Expanded and expandable granular materials

Abstract

To provide a method for producing a synthetic expandable granular material having controllable physical properties and controllable chemical composition.SOLUTION: A method of manufacturing an expanded granular material comprises the steps of: forming a mixture comprising a silicate material, an alkali compound and water; curing the mixture to form a solid precursor; crushing and / or milling the solid precursor to form an expandable granular material; and heating the granular material to form an expanded granular material.SELECTED DRAWING: None

Description

[Technical Field]

[0001] The present invention relates to intumescent and intumescent granular materials, methods for making intumescent and intumescent granular materials, thermal insulation products comprising intumescent granular materials, building materials and horticultural or agricultural substrates, and fire retardant materials comprising intumescent granular materials. [Background technology]

[0002] Expanded natural perlite is commonly used as a lightweight filler material, for example, in insulation and building materials. Desirable properties of expanded natural perlite products include low bulk density, low water absorption, low water retention, and low thermal conductivity. However, such properties depend on the chemical composition of the raw perlite before expansion. In particular, expansion of natural perlite is achieved by heating the natural perlite to remove the "bound" or "chemical" water present in the perlite matrix in the form of hydroxyl groups. Therefore, the degree of expansion achieved depends on the starting hydroxyl content. Because perlite is a naturally occurring material, its chemical composition, and particularly its hydroxyl content, is highly variable. Natural perlite often contains other mineral impurities, such as quartz and feldspar. Therefore, synthetic expandable granular materials with controllable physical properties and chemical compositions are desirable. Summary of the Invention

[0003] According to a first aspect, the present invention provides a method for producing an expanded granular material, comprising the steps of: silicate materials; alkaline compounds; and water forming a mixture comprising: curing the mixture to form a solid precursor; crushing and / or milling the solid precursor to form an expandable particulate material; heating the expandable granular material to form an expanded granular material; The present invention relates to a method comprising: According to a second aspect, the present invention relates to an expanded granular material produced by the method according to the first aspect. According to a third aspect, the present invention provides a method for producing a medicament for the treatment of a pulmonary arthritis, comprising Approximately 15kg / m 3 ~about 450kg / m 3 , for example, about 20 kg / m 3 ~about 100kg / m 3 , or approximately 20 kg / m 3 ~about 30kg / m 3 , or approximately 20 kg / m 3 ~about 40kg / m 3 , or approximately 55 kg / m 3 ~about 100kg / m 3 , or approximately 70 kg / m 3 ~about 100kg / m 3 loose bulk density measured in accordance with PI 200-77 ("PI" refers to the "Perlite Institute"); a resistance to consolidation measured according to PI 306-80 of from about 3 PSI to about 350 PSI at 2 inches, e.g., from about 3 PSI to about 200 PSI at 2 inches, or from about 3 PSI to about 100 PSI at 2 inches, or from about 3 PSI to about 10 PSI at 2 inches, or from about 30 PSI to about 80 PSI at 2 inches, or from about 40 PSI to about 75 PSI at 2 inches, or from about 5 PSI to about 20 PSI at 2 inches; and / or The expanded granular material has a thermal conductivity (λ, lambda value), measured in accordance with EN 12667, of between about 0.0300 W / mK and about 0.0700 W / mK, for example between about 0.0320 W / mK and about 0.0420 W / mK, between about 0.0350 W / mK and about 0.0400 W / mK, or between about 0.0360 W / mK and about 0.0410 W / mK, or between about 0.0320 W / mK and about 0.0340 W / mK, or between about 0.042 W / mK and about 0.055 W / mK, or between about 0.055 W / mK and about 0.070 W / mK. According to a fourth aspect, the present invention provides a method for producing a medicament for the treatment of a pulmonary arthritis, comprising about 0.1% to about 25% by weight, for example, about 0.2% to about 5% by weight, of XO (wherein X is an alkali metal such as Na or Li); about 0.1% to about 30% by weight, for example, about 1% to about 20% by weight Al2O3; about 30% to about 80% by weight, e.g., about 40% to about 60% by weight, of SiO2; and About 10% by mass to about 40% by mass, for example, about 15% by mass to about 30% by mass of HO An expandable material comprising: The intumescent material may include less than about 5% by weight, such as less than about 3.5% by weight, of B2O3. According to a fifth aspect, the present invention provides a method for producing an expandable material, comprising the steps of: (a) silicate materials; alkaline compounds; and water forming a mixture comprising: (i) the mixture may contain glass network formers, glass network intermediates and / or glass network modifiers other than silicon; (ii) the mixture may further comprise reactive silica; and / or (iii) the mixture may include two different silicate materials; (b) curing the mixture to form an expandable material; The present invention relates to a method comprising: According to a sixth aspect, the present invention relates to an expandable material produced by a method according to the fifth aspect. According to a seventh aspect, the present invention relates to an insulating product comprising an expanded granular material according to the second or third aspect, or an expanded granular material formed by expanding an intumescent material according to the fourth or sixth aspect, such as a bulk granular material for cavity wall insulation, a filler for acoustic or thermal insulation board, an acoustic or thermal insulation board, a granular filler for insulation of a cryogenic or cold vessel, or an insulating cryogenic or cold vessel. According to an eighth aspect, the present invention relates to a building material, for example a sheet such as a fibre cement sheet, a mortar or plaster such as a cementitious gypsum-based and / or acrylic-based mortar or plaster, or concrete, comprising an expanded granular material according to the second or third aspect, or an expansive material according to the fourth or sixth aspect, formed by expanding the same. According to a ninth aspect, the present invention relates to a horticultural or agricultural substrate or substrate component comprising expanded granular material according to the second or third aspect, or expanded granular material formed by expanding an intumescent material according to the fourth or sixth aspect. According to a tenth aspect, the present invention relates to a flame retardant material comprising an intumescent material according to the fourth or sixth aspect, or an intumescent material produced by the method according to the fifth aspect. According to an eleventh aspect, the present invention relates to the use of an expanded granular material according to the second or third aspect, or an expanded granular material formed by expanding an intumescent material according to the fourth or sixth aspect, in an insulating product, such as a bulk material for insulating cavity walls, an insulating board, or an insulating container such as a cryogenic or cryogenic container, or a building material, such as a sheet such as a fibre cement sheet, a mortar or plaster such as a cementitious gypsum-based and / or acrylic-based mortar or plaster, or concrete, or a horticultural or agricultural substrate or substrate component. DETAILED DESCRIPTION OF THE INVENTION

[0004] It has surprisingly been found that an intumescent material can be produced by forming a mixture containing a silicate material, an alkali compound, and water, and curing the mixture. The intumescent material (i.e., the curing mixture) can be expanded by heating to form the intumescent material. Thus, the curing mixture can be referred to as a solid precursor of the intumescent material.

[0005] Expanded granular materials can be produced by crushing a solid precursor to form an expandable granular material and heating the expandable granular material to form the expanded granular material. The expanded granular materials thus formed have been found to have beneficial physical properties, such as low loose bulk density, high resistance to compaction and grinding, and / or low thermal conductivity, making them suitable for use in thermal insulation products, soundproofing products, building materials, horticultural or agricultural applications, and as fire-retardant materials. The produced expandable materials have low concentrations of impurities and therefore typically form ideally expanded spherical particles with a high concentration (typically greater than 98%) of suspended solids, as described in more detail below.

[0006] initial mixture The first step in forming the intumescent, or intumescent, material involves forming a mixture including a silicate material; an alkali compound; and water.

[0007] Silicate Materials Throughout this specification and the appended claims, the term "silicate material" refers to a material containing substantial proportions of silicon and oxygen. Silicate materials include silicate salts, which have the general formula:

[0008]

number

[0009] The silicate material in the mixture may be a silicate glass. The silicate glass may primarily contain (e.g., consist of) silicon and oxygen. However, the silicate glass may also contain one or more elements in addition to silicon and oxygen. For example, the silicate glass may contain aluminum, sodium, iron, chromium, lead, zinc, calcium, manganese, magnesium, barium, potassium, boron, fluorine, germanium, sulfur, selenium, and / or tellurium in addition to silicon and oxygen. The silicate glass may be selected from fused silica glass, soda-lime glass, borosilicate glass, lead oxide glass, aluminosilicate glass, and silica-germania glass. The silicate glass may include (e.g., may be) virgin glass. Additionally or alternatively, the silicate glass may include (e.g., may be) recycled glass, such as recycled glass cullet.

[0010] Unless otherwise specified, particle size characteristics referred to herein for particulate materials such as powdered glass or minerals, when particle sizes are stated to be less than 300 μm, are as measured in the well-known manner by wet Malvern laser scattering (standard ISO 13320-1). In this technique, the size of particles in powders, suspensions, and emulsions can be measured using the diffraction of a laser beam based on the application of Mie theory. Such machines, such as the Malvern Mastersizer S (supplied by Malvern instruments), provide measurements and plots of the cumulative volume percentage of particles having a size less than a given "equivalent sphere diameter" (esd), referred to in the art as the "equivalent sphere diameter" (esd). Average particle size d 50 is the value of particle ESD thus determined, and its d 50 There are 50% by volume of particles with equivalent spherical diameters less than the value.

[0011] When particle sizes are stated to be 300 μm or larger, the particle size is measured by applying sieve size analysis. Specifically, a representative sample of the material is taken with a sampler (300-400 mL) and weighed. The sample is placed on top of a sieve with openings of 300 μm or larger (sieves with smaller openings can be used for finer samples). The sample is introduced into the sieve with the largest opening (located at the top) and a lid is attached on top. The column containing the sieve is shaken back and forth 30 times (as if scrolling) while maintaining contact with the ground. The column is then allowed to free fall four times from a height of 10 cm. The column is rotated 90° and the procedure is repeated. The fraction smaller than 300 μm is then analyzed using a laser particle analyzer.

[0012] The silicate glass may be provided in the form of crushed silicate glass (i.e., silicate glass cullet). The crushed silicate glass may have a maximum particle size of about 200 μm, for example, about 150 μm, or about 100 μm, or about 80 μm, or about 70 μm, or about 65 μm. The crushed silicate glass may have a particle size of about 100 μm or less, for example, about 80 μm or less, or about 60 μm or less, or about 50 μm or less, or about 40 μm or less, or about 35 μm or less, or about 30 μm or less, or about 29 μm or less, or about 28 μm or less. 50 The crushed silicate glass may have a d of about 5 μm or more, for example about 10 μm or more, or about 15 μm or more, or about 20 μm or more, or about 25 μm or more, or about 26 μm or more, or about 27 μm or more, or about 28 μm or more. 50 The crushed silicate glass may have a diameter of about 5 μm to about 100 μm, for example, about 10 μm to about 80 μm, or about 15 μm to about 50 μm, or about 20 μm to about 35 μm, or about 25 μm to about 30 μm, or about 26 μm to about 28 μm, or about 27 μm to about 28 μm, or about 27 μm to about 29 μm, or about 28 μm to about 29 μm. 50 may have The silicate glass may be crushed soda-lime glass having a maximum particle size of about 200 μm, e.g., about 150 μm, or about 100 μm, or about 80 μm, or about 70 μm, or about 65 μm. The silicate glass may have a diameter of about 5 μm to about 100 μm, e.g., about 10 μm to about 80 μm, or about 15 μm to about 50 μm, or about 20 μm to about 35 μm, or about 25 μm to about 30 μm, or about 27 μm to about 29 μm, or about 28 μm to about 29 μm. 50 The glass may be crushed soda lime glass having a The silicate glass may be a crushed borosilicate glass having a maximum particle size of about 200 μm, e.g., about 150 μm, or about 100 μm, or about 80 μm, or about 70 μm. The silicate glass may have a diameter of about 5 μm to about 100 μm, e.g., about 10 μm to about 80 μm, or about 15 μm to about 50 μm, or about 20 μm to about 35 μm, or about 25 μm to about 30 μm, or about 26 μm to about 28 μm, or about 27 μm to about 28 μm, or about 27 μm to about 29 μm. 50 The glass may be a crushed borosilicate glass having the formula:

[0013] Throughout this specification and the appended claims, unless otherwise specified, it is understood that the elemental composition of a glass, mineral, or mixture is expressed in terms of the oxide equivalent of the element present, as is standard in the art. For example, the composition of a glass, mineral, or mixture containing silicon, aluminum, iron, calcium, magnesium, potassium, sodium, and / or boron is expressed in terms of the equivalent content of SiO2, Al2O3, Fe2O3, CaO, MgO, KO2O, Na2O, and / or BO3, respectively. The elemental composition of a glass, mineral, or mixture can be determined using energy dispersive X-ray fluorescence (EDXRF), for example, using a Xepos instrument available from SPECTRO AI GmbH. Similarly, the mineralogical content of a material can be determined using X-ray diffraction, for example, using a SIEMENS D5000 Diffractometer with Cu Kα1 (with Ni filter) radiation, in the 2θ range of 2° to 72° and in steps of 0.02° / sec.

[0014] The silicate glass may contain about 50% by mass or more of SiO2, for example, about 60% by mass or more, or about 70% by mass or more, or about 75% by mass or more, or about 78% by mass or more. The silicate glass may contain about 100% by mass or less of SiO2, for example, about 90% by mass or less, or about 85% by mass or less, or about 80% by mass or less, or about 75% by mass or less, or about 72% by mass or less. The silicate glass may contain about 50% to about 100% by mass of SiO2, for example, about 60% to about 90% by mass, or about 70% to about 80% by mass, or about 70% to about 75% by mass, or about 70% to about 72% by mass, or about 75% to about 80% by mass, or about 78% to about 80% by mass. The silicate glass may be soda-lime glass containing about 50% to about 95% by mass of SiO2, for example, about 60% to about 90% by mass, or about 70% to about 80% by mass, or about 70% to about 75% by mass, or about 70% to about 72% by mass. The silicate glass may be borosilicate glass containing about 50% to about 95% by mass of SiO2, for example, about 60% to about 90% by mass, or about 70% to about 80% by mass, or about 75% to about 80% by mass, or about 78% to about 80% by mass.

[0015] The silicate glass may contain about 0.1% by weight or more, e.g., about 0.2% by weight or more, or about 0.3% by weight or more, or about 0.5% by weight or more, or about 1.0% by weight or more, or about 2.0% by weight or more, or about 3.0% by weight or more Al2O3. The silicate glass may contain about 10% by weight or less, e.g., about 8.0% by weight or less, or about 6.0% by weight or less, or about 5.0% by weight or less, or about 4.0% by weight or less, or about 3.5% by weight or less, or about 3.0% by weight or less, or about 2.0% by weight or less, or about 1.0% by weight or less, or about 0.5% by weight or less Al2O3. The silicate glass may contain about 0.1% to about 10% by mass of Al2O3, for example, about 0.2% to about 8.0% by mass, or about 0.3% to about 6.0% by mass, or about 0.3% to about 0.5% by mass, or about 0.3% to about 0.4% by mass, or about 2% to about 6% by mass, or about 3% to about 4% by mass. The silicate glass may also be soda-lime glass containing about 0.1% to about 10% by mass of Al2O3, for example, about 0.2% to about 8.0% by mass, or about 0.3% to about 6.0% by mass, or about 0.3% to about 0.5% by mass, or about 0.3% to about 0.4% by mass. The silicate glass may be a borosilicate glass containing about 0.1% to about 10% by mass of Al2O3, for example, about 0.2% to about 8.0% by mass, or about 0.3% to about 6.0% by mass, or about 2% to about 6% by mass, or about 3% to about 4% by mass.

[0016] The silicate glass may contain about 0.001% by weight or more, e.g., about 0.005% by weight or more, or about 0.01% by weight or more, or about 0.02% by weight or more, or about 0.03% by weight or more, or about 0.03% by weight or more, or about 0.04% by weight or more, or about 0.05% by weight or more, or about 0.06% by weight or more, or about 0.07% by weight or more, or about 0.08% by weight or more, of Fe2O3. The silicate glass may contain about 1.0% by weight or less, e.g., about 0.5% by weight or less, or about 0.1% by weight or less, or about 0.09% by weight or less, or about 0.08% by weight or less, or about 0.07% by weight or less, or about 0.06% by weight or less of Fe2O3. The silicate glass may contain about 0.001% to about 1.0% by mass of FeO, for example, about 0.005% to about 0.5% by mass, or about 0.01% to about 0.1% by mass, or about 0.04% to about 0.08% by mass, or about 0.05% to about 0.07% by mass, or about 0.05% to about 0.1% by mass, or about 0.06% to about 0.1% by mass, or about 0.07% to about 0.09% by mass. The silicate glass may be soda-lime glass containing about 0.001% to about 1.0% by mass of FeO, e.g., about 0.005% to about 0.5% by mass, or about 0.01% to about 0.1% by mass, or about 0.04% to about 0.08% by mass, or about 0.05% to about 0.07% by mass. The silicate glass may be borosilicate glass containing about 0.001% to about 1.0% by mass of FeO, e.g., about 0.005% to about 0.5% by mass, or about 0.01% to about 0.1% by mass, or about 0.05% to about 0.1% by mass, or about 0.06% to about 0.1% by mass, or about 0.07% to about 0.09% by mass.

[0017] The silicate glass may contain about 0.01% by weight or more, e.g., about 0.05% by weight or more, or about 0.1% by weight or more, or about 0.15% by weight or more, or about 1% by weight or more, or about 5% by weight or more, or about 10% by weight or more, or about 11% by weight or more of CaO. The silicate glass may contain about 20% by weight or less, e.g., about 15% by weight or less, or about 13% by weight or less, or about 10% by weight or less, or about 5% by weight or less, or about 1% by weight or less, or about 0.5% by weight or less, or about 0.2% by weight or less of CaO. The silicate glass may contain about 0.01% to about 20% by mass of CaO, for example, about 0.05% to about 15% by mass, or about 0.1% to about 13% by mass, or about 10% to about 20% by mass, or about 10% to about 15% by mass, or about 11% to about 13% by mass, or about 0.05% to about 1% by mass, or about 0.1% to about 1% by mass, or about 0.1% to about 0.2% by mass. The silicate glass may also be soda-lime glass containing about 0.01% to about 20% by mass of CaO, for example, about 0.05% to about 15% by mass, or about 0.1% to about 13% by mass, or about 10% to about 20% by mass, or about 10% to about 15% by mass, or about 11% to about 13% by mass. The silicate glass may be borosilicate glass containing about 0.01% by mass to about 20% by mass of CaO, for example, about 0.05% by mass to about 15% by mass, or about 0.1% by mass to about 13% by mass, or about 0.05% by mass to about 1% by mass, or about 0.1% by mass to about 1% by mass, or about 0.1% by mass to about 0.2% by mass.

[0018] The silicate glass may contain about 10% by mass or less, for example, about 5% by mass or less, or about 3% by mass or less, of MgO. The silicate glass may contain about 1% by mass or more, for example, about 2% by mass or more, or about 2.5% by mass or more, of MgO. The silicate glass may contain about 1% to about 10% by mass, for example, about 2% to about 5% by mass, or about 2.5% to about 3% by mass of MgO. The silicate glass may be soda-lime glass containing about 1% to about 10% by mass, for example, about 2% to about 5% by mass, or about 2.5% to about 3% by mass of MgO. The silicate glass may be substantially free of MgO, i.e., the silicate glass may be substantially free of MgO. For example, the silicate glass may contain 0.1% by weight or less, e.g., 0.01% by weight or less, or 0.001% by weight or less, of MgO. The silicate glass may be substantially free of MgO, e.g., a borosilicate glass containing 0.1% by weight or less, e.g., 0.01% by weight or less, or 0.001% by weight or less, of MgO.

[0019] The silicate glass may contain about 0.001% by weight or more, e.g., about 0.01% by weight or more, or about 0.04% by weight or more, or about 0.05% by weight or more, or about 0.1% by weight or more, or about 0.2% by weight or more, or about 0.3% by weight or more, or about 0.4% by weight or more of KO. The silicate glass may contain about 5% by weight or less, e.g., about 1% by weight or less, or about 0.5% by weight or less, or about 0.45% by weight or less, or about 0.2% by weight or less, or about 0.1% by weight or less, or about 0.06% by weight or less of KO. The silicate glass may contain about 0.001% to about 5% by mass of KO, for example, about 0.01% to about 1% by mass, or about 0.04% to about 0.5% by mass, or about 0.04% to about 0.1% by mass, or about 0.04% to about 0.06% by mass, or about 0.1% to about 1% by mass, or about 0.2% to about 0.5% by mass, or about 0.4% to about 0.5% by mass. The silicate glass may also be soda-lime glass containing about 0.001% to about 5% by mass of KO, for example, about 0.01% to about 1% by mass, or about 0.04% to about 0.5% by mass, or about 0.04% to about 0.1% by mass, or about 0.04% to about 0.06% by mass. The silicate glass may be a borosilicate glass containing about 0.01% to about 1% by mass, or about 0.04% to about 0.5% by mass, or about 0.1% to about 1% by mass, or about 0.2% to about 0.5% by mass, or about 0.4% to about 0.5% by mass of KO.

[0020] The silicate glass may contain about 1% by weight or more of NaO, for example, about 2% by weight or more, or about 3% by weight or more, or about 5% by weight or more, or about 10% by weight or more, or about 11% by weight or more, or about 12% by weight or more. The silicate glass may contain about 20% by weight or less of NaO, for example, about 15% by weight or less, or about 13% by weight or less, or about 10% by weight or less, or about 5% by weight or less, or about 4% by weight or less. The silicate glass may contain about 1% to about 20% by weight of NaO, for example, about 2% to about 15% by weight, or about 3% to about 13% by weight, or about 10% to about 15% by weight, or about 11% to about 13% by weight, or about 12% to about 13% by weight, or about 1% to about 5% by weight, or about 2% to about 4% by weight. The silicate glass may be soda-lime glass containing about 1% to about 20% by mass of NaO, for example, about 2% to about 15% by mass, or about 3% to about 13% by mass, or about 10% to about 15% by mass, or about 11% to about 13% by mass, or about 12% to about 13% by mass. The silicate glass may be borosilicate glass containing about 1% to about 20% by mass of NaO, for example, about 2% to about 15% by mass, or about 3% to about 13% by mass, or about 1% to about 5% by mass, or about 2% to about 4% by mass.

[0021] The silicate glass may contain about 1% by mass or more of B2O3, for example, about 5% by mass or more, or about 10% by mass or more, or about 13% by mass or more. The silicate glass may contain about 25% by mass or less of B2O3, for example, about 20% by mass or less, or about 15% by mass or less, or about 14% by mass or less. The silicate glass may contain about 1% to about 25% by mass of B2O3, for example, about 5% to about 20% by mass, or about 10% to about 15% by mass, or about 13% to about 14% by mass. The silicate glass may be borosilicate glass containing about 1% to about 25% by mass of B2O3, for example, about 5% to about 20% by mass, or about 10% to about 15% by mass, or about 13% to about 14% by mass.

[0022] The silicate glass may consist primarily of SiO2, Al2O3, Fe2O3, CaO, MgO, K2O, Na2O, and / or B2O3. The silicate glass may contain at least 80% by weight, e.g., at least 90% by weight, or at least 95% by weight, or at least 98% by weight, or at least 99% by weight of SiO2, Al2O3, Fe2O3, CaO, MgO, K2O, Na2O, and / or B2O3. The silicate glass may be soda-lime glass consisting primarily of SiO2, Al2O3, Fe2O3, CaO, MgO, K2O, and Na2O. The silicate glass may be borosilicate glass consisting primarily of SiO2, Al2O3, Fe2O3, CaO, K2O, Na2O, and B2O3.

