 6 to 18 hours, for example, about 10 to 12 hours, at a temperature of 150
    12/24 to 250 ° C, in particular from 175 to 225 ° C, in particular from 190 to 200 ° C and at a pressure of 5 to 20 bar, in particular from 8 to 15 bar. In an especially preferred embodiment, the rate of temperature rise is controlled according to the equipment's manufacturing instructions.
    The present invention also relates to aerated concrete construction materials and, in particular, aerated autoclaved concrete construction materials that can be obtained using the process described above.
    Considering the above, the present invention also relates to the use of an oxygen source as described above and at least one compound selected from sodium carbonate, sodium bicarbonate and sodium hydroxide for the manufacture of aerated concrete construction materials. , in particular for the manufacture of aerated autoclaved concrete construction materials, in particular for the manufacture of aerated concrete construction materials that can be obtained using the process described above.
    In the event that the disclosure of any patents, patent applications, and publications, incorporated herein by reference, conflicts with the description of this application, which may make an unclear term, this description will take precedence.
    The present invention is further illustrated below, without limiting its scope.
    Examples
    In the following examples, the containers used to mold the concrete have a volume of about 1000 mL and are made of plastic, such as polyvinyl chloride (PVC), polyethylene (PE), polypropylene (PP) or expanded polystyrene (EPS). In the following examples, the mixer used was an RW 25 IKA 140W Motor Stirrer mixer equipped with an axial flow impeller (stainless steel, 68 mm overall diameter, 10 mm gauge diameter), used at 600 rpm.
    The amounts of ingredients used in the various compositions described below are expressed in% by weight of the Dry Material (composed of cement, lime, plaster, sand and / or fly ash). The amount of water is expressed by the Water / Dry Material (A / MS) weight ratio.
    Example 1: silica sand and Al powder
    Aerated concrete blocks based on the mixture design summarized in Table 1 were produced according to the procedure below.
    Table 1
    Composition (%) Ex. 1 Portland cement 14.2 Lime 14.2 Plaster 2.6 Pure Silica Sand 69.0
    13/24
    Al powder 0.083
    Water / Material Ratio 0.62
    Dry
    All the solid components (i.e. Portland cement, lime, plaster, silica sand and powdered Al) were mixed together. Preheated water at a temperature of 60 ° C was added and the entire system was mixed for 30 seconds. The mixture was then poured into a plastic container and allowed to harden at room temperature for approximately 1 day. The stiffened body was then dried in an oven at
    85 ° C until dry (24-48 hours).
    The density of the resulting blocks was 0.55 g / ml.
    Examples 2-6: silica sand and hydrogen peroxide
    Aerated concrete blocks based on the mixture design summarized in Table 2 were produced according to the procedure below.
    Table 2
    Composition (%) Portland Cement Ex. 2-614.2 Lime 14.2
    Plaster 2.6 Pure Silica Sand 69.0 H 2 O 2 0.62 Na 2 CO3 5 Mn 2+ (ppm) 100 Water / Dry Material Ratio 0.62
    Five samples of Portland cement, lime, plaster and silica sand were mixed together. The sodium carbonate was dissolved in part of the water (concentration of about 20% by weight) preheated to various temperatures (see Table 3), the resulting solutions were added to the samples of the solid mixture and the mixtures were mixed for about 30 seconds. The catalyst was added as a 10 g / L aqueous solution of manganese sulfate and the mixtures were mixed for about 15 seconds. The hydrogen peroxide was added in the form of an aqueous solution with a concentration of about 6% by weight (starting from a 17% by weight aqueous solution of hydrogen peroxide diluted with part of the water), and then the part was added remaining water. The resulting mixtures were further mixed for 20 seconds. The mixtures were poured into plastic containers and allowed to harden at room temperature for approximately 1 day. The stiffened bodies were then dried in an oven at 85 ° C until dry (24-48 hours).
    The temperature of the molded bodies during the stiffening step was
    Monitored, and the results after 15 minutes of stiffening are shown in the
    Table 3.
