Bonded aggregate composition and binders for the same

Abstract

Bonded aggregate compositions such as concrete, concrete repair products, high temperature refractories, high temperature insulation and fire resistant insulation are made from an aqueous solution of phosphoric acid and a separate, storable dry mixture of suitable aggregate, monocalcium phosphate, and calcium in the form of calcium aluminate cement or calcium oxide. The proportion of wet to dry constituents is variable so as to select the working time and strength of the aggregate composition, typically on the order of ten to fifteen minutes. The mixture of the preferred dry constituents, and the binder to be mixed with the aggregate to yield the preferred dry mixture, are also disclosed. The binder system is particularly advantageous in that the same set of binder constituents can readily be employed with a variety of aggregates, reducing the cost of providing a variety of aggregate compositions due to the ready availability of the raw materials and obviating the need to stock different binders for different aggregate compositions. Cost is additionally reduced through the use of less purified, and therefore less expensive constituents.

1. A binder useful for bonding an aggregate into a rigid structure upon mixing and setting of said binder and said aggregate, said binder comprising:
 an acidic phosphate-providing component, said component being in a liquid phase at ambient temperature and pressure; and   a dry component comprising CaO, Al 2 O 3 , SiO 2 , and Fe 2 O 3  in proportions adequate to allow working upon mixing of said binder and said aggregate and adequate to yield a rigid structure upon setting of said mixed binder and aggregate, wherein said Fe 2 O 3  comprises between 0.8 and 1.0 percent by weight of said binder.   
     
     
       2. The binder of  claim 1 , wherein the acidic phosphate component comprises a phosphoric acid. 
     
     
       3. The binder of  claim 1 , wherein the acidic phosphate component comprises orthophosphoric acid. 
     
     
       4. The binder of  claim 1 , wherein said dry component comprises at least 0.25 percent by weight of said CaO. 
     
     
       5. A bondable aggregate composition comprising:
 an aggregate; and   a binder, said binder comprising:   an acidic phosphate-providing component, said component being in a liquid phase at ambient temperature and pressure; and   a dry component comprising CaO,Al 2 O 3 ,SiO 2 , and Fe 2 O 3  in proportions adequate to allow working upon mixing of said binder and said aggregate and adequate to yield a rigid structure upon setting of said mixed binder and aggregate, wherein said Fe 2 O 3  comprises between 0.8 and 1.0 percent by weight of said binder.   
     
     
       6. The bondable aggregate of  claim 5 , wherein said acidic phosphate component comprises a phosphoric acid. 
     
     
       7. The bondable aggregate of  claim 5 , wherein said acidic phosphate component comprises orthophosphoric acid. 
     
     
       8. The bondable aggregate composition of  claim 5  further comprising a porosity-providing component, said component comprising low melting point particles dispersed evenly throughout said composition. 
     
     
       9. A method for forming a bonded aggregate structure, said method comprising the steps of:
 admixing a wet or aqueous phosphate-providing component with a dry aggregate composition to form a mixture, said dry aggregate composition containing an aggregate and a binder component, said binder component comprising CaO,Al 2 O 3 ,SiO 2 , and Fe 2 O 3  in proportions adequate to yield a settable mixture, wherein said Fe 2 O 3  comprises between 0.8 and 1.0 percent by weight of said mixture; and   allowing said mixture to set.   
     
     
       10. The method of  claim 9 , wherein phosphate-providing component comprises a phosphoric acid. 
     
     
       11. The method of  claim 9 , wherein phosphate-providing component comprises orthophosphoric acid. 
     
     
       12. The method of  claim 9  further comprising applying said mixture into a mold during or after said admixing step in order to form a bonded aggregate structure. 
     
     
       13. The method of  claim 12  further comprising removing said bonded aggregate structure from said mold after said setting step. 
     
     
       14. The method of  claim 12 , wherein said mold comprises a compound selected from the group consisting of steel, wood, foam, or plastic. 
     
     
       15. The method of  claim 9  and further comprising applying said mixture onto a heat-containing vessel during or after said admixing step in order to line said vessel. 
     
     
       16. The method of  claim 15 , wherein the heat-containing vessel is an incinerator. 
     
     
       17. The method of claim,  15 , wherein the heat-containing vessel is a kiln. 
     
     
       18. The method of  claim 15 , wherein the heat-containing vessel is a cement kiln. 
     
     
       19. The method of  claim 15 , wherein the heat-containing vessel is a line kiln. 
     
     
       20. The method of  claim 15 , wherein the heat-containing vessel is a kaolin kiln. 
     
     
       21. The method of  claim 13 , wherein the heat-containing vessel is a furnace. 
     
     
       22. The method of  claim 21 , wherein the furnace is a fluidized catalytic cracking unit. 
     
     
       23. The method of  claim 21 , wherein the furnace is a sulfur reactor. 
     
     
       24. The method of  claim 21 , wherein the furnace is an ethylene cracker. 
     
     
       25. The method of  claim 21 , wherein the furnace is a coke calciner. 
     
     
       26. The method of  claim 9  further comprising applying said mixture into a vessel for containing an amorphous material during or after said admixing step in order to contain said amorphous material. 
     