[0023] The silicate glass may contain one or more elements or compounds in addition to SiO, AlO, FeO, CaO, MgO, KO, NaO, and / or BO. The silicate glass may contain about 0.001% by weight or more, e.g., about 0.01% by weight or more, or about 0.05% by weight or more, or about 0.1% by weight or more, of water and / or volatile materials (i.e., materials that contribute to "loss on ignition" (LOI)). The silicate glass may contain about 1% by weight or less, e.g., about 0.5% by weight or less, or about 0.2% by weight or less, or about 0.1% by weight or less, of water and / or volatile materials (i.e., materials that contribute to "loss on ignition" (LOI)). The silicate glass may contain from about 0.001% to about 1% by weight, e.g., from about 0.01% to about 0.5% by weight, or from about 0.05% to about 0.2% by weight, or from about 0.1% to about 0.2% by weight, of water and / or volatile materials (i.e., materials that contribute to "loss on ignition" (LOI)). The loss on ignition (LOI) of a material may be determined by heating a dry (ie moisture-free) finely ground sample of the material to 1050° C. for 1 hour and measuring the mass loss after heating.

[0024] The silicate glass may be soda-lime glass comprising about 60% to about 80% by weight of SiO2; about 0.1% to about 1% by weight of Al2O3; about 0.01% to about 0.1% by weight of Fe2O3; about 5% to about 20% by weight of CaO; about 1% to about 5% by weight of MgO; about 0.01% to about 0.1% by weight of KO2; and about 5% to about 20% by weight of Na2O; and may contain about 0.01% to about 0.5% by weight of water and / or volatile materials (i.e., materials that contribute to "loss on ignition" (LOI)). The silicate glass may be a borosilicate glass comprising about 70% to about 90% by weight SiO2; about 1% to about 10% by weight Al2O3; about 0.01% to about 0.15% by weight Fe2O3; about 0.05% to about 0.25% by weight CaO; about 0.1% to about 1% by weight KO; about 1% to about 5% by weight Na2O; and about 5% to about 20% by weight BO3; and optionally about 0.01% to about 0.5% by weight water and / or volatile materials (i.e., materials that contribute to "loss on ignition" (LOI)).

[0025] The silicate material in the mixture may be a silicate mineral. For purposes of this specification, the term "mineral" is not limited to crystalline materials, but also includes naturally occurring glasses (e.g., volcanic glasses such as obsidian or perlite), amorphous phases of minerals (e.g., metakaolin), sedimentary rocks (e.g., siliceous rocks), and fossilized biological materials (e.g., diatomaceous earth). The silicate mineral in the mixture may be a naturally occurring silicate mineral. The silicate mineral in the mixture may be a naturally occurring silicate mineral that has been subjected to physical and / or chemical treatment, such as calcination or heat treatment. Alternatively, the silicate mineral in the mixture may be a synthetic silicate mineral. The silicate mineral may be an aluminosilicate mineral.

[0026] The silicate material may be a volcanic glass. Volcanic glass may contain about 50% by weight or more of SiO2, for example, about 60% by weight or more, or about 65% by weight or more, or about 70% by weight or more, or about 75% by weight or more. Volcanic glass may contain about 95% by weight or less of SiO2, for example, about 90% by weight or less, or about 85% by weight or less, or about 80% by weight or less, or about 75% by weight or less, or about 70% by weight or less. Volcanic glass may contain about 50% to about 95% by weight of SiO2, for example, about 60% to about 90% by weight, or about 60% to about 80% by weight, or about 60% to about 70% by weight, or about 70% to about 80% by weight. The volcanic glass may contain about 5% by weight or more Al2O3, for example, about 8% by weight or more, or about 10% by weight or more, or about 12% by weight or more. The volcanic glass may contain about 25% by weight or less Al2O3, for example, about 20% by weight or less, or about 15% by weight or less, or about 12% by weight or less. The volcanic glass may contain about 5% to about 25% by weight Al2O3, for example, about 8% to about 20% by weight, for example, about 8% to about 12% by weight, or about 12% to about 15% by weight.

[0027] The volcanic glass may contain about 0.5% by weight or more, such as about 1% by weight or more, or about 2% by weight or more, Fe2O3. The volcanic glass may contain about 5% by weight or less, such as about 3% by weight or less, or about 2% by weight or less, Fe2O3. The volcanic glass may contain about 0.5% to about 5% by weight, such as about 1% to about 3% by weight, or about 2% to about 3% by weight, or about 1% to about 2% by weight, Fe2O3. The volcanic glass may contain about 0.5% by weight or more of CaO, for example, about 0.8% by weight or more. The volcanic glass may contain about 5% by weight or less of CaO, for example, about 3% by weight or less, or about 2% by weight or less. The volcanic glass may contain about 0.5% to about 5% by weight of CaO, for example, about 0.8% to about 3% by weight, or about 0.8% to about 2% by weight.

[0028] Volcanic glass may contain about 0.05% by weight or more of MgO, e.g., about 0.1% by weight or more, or about 0.2% by weight or more, or about 0.5% by weight or more, or about 1% by weight or more, or about 1.2% by weight or more. Volcanic glass may contain about 10% by weight or less of MgO, e.g., about 5% by weight or less, or about 2% by weight or less, or about 1% by weight or less, or about 0.5% by weight or less, or about 0.3% by weight or less. Volcanic glass may contain about 0.05% to about 10% by weight of MgO, e.g., about 0.1% to about 5% by weight, or about 0.2% to about 2% by weight, or about 0.2% to about 1% by weight, or about 0.2% to about 0.5% by weight, or about 0.2% to about 0.3% by weight, or about 1% to about 5% by weight, or about 1% to about 2% by weight. The volcanic glass may contain about 1% by weight or more, e.g., about 2% by weight or more, or about 3% by weight or more, or about 4% by weight or more, K2O. The volcanic glass may contain about 10% by weight or less, e.g., about 8% by weight or less, or about 6% by weight or less, or about 5% by weight or less, K2O. The volcanic glass may contain about 1% to about 10% by weight, e.g., about 2% to about 8% by weight, or about 3% to about 6% by weight, or about 4% to about 5% by weight, K2O.

[0029] The volcanic glass may contain about 1% by weight or more of Na2O, for example, about 2% by weight or more, or about 3% by weight or more. The volcanic glass may contain about 10% by weight or less of Na2O, for example, about 8% by weight or less, or about 6% by weight or less, or about 4% by weight or less. The volcanic glass may contain about 1% to about 10% by weight of Na2O, for example, about 2% to about 8% by weight, or about 3% to about 6% by weight, or about 3% to about 4% by weight. The volcanic glass may be substantially free of B2O3, for example, the volcanic glass may contain less than 1% by weight B2O3, such as less than 0.1% by weight, or less than 0.01% by weight.

[0030] Volcanic glass may contain about 1% by weight or more, e.g., about 2% by weight or more, or about 2.5% by weight or more, or about 3% by weight or more, or about 4% by weight or more, or about 5% by weight or more, of chemically bound water and / or volatile matter (i.e., substances that contribute to the "loss on ignition" (LOI)). Volcanic glass may contain about 10% by weight or less, e.g., about 8% by weight or less, or about 6% by weight or less, or about 4% by weight or less, or about 3% by weight or less, of chemically bound water and / or volatile matter (i.e., substances that contribute to the "loss on ignition" (LOI)). Volcanic glass may contain about 1% to about 10% by weight, e.g., about 2% to about 8% by weight, or about 2% to about 6% by weight, or about 2% to about 3% by weight, or about 5% to about 6% by weight. Volcanic glass may contain about 70% to about 80% by weight SiO2; about 5% to about 15% by weight Al2O3; about 0.5% to about 1.5% by weight Fe2O3; about 0.5% to about 2% by weight CaO; about 0.05% to about 1% by weight MgO; about 1% to about 10% by weight KO; about 1% to about 8% by weight Na2O; about 1% to about 5% by weight chemically bound water and / or volatile matter (i.e., materials that contribute to "loss on ignition" (LOI)), and may contain less than about 1% by weight B2O3. Volcanic glass may contain about 65% to about 75% by weight SiO2; about 8% to about 17% by weight Al2O3; about 1% to about 5% by weight Fe2O3; about 0.5% to about 2% by weight CaO; about 0.5% to about 5% by weight MgO; about 1% to about 10% by weight KO; about 1% to about 8% by weight Na2O; about 3% to about 8% by weight chemically bound water and / or volatile matter (i.e., materials that contribute to "loss on ignition" (LOI)), and may contain less than 1% by weight B2O3. The volcanic glass has a diameter of about 1 μm or more, for example, about 3 μm or more, or about 5 μm or more, or about 6 μm or more, or about 10 μm or more, or about 20 μm or more, or about 25 μm or more, or about 30 μm or more. 50The volcanic glass may have a diameter of about 250 μm or less, e.g., about 200 μm or less, or about 150 μm or less, or about 100 μm or less, or about 80 μm or less, or about 60 μm or less, or about 50 μm or less, or about 40 μm or less, or about 35 μm or less, or about 30 μm or less, or about 15 μm or less, or about 10 μm or less, or about 8 μm or less, or about 7 μm or less. 50 The volcanic glass may have a diameter of about 1 μm to about 250 μm, for example, about 1 μm to about 200 μm, or about 1 μm to about 150 μm, or about 1 μm to about 100 μm, or about 1 μm to about 80 μm, or about 1 μm to about 60 μm, or about 1 μm to about 50 μm, about 3 μm to about 40 μm, or about 5 μm to about 35 μm, or about 5 μm to about 10 μm, or about 5 μm to about 8 μm, or about 6 μm to about 7 μm, or about 20 μm to about 40 μm, or about 25 μm to about 35 μm. 50 may have

[0031] The silicate material (e.g., silicate glass or silicate mineral) may be a perlitic material. The perlitic material may be perlite. The perlitic material may be naturally occurring perlite, such as naturally occurring perlite ore. Naturally occurring perlite is an amorphous volcanic glass typically formed primarily of silicon dioxide in combination with aluminum oxide, sodium oxide, potassium oxide, iron oxide, magnesium oxide, and / or calcium oxide. Perlite may naturally form by hydration of obsidian. The perlitic material may contain minor crystalline phases, such as biotite, quartz, cristobalite, feldspar, or hydroxysodalite.

[0032] The perlitic material may be unexpanded perlite, such as unexpanded natural perlite ore. The unexpanded perlite, such as unexpanded natural perlite ore, may have a water content of greater than about 2% by mass. The unexpanded perlite, such as unexpanded natural perlite ore, may also be unexpanded perlite obtained from the tailings of natural perlite ore, such as unexpanded natural perlite ore. That is, the unexpanded perlite may be a perlitic material (i.e., a by-product) remaining after the more valuable fractions are removed from the unexpanded natural perlite ore. The tailings of natural perlite ore may be obtained from different stages of perlite ore processing.

[0033] The perlitic material (e.g., unexpanded natural perlite ore) may contain about 50% by weight or more of SiO2, for example, about 60% by weight or more, or about 65% by weight or more, or about 70% by weight or more, or about 75% by weight or more. The perlitic material (e.g., unexpanded natural perlite ore) may contain about 95% by weight or less of SiO2, for example, about 90% by weight or less, or about 85% by weight or less, or about 80% by weight or less, or about 75% by weight or less, or about 70% by weight or less. The perlitic material (e.g., unexpanded natural perlite ore) may contain about 50% to about 95% by weight of SiO2, for example, about 60% to about 90% by weight, or about 60% to about 80% by weight, or about 60% to about 70% by weight, or about 70% to about 80% by weight.

[0034] The perlitic material (e.g., unexpanded natural perlite ore) may contain about 5% by weight or more Al2O3, e.g., about 8% by weight or more, or about 10% by weight or more, or about 12% by weight or more. The perlitic material (e.g., unexpanded natural perlite ore) may contain about 25% by weight or less Al2O3, e.g., about 20% by weight or less, or about 15% by weight or less, or about 12% by weight or less. The perlitic material (e.g., unexpanded natural perlite ore) may contain about 5% to about 25% by weight Al2O3, e.g., about 8% to about 20% by weight, e.g., about 8% to about 12% by weight, or about 12% to about 15% by weight.

[0035] The perlitic material (e.g., unexpanded natural perlite ore) may contain about 0.5% by weight or more Fe2O3, such as about 1% by weight or more, or about 2% by weight or more. The perlitic material (e.g., unexpanded natural perlite ore) may contain about 5% by weight or less Fe2O3, such as about 3% by weight or less, or about 2% by weight or less. The perlitic material (e.g., unexpanded natural perlite ore) may contain about 0.5% to about 5% by weight Fe2O3, such as about 1% to about 3% by weight, or about 2% to about 3% by weight, or about 1% to about 2% by weight Fe2O3. The perlitic material (e.g., unexpanded natural perlite ore) may contain about 0.5% by weight or more, e.g., about 0.8% by weight or more, of CaO. The perlitic material (e.g., unexpanded natural perlite ore) may contain about 5% by weight or less, e.g., about 3% by weight or less, or about 2% by weight or less, of CaO. The perlitic material (e.g., unexpanded natural perlite ore) may contain about 0.5% to about 5% by weight, e.g., about 0.8% to about 3% by weight, or about 0.8% to about 2% by weight of CaO.

[0036] The perlitic material (e.g., unexpanded natural perlite ore) may contain about 0.05% by weight or more, e.g., about 0.1% by weight or more, or about 0.2% by weight or more, or about 0.5% by weight or more, or about 1% by weight or more, or about 1.2% by weight or more MgO. The perlitic material (e.g., unexpanded natural perlite ore) may contain about 10% by weight or less, e.g., about 5% by weight or less, or about 2% by weight or less, or about 1% by weight or less, or about 0.5% by weight or less, or about 0.3% by weight or less MgO. The perlitic material (e.g., unexpanded natural perlite ore) may contain about 0.05% to about 10% by weight of MgO, for example, about 0.1% to about 5% by weight, or about 0.2% to about 2% by weight, or about 0.2% to about 1% by weight, or about 0.2% to about 0.5% by weight, or about 0.2% to about 0.3% by weight, or about 1% to about 5% by weight, or about 1% to about 2% by weight. The perlitic material (e.g., unexpanded natural perlite ore) may contain about 1% by weight or more, e.g., about 2% by weight or more, or about 3% by weight or more, or about 4% by weight or more, of K2O. The perlitic material (e.g., unexpanded natural perlite ore) may contain about 10% by weight or less, e.g., about 8% by weight or less, or about 6% by weight or less, or about 5% by weight or less, of K2O. The perlitic material (e.g., unexpanded natural perlite ore) may contain about 1% to about 10% by weight, e.g., about 2% to about 8% by weight, or about 3% to about 6% by weight, or about 4% to about 5% by weight of K2O.

[0037] The perlitic material (e.g., unexpanded natural perlite ore) may contain about 1% by weight or more of NaO, e.g., about 2% by weight or more, or about 3% by weight or more. The perlitic material (e.g., unexpanded natural perlite ore) may contain about 10% by weight or less of NaO, e.g., about 8% by weight or less, or about 6% by weight or less, or about 4% by weight or less. The perlitic material (e.g., unexpanded natural perlite ore) may contain about 1% to about 10% by weight of NaO, e.g., about 2% to about 8% by weight, or about 3% to about 6% by weight, or about 3% to about 4% by weight. The perlitic material (e.g., unexpanded natural perlite ore) may be substantially free of B2O3. For example, the perlitic material (e.g., unexpanded natural perlite ore) may contain less than 1% by weight B2O3, e.g., less than 0.1% by weight, or less than 0.01% by weight B2O3.

[0038] The perlitic material (e.g., unexpanded natural perlite ore) may contain about 1% by weight or more, e.g., about 2% by weight or more, or about 2.5% by weight or more, or about 3% by weight or more, or about 4% by weight or more, or about 5% by weight or more of chemically bound water and / or volatile matter (i.e., materials that contribute to "loss on ignition" (LOI)). The perlitic material (e.g., unexpanded natural perlite ore) may contain about 10% by weight or less, e.g., about 8% by weight or less, or about 6% by weight or less, or about 4% by weight or less, or about 3% by weight or less of chemically bound water and / or volatile matter (i.e., materials that contribute to "loss on ignition" (LOI)). The perlitic material (e.g., unexpanded natural perlite ore) may contain from about 1% to about 10%, e.g., from about 2% to about 8%, or from about 2% to about 6%, or from about 2% to about 3%, or from about 5% to about 6%, by weight, of chemically bound water and / or volatile matter (i.e., materials that contribute to "loss on ignition" (LOI)). Perlitic materials (e.g., unexpanded natural perlite ore) may contain, by weight, about 70% to about 80% SiO2; about 5% to about 15% Al2O3; about 0.5% to about 1.5% Fe2O3; about 0.5% to about 2% CaO; about 0.05% to about 1% MgO; about 1% to about 10% KO; about 1% to about 8% NaO; about 1% to about 5% chemically bound water and / or volatile matter (i.e., materials that contribute to "loss on ignition" (LOI)), and may contain less than about 1% BO3.

[0039] Perlitic materials (e.g., unexpanded natural perlite ore) may contain, by weight, about 65% to about 75% SiO; about 8% to about 17% AlO; about 1% to about 5% FeO; about 0.5% to about 2% CaO; about 0.5% to about 5% MgO; about 1% to about 10% KO; about 1% to about 8% NaO; about 3% to about 8% chemically bound water and / or volatile matter (i.e., materials that contribute to "loss on ignition" (LOI)), and may contain less than 1% BO. Perlitic materials (e.g., unexpanded natural perlite ore, e.g., perlite tailings) may contain, by weight, about 67% to about 76% SiO; about 10% to about 14% AlO; about 1% to about 2.5% FeO; about 1% to about 1.5% CaO; about 0.25% to about 1.5% MgO; about 3% to about 5% KO; about 3.5% to about 4% NaO; about 2.51% to about 5% chemically bound water and / or volatile matter (i.e., materials that contribute to "loss on ignition" (LOI)), and may contain less than 1% BO.

[0040] The perlitic material (e.g., unexpanded natural perlite ore) has a diameter of about 1 μm or more, e.g., about 3 μm or more, or about 5 μm or more, or about 6 μm or more, or about 10 μm or more, or about 20 μm or more, or about 25 μm or more, or about 30 μm or more. 50 The perlitic material (e.g., unexpanded natural perlite ore) may have a diameter of about 250 μm or less, e.g., about 200 μm or less, or about 150 μm or less, or about 100 μm or less, or about 80 μm or less, or about 60 μm or less, or about 50 μm or less, or about 40 μm or less, or about 35 μm or less, or about 32 μm or less, or about 30 μm or less, or about 15 μm or less, or about 10 μm or less, or about 8 μm or less, or about 7 μm or less. 50 The perlitic material (e.g., unexpanded natural perlite ore) may have a diameter of about 1 μm to about 250 μm, for example, about 1 μm to about 200 μm, or about 1 μm to about 150 μm, or about 1 μm to about 100 μm, or about 1 μm to about 80 μm, or about 1 μm to about 60 μm, or about 1 μm to about 50 μm, about 3 μm to about 40 μm, or about 5 μm to about 32 μm, or about 5 μm to about 35 μm, or about 5 μm to about 10 μm, or about 5 μm to about 8 μm, or about 6 μm to about 7 μm, or about 20 μm to about 40 μm, or about 25 μm to about 35 μm. 50 may have

[0041] Perlitic materials (e.g., unexpanded natural perlite ore, e.g., perlite tailings) have a d of about 5 μm to about 32 μm. 50and may contain about 67% to about 76% by weight of SiO2; about 10% to about 14% by weight of Al2O3; about 1% to about 2.5% by weight of Fe2O3; about 1% to about 1.5% by weight of CaO; about 0.25% to about 1.5% by weight of MgO; about 3% to about 5% by weight of KO; about 3.5% to about 4% by weight of Na2O; about 2.51% to about 5% by weight of chemically bound water and / or volatile matter (i.e., materials that contribute to "loss on ignition" (LOI)), and may contain less than 1% by weight of B2O3.

[0042] The silicate material (e.g., silicate mineral) may be a phyllosilicate mineral. The phyllosilicate mineral may be a clay mineral, i.e., a hydrated aluminum phyllosilicate mineral. The silicate material (e.g., silicate mineral) may be selected from halloysite, kaolinite, illite, montmorillonite, nontronite, beidellite, vermiculite, talc, sepiolite, palygorskite, and pyrophyllite. The silicate material (e.g., silicate mineral) may be kaolin, such as calcined kaolin (i.e., metakaolin). The silicate material (e.g., silicate mineral) may be bentonite or any other smectite-containing clay mineral. The silicate material (e.g., silicate mineral) may be bentonite tailings, such as Na-bentonite tailings or Ca-bentonite tailings. The silicate material (eg, silicate mineral) may be diatomaceous earth or a diatomaceous earth-containing mineral, such as a mineral containing both diatomaceous earth and clay minerals (in any relative proportions).

[0043] The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may comprise about 30% by weight or more, e.g., about 40% by weight or more, or about 50% by weight or more, or about 60% by weight or more of SiO2. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may comprise up to about 100% by weight, e.g., about 99% by weight or less, or about 95% by weight or less, or about 90% by weight or less, or about 85% by weight or less, or about 80% by weight or less, or about 70% by weight or less, or about 60% by weight or less of SiO2. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain about 30% to about 100% by weight SiO2, e.g., about 40% to about 99% by weight, or about 50% to about 95% by weight, or about 60% to about 90% by weight, or about 60% to about 85% by weight. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain about 0.1% by weight or more NaO, e.g., about 0.5% by weight or more, or about 1% by weight or more, or about 2% by weight or more. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain about 40% by weight or less NaO, e.g., about 30% by weight or less, or about 20% by weight or less, or about 15% by weight or less. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain about 0.1% by weight to about 40% by weight NaO, e.g., about 0.5% by weight to about 30% by weight, or about 1% by weight to about 30% by weight, or about 2% by weight to about 15% by weight.

[0044] The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain substantially 0% by weight of KO. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain about 0.01% by weight or more of KO. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain about 20% by weight or less of KO, e.g., about 15% by weight or less, or about 10% by weight or less, or about 6% by weight or less of KO. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain about 0% to about 20% by weight of KO, e.g., about 0% to about 15% by weight, or about 0.01% to about 10% by weight, or about 0.01% to about 6% by weight.

[0045] The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain substantially 0% by weight of CaO. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain about 0.05% by weight or more of CaO. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain about 20% by weight or less of CaO, for example, about 15% by weight or less of CaO. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain about 0% to about 20% by weight of CaO, for example, about 0.05% to about 15% by weight of CaO. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain substantially 0% Al2O3 by mass. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain about 0.1% Al2O3 by mass or more. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain about 20% Al2O3 by mass or less, for example, about 15% Al2O3 by mass or less. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain about 0% to about 20% Al2O3 by mass, for example, about 0.1% to about 15% Al2O3 by mass.

[0046] The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain substantially 0% by weight of B2O3. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain about 0.01% by weight or more of B2O3, e.g., about 0.05% by weight or more, or about 0.1% by weight or more of B2O3. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain about 20% by weight or less of B2O3, e.g., about 15% by weight or less, or about 10% by weight or less of B2O3. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain about 0% to about 20% by weight of B2O3, for example, about 0% to about 15% by weight, or about 0.01% to about 10% by weight, or about 0.1% to about 10% by weight. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain substantially 0% by weight of PbO. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain about 0.01% by weight or more of PbO, e.g., about 0.05% by weight or more, or about 0.1% by weight or more of PbO. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain about 20% by weight or less of PbO, e.g., about 15% by weight or less, or about 10% by weight or less of PbO. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain about 0% to about 20% by weight of PbO, e.g., about 0% to about 15% by weight, or about 0.01% to about 10% by weight, or about 0.1% to about 10% by weight of PbO.