    The resulting block densities are summarized in Table 3.
    Table 3
    Ex. 2 Ex.3 Ex. 4 Ex. 5 Ex. 6 Water temperature (° C) 15 20 25 30 40 Molded body temperature (15 minutes) (° C) 24 35 48 58 Not measured Density (g / mL) 0.68 0.61 0.48 0.50 0.76
    These results show that the greatest expansion is obtained when water is added at a temperature from 20 to 30 ° C and, in particular, from 25 to 30 ° C.
    Examples 7-12: silica sand and hydrogen peroxide Aerated concrete blocks based on the mixing concepts summarized in
    Table 4 were produced according to the procedure below.
    Table 4
    Composition (%) Ex. 7 Ex. 8 Ex. 9 Ex. 10 Ex. 11 Ex. 12 Portland cement 14.2 14.2 14.2 14.2 14.2 14.2 Lime 14.2 14.2 14.2 14.2 14.2 14.2 Plaster 2.6 2.6 2.6 0 0 0 Pure Silica Sand 69.0 69.0 69.0 69.0 69.0 69.0 H 2 O 2 0.31 0.31 0.31 0.31 0.31 0.31 Νά2θθ3 4 5 6 4 5 6 Mn 2+ (ppm) 100 100 100 100 100 100 Water / Dry Material Ratio 0.62 0.62 0.62 0.62 0.62 0.62 Portland cement, lime, silica sand and plaster (if present) were misl rooted in
    set. The sodium carbonate was dissolved in part of the water (concentration of about 20% by weight) preheated to a temperature of about 26-27 ° C, the resulting solution was added to the solid mixture and the whole system was mixed for 30 seconds. The catalyst was added in the form of a 10 g / L aqueous solution of manganese sulfate and the mixture was mixed for 15 seconds. The hydrogen peroxide was added in the form of an aqueous solution with a concentration of about 6% by weight (starting from a 17% by weight aqueous solution of hydrogen peroxide diluted with part of the water), and then the part was added remaining water. The resulting mixture was mixed for 20 seconds. The mixtures were then poured into plastic containers and allowed to harden at room temperature for approximately 1 day. The
    15/24 stiffened bodies were then dried in an oven at 85 ° C until dry (24-48 hours).
    The resulting block densities are summarized in Table 5.
    Table 5
    Ex. 7 Ex. 8 Ex. 9 Ex. 10 Ex. 11 Ex. 12 Density (g / mL) 0.90 0.63 0.65 0.85 0.60 0.61
    These results show that, in these mixing designs, the optimal amount of Na 2 CO 3 is 5% by weight of the Dry Material, leading to the lowest densities regardless of the presence of gypsum. The expansion is slightly less when plaster is present, but, from the photos of the cured bodies in example 9 (Figure 1) and 11 (Figure 2), it can be seen that the bubbles were smaller when plaster was present.
    Example 13: pulverized fly ash and powdered Al
    Aerated concrete blocks based on the mixture design summarized in Table 6 were produced according to the procedure below.
    Table 6
    Composition (%) Ex. 13 Portland cement 14.3 Lime 3.4 Plaster 0.68 Fly ashsprayed type F (PFA-F) 81.6 Al powder 0.073 Water / Dry Material Ratio 0.43
    PFA was mixed with about 80-90% of the water to be added to the mixture for about 30-40 seconds, to form a suspension. Portland cement, lime and plaster were sequentially added to the PFA suspension, with an additional mixture for about 15-30 seconds after each addition. Powdered Al was added with the remainder of the water, and the mixture was further mixed for about 20 seconds. The mixture was then poured into a plastic container and allowed to harden at room temperature until maximum expansion was achieved (about 30-60 minutes). The stiffened body was then dried in an oven at 85 ° C until dry (24-48 hours).
    The resulting block density was 0.78 g / ml.
    Examples 14-17: pulverized fly ash and hydrogen peroxide
    Aerated concrete blocks based on the mixing concepts summarized in Table 7 were produced according to the procedure below.
