DECARBONIZED CEMENT BLENDS

Abstract

Various embodiments include cementitious compositions with low levels of embodied greenhouse gas emissions, in particular carbon dioxide, as a result of its production and/or use compared to conventional cementitious materials, such as portland cement. Various embodiments include any cementitious material or materials with low embodied carbon, as well as any material produced using this cement.

Description

Claims

1. A cementitious binder comprising at least 10% precipitated lime by mass and at least 20% at least one pozzolan by mass.

2. The cementitious binder of claim 1, wherein the precipitated lime comprises at least 90% calcium hydroxide by mass.

3. The cementitious binder of claim 2, wherein the cementitious binder comprises less than 50% portland cement clinker by mass.

4. The cementitious binder of claim 2, wherein the cementitious binder comprises less than 25% portland cement clinker by mass.

5. The cementitious binder of claim 3, wherein the cementitious binder comprises at least 1% calcium sulfate by mass.

6. The cementitious binder of claim 3, wherein the precipitated lime is an electrochemical and/or decarbonized precipitated lime.

7. The cementitious binder of claim 3, wherein the precipitated lime has a Barrett, Joyner, and Halenda pore volume of less than 0.02 mL/g.

8. The cementitious binder of claim 3, wherein the precipitated lime has a BET specific surface area of less than 5 m2/g.

9. The cementitious binder of claim 3, wherein the cementitious binder has a paste consistency water demand of less than 0.6 parts water per 1 part cementitious binder by mass.

10. The cementitious binder of claim 9, wherein the precipitated lime is an electrochemical and/or decarbonized precipitated lime.

11. The cementitious binder of claim 3, wherein the cementitious binder comprises at least 0.25% sodium hydroxide by mass.

12. The cementitious binder of claim 3, wherein the at least one pozzolan is a synthetic pozzolan.

13. The cementitious binder of claim 3, wherein the cementitious binder has a 3-day compressive strength of greater than 13 MPa in 2 inch cement mortar cube compressive strength tests, while achieving cement mortar flow greater than 105% as measured according to ASTM Standard C230, at a water to binder mass ratio of less than 0.55.

14. The cementitious binder of claim 12, wherein the cementitious binder has a 3-day compressive strength of greater than 13 MPa in 2 inch cement mortar cube compressive strength tests, while achieving cement mortar flow greater than 105% as measured according to ASTM Standard C230, at a water to binder mass ratio of less than 0.55.

15. The cementitious binder of claim 3, wherein the cementitious binder’s performance meets or exceeds requirements for a GU cement stated in ASTM Standard C1157-20a, including an autoclave length change not more than 0.80% as measured according to ASTM C151, an initial setting time not less than 45 minutes and not more than 420 minutes as measured according to ASTM C191, a mortar air content not more than 12% volume as measured according to ASTM C185, a 3-day compressive strength not less than 13.0 MPa as measured according to ASTM C109, a 7-day compressive strength not less than 20.0 MPa as measured according to ASTM C109, a 28-day compressive strength not less than 28.0 MPa as measured according to ASTM C109, and a mortar bar expansion at 14 days not more than 0.020% as measured according to ASTM C1038.

16. A cementitious binder comprising at least 10% lime by mass, at least 20% of at least one pozzolan by mass, and at least 5% of at least one material selected from the group consisting of tricalcium silicate, calcium aluminate cement, calcium sulfoaluminate cement, and ye’elemite.

17. The cementitious binder of claim 16, wherein the material comprises calcium sulfoaluminate cement.

18. The cementitious binder of claim 16, wherein the cementitious binder contains no portland cement clinker.

19. The cementitious binder of claim 18, wherein the lime is an electrochemical and/or decarbonized lime.

20. A method of forming a cementitious binder comprising: creating a calcium hydroxide through a precipitation reaction;selecting at least one pozzolan;selecting at least one material from the group consisting of portland cement, portland cement clinker, tricalcium silicate, ye’elemite, calcium aluminate cement, calcium sulfoaluminate cement, calcium carbonate, water reducing admixture, set accelerating admixture, defoaming admixture, air entraining admixture, and calcium sulfate; andblending the calcium hydroxide, at least one pozzolan, and the at least one material to create a uniform dry powder mixture.