[0047] The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain substantially 0% by weight of MgO. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain about 0.01% by weight or more, e.g., about 0.05% by weight or more, or about 0.1% by weight or more of MgO. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain about 10% by weight or less, e.g., about 5% by weight or less, or about 2% by weight or less of MgO. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain about 0% to about 10% by weight of MgO, e.g., about 0% to about 5% by weight, or about 0.01% to about 2% by weight, or about 0.1% to about 2% by weight of MgO. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain substantially 0% by weight BaO. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain about 0.01% by weight or more BaO, e.g., about 0.05% by weight or more, or about 0.1% by weight or more BaO. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain about 10% by weight or less BaO, e.g., about 5% by weight or less, or about 2% by weight or less BaO. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain about 0% to about 10% by weight BaO, e.g., about 0% to about 5% by weight, or about 0.01% to about 2% by weight, or about 0.1% to about 2% by weight BaO.

[0048] The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may include about 50% to about 95% by weight, e.g., about 60% to about 85% by weight, SiO2; about 1% to about 30% by weight, e.g., about 2% to about 15% by weight, Na2O; about 0% to about 15% by weight, e.g., about 0.01% to about 6% by weight, KO2; about 0% to about 20% by weight, e.g., about 0.05% to about 15% by weight, CaO; about 0% to about 20% by weight, e.g., about 0.1% to about 15% by weight, Al2O3; about 20% by weight or less, e.g., less than about 15% by weight, BO3; about 20% by weight or less, e.g., less than about 15% by weight, PbO; about 10% by weight or less, e.g., less than about 5% by weight, MgO; and about 10% by weight or less, e.g., less than about 5% by weight, BaO. The silicate material may be crystalline. Alternatively, the silicate material may be amorphous. The silicate material may comprise about 25% by weight or more, e.g., about 50% by weight or more, or about 75% by weight or more, or about 90% by weight or more of amorphous material. For example, the silicate material may comprise about 25% by weight to about 100% by weight, e.g., about 50% by weight to about 100% by weight, or about 75% by weight to about 100% by weight, or about 90% by weight to about 100% by weight of amorphous material.

[0049] Alkaline compounds An alkali compound is a compound of an alkali metal or an alkaline earth metal. Thus, the alkali compound may be an alkali metal compound or an alkaline earth metal compound.

[0050] The alkali compound may be an alkali salt. An alkali salt is a basic salt of an alkali metal or alkaline earth metal. Therefore, the alkali salt may be an alkali metal salt or an alkaline earth metal salt. The alkali salt may be a hydroxide, carbonate, or silicate salt of an alkali metal or alkaline earth metal, i.e., the alkali salt may be an alkali hydroxide, alkali carbonate, or alkali silicate. The alkali salt may be an alkali metal hydroxide, alkali metal carbonate, or alkali metal silicate. The alkali salt may be selected from sodium hydroxide (NaOH), lithium hydroxide (LiOH), potassium hydroxide (KOH), sodium carbonate (NaCO), lithium carbonate (LiCO), potassium carbonate (NaCO), sodium silicate (NaSiO, NaSiO, or NaSiO), lithium silicate (LiSiO, LiSiO, or LiSiO), and potassium silicate (KSiO, KSiO, or KSiO). In certain embodiments, the alkali salt is a sodium salt, for example, sodium hydroxide. In certain embodiments, the alkali salt is a lithium salt, such as lithium hydroxide. In certain embodiments, the alkali salt is a mixture of sodium and lithium salts, such as a mixture of sodium hydroxide and lithium hydroxide. The ratio of the mass percent of the sodium salt to the mass percent of the lithium salt in the mixture may be about 1 or more, such as about 1.5 or more. The ratio of the mass percent of the sodium salt to the mass percent of the lithium salt in the mixture may be about 20 or less, such as about 15 or less, or about 10 or less. The ratio of the mass percent of the sodium salt to the mass percent of the lithium salt in the mixture may be about 1 to about 20, such as about 1.5 to about 15, or about 1.5 to about 10. For example, the ratio of the mass percent of the sodium hydroxide to the mass percent of the lithium hydroxide in the mixture may be about 1 or more, such as about 1.5 or more. The ratio of the mass percent of the sodium hydroxide to the mass percent of the lithium hydroxide in the mixture may be about 20 or less, such as about 15 or less, or about 10 or less. The ratio of the weight percent sodium hydroxide to the weight percent lithium hydroxide in the mixture may be from about 1 to about 20, such as from about 1.5 to about 15, or from about 1.5 to about 10. The alkali salts may therefore be described as mixed alkali salts, such as sodium / lithium salts or sodium / potassium salts, such as sodium / lithium silicate or sodium / potassium silicate.

[0051] water The water in the mixture may contain one or more impurities, such as dissolved minerals. The water in the mixture may contain about 95% by weight or more HO, e.g., about 96% by weight or more, or about 97% by weight or more, or about 98% by weight or more, or about 99% by weight or more, or about 99.5% by weight or more. The water in the mixture may contain substantially 100% by weight HO. The water in the mixture may contain about 99.999% by weight or less HO, e.g., about 99.99% by weight or less, or about 99.9% by weight or less, or about 99.5% by weight or less, or about 99% by weight or less. The water in the mixture may comprise from about 95% to about 100% by weight HO, for example, from about 96% to about 99.999% by weight, or from about 98% to about 99.99% by weight, or from about 99% to about 99.9% by weight, or from about 95% to about 99.5% by weight, or from about 95% to about 99% by weight.

[0052] Reactive Silica The mixture may include reactive silica in addition to the silicate material, which, if present, has a different chemical composition and / or physical structure (e.g., crystalline, microcrystalline, nanocrystalline, or amorphous phase, microstructure, particle morphology, or shape) than the silicate material. The reactive silica may be a high surface area (i.e., particulate) form of silica. For example, the reactive silica may be about 50 m 2 / g or more, or approximately 100m 2 / g or more, or approximately 200m 2 / g or more, or approximately 300m 2 / g or more (e.g., it may include silica particles having such a specific surface area (e.g., BET specific surface area). 2 / g or less, for example, about 800m 2 / g or less, or approximately 600m 2 The reactive silica may have a specific surface area (e.g., a BET specific surface area) of about 50 m / g or less (e.g., may include particles of silica having such a specific surface area). 2 / g~about 1000m 2 / g, for example, about 100m 2 / g~about 1000m 2 / g, or approximately 200m 2 / g~about 1000m 2 / g, or approximately 300m 2 / g~about 1000m 2 / g, or approximately 50m 2 / g~about 800m 2 / g, or approximately 200m 2 / g~about 800m 2 / g, or approximately 100m 2 / g~about 800m 2 / g, or approximately 300m 2 / g~about 800m 2 / g, or approximately 50m 2 / g~about 600m 2 / g, or approximately 600m 2 / g~about 600m 2 / g, or approximately 100m 2 / g~about 600m 2 / g, or approximately 300m 2 / g~about 600m 2 / g (for example, it may include silica particles having such a specific surface area).

[0053] The reactive silica may be in the form of a medium surface area (i.e., particulate) form of silica. For example, the reactive silica may be in the form of a medium surface area (i.e., particulate) form of silica. 2 / g or more, or approximately 8m 2 / g or more, or approximately 10m 2 / g or more, or approximately 12m 2 / g or more, or approximately 15m 2 / g or more (e.g., BET specific surface area) (e.g., may include silica particles having such a specific surface area). 2 / g or less, for example, about 75m 2 / g or less, or about 50m 2 / g or less, or about 30m 2 The reactive silica may have a specific surface area (e.g., BET specific surface area) of about 5 m / g or less (e.g., may include silica particles having such a specific surface area). 2 / g~about 100m 2 / g, for example, about 8m 2 / g~about 100m 2 / g, or approximately 10 m 2 / g~about 100m 2 / g, or approximately 12 m 2 / g~about 100m 2 / g, or approximately 15m 2 / g~about 100m 2 / g, or approximately 5m 2 / g ~ approx. 75m 2 / g, or approximately 8m 2 / g ~ approx. 75m 2 / g, or approximately 10 m 2 / g ~ approx. 75m 2 / g, or approximately 12 m 2 / g ~ approx. 75m 2 / g, or approximately 15m 2 / g ~ approx. 75m 2 / g, or approximately 5m 2 / g~about 50m 2 / g, or approximately 8m 2 / g~about 50m 2 / g, or approximately 10 m 2 / g~about 50m 2 / g, or approximately 12 m 2 / g~about 50m 2 / g, or approximately 15m 2 / g~about 50m 2 / g, or approximately 5m 2 / g ~ approx. 30m 2 / g, or approximately 8m 2 / g ~ approx. 30m 2 / g, or approximately 10 m 2 / g ~ approx. 30m 2 / g, or approximately 12 m 2 / g ~ approx. 30m 2 / g, or approximately 15m 2 / g ~ approx. 30m 2 / g (for example, it may include silica particles having such a specific surface area).

[0054] The reactive silica may be a low surface area (i.e., particulate) form of silica. For example, the reactive silica may be in the form of a silica having a surface area of ​​about 1 m 2 / g or more, or approximately 2m 2 / g or more (e.g., BET specific surface area) (e.g., may include silica particles having such a specific surface area). 2 / g or less, for example, about 5m 2 / g or less, or about 3m 2 The reactive silica may have a specific surface area (e.g., BET specific surface area) of about 1 m / g or less (e.g., may include silica particles having such a specific surface area). 2 / g~about 10m 2 / g, for example, about 1 m 2 / g~about 5m 2 / g, or approximately 1 m 2 / g ~ approx. 3m 2 / g, or approximately 2m 2 / g~about 10m 2 / g, or approximately 2m 2 / g~about 5m 2 / g, or approximately 2m2 / g ~ approx. 3m 2 / g (for example, it may include silica particles having such a specific surface area).

[0055] The reactive silica may be predominantly (e.g., completely) amorphous. The reactive silica may be at least about 50% (e.g., by volume), such as at least about 60%, or at least about 70%, or at least about 80%, or at least about 90%, or at least about 95% amorphous.

[0056] The reactive silica may include silica fume (e.g., may be silica fume). Silica fume, also known as microsilica, is an amorphous polymorph of silicon dioxide. Silica fume may be provided in the form of a powder, for example, a powder of spherical particles. Silica fume particles have a diameter of about 10 nm or more, for example, about 50 nm or more, or about 100 nm or more, or about 200 nm or more, or about 500 nm or more. 50 The silica fume particles may have a diameter of about 5 μm or less, or about 1 μm or less, or about 900 nm or less, or about 800 nm or less, or about 600 nm or less, or about 500 nm or less, or about 400 nm or less, or about 300 nm or less, or about 200 nm or less. 50 The silica fume particles may have a diameter of about 10 nm to about 5 μm, for example, about 50 nm to about 1 μm, or about 100 nm to about 500 nm, or about 100 nm to about 200 nm. 50 may have Additionally or alternatively, the reactive silica may include fumed silica (e.g., may be fumed silica). Fumed silica, also known as pyrogenic silica, comprises branched aggregates of amorphous silicon dioxide primary particles. The silicon dioxide primary particles have a diameter of about 1 nm or greater, or about 5 nm or greater, or about 10 nm or greater. 50 The silicon dioxide primary particles may have a d of about 1 μm or less, or about 500 nm or less, or about 100 nm or less, or about 50 nm or less. 50The silicon dioxide primary particles may have a diameter of about 1 nm to about 1 μm, for example, about 5 nm to about 500 nm, or about 10 nm to about 100 nm, or about 10 nm to about 50 nm. 50 may have Additionally or alternatively, the reactive silica may comprise (eg be) silica gel, natural volcanic glass, perlitic material or burnt organic matter such as rice husk ash.

[0057] Glass network forming elements The mixture may contain glass network formers other than silicon. The glass network formers other than silicon in the mixture may be provided by silicate materials. Glass network formers are elements whose oxides can spontaneously form covalent glass network structures (e.g., conforming to the Zachariasen rule of glass network formation). Glass network formers include silicon, boron, germanium, and phosphorus. Therefore, the glass network-forming element other than silicon present in the mixture may be boron. For example, the silicate material may be a silicate glass, which is a boron-containing glass such as a borosilicate glass. Additionally or alternatively, the mixture may include one or more other boron sources, such as boric acid or one or more borates (e.g., Borax, i.e., sodium borate). Alternatively, the glass network former other than silicon present in the mixture may be germanium, for example, the silicate material may be a silicate glass, which is a germanium-containing glass such as a silica-germania glass. Alternatively, the glass network-forming element other than silicon present in the mixture may be phosphorus. For example, the silicate material may be a silicate glass, which is a phosphorus-containing glass. Additionally or alternatively, the mixture may include one or more other phosphorus sources, such as phosphoric acid or one or more phosphates.

[0058] Glass network intermediate element The mixture may include one or more glass network intermediate elements. The one or more glass network intermediate elements in the mixture may be provided by a silicate material. Glass network intermediate elements are elements whose oxides do not spontaneously form glass network structures, but which can function as glass network formers when combined with other glass network formers. Glass network intermediates include titanium, aluminum, zirconium, beryllium, magnesium, and zinc. The silicate material may be a silicate glass containing one or more glass network intermediate elements, such as titanium, aluminum, zirconium, beryllium, magnesium, or zinc. For example, the silicate glass may be an aluminum-containing glass, such as an aluminosilicate glass.

[0059] Glass network modifying elements The mixture may include one or more glass network modifying elements. The one or more glass network modifying elements present in the mixture may be provided by a silicate material and / or an alkali compound. A glass network modifier is an element whose oxide, alone or in combination with a glass network former, does not form a glass network structure. When present in a glass, the glass network modifier disrupts or modifies the glass network structure. Glass network modifiers are typically present in glass in ionic form, with the charge of the glass network modifier ion being counterbalanced by nearby non-bridging oxygen atoms covalently bonded to nearby glass network formers. Glass network modifiers include calcium, lead, lithium, sodium, and potassium. The silicate material may be a silicate glass containing one or more glass network modifiers, such as calcium, lead, lithium, sodium, or potassium.

[0060] mixture The mixture may contain about 5% by weight or more, such as about 10% by weight or more, or about 20% by weight or more, or about 30% by weight or more, or about 40% by weight or more, or about 50% by weight or more of the silicate material. The mixture may contain about 90% by weight or less, such as about 80% by weight or less, or about 70% by weight or less, or about 60% by weight or less of the silicate material. The mixture may be about 5% to about 90% by mass, for example, about 10% to about 90% by mass, or about 20% to about 90% by mass, or about 30% to about 90% by mass, or about 40% to about 90% by mass, or about 50% to about 90% by mass, or about 5% to about 80% by mass, or about 10% to about 80% by mass, or about 20% to about 80% by mass, or about 30% to about 80% by mass, or about 40% to about 80% by mass, or about 50% to about 80% by mass, or about 5% to about 80% by mass. The silicate material may comprise about 50% to about 60% by mass, about 10% to about 70% by mass, about 20% to about 70% by mass, about 30% to about 70% by mass, about 40% to about 70% by mass, about 50% to about 70% by mass, about 5% to about 60% by mass, about 10% to about 60% by mass, about 20% to about 60% by mass, about 30% to about 60% by mass, about 40% to about 60% by mass, or about 50% to about 60% by mass.

[0061] The mixture may contain about 5% by weight or more, such as about 10% by weight or more, or about 20% by weight or more, or about 30% by weight or more, or about 40% by weight or more, or about 50% by weight or more of the amorphous silicate material. The mixture may contain about 90% by weight or less, such as about 80% by weight or less, or about 70% by weight or less, or about 60% by weight or less of the amorphous silicate material. The mixture may be about 5% to about 90% by mass, for example, about 10% to about 90% by mass, or about 20% to about 90% by mass, or about 30% to about 90% by mass, or about 40% to about 90% by mass, or about 50% to about 90% by mass, or about 5% to about 80% by mass, or about 10% to about 80% by mass, or about 20% to about 80% by mass, or about 30% to about 80% by mass, or about 40% to about 80% by mass, or about 50% to about 80% by mass, or about 5% by mass. The amorphous silicate material may comprise about 70% by mass, or about 10% by mass to about 70% by mass, or about 20% by mass to about 70% by mass, or about 30% by mass to about 70% by mass, or about 40% by mass to about 70% by mass, or about 50% by mass to about 70% by mass, or about 5% by mass to about 60% by mass, or about 10% by mass to about 60% by mass, or about 20% by mass to about 60% by mass, or about 30% by mass to about 60% by mass, or about 40% by mass to about 60% by mass, or about 50% by mass to about 60% by mass.

[0062] The mixture may comprise about 5% by weight or more, such as about 10% by weight or more, or about 20% by weight or more, or about 30% by weight or more, or about 40% by weight or more, or about 50% by weight or more of the aluminosilicate material. The mixture may comprise about 90% by weight or less, such as about 80% by weight or less, or about 70% by weight or less, or about 60% by weight or less of the aluminosilicate material. The mixture may be about 5% to about 90% by mass, for example, about 10% to about 90% by mass, or about 20% to about 90% by mass, or about 30% to about 90% by mass, or about 40% to about 90% by mass, or about 50% to about 90% by mass, or about 5% to about 80% by mass, or about 10% to about 80% by mass, or about 20% to about 80% by mass, or about 30% to about 80% by mass, or about 40% to about 80% by mass, or about 50% to about 80% by mass, or about 5% by mass. The aluminosilicate material may comprise about 70% by mass, or about 10% by mass to about 70% by mass, or about 20% by mass to about 70% by mass, or about 30% by mass to about 70% by mass, or about 40% by mass to about 70% by mass, or about 50% by mass to about 70% by mass, or about 5% by mass to about 60% by mass, or about 10% by mass to about 60% by mass, or about 20% by mass to about 60% by mass, or about 30% by mass to about 60% by mass, or about 40% by mass to about 60% by mass, or about 50% by mass to about 60% by mass.

[0063] The mixture may contain about 5% by weight or more of silicate salt, for example about 10% by weight or more, or about 20% by weight or more, or about 30% by weight or more, or about 40% by weight or more, or about 50% by weight or more. The mixture may contain about 90% by weight or less of silicate salt, for example about 80% by weight or less, or about 70% by weight or less, or about 60% by weight or less. The mixture may be about 5% to about 90% by mass, for example, about 10% to about 90% by mass, or about 20% to about 90% by mass, or about 30% to about 90% by mass, or about 40% to about 90% by mass, or about 50% to about 90% by mass, or about 5% to about 80% by mass, or about 10% to about 80% by mass, or about 20% to about 80% by mass, or about 30% to about 80% by mass, or about 40% to about 80% by mass, or about 50% to about 80% by mass, or about 5% to about 80% by mass. The silicate salt may comprise about 50% to about 60% by mass, about 10% to about 70% by mass, about 20% to about 70% by mass, about 30% to about 70% by mass, about 40% to about 70% by mass, about 50% to about 70% by mass, about 5% to about 60% by mass, about 10% to about 60% by mass, about 20% to about 60% by mass, about 30% to about 60% by mass, about 40% to about 60% by mass, or about 50% to about 60% by mass.

[0064] The mixture may contain about 5% by weight or more of the aluminosilicate salt, for example about 10% by weight or more, or about 20% by weight or more, or about 30% by weight or more, or about 40% by weight or more, or about 50% by weight or more. The mixture may contain about 90% by weight or less of the aluminosilicate salt, for example about 80% by weight or less, or about 70% by weight or less, or about 60% by weight or less. The mixture may be about 5% to about 90% by mass, for example, about 10% to about 90% by mass, or about 20% to about 90% by mass, or about 30% to about 90% by mass, or about 40% to about 90% by mass, or about 50% to about 90% by mass, or about 5% to about 80% by mass, or about 10% to about 80% by mass, or about 20% to about 80% by mass, or about 30% to about 80% by mass, or about 40% to about 80% by mass, or about 50% to about 80% by mass, or about 5% by mass. The aluminosilicate salt may be present in an amount of about 70% by mass, about 10% by mass to about 70% by mass, about 20% by mass to about 70% by mass, about 30% by mass to about 70% by mass, about 40% by mass to about 70% by mass, about 50% by mass to about 70% by mass, about 5% by mass to about 60% by mass, about 10% by mass to about 60% by mass, about 20% by mass to about 60% by mass, about 30% by mass to about 60% by mass, about 40% by mass to about 60% by mass, or about 50% by mass to about 60% by mass.

[0065] The mixture may contain about 5% by weight or more, e.g., about 10% by weight or more, or about 20% by weight or more, or about 30% by weight or more, or about 40% by weight or more, or about 50% by weight or more of silicate glass. The mixture may contain about 90% by weight or less, e.g., about 80% by weight or less, or about 70% by weight or less, or about 60% by weight or less of silicate glass. The mixture may be about 5% to about 90% by mass, for example, about 10% to about 90% by mass, or about 20% to about 90% by mass, or about 30% to about 90% by mass, or about 40% to about 90% by mass, or about 50% to about 90% by mass, or about 5% to about 80% by mass, or about 10% to about 80% by mass, or about 20% to about 80% by mass, or about 30% to about 80% by mass, or about 40% to about 80% by mass, or about 50% to about 80% by mass, or about 5% to about 80% by mass. % to about 70 mass%, or about 10 mass% to about 70 mass%, or about 20 mass% to about 70 mass%, or about 30 mass% to about 70 mass%, or about 40 mass% to about 70 mass%, or about 50 mass% to about 70 mass%, or about 5 mass% to about 60 mass%, or about 10 mass% to about 60 mass%, or about 20 mass% to about 60 mass%, or about 30 mass% to about 60 mass%, or about 40 mass% to about 60 mass%, or about 50 mass% to about 60 mass% of silicate glass.

[0066] The mixture may contain about 5% by weight or more, e.g., about 10% by weight or more, or about 20% by weight or more, or about 30% by weight or more, or about 40% by weight or more, or about 50% by weight or more of aluminosilicate glass. The mixture may contain about 90% by weight or less, e.g., about 80% by weight or less, or about 70% by weight or less, or about 60% by weight or less of aluminosilicate glass. The mixture may be about 5% by mass to about 90% by mass, for example, about 10% by mass to about 90% by mass, or about 20% by mass to about 90% by mass, or about 30% by mass to about 90% by mass, or about 40% by mass to about 90% by mass, or about 50% by mass to about 90% by mass, or about 5% by mass to about 80% by mass, or about 10% by mass to about 80% by mass, or about 20% by mass to about 80% by mass, or about 30% by mass to about 80% by mass, or about 40% by mass to about 80% by mass, or about 50% by mass to about 80% by mass, or about 5% by mass to about 80% by mass. It may contain about 70% by mass, or about 10% to about 70% by mass, or about 20% to about 70% by mass, or about 30% to about 70% by mass, or about 40% to about 70% by mass, or about 50% to about 70% by mass, or about 5% to about 60% by mass, or about 10% to about 60% by mass, or about 20% to about 60% by mass, or about 30% to about 60% by mass, or about 40% to about 60% by mass, or about 50% to about 60% by mass of aluminosilicate glass.

[0067] The mixture may contain about 5% by weight or more, e.g., about 10% by weight or more, or about 20% by weight or more, or about 30% by weight or more, or about 40% by weight or more, or about 50% by weight or more of borosilicate glass. The mixture may contain about 90% by weight or less, e.g., about 80% by weight or less, or about 70% by weight or less, or about 60% by weight or less of borosilicate glass. The mixture may be about 5% to about 90% by mass, for example, about 10% to about 90% by mass, or about 20% to about 90% by mass, or about 30% to about 90% by mass, or about 40% to about 90% by mass, or about 50% to about 90% by mass, or about 5% to about 80% by mass, or about 10% to about 80% by mass, or about 20% to about 80% by mass, or about 30% to about 80% by mass, or about 40% to about 80% by mass, or about 50% to about 80% by mass, or about 5% by mass. The borosilicate glass may comprise about 70% by mass, or about 10% by mass to about 70% by mass, or about 20% by mass to about 70% by mass, or about 30% by mass to about 70% by mass, or about 40% by mass to about 70% by mass, or about 50% by mass to about 70% by mass, or about 5% by mass to about 60% by mass, or about 10% by mass to about 60% by mass, or about 20% by mass to about 60% by mass, or about 30% by mass to about 60% by mass, or about 40% by mass to about 60% by mass, or about 50% by mass to about 60% by mass.