    Table 7
    16/24
    Composition (%) Ex. 14 Ex. 15 Ex. 16 Ex. 17 Portland cement 14.3 14.3 14.3 14.3 Lime 3.4 3.4 3.4 3.4 Plaster 0.68 0.68 0.68 0.68 Fly ashsprayed type F (PFAF) 81.6 81.6 81.6 81.6 H 2 O 2 0.44 0.44 0.44 0.44 Na 2 CO 3 4 5 6 7 Water / Dry Material Ratio 0.43 0.43 0.43 0.43
    PFA was mixed with about 80-90% of the water to be added to the mixture for about 30-40 seconds, to form a suspension. Portland cement, lime and plaster were sequentially added to the PFA suspension, with an additional mixture for about 15-30 seconds after each addition. The sodium carbonate was dissolved in part of the water (concentration of about 20% by weight) preheated to a temperature of about 26-27 ° C, the resulting solution was added to the PFA / cement mixture and the entire system was mixed for 15-30 seconds. The hydrogen peroxide was added in the form of an aqueous solution with a concentration of about 6% by weight (starting from a 17% aqueous solution of hydrogen peroxide diluted with part of the water), and then the remaining part of the Water. The resulting mixture was mixed for about 1520 seconds. The mixtures were poured into plastic containers and allowed to harden at room temperature for approximately 1 day. The stiffened bodies were then dried in an oven at 85 ° C until dry (24-48 hours).
    The resulting block densities are summarized in Table 8.
    Table 8
    Ex. 14 Ex. 15 Ex. 16 Ex. 17 Density (g / mL) 0.85 0.66 0.53 0.70
    These results show that, in these mixing designs, the optimal amount of Na 2 CO 3 is 6% by weight of the total Dry Material (example 16, Figure 3).
    Example 18: pulverized fly ash and hydrogen peroxide
    Aerated concrete blocks based on the mixture design summarized in Table 9 were produced according to the same procedure as in examples 14-17.
    Table 9
    Composition (%) Ex. 18 Portland cement 14.3 Lime 3.4 Plaster 0.68
    17/24
    Fly ashsprayed type F (PFA-F) 81.6 H 2 O 2 0.44 Na 2 CO 3 6 Water / Dry Material Ratio 0.43
    The density of the resulting holes was 0.72 g / ml. Thus, there appears to be a relationship between the optimal amounts of Na 2 CO 3 and H 2 O 2 .
    Examples 19-23: pulverized fly ash and hydrogen peroxide
    Examples 14-16 (respectively 4, 5 and 6% by weight of Na 2 CO 3 ) were reproduced with other batches of cement and lime. Amounts of 3% Na 2 CO 3 were also tested. Aerated concrete blocks based on the mixing concepts summarized in Table 10 were produced according to the procedure of examples 14-17, except that the water was preheated to a temperature of 23 to 25 ° C instead of 2627 ° Ç.
    Table 10
    Composition (%) Ex. 19 Ex. 20 Ex. 21 Ex. 22 Ex. 23 Portland cement (lot different from Ex. 14-17) 14.3 14.3 14.3 14.3 14.3 Lime (batch other than Ex. 14-17) 3.4 3.4 3.4 3.4 3.4 Plaster 0.68 0.68 0.68 0.68 0.68 Fly ashsprayed type F (PFAF) 81.6 81.6 81.6 81.6 81.6 h 2 o 2 0.44 0.44 0.44 0.44 0.44 Na 2 CO 3 6 5 4 3 3 Water / Dry Material Ratio 0.43 0.43 0.43 0.43 0.43
    The resulting block densities are summarized in Table 11.
    Table 11
    Ex. 19 Ex. 20 Ex. 21 Ex. 22 Ex. 23Density (g / mL) n.m. n.m. 0.58 0.53 0.57 The densities of examples 1S and 20 were not measured (n.m.), because the mixture
    concrete was too viscous and did not expand. These results show that, in these mixing designs, the optimal amount of Na 2 CO 3 is 3% by weight of the total Dry Material (example 22, Figure 4; example 23). This shows that the optimal amount of
    18/24
    In 2 CO 3 it depends on the quality of the raw materials, especially on the quality of the cement materials.