     
       27. The method of  claim 26 , wherein said amorphous material comprises a molten metal. 
     
     
       28. The method of  claim 27 , wherein the metal comprises aluminum. 
     
     
       29. The method of  claim 27 , wherein the metal comprises steel. 
     
     
       30. The method of  claim 27 , wherein the metal comprises copper. 
     
     
       31. The method of  claim 27 , wherein the metal comprises iron. 
     
     
       32. The method of  claim 22 , wherein the metal comprises brass. 
     
     
       33. The method of  claim 22 , wherein the metal comprises bronze. 
     
     
       34. The method of  claim 27 , wherein the metal comprises magnesium. 
     
     
       35. The method of  claim 27 , wherein the metal comprises lead. 
     
     
       36. The method of  claim 12 , wherein the bonded aggregate structure is a burner tile or block. 
     
     
       37. The method of  claim 12 , wherein the bonded aggregate structure is a thermocouple sleeve. 
     
     
       38. The method of  claim 12 , wherein the bonded aggregate structure can convey a molten material therein. 
     
     
       39. A binder useful for bonding an aggregate into a rigid structure upon mixing and setting of said binder said aggregate, said binder comprising:
 an acidic phosphate-providing component, said component being in a liquid phase at ambient temperature and pressure; and   a dry component comprising CaO,Al 2 O 3 ,SiO 2 , and Fe 2 O 3  in proportions adequate to allow working upon mixing of said binder and said aggregate and adequate to yield a rigid structure upon setting of said mixed binder and aggregate, wherein said Fe 2 O 3  comprises approximately 1.0 percent by weight.   
     
     
       40. A binder useful for bonding aggregate into a rigid structure upon mixing and setting of said binder and said aggregate, said binder comprising:
 an acidic phosphate-providing component, said component being in a liquid phase at ambient temperature and pressure and comprising SO 4 ; and   a dry component comprising CaO,Al 2 O 3 ,SiO 2 , and Fe 2 O 3  in proportions adequate to allow working upon mixing of said binder and said aggregate and adequate to yield a rigid structure upon setting of said mixed binder and aggregate.   
     
     
       41. A binder useful for bonding an aggregate into a rigid structure upon mixing and setting of said binder and said aggregate, said binder comprising:
 an acidic phosphate-providing component, said component being in a liquid phase at ambient temperature and pressure, said phosphate-providing component having a specific gravity between approximately 1.14-1.71; and   a dry component comprising CaO,Al 2 O 3 ,SiO 2 , and Fe 2 O 3  in proportions adequate to allow working upon mixing of said binder and said aggregate and adequate to yield a rigid structure upon setting of said mixed binder and aggregate.   
     
     
       42. A method of forming a bonded aggregate structure, said method comprising:
 admixing a wet or aqueous phosphate-providing component with a dry aggregate composition to form a mixture with an amount of free water between 5.51 and 9.55 total weight percent, said phosphate-providing component having a specific gravity between approximately 1.14-1.71, said dry aggregate composition containing an aggregate and a binder component, said binder component comprising CaO, Al 2 O 3 , SiO 2 , P 2 O 5 , and Fe 2 O 3  in proportions adequate to yield a mixture setting in 8 to 30 minutes at 70 degrees Fahrenheit, where CaO and P 2 O 5  are present in a weight ratio of 0.40-0.52:1; and   allowing said mixture to set.   
     
     
       43. The method of claim 42 wherein said wet or aqueous phosphate providing component is present from 10 to 30 total weight percent and the structure is a refractory. 
     
     
       44. The method of claim 42 wherein said wet or aqueous phosphate providing component is present from 30 to 60 total weight percent and further comprising expanding or pumping said admixture prior to set. 
     
     
       45. The method of claim 42, wherein phosphate-providing component comprises a phosphoric acid. 
     
     
       46. The method of claim 42, wherein phosphate-providing component comprises orthophosphoric acid. 
     
     
       47. The method of claim 42 further comprising applying said mixture into a mold during or after said admixing step in order to form a bonded aggregate structure. 
     
     
       48. The method of claim 47 further comprising removing said bonded aggregate structure from said mold after said setting step. 
     
     
       49. The method of claim 47, wherein said mold comprises a compound selected from the group consisting of steel, wood, foam, and plastic. 
     
     
       50. The method of claim 42 and further comprising applying said mixture onto a heat-containing vessel during or after said admixing step in order to line said vessel. 
     