[0068] For example, the mixture may contain about 5% by weight or more, e.g., about 8% by weight or more, or about 10% by weight or more, or about 12% by weight or more, or about 13% by weight or more, or about 14% by weight or more of borosilicate glass. The mixture may contain about 50% by weight or less, e.g., about 30% by weight or less, or about 25% by weight or less, or about 20% by weight or less, or about 17% by weight or less, or about 16% by weight or less, or about 15% by weight or less, or about 14% by weight or less of borosilicate glass. The mixture may contain about 5% to about 50% by weight of borosilicate glass, for example, about 5% to about 30% by weight, or about 5% to about 25% by weight, or about 10% to about 20% by weight, or about 12% to about 16% by weight, or about 12% to about 14% by weight, or about 13% to about 14% by weight, or about 14% to about 16% by weight, or about 14% to about 15% by weight.

[0069] The mixture may contain about 5% by weight or more of silicate minerals, such as about 10% by weight or more, or about 20% by weight or more, or about 30% by weight or more, or about 40% by weight or more, or about 50% by weight or more. The mixture may contain about 90% by weight or less of silicate minerals, such as about 80% by weight or less, or about 70% by weight or less, or about 60% by weight or less. The mixture may be about 5% to about 90% by mass, for example, about 10% to about 90% by mass, or about 20% to about 90% by mass, or about 30% to about 90% by mass, or about 40% to about 90% by mass, or about 50% to about 90% by mass, or about 5% to about 80% by mass, or about 10% to about 80% by mass, or about 20% to about 80% by mass, or about 30% to about 80% by mass, or about 40% to about 80% by mass, or about 50% to about 80% by mass, or about 5% to about 80% by mass. The silicate mineral may be contained in an amount of about 50% to about 60% by mass, about 10% to about 70% by mass, about 20% to about 70% by mass, about 30% to about 70% by mass, about 40% to about 70% by mass, about 50% to about 70% by mass, about 5% to about 60% by mass, about 10% to about 60% by mass, about 20% to about 60% by mass, about 30% to about 60% by mass, about 40% to about 60% by mass, or about 50% to about 60% by mass.

[0070] The mixture may contain about 5% by weight or more of the aluminosilicate mineral, for example about 10% by weight or more, or about 20% by weight or more, or about 30% by weight or more, or about 40% by weight or more, or about 50% by weight or more. The mixture may contain about 90% by weight or less of the aluminosilicate mineral, for example about 80% by weight or less, or about 70% by weight or less, or about 60% by weight or less. The mixture may be about 5% to about 90% by mass, for example, about 10% to about 90% by mass, or about 20% to about 90% by mass, or about 30% to about 90% by mass, or about 40% to about 90% by mass, or about 50% to about 90% by mass, or about 5% to about 80% by mass, or about 10% to about 80% by mass, or about 20% to about 80% by mass, or about 30% to about 80% by mass, or about 40% to about 80% by mass, or about 50% to about 80% by mass, or about 5% by mass. The aluminosilicate mineral may be contained in an amount of about 70% by mass, about 10% by mass to about 70% by mass, about 20% by mass to about 70% by mass, about 30% by mass to about 70% by mass, about 40% by mass to about 70% by mass, about 50% by mass to about 70% by mass, about 5% by mass to about 60% by mass, about 10% by mass to about 60% by mass, about 20% by mass to about 60% by mass, about 30% by mass to about 60% by mass, about 40% by mass to about 60% by mass, or about 50% by mass to about 60% by mass.

[0071] The mixture may contain about 5% by weight or more, such as about 10% by weight or more, or about 20% by weight or more, or about 30% by weight or more, or about 40% by weight or more, or about 50% by weight or more volcanic glass. The mixture may contain about 90% by weight or less, such as about 80% by weight or less, or about 70% by weight or less, or about 60% by weight or less volcanic glass. The mixture may be about 5% to about 90% by mass, for example, about 10% to about 90% by mass, or about 20% to about 90% by mass, or about 30% to about 90% by mass, or about 40% to about 90% by mass, or about 50% to about 90% by mass, or about 5% to about 80% by mass, or about 10% to about 80% by mass, or about 20% to about 80% by mass, or about 30% to about 80% by mass, or about 40% to about 80% by mass, or about 50% to about 80% by mass, or about 5 The volcanic glass may comprise about 50% to about 60% by mass, about 10% to about 70% by mass, about 20% to about 70% by mass, about 30% to about 70% by mass, about 40% to about 70% by mass, about 50% to about 70% by mass, about 5% to about 60% by mass, about 10% to about 60% by mass, about 20% to about 60% by mass, about 30% to about 60% by mass, about 40% to about 60% by mass, or about 50% to about 60% by mass.

[0072] For example, the mixture may contain about 20% by weight or more of volcanic glass, e.g., about 25% by weight or more, or about 28% by weight or more, or about 30% by weight or more, or about 34% by weight or more. The mixture may contain about 50% by weight or less of volcanic glass, e.g., about 45% by weight or less, or about 40% by weight or less, or about 35% by weight or less, or about 30% by weight or less. The mixture may contain about 20% to about 50% by weight of volcanic glass, e.g., about 25% to about 45% by weight, or about 25% to about 35% by weight, or about 25% to about 30% by weight, or about 28% to about 30% by weight, or about 30% to about 40% by weight, or about 34% to about 35% by weight.

[0073] The mixture may contain about 5% by weight or more of perlitic material, such as about 10% by weight or more, or about 20% by weight or more, or about 30% by weight or more, or about 40% by weight or more, or about 50% by weight or more. The mixture may contain about 90% by weight or less of perlitic material, such as about 80% by weight or less, or about 70% by weight or less, or about 60% by weight or less. The mixture may be about 5% to about 90% by mass, for example, about 10% to about 90% by mass, or about 20% to about 90% by mass, or about 30% to about 90% by mass, or about 40% to about 90% by mass, or about 50% to about 90% by mass, or about 5% to about 80% by mass, or about 10% to about 80% by mass, or about 20% to about 80% by mass, or about 30% to about 80% by mass, or about 40% to about 80% by mass, or about 50% to about 80% by mass, or about 5% to about 80% by mass. % to about 70% by mass, or about 10% to about 70% by mass, or about 20% to about 70% by mass, or about 30% to about 70% by mass, or about 40% to about 70% by mass, or about 50% to about 70% by mass, or about 5% to about 60% by mass, or about 10% to about 60% by mass, or about 20% to about 60% by mass, or about 30% to about 60% by mass, or about 40% to about 60% by mass, or about 50% to about 60% by mass of pearlitic material.

[0074] For example, the mixture may contain about 20% by weight or more of perlitic material, e.g., about 25% by weight or more, or about 28% by weight or more, or about 30% by weight or more, or about 34% by weight or more. The mixture may contain about 50% by weight or less of perlitic material, e.g., about 45% by weight or less, or about 40% by weight or less, or about 35% by weight or less, or about 30% by weight or less. The mixture may contain about 20% by weight to about 50% by weight of perlitic material, e.g., about 25% by weight to about 45% by weight, or about 25% by weight to about 35% by weight, or about 25% by weight to about 30% by weight, or about 28% by weight to about 30% by weight, or about 30% by weight to about 40% by weight, or about 34% by weight to about 35% by weight.

[0075] The mixture may contain about 20% by weight or more of unexpanded natural perlite ore, for example, about 25% by weight or more, or about 28% by weight or more, or about 30% by weight or more, or about 34% by weight or more. The mixture may contain about 50% by weight or less of unexpanded natural perlite ore, for example, about 45% by weight or less, or about 40% by weight or less, or about 35% by weight or less, or about 30% by weight or less. The mixture may contain about 20% by weight to about 50% by weight, for example, about 25% by weight to about 45% by weight, or about 25% by weight to about 35% by weight, or about 25% by weight to about 30% by weight, or about 28% by weight to about 30% by weight, or about 30% by weight to about 40% by weight, or about 34% by weight to about 35% by weight of unexpanded natural perlite ore.

[0076] The mixture may contain about 5% by weight or more of the alkali compound, for example about 8% by weight or more, or about 10% by weight or more, or about 12% by weight or more, or about 15% by weight or more, or about 17% by weight or more. The mixture may contain about 30% by weight or less of the alkali compound, for example about 25% by weight or less, or about 20% by weight or less, or about 18% by weight or less, or about 17% by weight or less, or about 15% by weight or less, or about 14% by weight or less. The mixture may contain about 5% by mass to about 30% by mass of the alkali compound, for example, about 5% by mass to about 25% by mass, or about 5% by mass to about 20% by mass, or about 8% by mass to about 20% by mass, or about 8% by mass to about 18% by mass, or about 10% by mass to about 15% by mass, or about 12% by mass to about 15% by mass, or about 12% by mass to about 14% by mass, or about 10% by mass to about 14% by mass, or about 14% by mass to about 18% by mass, or about 15% by mass to about 17% by mass, or about 16% by mass to about 20% by mass.

[0077] The mixture may contain about 5% by weight or more of alkali hydroxide, such as about 8% by weight or more, or about 10% by weight or more, or about 12% by weight or more, or about 15% by weight or more, or about 17% by weight or more. The mixture may contain about 30% by weight or less of alkali hydroxide, such as about 25% by weight or less, or about 20% by weight or less, or about 18% by weight or less, or about 17% by weight or less, or about 15% by weight or less, or about 14% by weight or less. The mixture may contain about 5% to about 30% by weight of alkali hydroxide, for example, about 5% to about 25% by weight, or about 5% to about 20% by weight, or about 8% to about 20% by weight, or about 8% to about 18% by weight, or about 10% to about 15% by weight, or about 12% to about 15% by weight, or about 12% to about 14% by weight, or about 10% to about 14% by weight, or about 14% to about 18% by weight, or about 15% to about 17% by weight, or about 16% to about 20% by weight.

[0078] The mixture may comprise about 5% by weight or more of alkali carbonate, e.g., about 8% by weight or more, or about 10% by weight or more, or about 12% by weight or more, or about 15% by weight or more, or about 17% by weight or more. The mixture may comprise about 30% by weight or less of alkali carbonate, e.g., about 25% by weight or less, or about 20% by weight or less, or about 18% by weight or less, or about 17% by weight or less, or about 15% by weight or less, or about 14% by weight or less. The mixture may contain about 5% to about 30% by mass of alkali carbonate, for example, about 5% to about 25% by mass, or about 5% to about 20% by mass, or about 8% to about 20% by mass, or about 8% to about 18% by mass, or about 10% to about 15% by mass, or about 12% to about 15% by mass, or about 12% to about 14% by mass, or about 10% to about 14% by mass, or about 14% to about 18% by mass, or about 15% to about 17% by mass, or about 16% to about 20% by mass.

[0079] The mixture may contain about 5% by weight or more, such as about 8% by weight or more, or about 10% by weight or more, or about 12% by weight or more, or about 15% by weight or more, or about 17% by weight or more of alkali silicate. The mixture may contain about 30% by weight or less, such as about 25% by weight or less, or about 20% by weight or less, or about 18% by weight or less, or about 17% by weight or less, or about 15% by weight or less, or about 14% by weight or less of alkali silicate. The mixture may contain about 5% to about 30% by weight of alkali silicate, for example, about 5% to about 25% by weight, or about 5% to about 20% by weight, or about 8% to about 20% by weight, or about 8% to about 18% by weight, or about 10% to about 15% by weight, or about 12% to about 15% by weight, or about 12% to about 14% by weight, or about 10% to about 14% by weight, or about 14% to about 18% by weight, or about 15% to about 17% by weight, or about 16% to about 20% by weight.

[0080] For example, the mixture may contain about 5% by weight or more, e.g., about 8% by weight or more, or about 10% by weight or more, or about 12% by weight or more, or about 15% by weight or more, or about 17% by weight or more of sodium hydroxide, lithium hydroxide, and / or potassium hydroxide. The mixture may contain about 30% by weight or less, e.g., about 25% by weight or less, or about 20% by weight or less, or about 18% by weight or less, or about 17% by weight or less, or about 15% by weight or less, or about 14% by weight or less of sodium hydroxide, lithium hydroxide, and / or potassium hydroxide. The mixture may contain about 5% by mass to about 30% by mass, for example, about 5% by mass to about 25% by mass, or about 5% by mass to about 20% by mass, or about 8% by mass to about 20% by mass, or about 8% by mass to about 18% by mass, or about 10% by mass to about 15% by mass, or about 12% by mass to about 15% by mass, or about 12% by mass to about 14% by mass, or about 10% by mass to about 14% by mass, or about 14% by mass to about 18% by mass, or about 15% by mass to about 17% by mass, or about 16% by mass to about 20% by mass of sodium hydroxide, lithium hydroxide, and / or potassium hydroxide.

[0081] The mixture may contain about 5% by weight or more, e.g., about 8% by weight or more, or about 10% by weight or more, or about 12% by weight or more, or about 15% by weight or more, or about 17% by weight or more of sodium carbonate, lithium carbonate, and / or potassium carbonate. The mixture may contain about 30% by weight or less, e.g., about 25% by weight or less, or about 20% by weight or less, or about 18% by weight or less, or about 17% by weight or less, or about 15% by weight or less, or about 14% by weight or less of sodium carbonate, lithium carbonate, and / or potassium carbonate. The mixture may contain about 5% by mass to about 30% by mass, for example, about 5% by mass to about 25% by mass, or about 5% by mass to about 20% by mass, or about 8% by mass to about 20% by mass, or about 8% by mass to about 18% by mass, or about 10% by mass to about 15% by mass, or about 12% by mass to about 15% by mass, or about 12% by mass to about 14% by mass, or about 10% by mass to about 14% by mass, or about 14% by mass to about 18% by mass, or about 15% by mass to about 17% by mass, or about 16% by mass to about 20% by mass of sodium carbonate, lithium carbonate, and / or potassium carbonate.

[0082] The mixture may contain about 5% by weight or more, e.g., about 8% by weight or more, or about 10% by weight or more, or about 12% by weight or more, or about 15% by weight or more, or about 17% by weight or more of sodium, lithium and / or potassium silicate. The mixture may contain about 30% by weight or less, e.g., about 25% by weight or less, or about 20% by weight or less, or about 18% by weight or less, or about 17% by weight or less, or about 15% by weight or less, or about 14% by weight or less of sodium, lithium and / or potassium silicate. The mixture may contain about 5% by mass to about 30% by mass, for example, about 5% by mass to about 25% by mass, or about 5% by mass to about 20% by mass, or about 8% by mass to about 20% by mass, or about 8% by mass to about 18% by mass, or about 10% by mass to about 15% by mass, or about 12% by mass to about 15% by mass, or about 12% by mass to about 14% by mass, or about 10% by mass to about 14% by mass, or about 14% by mass to about 18% by mass, or about 15% by mass to about 17% by mass, or about 16% by mass to about 20% by mass of sodium silicate, lithium silicate, and / or potassium silicate.

[0083] The mixture may contain about 15% by weight or more of water, for example, about 20% by weight or more, or about 22% by weight or more, or less than about 25% by weight. The mixture may contain about 45% by weight or less of water, for example, about 40% by weight or less, or about 35% by weight or less, or about 30% by weight or less. The mixture may contain about 15% to about 45% by weight of water, for example, about 20% to about 40% by weight, or about 20% to about 30% by weight, or about 25% to about 30% by weight.

[0084] The mixture may include two different silicate materials. For example, the mixture may include a silicate glass (e.g., an aluminosilicate glass) and a silicate mineral (e.g., an aluminosilicate mineral). The mixture may include about 5% by weight or more, e.g., about 8% by weight or more, or about 10% by weight or more, or about 12% by weight or more, or about 15% by weight or more, or about 20% by weight or more of the silicate glass (e.g., an aluminosilicate glass). The mixture may include about 50% by weight or less, e.g., about 40% by weight or less, or about 30% by weight or less, or about 25% by weight or less, or about 20% by weight or less, or about 16% by weight or less of the silicate glass (e.g., an aluminosilicate glass). The mixture may contain about 5% to about 50% by weight of silicate glass (e.g., aluminosilicate glass), e.g., about 8% to about 40% by weight, or about 10% to about 30% by weight, or about 10% to about 20% by weight, or about 12% to about 16% by weight. Additionally, the mixture may contain about 10% or more by weight of silicate mineral (e.g., aluminosilicate mineral), e.g., about 15% or more by weight, or about 20% or more by weight, or about 25% or more by weight. The mixture may contain about 60% or less by weight of silicate mineral (e.g., aluminosilicate mineral), e.g., about 50% or less by weight, or about 45% or less by weight, or about 40% or less by weight, or about 35% or less by weight. The mixture may contain from about 10% to about 60% by weight, for example, from about 15% to about 50% by weight, or from about 20% to about 45% by weight, or from about 25% to about 45% by weight, or from about 25% to about 30% by weight of silicate mineral (e.g., aluminosilicate mineral).

[0085] Alternatively, the mixture may include a first silicate glass (e.g., a first aluminosilicate glass) and a second silicate glass (e.g., a second aluminosilicate glass). The mixture may include about 5% by weight or more of the first silicate glass (e.g., the first aluminosilicate glass), e.g., about 8% by weight or more, or about 10% by weight or more, or about 12% by weight or more, or about 15% by weight or more, or about 20% by weight or more. The mixture may include about 50% by weight or less of the first silicate glass (e.g., the first aluminosilicate glass), e.g., about 40% by weight or less, or about 30% by weight or less, or about 25% by weight or less, or about 20% by weight or less, or about 16% by weight or less. The mixture may contain about 5% to about 50% by weight of the first silicate glass (e.g., the first aluminosilicate glass), e.g., about 8% to about 40% by weight, or about 10% to about 30% by weight, or about 10% to about 20% by weight, or about 12% to about 16% by weight. Additionally, the mixture may contain about 5% or more by weight of the second silicate glass (e.g., the second aluminosilicate glass), e.g., about 8% or more by weight, or about 10% or more by weight, or about 12% or more by weight, or about 15% or more by weight, or about 20% or more by weight. The mixture may contain about 50% or less by weight of the second silicate glass (e.g., the second aluminosilicate glass), e.g., about 40% or less by weight, or about 30% or less by weight, or about 25% or less by weight, or about 20% or less by weight, or about 16% or less by weight. The mixture may include about 5% to about 50% by weight, for example, about 8% to about 40% by weight, or about 10% to about 30% by weight, or about 10% to about 20% by weight, or about 12% to about 16% by weight of the second silicate glass (e.g., the second aluminosilicate glass).

[0086] One of the two different silicate materials may be selected from a perlitic material, such as unexpanded natural perlite ore having a water content of greater than about 2% by weight; a phyllosilicate mineral, such as bentonite, kaolin, or calcined kaolin; or diatomaceous earth. Additionally or alternatively, one of the two different silicate materials may be selected from fused silica glass, soda-lime glass, borosilicate glass, lead oxide glass, aluminosilicate glass, and silica-germania glass. For example, the mixture may be volcanic glasses, such as perlitic materials, for example unexpanded natural perlite ore having a water content of more than about 2% by weight; a first silicate material selected from a phyllosilicate mineral, such as bentonite, kaolin, or calcined kaolin; and diatomaceous earth; or a combination thereof; and It may include a second silicate material selected from fused silica glass, soda-lime glass, borosilicate glass, lead oxide glass, aluminosilicate glass, and silica-germania glass.

[0087] The mixture may include a first silicate material that is a perlitic material and a second silicate material selected from fused silica glass, soda-lime glass, borosilicate glass, lead oxide glass, aluminosilicate glass, and silica-germania glass. The mixture may include perlitic material, such as unexpanded natural perlite ore having a water content greater than about 2% by weight, and a silicate glass other than perlitic material. For example, the mixture may include perlitic material, such as unexpanded natural perlite ore having a water content greater than about 2% by weight, and a borosilicate glass. Both the first silicate material and the second silicate material may be silicate glasses. For example, the mixture may include two different silicate glasses selected from fused silica glass, soda-lime glass, borosilicate glass, lead oxide glass, aluminosilicate glass, and silica-germania glass. The mixture may include borosilicate glass and soda-lime glass.

[0088] The mixture may contain three or more different silicate materials. For example, the mixture may contain a first silicate glass, a second silicate glass different from the first silicate glass, and a silicate mineral different from the first and second silicate glasses. For example, the mixture may contain first and second silicate glasses selected from spent silica glass, soda-lime glass, borosilicate glass, lead oxide glass, aluminosilicate glass, and silica-germanium glass; and a silicate mineral selected from volcanic glass, such as perlitic material, for example, unexpanded natural perlite ore having a water content of more than about 2% by weight; a phyllosilicate mineral, such as bentonite, kaolin, or calcined kaolin; diatomaceous earth; or a combination thereof, such as Moller (i.e., a clayey diatomite containing both clay minerals and diatomaceous earth). The mixture may include borosilicate glass, soda-lime glass, and perlitic material (eg, unexpanded natural perlite ore having a water content greater than about 2% by weight).

[0089] Whenever a mixture is described as including both a silicate material (e.g., a silicate glass or a silicate mineral) and a perlitic material, it is understood that the silicate material (e.g., a silicate glass or a silicate mineral) is not a perlitic material. Similarly, whenever a mixture is described as including both a silicate glass and a silicate mineral, the silicate glass and the silicate mineral are not the same material, i.e., the silicate glass and the silicate mineral differ in chemical composition and / or physical structure, e.g., crystalline or amorphous phase and / or microstructure.

[0090] The mixture may contain about 1% by weight or more, for example about 5% by weight or more, or about 8% by weight or more, or about 10% by weight or more, or about 12% by weight or more, or about 14% by weight or more, or about 20% by weight or more, or about 30% by weight or more, or about 35% by weight or more, or about 40% by weight or more reactive silica. The mixture may contain about 60% by weight or less reactive silica, for example about 50% by weight or less, or about 45% by weight or less, or about 40% by weight or less, or about 30% by weight or less, or about 20% by weight or less, or about 18% by weight or less, or about 15% by weight or less. The mixture may contain about 1% to about 60% by weight of reactive silica, for example, about 5% to about 50% by weight, or about 5% to about 45% by weight, or about 5% to about 25% by weight, or about 5% to about 20% by weight, or about 8% to about 20% by weight, or about 8% to about 18% by weight, or about 8% to about 12% by weight, or about 10% to about 18% by weight, or about 12% to about 18% by weight, or about 14% to about 15% by weight, or about 20% to about 60% by weight, or about 30% to about 50% by weight, or about 35% to about 45% by weight.

[0091] For example, the mixture may contain about 1% by weight or more, such as about 5% by weight or more, or about 8% by weight or more, or about 10% by weight or more, or about 12% by weight or more, or about 14% by weight or more, or about 20% by weight or more, or about 30% by weight or more, or about 35% by weight or more, or about 40% by weight or more silica fume. The mixture may contain about 60% by weight or less, such as about 50% by weight or less, or about 45% by weight or less, or about 40% by weight or less, or about 30% by weight or less, or about 20% by weight or less, or about 18% by weight or less, or about 15% by weight or less silica fume. The mixture may contain from about 1% to about 60% by weight, for example, from about 5% to about 50% by weight, or from about 5% to about 45% by weight, or from about 5% to about 25% by weight, or from about 5% to about 20% by weight, or from about 8% to about 20% by weight, or from about 8% to about 18% by weight, or from about 8% to about 12% by weight, or from about 10% to about 18% by weight, or from about 12% to about 18% by weight, or from about 14% to about 15% by weight, or from about 20% to about 60% by weight, or from about 30% to about 50% by weight, or from about 35% to about 45% by weight of silica fume.