    Examples 24-28: pulverized fly ash, silica sand and hydrogen peroxide
    Aerated concrete blocks based on the mixing concepts summarized in
    Table 12 were produced according to the procedure of examples 14-17, in which the silica sand was added to the PFA suspension sequentially with the addition of Portland cement, lime and plaster, and in which the water was preheated to temperatures from 24.5 to 26 ° C.
    Table 12
    Composition (%) Ex. 24 Ex. 25 Ex. 26 Ex. 27 Ex. 28 Portland cement 14.3 14.3 14.3 14.3 14.3 Lime 3.4 3.4 3.4 3.4 3.4 Plaster 0.68 0.68 0.68 0.68 0.68 Pure Silica Sand 70 69 71 71 71 Fly ashsprayed type F (PFAF) 10 10 10 10 10 H 2 O 2 0.44 0.44 0.44 0.44 0.44 Na 2 CO 3 5 4 3 3 3 Water / Dry Material Ratio 0.6 0.6 0.5 0.4 0.43
    The resulting block densities are summarized in Table 13.
    Table 13
    Ex. 24 Ex. 25 Ex. 26 Ex. 27 Ex. 28 Density (g / mL) 0.60 0.65 0.74 0.62 0.61
    The density results from examples 24 and 25 (Figure 5) are not bad, but it appears that the water ratio was too high for these mixing designs, as 15 water was present at the top of the blocks before curing. These results show that, in these mixing designs, the optimal amount of Na 2 CO 3 is 3% by weight of the total Dry Material and the optimal ratio of water to Dry Material is around 0.43 (example 28, Figure 6) .
    Examples 29-31: pulverized fly ash, silica sand and hydrogen peroxide
    Aerated concrete blocks based on the mixing concepts summarized in Table 14 were produced according to the procedure of examples 24-28, with the water having been preheated to temperatures of 24 to 24.5 ° C.
    Table 14
    19/24
    Composition (%) Ex. 29 Ex. 30 Ex. 31 Portland cement 14.3 14.3 14.3 Lime 3.4 3.4 3.4 Plaster 0.68 0.69 0.68 Pure Silica Sand 75 71 69 Fly ashsprayed type F (PFAF) 5 10 15 H 2 O 2 0.44 0.44 0.44 Na 2 CO 3 3 3 3 Water / Dry Material Ratio 0.44 0.44 0.44
    The resulting block densities are summarized in Table 15.
    Table 15
    Ex. 29 Ex. 30 Ex. 31 Density (g / mL) 0.60 0.61 0.60
    These results show that the density is more or less constant. Still, the size of the bubbles appears to be better in example 29 (Figure 7) compared to example 31 (Figure 8).
    Examples 32-36: pulverized fly ash, silica sand and hydrogen peroxide
    Aerated concrete blocks based on the mixing concepts summarized in Table 16 were produced according to the procedure of examples 24-28, with the water having been preheated to temperatures of 24 to 25 ° C.
    Table 16
    Composition (%) Ex. 32 Ex. 33 Ex. 34 Ex. 35 Ex. 36 Portland cement 14.3 14.3 14.3 14.3 14.3 Lime 4.2 5.1 5.1 4.2 4.2 Plaster 0.68 0.68 0.68 2.3 0.68 Pure Silica Sand 70 69 68 69 74 Fly ashsprayed type F (PFA-F) 10 10 10 10 5 H 2 O 2 0.44 0.44 0.44 0.44 0.44 Na 2 CO 3 3 3 4 3 3 Water / Dry Material Ratio 0.43 0.43 0.43 0.43 0.43
    The resulting block densities are summarized in Table 17.