     
       51. The method of claim 50, wherein the heat-containing vessel is an incinerator. 
     
     
       52. The method of claim 50, wherein the heat-containing vessel is a kiln. 
     
     
       53. The method of claim 50, wherein the heat-containing vessel is a cement kiln. 
     
     
       54. The method of claim 50, wherein the heat-containing vessel is a lime kiln. 
     
     
       55. The method of claim 50, wherein the heat-containing vessel is a kaolin kiln. 
     
     
       56. The method of claim 48, wherein the heat-containing vessel is a furnace. 
     
     
       57. The method of claim 56, wherein the furnace is a fluidized catalytic cracking unit. 
     
     
       58. The method of claim 56, wherein the furnace is a sulfur reactor. 
     
     
       59. The method of claim 56, wherein the furnace is an ethylene cracker. 
     
     
       60. The method of claim 56, wherein the furnace is a coke calciner. 
     
     
       61. The method of claim 42 further comprising applying said mixture into a vessel for containing an amorphous material during or after said admixing step in order to contain said amorphous material. 
     
     
       62. The method of claim 61, wherein said amorphous material comprises a molten metal. 
     
     
       63. The method of claim 62, wherein the metal comprises aluminum. 
     
     
       64. The method of claim 62, wherein the metal comprises steel. 
     
     
       65. The method of claim 62, wherein the metal comprises copper. 
     
     
       66. The method of claim 62, wherein the metal comprises iron. 
     
     
       67. The method of claim 57, wherein the metal comprises brass. 
     
     
       68. The method of claim 57, wherein the metal comprises bronze. 
     
     
       69. The method of claim 62, wherein the metal comprises magnesium. 
     
     
       70. The method of claim 62, wherein the metal comprises lead. 
     
     
       71. The method of claim 47, wherein the bonded aggregate structure is a burner tile or block. 
     
     
       72. The method of claim 47, wherein the bonded aggregate structure is a thermocouple sleeve. 
     
     
       73. The method of claim 47, wherein the bonded aggregate structure can convey a molten material therein. 
     
     
       74. A method for forming a bonded aggregate structure, said method comprising:
 admixing a wet or aqueous phosphate-providing component with a dry aggregate composition to form a mixture with an amount of free water between 5.51 and 9.55 total weight percent, said phosphate-providing component having a specific gravity between approximately 1.14-1.71, said dry aggregate composition containing an aggregate and a binder component, said binder component comprising CaO, Al 2 O 3 , SiO 2 , P 2 O 5 , and Fe 2 O 3  in proportions adequate to yield a settable mixture, where CaO and P 2 O 5  are present in a weight ratio of 0.40-0.52:1;   allowing said mixture to set; and   exposing the structure to temperature between about 2200° F.-3400° F. without prior predrying or prefiring.   
     
     
       75. The method of claim 74, wherein phosphate-providing component comprises a phosphoric acid. 
     
     
       76. The method of claim 74, wherein phosphate-providing component comprises orthophosphoric acid. 
     
     
       77. The method of claim 74 further comprising applying said mixture into a mold during or after said admixing step in order to form a bonded aggregate structure. 
     
     
       78. The method of claim 77 further comprising removing said bonded aggregate structure from said mold after said setting step. 
     
     
       79. The method of claim 77, wherein said mold comprises a compound selected from the group consisting of steel, wood, foam, or plastic. 
     
     
       80. The method of claim 74 and further comprising applying said mixture onto a heat-containing vessel during or after said admixing step in order to line said vessel. 
     
     
       81. The method of claim 80, wherein the heat-containing vessel is an incinerator. 
     
     
       82. The method of claim 80, wherein the heat-containing vessel is a kiln. 
     
     
       83. The method of claim 80, wherein the heat-containing vessel is a cement kiln. 
     
     
       84. The method of claim 80, wherein the heat-containing vessel is a lime kiln. 
     
     
       85. The method of claim 80, wherein the heat-containing vessel is a kaolin kiln. 
     
     
       86. The method of claim 78, wherein the heat-containing vessel is a furnace. 
     
     
       87. The method of claim 86, wherein the furnace is a fluidized catalytic cracking unit. 
     
     
       88. The method of claim 86, wherein the furnace is a sulfur reactor. 
     
     
       89. The method of claim 86, wherein the furnace is an ethylene cracker. 
     
     
       90. The method of claim 86, wherein the furnace is a coke calciner. 
     
     
       91. The method of claim 74 further comprising applying said mixture into a vessel for containing an amorphous material during or after said admixing step in order to contain said amorphous material. 
     
     
       92. The method of claim 91, wherein said amorphous material comprises a molten metal. 
     
     
       93. The method of claim 92, wherein the metal comprises aluminum. 
     
     
       94. The method of claim 92, wherein the metal comprises steel. 
     
     
       95. The method of claim 92, wherein the metal comprises copper. 
     
     
       96. The method of claim 92, wherein the metal comprises iron. 
     
     
       97. The method of claim 87, wherein the metal comprises brass. 
     
     
       98. The method of claim 87, wherein the metal comprises bronze. 
     
     
       99. The method of claim 92, wherein the metal comprises magnesium. 
     
     
       100. The method of claim 92, wherein the metal comprises lead. 
     
     
       101. The method of claim 77, wherein the bonded aggregate structure is a burner tile or block. 
     
     
       102. The method of claim 77, wherein the bonded aggregate structure is a thermocouple sleeve. 
     
     
       103. The method of claim 77, wherein the bonded aggregate structure can convey a molten material therein.