[0092] Alternatively, the mixture may contain about 1% by weight or more, e.g., about 5% by weight or more, or about 8% by weight or more, or about 10% by weight or more, or about 12% by weight or more, or about 14% by weight or more, or about 20% by weight or more, or about 30% by weight or more, or about 35% by weight or more, or about 40% by weight or more fumed silica. The mixture may contain about 60% by weight or less, e.g., about 50% by weight or less, or about 45% by weight or less, or about 40% by weight or less, or about 30% by weight or less, or about 20% by weight or less, or about 18% by weight or less, or about 15% by weight or less fumed silica. The mixture may contain about 1% to about 60% by weight of fumed silica, for example, about 5% to about 50% by weight, or about 5% to about 45% by weight, or about 5% to about 25% by weight, or about 5% to about 20% by weight, or about 8% to about 20% by weight, or about 8% to about 18% by weight, or about 8% to about 12% by weight, or about 10% to about 18% by weight, or about 12% to about 18% by weight, or about 14% to about 15% by weight, or about 20% to about 60% by weight, or about 30% to about 50% by weight, or about 35% to about 45% by weight.

[0093] The mixture may contain about 5% to about 80% by weight, for example, about 10% to about 70% by weight, or about 10% to about 20% by weight, or about 20% to about 70% by weight, or about 30% to about 70% by weight, or about 40% to about 70% by weight, or about 50% to about 70% by weight of the silicate material; about 5% to about 30% by weight, for example, about 5% to about 20% by weight of the alkali compound; and about 20% to about 40% by weight, for example, about 20% to about 30% by weight of water. For example, the mixture may consist of about 40% to about 80% by weight, e.g., about 50% to about 70% by weight, of a silicate material; about 5% to about 30% by weight, e.g., about 5% to about 20% by weight, of an alkali compound; and about 20% to about 50% by weight, e.g., about 20% to about 40% by weight, of water. The mixture may consist of about 40% to about 80% by weight, e.g., about 50% to about 70% by weight, of a silicate glass (e.g., borosilicate glass); about 5% to about 30% by weight, e.g., about 5% to about 20% by weight, of an alkali compound; and about 20% to about 50% by weight, e.g., about 20% to about 40% by weight, of water.

[0094] The mixture may include about 5% to about 80% by weight, for example, about 10% to about 70% by weight, or about 10% to about 50% by weight, or about 10% to about 30% by weight of silicate material; about 10% to about 60% by weight, for example, about 15% to about 50% by weight of reactive silica other than silicate material; about 5% to about 30% by weight, for example, about 5% to about 25% by weight of alkali compound; and about 20% to about 40% by weight, for example, about 20% to about 35% by weight of water. For example, the mixture may consist of about 5% to about 80% by weight, e.g., about 10% to about 70% by weight, or about 10% to about 50% by weight, or about 10% to about 30% by weight of silicate glass (e.g., borosilicate glass and / or soda-lime glass); about 10% to about 60% by weight, e.g., about 15% to about 50% by weight of reactive silica; about 5% to about 30% by weight, e.g., about 5% to about 25% by weight of an alkali compound; and about 20% to about 40% by weight, e.g., about 20% to about 35% by weight of water.

[0095] The mixture may include about 5% to about 50% by weight, for example about 5% to about 40% by weight, of a first silicate material; about 5% to about 50% by weight, for example about 5% to about 40% by weight, of a second silicate material; about 5% to about 30% by weight, for example about 5% to about 25% by weight, of an alkali compound; and about 20% to about 40% by weight, for example about 20% to about 35% by weight, of water. The mixture may include about 5% to about 50% by weight, for example, about 5% to about 40% by weight, of a first silicate glass (e.g., borosilicate glass); about 5% to about 50% by weight, for example, about 5% to about 40% by weight, of a second silicate glass (e.g., soda-lime glass); about 5% to about 30% by weight, for example, about 5% to about 25% by weight, of an alkali compound; and about 20% to about 40% by weight, for example, about 20% to about 35% by weight, of water.

[0096] The mixture may include about 5% to about 50% by weight, for example, about 5% to about 40% by weight, of silicate glass (e.g., borosilicate and / or soda-lime glass); about 5% to about 50% by weight, for example, about 5% to about 40% by weight, of a silicate mineral other than silicate glass; about 5% to about 30% by weight, for example, about 5% to about 25% by weight, of an alkali compound; and about 20% to about 40% by weight, for example, about 20% to about 35% by weight, of water. The mixture may include about 5% to about 50%, e.g., about 5% to about 40%, by weight, of perlitic material (e.g., unexpanded natural perlite ore having a water content greater than about 2% by weight); about 5% to about 50%, e.g., about 5% to about 40%, by weight, of silicate glass other than perlitic material (e.g., borosilicate and / or soda-lime glass); about 5% to about 30%, e.g., about 5% to about 25%, by weight, of an alkali compound; and about 20% to about 40%, e.g., about 20% to about 35%, by weight, of water.

[0097] The mixture may include about 5% to about 50% by weight, for example, about 5% to about 40% by weight, of the first silicate material; about 5% to about 50% by weight, for example, about 5% to about 40% by weight, of the second silicate material; about 5% to about 50% by weight, for example, about 5% to about 40% by weight, of reactive silica other than the first and second silicate materials; about 5% to about 30% by weight, for example, about 5% to about 25% by weight, of an alkali compound; and about 20% to about 40% by weight, for example, about 20% to about 35% by weight, of water. The mixture may include about 5% to about 50% by weight, for example about 5% to about 40% by weight, of the first silicate glass; about 5% to about 50% by weight, for example about 5% to about 40% by weight, of the second silicate glass; about 5% to about 50% by weight, for example about 5% to about 40% by weight, of reactive silica; about 5% to about 30% by weight, for example about 5% to about 25% by weight, of an alkali compound; and about 20% to about 40% by weight, for example about 20% to about 35% by weight, of water.

[0098] The mixture may include about 5% to about 50% by weight, for example, about 5% to about 40% by weight, of silicate glass; about 5% to about 50% by weight, for example, about 5% to about 40% by weight, of silicate mineral; about 5% to about 50% by weight, for example, about 5% to about 40% by weight, of reactive silica; about 5% to about 30% by weight, for example, about 5% to about 25% by weight, of an alkali compound; and about 20% to about 40% by weight, for example, about 20% to about 35% by weight, of water. The mixture may include about 5% to about 50%, e.g., about 5% to about 40%, by weight, of perlitic material (e.g., unexpanded natural perlite ore having a water content greater than about 2% by weight); about 5% to about 50%, e.g., about 5% to about 40%, by weight, of silicate glass other than perlitic material (e.g., borosilicate glass and / or soda-lime glass); about 5% to about 50%, e.g., about 5% to about 40%, by weight, of reactive silica other than the first and second silicate materials; about 5% to about 30%, e.g., about 5% to about 25%, by weight, of an alkali compound; and about 20% to about 40%, e.g., about 20% to about 35%, by weight, of water.

[0099] The mixture may contain about 5% to about 25% by weight, for example, about 10% to about 20% by weight, of silicate glass; about 1% to about 50% by weight, for example, about 5% to about 45% by weight, of reactive silica; about 5% to about 30% by weight, for example, about 10% to about 20% by weight, of an alkali compound; about 20% to about 40% by weight, for example, about 20% to about 30% by weight, of water, and about 20% to about 55% by weight, for example, about 25% to about 50% by weight, of a perlitic material. For example, the mixture may contain about 5% to about 25% by weight, for example, about 10% to about 20% by weight, of borosilicate glass; about 5% to about 20% by weight, for example, about 10% to about 45% by weight, of silica fume; about 5% to about 20% by weight, for example, about 10% to about 20% by weight, of sodium hydroxide and / or lithium hydroxide; about 20% to about 40% by weight, for example, about 20% to about 30% by weight, of water, and may also contain about 20% to about 55% by weight, for example, about 25% to about 50% by weight, of unexpanded natural perlite ore.

[0100] The mixture may include about 5% to about 25% by weight, e.g., about 10% to about 20% by weight, of silicate glass; about 20% to about 50% by weight, e.g., about 25% to about 45% by weight, of perlitic material; about 5% to about 20% by weight, e.g., about 10% to about 15% by weight, of reactive silica; about 5% to about 20% by weight, e.g., about 10% to about 17% by weight, of an alkali compound; and about 20% to about 40% by weight, e.g., about 20% to about 30% by weight, of water. For example, the mixture may include about 5% to about 25% by weight, e.g., about 10% to about 20% by weight, of borosilicate glass; about 20% to about 50% by weight, e.g., about 25% to about 45% by weight, of unexpanded natural perlite ore; about 5% to about 20% by weight, e.g., about 10% to about 15% by weight, of silica fume; about 5% to about 20% by weight, e.g., about 10% to about 17% by weight, of sodium hydroxide and / or lithium hydroxide; and about 20% to about 40% by weight, e.g., about 20% to about 30% by weight, of water. The mixture may comprise (e.g., consist essentially of, or consist of) about 10% to about 15% by weight of silicate glass; about 35% to about 45% by weight of reactive silica; about 15% to about 20% by weight of an alkali compound; and about 25% to about 35% by weight of water. For example, the mixture may comprise (e.g., consist essentially of, or consist of) about 10% to about 15% by weight of borosilicate glass; about 35% to about 45% by weight of silica fume; about 15% to about 20% by weight of sodium hydroxide and / or lithium hydroxide; and about 25% to about 35% by weight of water.

[0101] The mixture may comprise (e.g., consist essentially of, or consist of) about 30% to about 40% by weight of perlitic material, about 10% to about 20% by weight of silicate glass, about 5% to about 15% by weight of reactive silica, about 10% to about 15% by weight of an alkali compound, and about 20% to about 30% by weight of water. For example, the mixture may comprise (e.g., consist essentially of, or consist of) about 30% to about 40% by weight of unexpanded natural perlite ore, about 10% to about 20% by weight of borosilicate glass, about 5% to about 15% by weight of silica fume, about 10% to about 15% by weight of sodium hydroxide and / or lithium hydroxide, and about 20% to about 30% by weight of water.

[0102] The mixture may comprise (e.g., consist essentially of, or consist of) about 25% to about 35% by weight of perlitic material; about 10% to about 20% by weight of silicate glass; about 10% to about 20% by weight of reactive silica; about 10% to about 20% by weight of an alkali compound; and about 20% to about 30% by weight of water. For example, the mixture may comprise (e.g., consist essentially of, or consist of) about 25% to about 35% by weight of unexpanded natural perlite ore; about 10% to about 20% by weight of borosilicate glass; about 10% to about 20% by weight of silica fume; about 10% to about 20% by weight of sodium hydroxide and / or lithium hydroxide; and about 20% to about 30% by weight of water.

[0103] The mixture may comprise (e.g., consist essentially of, or consist of) about 20% to about 50% by weight silicate mineral, about 10% to about 20% by weight silicate glass, about 5% to about 45% by weight reactive silica, about 5% to about 30% by weight alkali compound, and about 15% to about 40% by weight water. For example, the mixture may comprise (e.g., consist essentially of, or consist of) about 20% to about 50% by weight perlitic material, about 10% to about 20% by weight borosilicate and / or soda-lime glass, about 5% to about 45% by weight silica fume, about 5% to about 30% by weight sodium hydroxide and / or lithium hydroxide, and about 15% to about 40% by weight water. The mixture may include (e.g., consist essentially of, or consist of) about 20% to about 50% by weight perlitic material; about 10% to about 20% by weight borosilicate and / or soda-lime glass; about 5% to about 45% by weight silica fume; about 5% to about 20% by weight sodium hydroxide; about 0% to about 10% by weight lithium hydroxide; and about 15% to about 40% by weight water.

[0104] The mixture may contain about 0.01% by weight or more, e.g., about 0.1% by weight or more, or about 1% by weight or more, of glass network formers other than silicon. The mixture may contain about 20% by weight or less, e.g., about 15% by weight or less, or about 10% by weight or less, or about 5% by weight or less, or about 3% by weight or less, or about 1% by weight or less, of glass network formers other than silicon. The mixture may contain about 0.01% to about 10% by weight, e.g., about 0.01% to about 5% by weight, or about 0.01% to about 3% by weight, or about 0.01% to about 1% by weight of glass network formers other than silicon. For example, the mixture may contain about 0.01% by weight or more, e.g., about 0.1% by weight or more, or about 1% by weight or more, of boron. The mixture may contain about 20% by weight or less, e.g., about 15% by weight or less, or about 10% by weight or less, or about 5% by weight or less, or about 3% by weight or less, or about 1% by weight or less, of boron. The mixture may contain about 0.01% by weight to about 10% by weight, e.g., about 0.01% by weight to about 5% by weight, or about 0.01% by weight to about 3% by weight, or about 0.01% by weight to about 1% by weight of boron.

[0105] The mixture may include an amount of boron such that the setting mixture (i.e., solid precursor or expandable material) and / or the expandable material includes less than about 5.0 wt. % B2O3, such as less than about 3.5 wt. % B2O3. The mixture may contain about 0.01% by weight or more of the glass network intermediate element, for example, about 0.1% by weight or more, or about 1% by weight or more. The mixture may contain about 20% by weight or less, for example, about 15% by weight or less, or about 10% by weight or less, or about 5% by weight or less, or about 3% by weight or less, or about 1% by weight or less of the glass network intermediate element. The mixture may contain about 0.01% to about 10% by weight, for example, about 0.01% to about 5% by weight, or about 0.01% to about 3% by weight, or about 0.01% to about 1% by weight of the glass network intermediate element. The mixture may contain about 0.01% by weight or more, e.g., about 0.1% by weight or more, or about 1% by weight or more, of glass network modifier elements. The mixture may contain about 20% by weight or less, e.g., about 15% by weight or less, or about 10% by weight or less, or about 5% by weight or less, or about 3% by weight or less, or about 1% by weight or less, of glass network modifier elements. The mixture may contain about 0.01% to about 10% by weight, e.g., about 0.01% to about 5% by weight, or about 0.01% to about 3% by weight, or about 0.01% to about 1% by weight of glass network modifier elements.

[0106] The ratio of the total weight percent of reactive silica in the mixture to the total weight percent of silicate glass in the mixture, i.e.

number

[0107] The ratio of the total mass % of silica fume in the mixture to the total mass % of borosilicate glass in the mixture, i.e.

number

[0108] The ratio of the sum of the total mass % of reactive silica and silicate minerals in the mixture to the total mass % of silicate glass in the mixture, i.e.

number

[0109] The ratio of the sum of the total mass percent of silica fume and perlitic materials in the mixture to the total mass percent of borosilicate glass in the mixture, i.e.

number

[0110] The ratio of the total weight percent reactive silica in the mixture to the total weight percent silicate minerals in the mixture may be about 0.1 or greater, or about 0.2 or greater, or about 0.3 or greater. The ratio of the total weight percent silicon in the mixture to the total weight percent sodium in the mixture (i.e., the Si / Na ratio) may be about 1 or greater, or about 1.2 or greater, or about 1.4 or greater, or about 1.5 or greater. The Si / Na ratio may be about 4 or less, or about 3.5 or less, or about 3 or less, or about 2.9 or less. The Si / Na ratio may be about 1 to about 4, for example, about 1.2 to about 3.5, or about 1.4 to about 3, or about 1.5 to about 2.9.

[0111] Expandable materials The curing mixture (i.e., solid precursor or expandable material) may comprise about 0.01% by weight or more, e.g., about 0.1% by weight or more, or about 0.2% by weight or more, or about 0.3% by weight or more, or about 0.4% by weight or more, or about 1% by weight or more, or about 1.5% by weight or more, or about 2% by weight or more, or about 3% by weight or more of X2O (where X is an alkali metal such as Na or Li). The curing mixture (i.e., solid precursor or expandable material) may comprise about 25% by weight or less, e.g., about 20% by weight or less, or about 15% by weight or less, or about 10% by weight or less, or about 5% by weight or less, or about 3% by weight or less, or about 2% by weight or less, or about 1% by weight or less, or about 0.6% by weight or less of X2O (where X is an alkali metal such as Na or Li). The curing mixture (i.e., solid precursor or expandable material) may have an average molecular weight of from about 0.01% to about 25% by weight, e.g., from about 0.01% to about 20% by weight, or from about 0.01% to about 15% by weight, or from about 0.01% to about 10% by weight, or from about 0.1% to about 20% by weight, or from about 0.1% to about 15% by weight, or from about 0.1% to about 10% by weight, or from about 1% to about 20% by weight, or from about 1% to about 15% by weight, or from about 1% to about 10% by weight, Alternatively, it may contain about 3% to about 20% by mass, or about 3% to about 15% by mass, or about 3% to about 10% by mass, or about 0.1% to about 5% by mass, or about 0.2% to about 5% by mass, or about 0.2% to about 1% by mass, or about 0.4% to about 1% by mass, or about 0.4% to about 0.6% by mass, or about 1% to about 3% by mass, or about 1% to about 2% by mass of XO (wherein X is an alkali metal such as Na or Li).

[0112] For example, the setting mixture (i.e., solid precursor or expandable material) may contain about 0.01% by weight or more NaO, e.g., about 0.1% by weight or more, or about 0.2% by weight or more, or about 0.3% by weight or more, or about 0.4% by weight or more, or about 1% by weight or more, or about 1.5% by weight or more, or about 2% by weight or more, or about 3% by weight or more. The setting mixture (i.e., solid precursor or expandable material) may contain about 25% by weight or less NaO, e.g., about 20% by weight or less, or about 15% by weight or less, or about 10% by weight or less, or about 5% by weight or less, or about 3% by weight or less, or about 2% by weight or less, or about 1% by weight or less, or about 0.6% by weight or less. The curing mixture (i.e., solid precursor or expandable material) may have a concentration of from about 0.01% to about 25% by weight, e.g., from about 0.01% to about 20% by weight, or from about 0.01% to about 15% by weight, or from about 0.01% to about 10% by weight, or from about 0.1% to about 20% by weight, or from about 0.1% to about 15% by weight, or from about 0.1% to about 10% by weight, or from about 1% to about 20% by weight, or from about 1% to about 15% by weight, or It may contain 1% by mass to about 10% by mass, or about 3% by mass to about 20% by mass, or about 3% by mass to about 15% by mass, or about 3% by mass to about 10% by mass, or about 0.1% by mass to about 5% by mass, or about 0.2% by mass to about 5% by mass, or about 0.2% by mass to about 1% by mass, or about 0.4% by mass to about 1% by mass, or about 0.4% by mass to about 0.6% by mass, or about 1% by mass to about 3% by mass, or about 1% by mass to about 2% by mass of Na2O.

[0113] The curing mixture (i.e., solid precursor or expandable material) may contain about 0.01% by weight or more, e.g., about 0.1% by weight or more, or about 0.2% by weight or more, or about 0.3% by weight or more, or about 0.4% by weight or more, or about 1% by weight or more, or about 1.5% by weight or more, or about 2% by weight or more, or about 3% by weight or more LiO. The curing mixture (i.e., solid precursor or expandable material) may contain about 25% by weight or less, e.g., about 20% by weight or less, or about 15% by weight or less, or about 10% by weight or less, or about 5% by weight or less, or about 3% by weight or less, or about 2% by weight or less, or about 1% by weight or less, or about 0.6% by weight or less LiO. The curing mixture (i.e., solid precursor or expandable material) may have a concentration of from about 0.01% to about 25% by weight, e.g., from about 0.01% to about 20% by weight, or from about 0.01% to about 15% by weight, or from about 0.01% to about 10% by weight, or from about 0.1% to about 20% by weight, or from about 0.1% to about 15% by weight, or from about 0.1% to about 10% by weight, or from about 1% to about 20% by weight, or from about 1% to about 15% by weight, or It may contain 1% by mass to about 10% by mass, or about 3% by mass to about 20% by mass, or about 3% by mass to about 15% by mass, or about 3% by mass to about 10% by mass, or about 0.1% by mass to about 5% by mass, or about 0.2% by mass to about 5% by mass, or about 0.2% by mass to about 1% by mass, or about 0.4% by mass to about 1% by mass, or about 0.4% by mass to about 0.6% by mass, or about 1% by mass to about 3% by mass, or about 1% by mass to about 2% by mass of LiO.

[0114] The curing mixture (i.e., solid precursor or expandable material) may comprise about 0.1% by weight or more, e.g., about 0.2% by weight or more, or about 0.4% by weight or more, or about 1% by weight or more, or about 2% by weight or more, or about 3% by weight or more, or about 4% by weight or more Al2O3. The curing mixture (i.e., solid precursor or expandable material) may comprise about 30% by weight or less, e.g., about 25% by weight or less, or about 20% by weight or less, or about 15% by weight or less, or about 10% by weight or less, or about 8% by weight or less, or about 6% by weight or less, or about 5% by weight or less, or about 4% by weight or less, or about 1% by weight or less, or about 0.8% by weight or less Al2O3. The curing mixture (i.e., solid precursor or expandable material) may include about 0.1% to about 30% by weight AlO, e.g., about 0.1% to about 25% by weight, or about 0.1% to about 20% by weight, or about 0.1% to about 15% by weight, or about 0.2% to about 10% by weight, or about 0.4% to about 1% by weight, or about 0.4% to about 0.8% by weight, or about 1% to about 5% by weight, or about 2% to about 5% by weight, or about 2% to about 4% by weight, or about 4% to about 5% by weight. The curing mixture (i.e., solid precursor or expandable material) may contain about 30% by weight or more of SiO2, e.g., about 35% by weight or more, or about 40% by weight or more, or about 45% by weight or more. The curing mixture (i.e., solid precursor or expandable material) may contain about 80% by weight or less of SiO2, e.g., about 70% by weight or less, or about 60% by weight or less, or about 55% by weight or less, or about 50% by weight or less. The curing mixture (i.e., solid precursor or expandable material) may contain about 30% by weight to about 80% by weight of SiO2, e.g., about 30% by weight to about 70% by weight, or about 30% by weight to about 60% by weight, or about 35% by weight to about 55% by weight, or about 40% by weight to about 50% by weight of SiO2.

[0115] The curing mixture (i.e., solid precursor or expandable material) may contain about 0.001% by weight or more FeO, e.g., about 0.01% by weight or more, or about 0.05% by weight or more, or about 0.1% by weight or more, or about 0.2% by weight or more, or about 0.3% by weight or more. The curing mixture (i.e., solid precursor or expandable material) may contain about 1% by weight or less FeO, or about 0.5% by weight or less, or about 0.4% by weight or less, or about 0.1% by weight or less FeO. The curing mixture (i.e., solid precursor or expandable material) may contain about 0.001% by weight to about 1% by weight FeO, e.g., about 0.01% by weight to about 0.5% by weight, or about 0.05% by weight to about 0.5% by weight, or about 0.05% by weight to about 0.1% by weight, or about 0.3% by weight to about 0.5% by weight, or about 0.3% by weight to about 0.4% by weight FeO.

[0116] The setting mixture (i.e., solid precursor or expandable material) may contain about 0.01% by weight or more, e.g., about 0.05% by weight or more, or about 0.1% by weight or more, or about 0.15% by weight or more, or about 0.2% by weight or more, or about 0.3% by weight or more, or about 0.4% by weight or more, or about 0.5% by weight or more CaO. The setting mixture (i.e., solid precursor or expandable material) may contain about 2% by weight or less, e.g., about 1% by weight or less, or about 0.8% by weight or less, or about 0.6% by weight or less, or about 0.5% by weight or less CaO. The setting mixture (i.e., solid precursor or expandable material) may contain about 0.01% to about 2% by weight CaO, e.g., about 0.05% to about 1% by weight, or about 0.1% to about 0.8% by weight, or about 0.15% to about 0.2% by weight, or about 0.3% to about 0.6% by weight, or about 0.3% to about 0.5% by weight, or about 0.5% to about 0.6% by weight.