    Table 17
    20/24
    Ex. 32 Ex. 33 Ex. 34 Ex. 35 Ex. 36 Density (g / mL) 0.57 0.59 0.81 0.60 0.60
    These results and the comparison of the photos in examples 32 (Figure 9), 33 (Figure 10), 35 (Figure 11) and 36 (Figure 12) show that the best bubble size is obtained in example 36, comprising 5% PFA- C and an additional amount of lime (CaO). The bubble size of example 36 (Figure 12) is even slightly better than the bubble size of example 29 (see Figure 7).
    Examples 37-41: Al and sodium carbonate
    Aerated concrete blocks based on the mixing concepts summarized in Table 18 were produced according to the procedure of example 1 (room temperature).
    Table 18
    Composition (%) Ex. 37 Ex. 38 Ex. 39 Ex. 40 Ex. 41 Portland cement 14.2 14.2 14.2 14.2 14.2 Lime 14.2 14.2 14.2 14.2 14.2 Plaster 2.6 2.6 2.6 2.6 2.6 Pure Silica Sand 69 69 69 69 69 Al (dry) 0.083 0.083 0.083 0.083 0.083 Na 2 CO 3 0 0.3 0.4 0.5 5 Water / Dry Material Ratio 0.62 0.62 0.62 0.62 0.62 The densities of the resulting blocks est estantes; summarized in Table 19.
    Table 19
    Ex. 32 Ex. 33 Ex. 34 Ex. 35 Ex. 36 Density (g / mL) 0.561 0.535 0.515 0.495 0.774
    The recorded temperature profiles show that a rapid increase in temperature is correlated with higher concentrations of Na 2 CO 3 , meaning a faster hardening of the cement mass that prevents complete gas release or retention.
    Figures 13 and 14 show the expansion and bubble size of a test performed with Al and Al and 0.5% Na 2 CO 3 , respectively.
    Examples 42-46: Hydrogen peroxide and sodium carbonate.
    Aerated concrete blocks based on the mixing concepts summarized in
    Table 20 were produced according to the procedure of example 2, with the exception of the H 2 O 2 content , which was 0.44% by weight (room temperature).
    Table 20
    Composition (%) Ex. 42 Ex. 43 Ex. 44 Ex. 45 Ex. 46 Portland cement 14.2 14.2 14.2 14.2 14.2
    21/24
    Lime 14.2 14.2 14.2 14.2 14.2 Plaster 2.6 2.6 2.6 2.6 2.6 Pure Silica Sand 69 69 69 69 69 H 2 O 2 0.44 0.44 0.44 0.44 0.44 Νβ2θθ3 0 3 4 5 6 Water / Dry Material Ratio 0.62 0.62 0.62 0.62 0.62 The densities of the resulting blocks are summarized in Table 21.
    Table 21
    Ex. 42 Ex. 43 Ex. 44 Ex. 45 Ex. 46 Density (g / mL) 0.900 0.697 0.593 0.567 0.670
    Figure 15 shows the expansion and bubble size of a test performed with H2O2 and 5% Ν3 2 00 3 .
    Examples 47-50: Influence of water temperature.
    Aerated concrete blocks were produced according to the procedure of example 45, with the exception of variable water temperature. The resulting block densities are summarized in Table 22.
    Table 22
    Ex. 47 Ex. 48 Ex. 49 Ex. 50 Temperature (° C) 15 20 25 30 Density (g / mL) 0.587 0.567 0.590 0.806
    Examples 51-55: Different mixing times for dry components and H 2 O / Na 2 CO 3 / H 2 O 2 = A and addition of Mn to the mixture = B.
    Aerated concrete blocks were produced according to the procedure of example 45, with different times for mixing dry components and H 2 O / Na 2 CO 3 / H 2 O 2 = A and adding Mn to the mixture = B. The densities of The resulting blocks are summarized in Table 23. In example 55, the water ratio was 0.58.
    Table 23
    Ex. 51 Ex. 52 Ex. 53 Ex. 54 Ex. 55 Mixture A 1’30 " 2’30 " 2' 2' 2' Mixture B 30 ” 30 ” 30 ” 60 ” 30 ” Density (g / mL) 0.610 0.616 0.591 0.629 0.609
    Figure 16 shows the expansion and size of the bubbles in a test performed with
    H 2 O 2 and 5% Na 2 CO 3 . H 2 O 2 is added to the water mixture together with Na 2 CO 3 (example 53).
    Examples 56-58: Influence of the Mn concentration in the mixture.
    Aerated concrete blocks were produced according to the procedure of example 54, with different concentrations of Mn catalyst. Block densities
    The resulting 22/24 are summarized in Table 24.
    Table 24
    Ex. 56 Ex. 57 Ex. 58 Mn (ppm) 0 50 100 Density (g / mL) 0.941 0.829 0.629
    Examples 59-61: Effect of MnO 2 .
    Solid MnO 2 was added as an alternative catalyst. Solids, water, H 2 O 2 and
    Na 2 CO 3 were added and mixed for 2 minutes. Then, MnO 2 was added and mixed for 30 seconds. This test was carried out with and without Na 2 CO 3 . Test 61 was performed by mixing the solid catalyst with the other solids. The resulting block densities are summarized in Table 25.
    Table 25
    Ex. 59 Ex. 60 Ex. 61 MnO 2 with Na 2 CO 3 isolated with sand Mn equivalents (ppm) 100 100 100 Density (g / mL) 1,051 0.87 1.19
    Examples 62-64: Effect of NaHCO 3 .
    Aerated concrete blocks were produced according to the procedure of example 45, with different concentrations of bicarbonate. The resulting block densities are summarized in Table 26.
    Table 26
    Ex. 62 Ex. 63 Ex. 64 NaHCO 3 (%) 3 4 1 Density (g / mL) 1,051 0.953 0.933
    Examples 65-67: Effect of Na 2 CO 3 (low concentrations).
    Aerated concrete blocks were produced according to the following procedure: mix water, Na 2 CO 3 and H 2 O 2 for 2 minutes, then add Mn, in the form of MnSO 4 , H 2 O, mix for 30 seconds. The water ratio was 0.58. The resulting block densities are summarized in Table 27.
    Table 27
    Ex. 62 Ex. 63 Ex. 64 Na 2 CO 3 (%) 0.5 0.2 1 Density (g / mL) 0.548 0.581 0.582
    Figures 17 and 18 show the expansion and bubble size of a test performed with H 2 O 2 and 0.5% Na 2 CO 3 . H 2 O 2 was added to the water mixture together with Na 2 CO 3 (example 62) and the expansion and size of the bubbles were carried out with H 2 O 2
    23/24 and 1% Na 2 CO 3 . H 2 O 2 is added to the water mixture together with Na 2 CO 3 (example 64), respectively.
    Examples 68-74: Effect of the water temperature of 45 ° C. (different water ratios).
    Aerated concrete blocks were produced according to the following procedure: mix water (T = 45 ° C), Na 2 CO 3 and H 2 O 2 for 2 minutes, then add Mn, in the form of MnSO 4 , H 2 O, mix for 30 seconds. The water ratio was 0.58 and 0.62. Example 68 was performed with Al instead of H 2 O 2 . The resulting block densities are summarized in Table 28.
    Table 28
    Ex. 68 Ex. 69 Ex. 70 Ex. 71 Ex. 72 Ex. 73 Ex. 74 Na 2 CO 3 (%) 0 5 0.5 0.2 0.2 0.5 1.5 Water ratio 0.58 0.58 0.58 0.58 0.62 0.62 0.62 Density (g / mL) 0.548 0.740 0.731 0.644 0.634 0.634 0.740
    Figure 19 shows the expansion and bubble size of a test performed with Al and water (T = 45 ° C) (example 68).
    Examples 75-77: Effect of water temperature of 45 ° C and water ratios of 0.76.
    Aerated concrete blocks were produced according to the procedure used in example 69 with different levels of sodium carbonate and water ratio of 0.76. The resulting block densities are summarized in Table 29.