[0117] The curing mixture (i.e., solid precursor or expandable material) may contain about 0.001% by weight or more, e.g., about 0.005% by weight or more, or about 0.01% by weight or more, or about 0.05% by weight or more, MgO. The curing mixture (i.e., solid precursor or expandable material) may contain about 1% by weight or less, or about 0.5% by weight or less, or about 0.1% by weight or less, MgO. The curing mixture (i.e., solid precursor or expandable material) may contain about 0.001% to about 1% by weight, e.g., about 0.005% to about 0.5% by weight, or about 0.01% to about 0.1% by weight, or about 0.05% to about 0.1% by weight, MgO.

[0118] The setting mixture (i.e., solid precursor or expandable material) may contain about 0.05% by weight or more, e.g., about 0.1% by weight or more, or about 0.15% by weight or more, or about 0.2% by weight or more, or less than about 0.5% by weight, or about 1% by weight or more, or about 1.2% by weight or more of KO. The setting mixture (i.e., solid precursor or expandable material) may contain about 5% by weight or less, e.g., about 3% by weight or less, or about 2% by weight or less, or about 1.6% by weight or less, or about 1% by weight or less, or about 0.5% by weight or less of KO. The curing mixture (i.e., solid precursor or expandable material) may include about 0.05% to about 5% by weight, e.g., about 0.1% to about 3% by weight, or about 0.15% to about 2% by weight, or about 0.15% to about 1% by weight, or about 0.15% to about 0.5% by weight, or about 0.5% to about 3% by weight, or about 0.5% to about 2% by weight, or about 1% to about 2% by weight, or about 1.2% to about 1.6% by weight, of KO. The curing mixture (i.e., solid precursor or expandable material) may contain about 0.1% by weight or more of B2O3, e.g., about 0.5% by weight or more, or about 1% by weight or more, or about 1.5% by weight or more. The curing mixture (i.e., solid precursor or expandable material) may contain about 5% by weight or less of B2O3, e.g., about 3.5% by weight or less, or about 3% by weight or less, or about 2.5% by weight or less. The curing mixture (i.e., solid precursor or expandable material) may contain about 0.1% to about 5% by weight of B2O3, e.g., about 0.5% to about 3.5% by weight, or about 1% to about 2.5% by weight.

[0119] The curing mixture (i.e., solid precursor or intumescent material) may contain about 10% by weight or more, e.g., about 15% by weight or more, or about 20% by weight or more, or about 25% by weight or more, of water and / or volatile substances (i.e., substances that contribute to the "loss on ignition" (LOI)). The curing mixture (i.e., solid precursor or intumescent material) may contain about 50% by weight or less, e.g., about 40% by weight or less, or about 30% by weight or less, of water and / or volatile substances (i.e., substances that contribute to the "loss on ignition" (LOI)). The curing mixture (i.e., solid precursor or intumescent material) may contain about 10% to about 50% by weight, e.g., about 15% to about 40% by weight, or about 20% to about 30% by weight, or about 25% to about 40% by weight, or about 25% to about 30% by weight of water and / or volatile substances (i.e., substances that contribute to the "loss on ignition" (LOI)).

[0120] The curing mixture (i.e., solid precursor or expandable material) may contain about 0.1% to about 25%, e.g., about 0.2% to about 5%, by weight, of XO (where X is an alkali metal such as Na or Li); about 0.1% to about 30%, e.g., about 0.2% to about 20%, by weight, of AlO; about 30% to about 80%, e.g., about 40% to about 60%, by weight, of SiO; about 10% to about 40%, e.g., about 15% to about 30%, by weight, of HO, and may contain about 5% or less, e.g., about 3.5% or less, by weight, of BO.

[0121] The curing mixture (i.e., solid precursor or expandable material) may contain from about 0.1% to about 25%, e.g., from about 0.2% to about 5%, by weight, of XO (wherein X is an alkali metal such as Na or Li); from about 0.1% to about 30%, e.g., from about 0.2% to about 10%, by weight, of AlO; from about 30% to about 80%, e.g., from about 40% to about 60%, by weight, of SiO; from about 0.01% to about 2%, e.g., about 0.05% by weight about 0.01% by mass to about 1% by mass, for example, about 0.05% by mass to about 0.8% by mass of CaO; about 1% by mass or less, for example, about 0.5% by mass or less of MgO; about 0.05% by mass to about 3% by mass, for example, about 0.1% by mass to about 2% by mass of KO; about 10% by mass to about 40% by mass, for example, about 15% by mass to about 30% by mass of HO, and may also contain about 5% by mass or less, for example, about 3.5% by mass or less of BO. The setting mixture (i.e., solid precursor or intumescent material) may be amorphous (i.e., non-crystalline). The setting mixture (i.e., solid precursor or intumescent material) may comprise an inorganic polymer network, i.e., an inorganic polymer network incorporating water, for example, in the form of hydroxyl groups. Thus, the setting mixture (i.e., solid precursor or intumescent material) may be described as a synthetic perlitic material, for example, synthetic perlite.

[0122] method The method may include dissolving an alkaline compound in water to form an alkaline aqueous solution. Dissolving the alkaline compound in water may be an exothermic process. The method may include adding a silicate material to the alkaline aqueous solution and stirring. Adding the silicate material to the alkaline aqueous solution may include adding any other input materials, including any silicate glass, silicate material, and / or reactive silica, to the alkaline aqueous solution. The method may include stirring the mixture, typically for 1 to 10 minutes, to form a paste. Heat generated during dissolution of the alkaline compound may assist in dissolving the other input materials.

[0123] The method may include shaping the mixture before curing. The mixture may be cured in an oven. The mixture may be cured at a temperature of about 250°C or less, for example, about 20°C to about 200°C, or about 20°C to about 150°C, or about 20°C to about 120°C, or about 50°C to about 120°C, or about 50°C to about 110°C, or about 70°C to about 100°C. The mixture may be cured for about 1 hour or more, for example, about 2 hours or more, or about 4 hours or more, or about 6 hours or more, or about 8 hours or more, or about 10 hours or more, or about 12 hours or more, or about 24 hours or more. The mixture may be cured for about 72 hours or less, for example, about 48 hours or less, or about 24 hours or less. The mixture may be allowed to cure for about 1 hour to about 72 hours, for example, about 2 hours to about 48 hours, or about 4 hours to about 24 hours, or about 4 hours to about 12 hours, or about 12 hours to about 72 hours, or about 24 hours to about 72 hours.

[0124] During curing, the mixture may polymerize to form an inorganic polymer network. Polymerization of the mixture may be similar to a geopolymerization process, in which aluminosilicate materials polymerize after alkaline activation to form a rigid three-dimensional framework of SiO and AlO tetrahedra linked by shared oxygen. The morphology of the framework formed (i.e., poly(sialate), poly(sialate-siloxo), or poly(sialate-disiloxo)) depends on the ratio of SiO to AlO in the initial mixture. However, the inorganic polymer network formed during curing of the mixture in the present invention is typically less rigid and more linear than geopolymers and incorporates a large amount of water.

[0125] The solid precursor may be crushed after hardening to form a granular material (i.e., a granular expandable material). The method may include sieving the solid precursor (i.e., the granular material) after crushing. The method may include crushing (and optionally sieving) the solid precursor to a particle size (e.g., d) of about 10 μm or more, e.g., about 50 μm or more, or about 100 μm or more, or about 250 μm or more, or about 500 μm or more, or about 750 μm or more, or about 1 mm or more. 50The method may include crushing (and optionally sieving) the solid precursor to obtain a granular material (i.e., granular expandable material) having an average particle size (e.g., d) of about 10 mm or less, e.g., about 8 mm or less, or about 6 mm or less, or about 4 mm or less, 2 mm or less, or about 1.5 mm or less, or about 1 mm or less. 50 The method may include crushing (and optionally sieving) the solid precursor to obtain a granular material (i.e., granular expandable material) having an average particle size (e.g., d) of about 10 μm to about 10 mm, or about 10 μm to about 8 mm, or about 10 μm to about 6 mm, or about 10 μm to about 4 mm, or about 10 μm to about 2 mm, or about 100 μm to about 2 mm, or about 500 μm to about 1 mm, or about 250 μm to about 750 μm, or about 500 μm to about 1.5 mm, or about 750 μm to about 1.5 mm. 50 The method may include obtaining a granular material (i.e., a granular expandable material) having a granular composition.

[0126] The method may include two or more crushing and / or sieving steps. For example, the method may include crushing a solid precursor in a first crushing step to form a particulate material having a first particle size; determining the first particle size; and then crushing the particulate material in a second crushing step to form a particulate material having a second particle size, the second particle size being smaller than the first particle size.

[0127] The method may include heating the granular material (i.e., the granular intumescent material) to form an expanded granular material. The method may include heating the granular material (i.e., the granular intumescent material) to a temperature of about 1100°C or less, e.g., about 1000°C or less, or about 900°C or less, or about 700°C or less, or about 600°C or less. The method may include heating the granular material (i.e., the granular intumescent material) to a temperature of about 200°C or more, e.g., about 300°C or more, or about 400°C or more. The method may include heating the granular material (i.e., the granular intumescent material) to a temperature of about 200°C to about 1100°C, e.g., about 200°C to about 1000°C, or about 200°C to about 900°C, or about 300°C to about 700°C, or about 300°C to about 700°C, or about 400°C to about 600°C. The method may include heating the granular material (i.e., the granular expandable material) in a furnace, for example, in a furnace selected from an infrared (IR) furnace, an electrically heated furnace, a natural gas or LPG expansion furnace, a muffle furnace (e.g., a laboratory muffle furnace), or a fluidized bed (FB) reactor. The furnace may be a horizontal furnace, a vertical furnace, or a tilted furnace. The method may include heating the granular material (i.e., the granular expandable material) in a fluidized bed reactor.

[0128] The method comprises crushing (and optionally sieving) the solid precursor to a particle size (e.g., d 50 and heating the granular material (i.e., the granular intumescent material) in an infrared (IR) furnace to form an intumescent granular material. An exemplary IR furnace includes an Elstein HTS (125 x 125 mm) ceramic infrared panel radiator operating at 64 kW / m with a maximum operating temperature of 860°C. The IR furnace may include a steel vibrating plate for vibrating the granular material during heating. An exemplary mechanical vibrating element is available from Italvibras G. Silingardi SpA, such as Model M3 / 45-S02, Series: AA, CFKN 0.44 / 0.64, RPM 3000 / 3800. The method involves crushing (and optionally sieving) a solid precursor to a particle size of about 500 μm or less (e.g., d 50 and heating the granular material (i.e., the granular expandable material) in an electric furnace (e.g., a vertical electric furnace) to form the expanded granular material.

[0129] characteristics Expanded granular material is approximately 15 kg / m 3 More than, for example, about 20 kg / m 3 or more, or approximately 30 kg / m 3 or more, or approximately 40 kg / m 3 or more, or approximately 50 kg / m 3 or more, or approximately 55 kg / m 3 or more, or approximately 60 kg / m 3 or more, or approximately 65 kg / m 3 or more, or approximately 70 kg / m 3 The expanded granular material may have a loose bulk density measured in accordance with PI 200-77 of not less than about 450 kg / m 3 Below, for example, about 400 kg / m 3 or less, or approximately 350 kg / m 3 or less, or about 300 kg / m 3 or less, or approximately 250 kg / m 3 or less, or about 200 kg / m 3 or less, or approximately 150 kg / m 3 or less, or about 100 kg / m 3 or less, or about 80 kg / m 3 or less, or about 70 kg / m 3 or less, or about 60 kg / m 3 or less, or about 50 kg / m 3 or less, or about 40 kg / m 3 It may have a loose bulk density measured in accordance with PI 200-77 below.

[0130] Expanded granular material is approximately 15 kg / m 3 ~about 450kg / m 3 , for example, about 15 kg / m 3 ~about 400kg / m 3, or approximately 15 kg / m 3 ~About 350kg / m 3 , or approximately 15 kg / m 3 ~about 300kg / m 3 , or approximately 15 kg / m 3 ~about 250kg / m 3 , or approximately 15 kg / m 3 ~about 200kg / m 3 , or approximately 15 kg / m 3 ~Approx. 150kg / m 3 , or approximately 15 kg / m 3 ~about 100kg / m 3 , or approximately 15 kg / m 3 ~about 80kg / m 3 , or approximately 15 kg / m 3 ~about 70kg / m 3 , or approximately 15 kg / m 3 ~about 60kg / m 3 , or approximately 15 kg / m 3 ~about 50kg / m 3 , or approximately 15 kg / m 3 ~about 40kg / m 3 The composition may have a loose bulk density measured in accordance with PI 200-77 of the United States Patent No. 5,620,421. Expanded granular material is approximately 20 kg / m 3 ~about 450kg / m 3 , for example, about 20 kg / m 3 ~about 400kg / m 3 , or about 20 kg / m 3 ~About 350kg / m 3 , or about 20 kg / m 3 ~about 300kg / m 3 , or about 20 kg / m 3 ~about 250kg / m 3 , or about 20 kg / m 3 ~about 200kg / m 3 , or about 20 kg / m 3 ~Approx. 150kg / m 3 , or about 20 kg / m 3 ~about 100kg / m 3 , or about 20 kg / m 3 ~about 80kg / m 3 , or about 20 kg / m 3 ~about 70kg / m3 , or about 20 kg / m 3 ~about 60kg / m 3 , or about 20 kg / m 3 ~about 50kg / m 3 , or about 20 kg / m 3 ~about 40kg / m 3 The composition may have a loose bulk density measured in accordance with PI 200-77 of the United States Patent No. 5,620,421.

[0131] Expanded granular material is approximately 30 kg / m 3 ~about 450kg / m 3 , for example, about 30 kg / m 3 ~about 400kg / m 3 , or approximately 30 kg / m 3 ~About 350kg / m 3 , or approximately 30 kg / m 3 ~about 300kg / m 3 , or approximately 30 kg / m 3 ~about 250kg / m 3 , or approximately 30 kg / m 3 ~about 200kg / m 3 , or approximately 30 kg / m 3 ~Approx. 150kg / m 3 , or approximately 30 kg / m 3 ~about 100kg / m 3 , or approximately 30 kg / m 3 ~about 80kg / m 3 , or approximately 30 kg / m 3 ~about 70kg / m 3 , or approximately 30 kg / m 3 ~about 60kg / m 3 , or approximately 30 kg / m 3 ~about 50kg / m 3 , or approximately 30 kg / m 3 ~about 40kg / m 3 The composition may have a loose bulk density measured in accordance with PI 200-77 of the United States Patent No. 5,620,421. Expanded granular material is approximately 40 kg / m 3 ~about 450kg / m 3 , for example, about 40 kg / m 3 ~about 400kg / m 3 , or about 40 kg / m 3 ~About 350kg / m 3, or about 40 kg / m 3 ~about 300kg / m 3 , or about 40 kg / m 3 ~about 250kg / m 3 , or about 40 kg / m 3 ~about 200kg / m 3 , or about 40 kg / m 3 ~Approx. 150kg / m 3 , or about 40 kg / m 3 ~about 100kg / m 3 , or about 40 kg / m 3 ~about 80kg / m 3 , or about 40 kg / m 3 ~about 70kg / m 3 , or about 40 kg / m 3 ~about 60kg / m 3 , or about 40 kg / m 3 ~about 50kg / m 3 , or about 40 kg / m 3 ~about 40kg / m 3 The composition may have a loose bulk density measured in accordance with PI 200-77 of the United States Patent No. 5,620,421.

[0132] Expanded granular material is approximately 50 kg / m 3 ~about 450kg / m 3 , for example, about 50 kg / m 3 ~about 400kg / m 3 , or about 50 kg / m 3 ~About 350kg / m 3 , or about 50 kg / m 3 ~about 300kg / m 3 , or about 50 kg / m 3 ~about 250kg / m 3 , or about 50 kg / m 3 ~about 200kg / m 3 , or about 50 kg / m 3 ~Approx. 150kg / m 3 , or about 50 kg / m 3 ~about 100kg / m 3 , or about 50 kg / m 3 ~about 80kg / m 3 , or about 50 kg / m 3 ~about 70kg / m 3 , or about 50 kg / m3 ~about 60kg / m 3 , or about 50 kg / m 3 ~about 50kg / m 3 , or about 50 kg / m 3 ~about 40kg / m 3 The composition may have a loose bulk density measured in accordance with PI 200-77 of the United States Patent No. 5,620,421. Expanded granular material is approximately 55 kg / m 3 ~about 450kg / m 3 , for example, about 55 kg / m 3 ~about 400kg / m 3 , or approximately 55 kg / m 3 ~About 350kg / m 3 , or approximately 55 kg / m 3 ~about 300kg / m 3 , or approximately 55 kg / m 3 ~about 250kg / m 3 , or approximately 55 kg / m 3 ~about 200kg / m 3 , or approximately 55 kg / m 3 ~Approx. 150kg / m 3 , or approximately 55 kg / m 3 ~about 100kg / m 3 , or approximately 55 kg / m 3 ~about 80kg / m 3 , or approximately 55 kg / m 3 ~about 70kg / m 3 , or approximately 55 kg / m 3 ~about 60kg / m 3 , or approximately 55 kg / m 3 ~about 50kg / m 3 , or approximately 55 kg / m 3 ~about 40kg / m 3 The composition may have a loose bulk density measured in accordance with PI 200-77 of the United States Patent No. 5,620,421.

[0133] Expanded granular material is approximately 60 kg / m 3 ~about 450kg / m 3 , for example, about 60 kg / m 3 ~about 400kg / m 3 , or approximately 60 kg / m 3 ~About 350kg / m 3 , or approximately 60 kg / m 3~about 300kg / m 3 , or approximately 60 kg / m 3 ~about 250kg / m 3 , or approximately 60 kg / m 3 ~about 200kg / m 3 , or approximately 60 kg / m 3 ~Approx. 150kg / m 3 , or approximately 60 kg / m 3 ~about 100kg / m 3 , or approximately 60 kg / m 3 ~about 80kg / m 3 , or approximately 60 kg / m 3 ~about 70kg / m 3 , or approximately 60 kg / m 3 ~about 60kg / m 3 , or approximately 60 kg / m 3 ~about 50kg / m 3 , or approximately 60 kg / m 3 ~about 40kg / m 3 The composition may have a loose bulk density measured in accordance with PI 200-77 of the United States Patent No. 5,620,421. Expanded granular material is approximately 65 kg / m 3 ~about 450kg / m 3 , for example, about 65 kg / m 3 ~about 400kg / m 3 , or approximately 65 kg / m 3 ~About 350kg / m 3 , or approximately 65 kg / m 3 ~about 300kg / m 3 , or approximately 65 kg / m 3 ~about 250kg / m 3 , or approximately 65 kg / m 3 ~about 200kg / m 3 , or approximately 65 kg / m 3 ~Approx. 150kg / m 3 , or approximately 65 kg / m 3 ~about 100kg / m 3 , or approximately 65 kg / m 3 ~about 80kg / m 3 , or approximately 65 kg / m 3 ~about 70kg / m 3 , or approximately 65 kg / m 3 ~about 60kg / m 3 , or approximately 65 kg / m3 ~about 50kg / m 3 , or approximately 65 kg / m 3 ~about 40kg / m 3 The composition may have a loose bulk density measured in accordance with PI 200-77 of the United States Patent No. 5,620,421.

[0134] Expanded granular material is approximately 70 kg / m 3 ~about 450kg / m 3 , for example, about 70 kg / m 3 ~about 400kg / m 3 , or about 70 kg / m 3 ~About 350kg / m 3 , or about 70 kg / m 3 ~about 300kg / m 3 , or about 70 kg / m 3 ~about 250kg / m 3 , or about 70 kg / m 3 ~about 200kg / m 3 , or about 70 kg / m 3 ~Approx. 150kg / m 3 , or about 70 kg / m 3 ~about 100kg / m 3 , or about 70 kg / m 3 ~about 80kg / m 3 , or about 70 kg / m 3 ~about 70kg / m 3 , or about 70 kg / m 3 ~about 60kg / m 3 , or about 70 kg / m 3 ~about 50kg / m 3 , or about 70 kg / m 3 ~about 40kg / m 3 The composition may have a loose bulk density measured in accordance with PI 200-77 of the United States Patent No. 5,620,421.

[0135] The loose bulk density of a material can be measured by taking a sample of the material (750-1000 mL) with a sampler, pouring the sample into a weighed cylinder, and carefully allowing it to settle without disturbing the sample. The mass and volume of the sample are then recorded, and the loose bulk density is calculated as follows: Loose bulk density [kg / m 3 ]=1000×mass[g] / volume[mL]

[0136] In addition to, or as an alternative to, any of the loose bulk densities mentioned above, the expanded granular material may have a resistance to compaction as measured in accordance with PI 306-80 of about 3 PSI at 2" or greater, e.g., about 5 PSI at 2" or greater, or about 10 PSI at 2", or about 20 PSI at 2", or about 30 PSI at 2", or about 40 PSI at 2". The expanded granular material may have a resistance to compaction as measured in accordance with PI 306-80 of about 350 PSI at 2" or less, for example about 300 PSI at 2" or less, or about 250 PSI at 2", or about 200 PSI at 2", or about 100 PSI at 2", or about 90 PSI at 2", or about 80 PSI at 2", or about 75 PSI at 2", or about 50 PSI at 2", or about 40 PSI at 2", or about 30 PSI at 2", or about 20 PSI at 2", or about 15 PSI at 2", or about 10 PSI at 2". The expanded granular material may have a resistance to compaction measured according to PI 306-80 of from about 3 PSI to about 350 PSI at 2", for example, from about 3 PSI to about 300 PSI at 2", or from about 3 PSI to about 250 PSI at 2", or from about 3 PSI to about 200 PSI at 2", or from about 3 PSI to about 100 PSI at 2", or from about 3 PSI to about 90 PSI at 2", or from about 3 PSI to about 80 PSI at 2", or from about 3 PSI to about 75 PSI at 2", or from about 3 PSI to about 50 PSI at 2", or from about 3 PSI to about 40 PSI at 2", or from about 3 PSI to about 30 PSI at 2", or from about 3 PSI to about 20 PSI at 2", or from about 3 PSI to about 15 PSI at 2", or from about 3 PSI to about 10 PSI at 2".

[0137] The expanded granular material may have a resistance to compaction measured according to PI 306-80 of from about 5 PSI to about 350 PSI at 2", for example, from about 5 PSI to about 300 PSI at 2", or from about 5 PSI to about 250 PSI at 2", or from about 5 PSI to about 200 PSI at 2", or from about 5 PSI to about 100 PSI at 2", or from about 5 PSI to about 90 PSI at 2", or from about 5 PSI to about 80 PSI at 2", or from about 5 PSI to about 75 PSI at 2", or from about 5 PSI to about 50 PSI at 2", or from about 5 PSI to about 40 PSI at 2", or from about 5 PSI to about 30 PSI at 2", or from about 5 PSI to about 20 PSI at 2", or from about 5 PSI to about 15 PSI at 2", or from about 5 PSI to about 10 PSI at 2". The expanded granular material may be pressurized to a pressure of about 10 PSI to about 350 PSI at 2", for example, about 10 PSI to about 300 PSI at 2", or about 10 PSI to about 250 PSI at 2", or about 10 PSI to about 200 PSI at 2", or about 10 PSI to about 100 PSI at 2", or about 10 PSI to about 90 PSI at 2", or about 10 PSI to about 80 PSI at 2", or about 10 PSI to about 100 PSI at 2". PSI to about 75 PSI, or about 10 PSI to about 50 PSI at 2", or about 10 PSI to about 40 PSI at 2", or about 10 PSI to about 30 PSI at 2", or about 10 PSI to about 20 PSI at 2", or about 10 PSI to about 15 PSI at 2", or about 10 PSI to about 10 PSI at 2".

[0138] The expanded granular material may be pressurized to a pressure of about 20 PSI to about 350 PSI at 2", for example, about 20 PSI to about 300 PSI at 2", or about 20 PSI to about 250 PSI at 2", or about 20 PSI to about 200 PSI at 2", or about 20 PSI to about 100 PSI at 2", or about 20 PSI to about 90 PSI at 2", or about 20 PSI to about 80 PSI at 2", or about 20 PSI to about 100 PSI at 2". PSI to about 75 PSI, or about 20 PSI to about 50 PSI at 2", or about 20 PSI to about 40 PSI at 2", or about 20 PSI to about 30 PSI at 2", or about 20 PSI to about 20 PSI at 2", or about 20 PSI to about 15 PSI at 2", or about 20 PSI to about 10 PSI at 2". The expanded granular material may be pressurized to a pressure of about 30 PSI to about 350 PSI at 2", for example, about 30 PSI to about 300 PSI at 2", or about 30 PSI to about 250 PSI at 2", or about 30 PSI to about 200 PSI at 2", or about 30 PSI to about 100 PSI at 2", or about 30 PSI to about 90 PSI at 2", or about 30 PSI to about 80 PSI at 2", or about 30 PSI to about 30 PSI to about 75 PSI, or about 30 PSI to about 50 PSI at 2", or about 30 PSI to about 40 PSI at 2", or about 30 PSI to about 30 PSI at 2", or about 30 PSI to about 20 PSI at 2", or about 30 PSI to about 15 PSI at 2", or about 30 PSI to about 10 PSI at 2".

[0139] The expanded granular material may be from about 40 PSI to about 3500 PSI at 2", for example, from about 40 PSI to about 300 PSI at 2", or from about 40 PSI to about 250 PSI at 2", or from about 40 PSI to about 200 PSI at 2", or from about 40 PSI to about 100 PSI at 2", or from about 40 PSI to about 90 PSI at 2", or from about 40 PSI to about 80 PSI at 2", or from about 40 PSI to about 80 PSI at 2". It may have a resistance to consolidation as measured in accordance with PI 306-80 of from 0 PSI to about 75 PSI, or from about 40 PSI to about 50 PSI at 2", or from about 40 PSI to about 40 PSI at 2", or from about 40 PSI to about 30 PSI at 2", or from about 40 PSI to about 20 PSI at 2", or from about 40 PSI to about 15 PSI at 2", or from about 40 PSI to about 10 PSI at 2".

[0140] Additionally or alternatively, the expanded granular material may have a resistance to compaction as measured in accordance with PI 306-80 of about 0.5 PSI at 1" or more, for example about 1 PSI at 1" or more, or about 2 PSI at 1", or about 2.5 PSI at 1". The expanded granular material may have a resistance to compaction as measured in accordance with PI 306-80 of about 50 PSI at 1", for example about 40 PSI at 1", or about 30 PSI at 1". The expanded granular material may have a resistance to compaction as measured in accordance with PI 306-80 of between about 0.5 PSI at 1" and about 50 PSI at 1", for example between about 1 PSI at 1" and about 40 PSI at 1", or between about 2 PSI at 1" and about 40 PSI at 1", or between about 2.5 PSI at 1" and about 30 PSI at 1".

[0141] The consolidation resistance of a material can be measured by taking a representative sample of the material, approximately 500 mL in volume, with a sampler. The sample is placed in the container of a computer-controlled hydraulic press. The container is shaken 25 times to allow the sample to settle. An additional 250 mL of material is then added to the container. The sample is again allowed to settle by shaking 25 more times. The sample is then leveled on top of the container. The sample is pressed under the automatic hydraulic press at a speed of 20 mm / min and a maximum load of 6800 N (or 2800 N for very light samples). The computer continuously records the load and sample displacement and plots the data as a graph. Once the maximum load is reached, the instrument calculates the total displacement and zero deformation point. The load / displacement data is exported and the respective load values ​​(B) for 1 inch (i.e., 1") and 2 inch (i.e., 2") displacements (adding the zero deformation point, i.e., 1 inch deformation distance (mm) = 25.4 + zero deformation point (mm)) are used to calculate the consolidation resistance according to the following: Consolidation resistance [PSI]=(B[N] / A[m 2 ]) * 0.000145037738007 where A is the cross-sectional area of ​​the vessel.

[0142] In addition to, or as an alternative to, the loose bulk density and / or resistance to compaction mentioned above, the expanded granular material may have a thermal conductivity (i.e., λ, lambda value) measured in accordance with EN12667 of about 0.0300 W / mK or more, for example about 0.0310 W / mK or more, or about 0.0320 W / mK or more, or about 0.0330 W / mK or more, or about 0.0340 W / mK or more, or about 0.0350 W / mK or more, or about 0.0360 W / mK or more. The expanded particulate material has a thermal conductivity of about 0.0700 W / mK or less, for example about 0.0600 W / mK or less, or about 0.0500 W / mK or less, or about 0.0490 W / mK or less, or about 0.0480 W / mK or less, or about 0.0470 W / mK or less, or about 0.0460 W / mK or less, or about 0.0450 W / mK or less, or about 0.0440 W / mK or less, or about 0.0430 W / mK or less, may have a thermal conductivity as measured in accordance with EN 12667 of about 0.0420 W / mK or less, or about 0.0410 W / mK or less, or about 0.0400 W / mK or less, or about 0.0390 W / mK or less, or about 0.0380 W / mK or less, or about 0.0370 W / mK or less, or about 0.0360 W / mK or less, or about 0.0350 W / mK or less, or about 0.0340 W / mK or less.

[0143] The expandable granular material has a thermal conductivity of about 0.0300 W / mK to about 0.0700 W / mK, for example, about 0.0300 W / mK to about 0.0600 W / mK, or about 0.0300 W / mK to about 0.0500 W / mK, about 0.0300 W / mK to about 0.0490 W / mK, or about 0.0300 W / mK to about 0.0480 W / mK, or about 0.0300 W / mK to about 0.04 70 W / mK, or about 0.0300 W / mK to about 0.0460 W / mK, or about 0.0300 W / mK to about 0.0450 W / mK, or about 0.0300 W / mK to about 0.0440 W / mK, or about 0.0300 W / mK to about 0.0430 W / mK, or about 0.0300 W / mK to about 0.0420 W / mK, or about 0.0300 W / mK to about 0.0410 W / mK, or about 0.0300 W / mK to about 0.0400 W / mK, or about 0.0300 W / mK to about 0.0390 W / mK, or 0.0300 W / mK to about 0.0380 W / mK, or about 0.0300 W / mK to about 0.0370 W / mK, or 0.0300 W / mK to about 0.0380 W / mK, or about 0.0300 W / mK The thermal conductivity (i.e., λ, lambda value) measured in accordance with EN 12667 may be from about 0.0360 W / mK to about 0.0360 W / mK, or from about 0.0300 W / mK to about 0.0380 W / mK, or from about 0.0300 W / mK to about 0.0350 W / mK, or from 0.0300 W / mK to about 0.0380 W / mK, or from about 0.0300 W / mK to about 0.0340 W / mK.

[0144] The expandable granular material has a thermal conductivity of about 0.0310 W / mK to about 0.0500 W / mK, for example, about 0.0310 W / mK to about 0.0490 W / mK, or about 0.0310 W / mK to about 0.0480 W / mK, or about 0.0310 W / mK to about 0.0470 W / mK, or about 0.0310 W / mK to about 0.0460 W / mK, or about 0.0 0.0310 W / mK to about 0.0450 W / mK, or about 0.0310 W / mK to about 0.0440 W / mK, or about 0.0310 W / mK to about 0.0430 W / mK, or about 0.0310 W / mK to about 0.0420 W / mK, or about 0.0310 W / mK to about 0.0410 W / mK, or about 0.0310 W / mK about 0.0400 W / mK, or about 0.0310 W / mK to about 0.0390 W / mK, or 0.0310 W / mK to about 0.0380 W / mK, or about 0.0310 W / mK to about 0.0370 W / mK, or 0.0310 W / mK to about 0.0380 W / mK, or about 0.0310 W / mK to about 0.0360 W / mK, Alternatively, it may have a thermal conductivity (i.e., λ, lambda value) measured in accordance with EN 12667 of 0.0310 W / mK to about 0.0380 W / mK, or about 0.0310 W / mK to about 0.0350 W / mK, or 0.0310 W / mK to about 0.0380 W / mK, or about 0.0310 W / mK to about 0.0340 W / mK.

[0145] The expandable granular material has a thermal conductivity of about 0.0320 W / mK to about 0.0500 W / mK, for example, about 0.0320 W / mK to about 0.0490 W / mK, or about 0.0320 W / mK to about 0.0480 W / mK, or about 0.0320 W / mK to about 0.0470 W / mK, or about 0.0320 W / mK to about 0.0460 W / mK, or about 0.0 0.0320 W / mK to about 0.0450 W / mK, or about 0.0320 W / mK to about 0.0440 W / mK, or about 0.0320 W / mK to about 0.0430 W / mK, or about 0.0320 W / mK to about 0.0420 W / mK, or about 0.0320 W / mK to about 0.0410 W / mK, or about 0.0320 W / mK about 0.0400 W / mK, or about 0.0320 W / mK to about 0.0390 W / mK, or 0.0320 W / mK to about 0.0380 W / mK, or about 0.0320 W / mK to about 0.0370 W / mK, or 0.0320 W / mK to about 0.0380 W / mK, or about 0.0320 W / mK to about 0.0360 W / mK, Alternatively, it may have a thermal conductivity (i.e., λ, lambda value) measured in accordance with EN 12667 of 0.0320 W / mK to about 0.0380 W / mK, or about 0.0320 W / mK to about 0.0350 W / mK, or 0.0320 W / mK to about 0.0380 W / mK, or about 0.0320 W / mK to about 0.0340 W / mK.

[0146] The expandable granular material has a thermal conductivity of about 0.0330 W / mK to about 0.0500 W / mK, for example, about 0.0330 W / mK to about 0.0490 W / mK, or about 0.0330 W / mK to about 0.0480 W / mK, or about 0.0330 W / mK to about 0.0470 W / mK, or about 0.0330 W / mK to about 0.0460 W / mK, or about 0.0 0.0330 W / mK to about 0.0450 W / mK, or about 0.0330 W / mK to about 0.0440 W / mK, or about 0.0330 W / mK to about 0.0430 W / mK, or about 0.0330 W / mK to about 0.0420 W / mK, or about 0.0330 W / mK to about 0.0410 W / mK, or about 0.0330 W / mK about 0.0400 W / mK, or about 0.0330 W / mK to about 0.0390 W / mK, or 0.0330 W / mK to about 0.0380 W / mK, or about 0.0330 W / mK to about 0.0370 W / mK, or 0.0330 W / mK to about 0.0380 W / mK, or about 0.0330 W / mK to about 0.0360 W / mK, Alternatively, it may have a thermal conductivity (i.e., λ, lambda value) measured in accordance with EN 12667 of 0.0330 W / mK to about 0.0380 W / mK, or about 0.0330 W / mK to about 0.0350 W / mK, or 0.0330 W / mK to about 0.0380 W / mK, or about 0.0330 W / mK to about 0.0340 W / mK.

[0147] The expanded granular material has a thermal conductivity of about 0.0340 W / mK to about 0.0500 W / mK, for example, about 0.0340 W / mK to about 0.0490 W / mK, or about 0.0340 W / mK to about 0.0480 W / mK, or about 0.0340 W / mK to about 0.0470 W / mK, or about 0.0340 W / mK to about 0.0460 W / mK, or about 0.0 0.0340 W / mK to about 0.0450 W / mK, or about 0.0340 W / mK to about 0.0440 W / mK, or about 0.0340 W / mK to about 0.0430 W / mK, or about 0.0340 W / mK to about 0.0420 W / mK, or about 0.0340 W / mK to about 0.0410 W / mK, or about 0.0340 W / mK to about 0.0400 W / mK, or about 0.0340 W / mK to about 0.0390 W / mK, or 0.0340 W / mK to about 0.0380 W / mK, or about 0.0340 W / mK to about 0.0370 W / mK, or 0.0340 W / mK to about 0.0380 W / mK, or about 0.0340 W / mK to about 0.0360 W / mK, Alternatively, it may have a thermal conductivity (i.e., λ, lambda value) measured in accordance with EN 12667 of 0.0340 W / mK to about 0.0380 W / mK, or about 0.0340 W / mK to about 0.0350 W / mK, or 0.0340 W / mK to about 0.0380 W / mK, or about 0.0340 W / mK to about 0.0340 W / mK.

[0148] The expandable granular material has a thermal conductivity of about 0.0350 W / mK to about 0.0500 W / mK, for example, about 0.0350 W / mK to about 0.0490 W / mK, or about 0.0350 W / mK to about 0.0480 W / mK, or about 0.0350 W / mK to about 0.0470 W / mK, or about 0.0350 W / mK to about 0.0460 W / mK, or about 0.0 0.0350 W / mK to about 0.0450 W / mK, or about 0.0350 W / mK to about 0.0440 W / mK, or about 0.0350 W / mK to about 0.0430 W / mK, or about 0.0350 W / mK to about 0.0420 W / mK, or about 0.0350 W / mK to about 0.0410 W / mK, or about 0.0350 W / mK to about 0.0400 W / mK, or about 0.0350 W / mK to about 0.0390 W / mK, or 0.0350 W / mK to about 0.0380 W / mK, or about 0.0350 W / mK to about 0.0370 W / mK, or 0.0350 W / mK to about 0.0380 W / mK, or about 0.0350 W / mK to about 0.0360 W / mK, Alternatively, it may have a thermal conductivity (i.e., λ, lambda value) measured in accordance with EN 12667 of 0.0350 W / mK to about 0.0380 W / mK, or about 0.0350 W / mK to about 0.0350 W / mK, or 0.0350 W / mK to about 0.0380 W / mK, or about 0.0350 W / mK to about 0.0340 W / mK.

[0149] The expandable granular material has a thermal conductivity of about 0.0360 W / mK to about 0.0500 W / mK, for example, about 0.0360 W / mK to about 0.0490 W / mK, or about 0.0360 W / mK to about 0.0480 W / mK, or about 0.0360 W / mK to about 0.0470 W / mK, or about 0.0360 W / mK to about 0.0460 W / mK, or about 0 0.0360W / mK to about 0.0450W / mK, or about 0.0360W / mK to about 0.0440W / mK, or about 0.0360W / mK to about 0.0430W / mK, or about 0.0360W / mK to about 0.0420W / mK, or about 0.0360W / mK to about 0.0410W / mK, or about 0.0360W / mK to about 0.0400 W / mK, or about 0.0360 W / mK to about 0.0390 W / mK, or 0.0360 W / mK to about 0.0380 W / mK, or about 0.0360 W / mK to about 0.0370 W / mK, or 0.0360 W / mK to about 0.0380 W / mK, or about 0.0360 W / mK to about 0.0360 W / mK, Alternatively, it may have a thermal conductivity (i.e., λ, lambda value) measured in accordance with EN 12667 of 0.0360 W / mK to about 0.0380 W / mK, or about 0.0360 W / mK to about 0.0350 W / mK, or 0.0360 W / mK to about 0.0380 W / mK, or about 0.0360 W / mK to about 0.0340 W / mK. The expanded granular material may have a thermal conductivity (ie, λ, lambda value) measured in accordance with EN 12667 of from about 0.042 W / mK to about 0.055 W / mK, or from about 0.055 W / mK to about 0.070 W / mK. For example, the expanded granular material has a density of about 15 kg / m 3 ~about 450kg / m 3 , for example, about 20 kg / m 3 ~about 100kg / m 3 , or approximately 20 kg / m 3 ~about 30kg / m 3 , or approximately 20 kg / m 3 ~about 40kg / m 3 , or approximately 55 kg / m 3 ~about 100kg / m 3 , or approximately 70 kg / m 3 ~about 100kg / m 3a loose bulk density measured in accordance with PI 200-77 of from about 3 PSI to about 100 PSI at 2 inches, e.g., from about 3 PSI to about 10 PSI at 2 inches, or from about 30 PSI to about 80 PSI at 2 inches, or from about 40 PSI to about 75 PSI at 2 inches, or from about 5 PSI to about 20 PSI at 2 inches; and / or a resistance to compaction measured in accordance with PI 306-80 of from about 0.0300 W / mK to about 0.0700 W / mK, e.g., from about 0 The thermal conductivity may be from about 0.0320 W / mK to about 0.0420 W / mK, from about 0.0350 W / mK to about 0.0400 W / mK, or from about 0.0360 W / mK to about 0.0410 W / mK, or from about 0.0320 W / mK to about 0.0340 W / mK, or from about 0.042 W / mK to about 0.055 W / mK, or from about 0.055 W / mK to about 0.070 W / mK, as measured in accordance with EN 12667.

[0150] The thermal conductivity of a material can be measured using a Netzsch HFM 436 / 3 Lambda Heat Flow Meter. The material sample is held under standard laboratory conditions before measurements are taken. The loosely packed sample is placed in a custom frame constructed from a 30 x 30 x 2.5 cm piece of XPS, with inner dimensions of 15 x 15 cm and a thin plastic membrane at the bottom to hold the loosely packed sample in place. The average temperature, as well as the temperature difference between the cold and hot plates, are both set to 10°C.

[0151] The expanded granular material is (a) Approx. 18kg / m 3 ~about 30kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) Resistance to compaction measured in accordance with PI 306-80 of about 4 PSI to about 8 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0300 W / mK to approximately 0.0400 W / mK may have

[0152] The expanded granular material is (a) Approximately 50kg / m 3 ~about 100kg / m 3loose bulk density measured in accordance with PI 200-77; (b) Resistance to compaction measured in accordance with PI 306-80 from about 30 PSI to about 80 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0350 W / mK to approximately 0.0450 W / mK may have

[0153] The expanded granular material is (a) Approximately 70kg / m 3 ~About 105kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) Resistance to compaction measured in accordance with PI 306-80 from about 40 PSI to about 75 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0350 W / mK to approximately 0.0450 W / mK may have

[0154] The expanded granular material is (a) Approx. 20kg / m 3 ~about 40kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) Resistance to compaction measured in accordance with PI 306-80 from about 5 PSI to about 15 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0310 W / mK to approximately 0.0350 W / mK may have

[0155] The expanded granular material is about 0.1% to about 1% by weight AlO; less than about 0.2% by weight FeO; about 0.05% to about 0.5% by weight CaO; less than about 0.1% by weight MgO; about 0.05% to about 0.5% by weight KO; about 1% to about 3% by weight BO; and one or more silicate materials and / or reactive silicas containing from about 0.1 to about 1% by weight water and / or volatiles (i.e., materials that contribute to "loss on ignition" (LOI)); alkaline compounds; and water It may be formed from a mixture comprising: The expanded granular material is (a) Approx. 18kg / m 3 ~about 30kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) Resistance to compaction measured in accordance with PI 306-80 of about 4 PSI to about 8 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0300 W / mK to approximately 0.0400 W / mK may have

[0156] The expanded granular material is about 42% to about 52% by weight of SiO2; about 1.2% to about 2.4% by weight of Na2O; about 3% to about 6% by weight of Al2O3; about 0.1% to about 1% by weight of Fe2O3; about 0.1% to about 1% by weight of CaO; less than about 0.2% by weight of MgO; about 1% to about 2% by weight of K2O; about 1% to about 3% by weight of B2O3; and one or more silicate materials and / or reactive silicas containing about 0.5 to about 1.5% by weight of water and / or volatiles (i.e., materials that contribute to "loss on ignition" (LOI)); alkaline compounds; and water It may be formed from a mixture comprising: The expanded granular material is (a) Approximately 50kg / m 3 ~about 100kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) Resistance to compaction measured in accordance with PI 306-80 from about 30 PSI to about 80 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0350 W / mK to approximately 0.0450 W / mK may have

[0157] The expanded granular material is about 42% to about 52% by weight of SiO2; about 1.2% to about 2.4% by weight of Na2O; about 3% to about 6% by weight of Al2O3; about 0.1% to about 1% by weight of Fe2O3; about 0.1% to about 1% by weight of CaO; less than about 0.2% by weight of MgO; about 1% to about 2% by weight of K2O; about 1% to about 3% by weight of B2O3; and one or more silicate materials and / or reactive silicas containing about 0.5 to about 1.5% by weight of water and / or volatiles (i.e., materials that contribute to "loss on ignition" (LOI)); alkaline compounds; and water It may be formed from a mixture comprising: The expanded granular material is (a) Approximately 70kg / m 3 ~About 105kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) Resistance to compaction measured in accordance with PI 306-80 from about 40 PSI to about 75 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0350 W / mK to approximately 0.0450 W / mK may have

[0158] The expanded granular material is about 42% to about 52% by weight SiO2; about 1.2% to about 2.4% by weight Na2O; about 2.5% to about 4.5% by weight Al2O3; about 0.1% to about 1% by weight Fe2O3; about 0.1% to about 1% by weight CaO; less than about 0.2% by weight MgO; about 1% to about 2% by weight K2O; about 1% to about 3% by weight B2O3; and one or more silicate materials and / or reactive silicas containing about 0.5 to about 1.5% by weight water and / or volatiles (i.e., materials that contribute to "loss on ignition" (LOI)); alkaline compounds; and water It may be formed from a mixture comprising: The expanded granular material is (a) Approx. 20kg / m 3 ~about 40kg / m 3loose bulk density measured in accordance with PI 200-77; (b) Resistance to compaction measured in accordance with PI 306-80 from about 5 PSI to about 15 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0310 W / mK to approximately 0.0350 W / mK may have

[0159] The expanded granular material may be formed from a mixture comprising about 10% to about 15% by weight borosilicate glass; about 35% to about 45% by weight silica fume; about 15% to about 20% by weight sodium hydroxide; and about 25% to about 32% by weight water; the expanded granular material may be formed from a mixture comprising: (a) Approx. 18kg / m 3 ~about 30kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) Resistance to compaction measured in accordance with PI 306-80 of about 4 PSI to about 8 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0300 W / mK to approximately 0.0400 W / mK may have

[0160] The expanded granular material may be formed from a mixture comprising about 12% to about 18% by weight borosilicate glass; about 5% to about 15% by weight silica fume; about 10% to about 15% by weight sodium hydroxide; and about 20% to about 30% by weight water; the expanded granular material may be formed from a mixture comprising: (a) Approximately 50kg / m 3 ~about 100kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) Resistance to compaction measured in accordance with PI 306-80 from about 30 PSI to about 80 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0350 W / mK to approximately 0.0450 W / mK may have

[0161] The expanded granular material may be formed from a mixture comprising about 12% to about 18% by weight borosilicate glass; about 5% to about 10% by weight silica fume; about 8% to about 16% by weight sodium hydroxide; and about 20% to about 32% by weight water; the expanded granular material may be formed from a mixture comprising: (a) Approximately 70kg / m 3 ~About 105kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) Resistance to compaction measured in accordance with PI 306-80 from about 40 PSI to about 75 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0350 W / mK to approximately 0.0450 W / mK may have

[0162] The expanded granular material may be formed from a mixture comprising about 10% to about 20% by weight borosilicate glass; about 10% to about 20% by weight silica fume; about 10% to about 20% by weight sodium hydroxide; and about 20% to about 30% by weight water; the expanded granular material may be formed from a mixture comprising: (a) Approx. 20kg / m 3 ~about 40kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) Resistance to compaction measured in accordance with PI 306-80 from about 5 PSI to about 15 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0310 W / mK to approximately 0.0350 W / mK may have

[0163] The expanded granular material may be formed by heating an expandable granular material having a particle size of about 0.125 mm to about 1 mm (as determined by particle size distribution by sieving), the expandable granular material comprising: about 0.1% to about 1% by weight AlO; less than about 0.2% by weight FeO; about 0.05% to about 0.5% by weight CaO; less than about 0.1% by weight MgO; about 0.05% to about 0.5% by weight KO; about 1% to about 3% by weight BO; and one or more silicate materials and / or reactive silicas containing from about 0.1 to about 1% by weight water and / or volatiles (i.e., materials that contribute to "loss on ignition" (LOI)); alkaline compounds; and water It may be formed from a mixture comprising: The expanded granular material is (a) Approx. 18kg / m 3 ~about 30kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) Resistance to compaction measured in accordance with PI 306-80 of about 4 PSI to about 8 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0300 W / mK to approximately 0.0400 W / mK may have