    Table 29
    Ex. 68 Ex. 69 Ex. 70 Na 2 CO 3 (%) 0 0.2 0.5 Density (g / mL) 0.552 0.480 0.496
    Figures 20 and 21 show the expansion and size of the bubbles of tests carried out with H 2 O 2 and Na 2 CO 3 (0.2 and 0.5%, respectively). The water temperature was ° C, the water ratio was 0.76 (examples 69 and 70).
    Brief description of the figures
    The figures correspond to photos of cured aerated concrete blocks.
    Figure 1: photo of a cured body from example 9 (with a needle with a diameter of 1 mm)
    Figure 2: photo of a cured body from example 11 (with a needle with a diameter of 1 mm)
    Figure 3: photo of a cured body from example 16 (with a needle with a diameter of 1 mm)
    Figure 4: photo of a cured body from example 22
    Figure 5: photo of a cured body from example 25 (with a needle with a diameter of 1 mm)
    24/24
    Figure 6: photo of a cured body from example 28 (with a needle with a diameter of 1 mm)
    Figure 7: photo of a cured body from example 29 (with a needle with a diameter of 1 mm)
    Figure 8: photo of a cured body from example 31 (with a needle with a diameter of 1 mm)
    Figure 9: photo of a cured body from example 32 (with a needle with a diameter of 1 mm)
    Figure 10: photo of a cured body from example 33 (with a needle with a diameter of 1 mm)
    Figure 11: photo of a cured body from example 35 (with a needle with a diameter of 1 mm)
    Figure 12: photo of a cured body from example 36 (with a needle with a diameter of 1 mm)
    Figure 13: Photo of the expansion and bubble size of a test performed with Al alone (example 37).
    Figure 14: Photo of the expansion and bubble size of a test performed with Al and 0.5% Na 2 CO 3 (example 40).
    Figure 15: Photo of the expansion and bubble size of a test performed with H 2 O 2 and 5% Na 2 CO 3 (example 45).
    Figure 16: Photo of the expansion and bubble size of a test performed with H 2 O 2 and 5% Na 2 CO 3 . H 2 O 2 is added to the water mixture together with Na 2 CO 3 (example 53).
    Figure 17: Photo of the expansion and bubble size of a test performed with H 2 O 2 and 0.5% Na 2 CO 3 . H 2 O 2 was added to the water mixture together with Nà 2 CO 3 (example 62).
    Figure 18: Photo of the expansion and size of the bubbles performed with H 2 O 2 and 1% Na 2 CO 3 . H 2 O 2 is added to the water mixture together with Na 2 CO 3 (example 64), respectively.
    Figure 19: Photo of the expansion and size of the bubbles made with Al and water (T = 45 ° C) (example 68).
    Figure 20: Photo of the expansion and size of the bubbles performed with H 2 O 2 and Na 2 CO 3 (0.2%). The water temperature was 45 ° C, the water ratio was 0.76 (example 69).
    Figure 21: Photo of the expansion and size of the bubbles performed with H 2 O 2 and Na 2 CO 3 (0.5%). The water temperature was 45 ° C, the water ratio was 0.76 (example 70).
    权利要求:
    Claims (10)
    [1]
    1 - Process of manufacturing aerated concrete construction materials, characterized by the fact that it comprises the following steps:
    The. preparing a composition comprising at least water, a cementitious material, calcium oxide, a compound comprising reactive silicon dioxide, an oxygen source, and a compound selected from sodium carbonate, sodium bicarbonate and sodium hydroxide,
    B. pour the mixture from step (a) into a mold and let the mixture consolidate, thereby forming a stiffened body,
    ç. remove the stiffened body from the mold,
    d. optionally cut and configure the stiffened body, and
    and. heal the stiffened body.
    [2]
    2 - Process according to claim 1, characterized by the fact that the construction material is selected from blocks, bricks, lintels, planks, beams, roof tiles, preferably blocks and bricks.
    [3]
    3 - Process according to claim 1 or 2, characterized by the fact that the oxygen source is selected from hydrogen peroxide, sodium percarbonate, sodium perborate, calcium peroxide, magnesium peroxide, zinc peroxide, mixed peroxide calcium / magnesium and mixtures thereof.
    [4]
    Process according to any one of claims 1 to 3, characterized in that the compound comprising reactive silicon dioxide is selected from sodium silicates; aluminum silicate; calcium silicates; precipitated silica; smoke silica; silicate sand, preferably crushed silicate sand or pure quartz sand, in particular crushed silica sand; diatomaceous earth; fly ash, in particular powdered fly ash, in particular powdered fly ash, more preferably type F powdered fly ash; crushed granulated blast furnace slag and mixtures thereof.
    [5]
    Process according to any one of claims 1 to 4, characterized in that the composition of step (a) comprises at least one aggregate, preferably a fine aggregate, in particular a selected aggregate of sand, bagacina, dry clay or finely crushed cooked, crushed aerated autoclaved concrete, and mixtures of these.
    [6]
    Process according to any one of claims 1 to 5, characterized in that the composition of step (a) comprises at least one compound selected from limestone, calcium carbonate, plaster, hemihydrated calcium sulfate, anhydrite and mixtures thereof .
    [7]
    Process according to any one of claims 1 to 6, characterized
    2/2 because the composition of step (a) comprises at least one catalyst, preferably selected from
    - metals and metal derivatives, preferably transition metals and transition metal derivatives, more preferably oxides and salts of transition metals, in particular Mn, Fe, Cu, Co, Pd and their derivatives, in particular MnO 2 , MnSO 4 , CuO, FeSO 4 , FeO, Fe 2 O 3 , FeCI 3 and KMnO 4 ; and
    - enzymes, in particular catalases.
    [8]
    Process according to any one of claims 1 to 7, characterized in that the composition of step (a) comprises at least one hypochlorite, preferably selected from calcium hypochlorite, sodium hypochlorite and mixtures thereof.
    [9]
    Process according to any one of claims 1 to 8, characterized in that the composition of step (a) is prepared according to the following steps:
    i. mixing, optionally in the presence of part of the water, the at least one cementitious material with the at least one compound comprising reactive silicon dioxide and with the other components optionally used in the Dry Material, ii. add at least one selected compound of sodium carbonate, sodium bicarbonate and sodium hydroxide, optionally in a premix with part of the water, to the mixture of step (i) and homogenize the mixture, preferably by mixing for 1 at 600 seconds, more preferably from 5 to 300 seconds, and iii. add the oxygen source and the remaining part of the water, in which these compounds are optionally totally or partially premixed, to the mixture of step (ii), and homogenize the mixture, preferably by mixing for 1 to 120 seconds, more preferably from 5 to 60 seconds.
    [10]
    Process according to any one of claims 1 to 9, characterized in that, in step (d), the stiffened body of step (c) is cured under ambient conditions, in a climatic chamber, in an oven or in an autoclave, preferably in an autoclave.
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    同族专利:
    公开号 | 公开日
    US20130087075A1|2013-04-11|
    WO2011135083A1|2011-11-03|
    CN102918002B|2016-04-20|
    EP2383238A1|2011-11-02|
    EP2563740A1|2013-03-06|
    CN102918002A|2013-02-06|
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    法律状态:
    2020-05-05| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2020-05-12| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|
    2020-09-15| B11B| Dismissal acc. art. 36, par 1 of ipl - no reply within 90 days to fullfil the necessary requirements|
    2021-10-19| B350| Update of information on the portal [chapter 15.35 patent gazette]|
    优先权:
    申请号 | 申请日 | 专利标题
    EP20100161496|EP2383238A1|2010-04-29|2010-04-29|Process for the manufacture of aerated concrete construction materials and construction materials obtained thereof|
    PCT/EP2011/056857|WO2011135083A1|2010-04-29|2011-04-29|Process for the manufacture of aerated concrete construction materials and construction materials obtained thereof|
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