[0164] The expanded granular material may be formed by heating an expandable granular material having a particle size of about 2 mm or less (as determined by particle size distribution by sieving), the expandable granular material comprising: about 42% to about 52% by weight of SiO2; about 1.2% to about 2.4% by weight of Na2O; about 3% to about 6% by weight of Al2O3; about 0.1% to about 1% by weight of Fe2O3; about 0.1% to about 1% by weight of CaO; less than about 0.2% by weight of MgO; about 1% to about 2% by weight of K2O; about 1% to about 3% by weight of B2O3; and one or more silicate materials and / or reactive silicas containing about 0.5 to about 1.5% by weight of water and / or volatiles (i.e., materials that contribute to "loss on ignition" (LOI)); alkaline compounds; and water It may be formed from a mixture comprising: The expanded granular material is (a) Approximately 50kg / m 3 ~about 100kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) Resistance to compaction measured in accordance with PI 306-80 from about 30 PSI to about 80 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0350 W / mK to approximately 0.0450 W / mK may have

[0165] The expanded granular material may be formed by heating an expandable granular material having a particle size of about 0.1 mm to about 1 mm (as determined by particle size distribution by sieving), the expandable granular material comprising: about 42% to about 52% by weight of SiO2; about 1.2% to about 2.4% by weight of Na2O; about 3% to about 6% by weight of Al2O3; about 0.1% to about 1% by weight of Fe2O3; about 0.1% to about 1% by weight of CaO; less than about 0.2% by weight of MgO; about 1% to about 2% by weight of K2O; about 1% to about 3% by weight of B2O3; and one or more silicate materials and / or reactive silicas containing about 0.5 to about 1.5% by weight of water and / or volatiles (i.e., materials that contribute to "loss on ignition" (LOI)); alkaline compounds; and water- It may be formed from a mixture comprising: The expanded granular material is (a) Approximately 70kg / m 3 ~About 105kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) Resistance to compaction measured in accordance with PI 306-80 from about 40 PSI to about 75 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0350 W / mK to approximately 0.0450 W / mK may have

[0166] The expanded granular material may be formed by heating an expandable granular material having a particle size of less than about 1 mm (as determined by particle size distribution by sieving), the expandable granular material comprising: about 42% to about 52% by weight SiO2; about 1.2% to about 2.4% by weight Na2O; about 2.5% to about 4.5% by weight Al2O3; about 0.1% to about 1% by weight Fe2O3; about 0.1% to about 1% by weight CaO; less than about 0.2% by weight MgO; about 1% to about 2% by weight K2O; about 1% to about 3% by weight B2O3; and one or more silicate materials and / or reactive silicas containing about 0.5 to about 1.5% by weight water and / or volatiles (i.e., materials that contribute to "loss on ignition" (LOI)); Alkaline salts; and water It may be formed from a mixture comprising: The expanded granular material is (a) Approx. 20kg / m 3 ~about 40kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) Resistance to compaction measured in accordance with PI 306-80 from about 5 PSI to about 15 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0310 W / mK to approximately 0.0350 W / mK may have

[0167] The expanded granular material may be formed by heating an expandable granular material having a particle size of about 0.5 mm to about 1 mm (as determined by particle size distribution by sieving), the expandable granular material comprising: about 0.1% to about 1% by weight AlO; less than about 0.2% by weight FeO; about 0.05% to about 0.5% by weight CaO; less than about 0.1% by weight MgO; about 0.05% to about 0.5% by weight KO; about 1% to about 3% by weight BO; and one or more silicate materials and / or reactive silicas containing from about 0.1 to about 1% by weight water and / or volatiles (i.e., materials that contribute to "loss on ignition" (LOI)); alkaline compounds; and water It may be formed from a mixture comprising: The expanded granular material is (a) Approx. 18kg / m 3 ~about 25kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) Resistance to compaction measured in accordance with PI 306-80 of about 4 PSI to about 8 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0320 W / mK to approximately 0.0360 W / mK may have

[0168] The expanded granular material may be formed by heating an expandable granular material having a particle size of about 0.125 mm to about 0.5 mm (as determined by particle size distribution by sieving), the expandable granular material comprising: about 0.1% to about 1% by weight AlO; less than about 0.2% by weight FeO; about 0.05% to about 0.5% by weight CaO; less than about 0.1% by weight MgO; about 0.05% to about 0.5% by weight KO; about 1% to about 3% by weight BO; and one or more silicate materials and / or reactive silicas containing from about 0.1 to about 1% by weight water and / or volatiles (i.e., materials that contribute to "loss on ignition" (LOI)); alkaline compounds; and water It may be formed from a mixture comprising: The expanded granular material is (a) Approx. 25kg / m 3 ~about 30kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) Resistance to compaction measured in accordance with PI 306-80 of about 4 PSI to about 8 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0310 W / mK to approximately 0.0350 W / mK may have

[0169] The expanded granular material may be formed by heating an expandable granular material having a particle size of about 0.3 mm to about 2 mm (as determined by particle size distribution by sieving), the expandable granular material comprising: about 42% to about 52% by weight of SiO2; about 1.2% to about 2.4% by weight of Na2O; about 3% to about 6% by weight of Al2O3; about 0.1% to about 1% by weight of Fe2O3; about 0.1% to about 1% by weight of CaO; less than about 0.2% by weight of MgO; about 1% to about 2% by weight of K2O; about 1% to about 3% by weight of B2O3; and one or more silicate materials and / or reactive silicas containing about 0.5 to about 1.5% by weight of water and / or volatiles (i.e., materials that contribute to "loss on ignition" (LOI)); alkaline compounds; and water It may be formed from a mixture comprising: The expanded granular material is (a) Approximately 55kg / m 3 ~about 65kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) a resistance to compaction measured in accordance with PI 306-80 of about 35 PSI to about 40 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0360 W / mK to approximately 0.0400 W / mK may have

[0170] The expanded granular material may be formed by heating an expandable granular material having a particle size of less than about 0.3 mm (as determined by particle size distribution by sieving), the expandable granular material comprising: about 42% to about 52% by weight of SiO2; about 1.2% to about 2.4% by weight of Na2O; about 3% to about 6% by weight of Al2O3; about 0.1% to about 1% by weight of Fe2O3; about 0.1% to about 1% by weight of CaO; less than about 0.2% by weight of MgO; about 1% to about 2% by weight of K2O; about 1% to about 3% by weight of B2O3; and one or more silicate materials and / or reactive silicas containing about 0.5 to about 1.5% by weight of water and / or volatiles (i.e., materials that contribute to "loss on ignition" (LOI)); alkaline compounds; and water It may be formed from a mixture comprising: The expanded granular material is (a) Approximately 90kg / m 3 ~about 100kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) Resistance to compaction measured in accordance with PI 306-80 of about 70 PSI to about 80 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0370 W / mK to approximately 0.0420 W / mK may have

[0171] The expanded granular material may be formed by heating an expandable granular material having a particle size of about 0.5 mm to about 1 mm (as determined by particle size distribution by sieving), the expandable granular material comprising: about 42% to about 52% by weight of SiO2; about 1.2% to about 2.4% by weight of Na2O; about 3% to about 6% by weight of Al2O3; about 0.1% to about 1% by weight of Fe2O3; about 0.1% to about 1% by weight of CaO; less than about 0.2% by weight of MgO; about 1% to about 2% by weight of K2O; about 1% to about 3% by weight of B2O3; and one or more silicate materials and / or reactive silicas containing about 0.5 to about 1.5% by weight of water and / or volatiles (i.e., materials that contribute to "loss on ignition" (LOI)); alkaline compounds; and water It may be formed from a mixture comprising: The expanded granular material is (a) Approximately 75kg / m 3 ~about 85kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) Resistance to compaction measured in accordance with PI 306-80 of about 40 PSI to about 50 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0370 W / mK to approximately 0.0410 W / mK may have

[0172] The expanded granular material may be formed by heating an expandable granular material having a particle size of about 0.125 mm to about 0.5 mm (as determined by particle size distribution by sieving), the expandable granular material comprising: about 42% to about 52% by weight of SiO2; about 1.2% to about 2.4% by weight of Na2O; about 3% to about 6% by weight of Al2O3; about 0.1% to about 1% by weight of Fe2O3; about 0.1% to about 1% by weight of CaO; less than about 0.2% by weight of MgO; about 1% to about 2% by weight of K2O; about 1% to about 3% by weight of B2O3; and one or more silicate materials and / or reactive silicas containing about 0.5 to about 1.5% by weight of water and / or volatiles (i.e., materials that contribute to "loss on ignition" (LOI)); alkaline compounds; and water It may be formed from a mixture comprising: The expanded granular material is (a) Approx. 78kg / m 3 ~about 86kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) Resistance to compaction measured in accordance with PI 306-80 from about 60 PSI to about 74 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0360 W / mK to approximately 0.0420 W / mK may have

[0173] The expanded granular material may be formed by heating an expandable granular material having a particle size of about 0.1 mm to about 1 mm (as determined by particle size distribution by sieving), the expandable granular material comprising: about 42% to about 52% by weight of SiO2; about 1.2% to about 2.4% by weight of Na2O; about 3% to about 6% by weight of Al2O3; about 0.1% to about 1% by weight of Fe2O3; about 0.1% to about 1% by weight of CaO; less than about 0.2% by weight of MgO; about 1% to about 2% by weight of K2O; about 1% to about 3% by weight of B2O3; and one or more silicate materials and / or reactive silicas containing about 0.5 to about 1.5% by weight of water and / or volatiles (i.e., materials that contribute to "loss on ignition" (LOI)); alkaline compounds; and water It may be formed from a mixture comprising: The expanded granular material is (a) Approximately 70kg / m 3 ~About 105kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) Resistance to compaction measured in accordance with PI 306-80 of about 60 PSI to about 75 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0360 W / mK to approximately 0.0430 W / mK may have

[0174] The expanded granular material may be formed by heating an expandable granular material having a particle size of about 0.5 mm to about 1 mm (as determined by particle size distribution by sieving), the expandable granular material comprising: about 42% to about 52% by weight SiO2; about 1.2% to about 2.4% by weight Na2O; about 2.5% to about 4.5% by weight Al2O3; about 0.1% to about 1% by weight Fe2O3; about 0.1% to about 1% by weight CaO; less than about 0.2% by weight MgO; about 1% to about 2% by weight K2O; about 1% to about 3% by weight B2O3; and one or more silicate materials and / or reactive silicas containing about 0.5 to about 1.5% by weight water and / or volatiles (i.e., materials that contribute to "loss on ignition" (LOI)); alkaline compounds; and water It may be formed from a mixture comprising: The expanded granular material is (a) Approx. 20kg / m 3 ~about 30kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) Resistance to compaction measured in accordance with PI 306-80 of about 5 PSI to about 10 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0310 W / mK to approximately 0.0360 W / mK may have

[0175] The expanded granular material may be formed by heating an expandable granular material having a particle size of about 0.125 mm to about 0.5 mm (as determined by particle size distribution by sieving), the expandable granular material comprising: about 42% to about 52% by weight SiO2; about 1.2% to about 2.4% by weight Na2O; about 2.5% to about 4.5% by weight Al2O3; about 0.1% to about 1% by weight Fe2O3; about 0.1% to about 1% by weight CaO; less than about 0.2% by weight MgO; about 1% to about 2% by weight K2O; about 1% to about 3% by weight B2O3; and one or more silicate materials and / or reactive silicas containing about 0.5 to about 1.5% by weight water and / or volatiles (i.e., materials that contribute to "loss on ignition" (LOI)); alkaline compounds; and water It may be formed from a mixture comprising: The expanded granular material is (a) Approx. 25kg / m 3 ~about 35kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) Resistance to compaction measured in accordance with PI 306-80 from about 5 PSI to about 15 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0310 W / mK to approximately 0.0350 W / mK may have

[0176] The expanded granular material may be formed by heating an expandable granular material having a particle size of less than about 0.3 mm (as determined by particle size distribution by sieving), the expandable granular material comprising: about 42% to about 52% by weight SiO2; about 1.2% to about 2.4% by weight Na2O; about 2.5% to about 4.5% by weight Al2O3; about 0.1% to about 1% by weight Fe2O3; about 0.1% to about 1% by weight CaO; less than about 0.2% by weight MgO; about 1% to about 2% by weight K2O; about 1% to about 3% by weight B2O3; and one or more silicate materials and / or reactive silicas containing about 0.5 to about 1.5% by weight water and / or volatiles (i.e., materials that contribute to "loss on ignition" (LOI)); Alkaline salts; and water It may be formed from a mixture comprising: The expanded granular material is (a) Approx. 30kg / m 3 ~about 40kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) Resistance to compaction measured in accordance with PI 306-80 from about 8 PSI to about 16 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0300 W / mK to approximately 0.0350 W / mK may have

[0177] The expanded granular material may be formed by heating an expandable granular material having a particle size of about 0.5 mm to about 1 mm (as determined by particle size distribution by sieving), and the expandable granular material may be formed from a mixture including about 10% to about 15% by weight borosilicate glass; about 35% to about 45% by weight silica fume; about 15% to about 20% by weight sodium hydroxide; and about 25% to about 32% by weight water; the expanded granular material may be formed from a mixture including about 10% to about 15% by weight borosilicate glass; about 35% to about 45% by weight silica fume; about 15% to about 20% by weight sodium hydroxide; and about 25% to about 32% by weight water; (a) Approx. 18kg / m 3 ~about 25kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) Resistance to compaction measured in accordance with PI 306-80 of about 4 PSI to about 8 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0320 W / mK to approximately 0.0360 W / mK may have

[0178] The expanded granular material may be formed by heating an expandable granular material having a particle size of about 0.125 mm to about 0.5 mm (as determined by particle size distribution by sieving), and the expandable granular material may be formed from a mixture including about 10% to about 15% by weight borosilicate glass; about 35% to about 45% by weight silica fume; about 15% to about 20% by weight sodium hydroxide; and about 25% to about 32% by weight water; the expanded granular material may be formed from a mixture including about 10% to about 15% by weight borosilicate glass; about 35% to about 45% by weight silica fume; about 15% to about 20% by weight sodium hydroxide; and about 25% to about 32% by weight water; (a) Approx. 25kg / m 3 ~about 30kg / m 3loose bulk density measured in accordance with PI 200-77; (b) Resistance to compaction measured in accordance with PI 306-80 of about 4 PSI to about 8 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0310 W / mK to approximately 0.0350 W / mK may have

[0179] The expanded granular material may be formed by heating an expandable granular material having a particle size of about 0.3 mm to about 2 mm (as determined by particle size distribution by sieving), and the expandable granular material may be formed from a mixture including about 12% to about 18% by weight borosilicate glass; about 5% to about 15% by weight silica fume; about 10% to about 15% by weight sodium hydroxide; and about 20% to about 30% by weight water; the expanded granular material may be formed from a mixture including about 12% to about 18% by weight borosilicate glass; about 5% to about 15% by weight silica fume; about 10% to about 15% by weight sodium hydroxide; and about 20% to about 30% by weight water; (a) Approximately 55kg / m 3 ~about 65kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) a resistance to compaction measured in accordance with PI 306-80 of about 35 PSI to about 40 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0360 W / mK to approximately 0.0400 W / mK may have

[0180] The expanded granular material may be formed by heating an expandable granular material having a particle size of less than about 0.3 mm (as determined by particle size distribution by sieving), and the expandable granular material may be formed from a mixture including about 12% to about 18% by weight borosilicate glass; about 5% to about 15% by weight silica fume; about 10% to about 15% by weight sodium hydroxide; and about 20% to about 30% by weight water; the expanded granular material may be formed from a mixture including about 12% to about 18% by weight borosilicate glass; about 5% to about 15% by weight silica fume; about 10% to about 15% by weight sodium hydroxide; and about 20% to about 30% by weight water; (a) Approximately 90kg / m 3 ~about 100kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) Resistance to compaction measured in accordance with PI 306-80 of about 70 PSI to about 80 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0370 W / mK to approximately 0.0420 W / mK may have

[0181] The expanded granular material may be formed by heating an expandable granular material having a particle size of about 0.5 mm to about 1 mm (as determined by particle size distribution by sieving), and the expandable granular material may be formed from a mixture including about 12% to about 18% by weight borosilicate glass; about 5% to about 10% by weight silica fume; about 8% to about 16% by weight sodium hydroxide; and about 20% to about 32% by weight water; the expanded granular material may be formed from a mixture including about 12% to about 18% by weight borosilicate glass; about 5% to about 10% by weight silica fume; about 8% to about 16% by weight sodium hydroxide; and about 20% to about 32% by weight water; (a) Approximately 75kg / m 3 ~about 85kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) Resistance to compaction measured in accordance with PI 306-80 of about 40 PSI to about 50 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0370 W / mK to approximately 0.0410 W / mK may have

[0182] The expanded granular material may be formed by heating an expandable granular material having a particle size of about 0.125 mm to about 0.5 mm (as determined by particle size distribution by sieving), and the expandable granular material may be formed from a mixture including about 12% to about 18% by weight borosilicate glass; about 5% to about 10% by weight silica fume; about 8% to about 16% by weight sodium hydroxide; and about 20% to about 32% by weight water; the expanded granular material may be formed from a mixture including about 12% to about 18% by weight borosilicate glass; about 5% to about 10% by weight silica fume; about 8% to about 16% by weight sodium hydroxide; and about 20% to about 32% by weight water; (a) Approx. 78kg / m 3 ~about 86kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) Resistance to compaction measured in accordance with PI 306-80 from about 60 PSI to about 74 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0360 W / mK to approximately 0.0420 W / mK may have

[0183] The expanded granular material may be formed by heating an expandable granular material having a particle size of about 0.1 mm to about 1 mm (as determined by particle size distribution by sieving), and the expandable granular material may be formed from a mixture including about 12% to about 18% by weight borosilicate glass; about 5% to about 10% by weight silica fume; about 8% to about 16% by weight sodium hydroxide; and about 20% to about 32% by weight water; the expanded granular material may be formed from a mixture including about 12% to about 18% by weight borosilicate glass; about 5% to about 10% by weight silica fume; about 8% to about 16% by weight sodium hydroxide; and about 20% to about 32% by weight water; (a) Approximately 70kg / m 3 ~About 105kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) Resistance to compaction measured in accordance with PI 306-80 of about 60 PSI to about 75 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0360 W / mK to approximately 0.0430 W / mK may have

[0184] The expanded granular material may be formed by heating an expandable granular material having a particle size of about 0.5 mm to about 1 mm (as determined by particle size distribution by sieving), and the expandable granular material may be formed from a mixture including about 10% to about 20% by weight of borosilicate glass; about 10% to about 20% by weight of silica fume; about 10% to about 20% by weight of sodium hydroxide; and about 20% to about 30% by weight of water; the expanded granular material may be formed from a mixture including about 10% to about 20% by weight of borosilicate glass; about 10% to about 20% by weight of silica fume; about 10% to about 20% by weight of sodium hydroxide; and about 20% to about 30% by weight of water; (a) Approx. 20kg / m 3 ~about 30kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) Resistance to compaction measured in accordance with PI 306-80 of about 5 PSI to about 10 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0310 W / mK to approximately 0.0360 W / mK may have

[0185] The expanded granular material may be formed by heating an expandable granular material having a particle size of about 0.125 mm to about 0.5 mm (as determined by particle size distribution by sieving), and the expandable granular material may be formed from a mixture including about 10% to about 20% by weight borosilicate glass; about 10% to about 20% by weight silica fume; about 10% to about 20% by weight sodium hydroxide; and about 20% to about 30% by weight water; the expanded granular material may be formed from a mixture including about 10% to about 20% by weight borosilicate glass; about 10% to about 20% by weight silica fume; about 10% to about 20% by weight sodium hydroxide; and about 20% to about 30% by weight water; (a) Approx. 25kg / m 3 ~about 35kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) Resistance to compaction measured in accordance with PI 306-80 from about 5 PSI to about 15 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0310 W / mK to approximately 0.0350 W / mK may have

[0186] The expanded granular material may be formed by heating an expandable granular material having a particle size of less than about 0.3 mm (as determined by particle size distribution by sieving), and the expandable granular material may be formed from a mixture including about 10% to about 20% by weight borosilicate glass; about 10% to about 20% by weight silica fume; about 10% to about 20% by weight sodium hydroxide; and about 20% to about 30% by weight water; the expanded granular material may be formed from a mixture including about 10% to about 20% by weight borosilicate glass; about 10% to about 20% by weight silica fume; about 10% to about 20% by weight sodium hydroxide; and about 20% to about 30% by weight water; (a) Approx. 30kg / m 3 ~about 40kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) Resistance to compaction measured in accordance with PI 306-80 from about 8 PSI to about 16 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0300 W / mK to approximately 0.0350 W / mK may have

[0187] The expanded granular material may have a water absorbency (grams of water absorbed per gram of expanded granular material) of about 0.1 g / g or more, e.g., about 0.2 g / g or more, or about 0.5 g / g or more, or about 1 g / g or more. The expanded granular material may have a water absorbency (grams of water absorbed per gram of expanded granular material) of about 15 g / g or less, e.g., about 10 g / g or less. The expanded granular material may have a water absorbency (grams of water absorbed per gram of expanded granular material) of about 0.1 g / g to about 15 g / g, e.g., about 0.2 g / g to about 15 g / g, or about 0.5 g / g to about 10 g / g, or about 1 g / g to about 10 g / g. The water absorption of a granular material can be measured by first accurately weighing 500 ml of the granular material and recording the mass of the sample. The 500 ml sample is transferred to a 500 ml cylinder with a very fine sieve at the bottom, sufficient to retain the granular material within the cylinder while allowing water to pass through. The cylinder is tapped 10 times to allow the material to settle. 250 g of water is weighed and poured into the cylinder containing the granular material. A timer is started, and the mass of water passing through the material and exiting the cylinder is measured after 3, 5, 7, 10, and 30 minutes. The water absorption of a granular material is therefore the mass of water that did not pass through the cylinder (i.e., the mass of water absorbed) per mass of granular material in the cylinder (expressed in g / g).

[0188] The expanded granular material may have a water repellency of about 40% or more, e.g., about 50% or more, or about 60% or more, or about 65% or more. The expanded granular material may have a water repellency of about 95% or less, e.g., about 90% or less. The expanded granular material may have a water repellency of about 40% to about 95%, e.g., about 50% to about 95%, or about 60% to about 95%, or about 65% to about 90%. The water repellency of a material can be determined by taking a representative sample of the material (500 mL) with a sampler and weighing the sample. Using a funnel, transfer the sample to a graduated cylinder with a perforated base. To allow the sample to settle, drop the cylinder from a height of approximately 7.5 cm 10 times. Pour 250 g of deionized water slowly into the cylinder containing the sample, taking care to avoid water loss or cavitation in the sample. At 3, 5, 7, 10, and 30 minutes, collect the water that passes through the sample in a weighed glass beaker below the cylinder, and weigh the water in the glass beaker. After 30 minutes, tilt the cylinder 45° to pour off any remaining water. The water absorption rate over 30 minutes is then calculated according to the following formula:

[0189]

number

[0190] The expanded granular material may contain about 95% or more, such as about 97% or more, or about 99% or more, suspended matter. The expanded granular material may contain up to 100% suspended matter. The expanded granular material may contain about 95% to about 100%, such as about 97% to about 100%, or about 99% to about 100% suspended matter. The number of suspended particles in a sample of material is determined using an Imhoff cone. Specifically, 600 mL of deionized water is poured into an Imhoff cone fixed vertically on a rack. An additional 50 mL of deionized water containing 20 drops of bromothymol blue or methylene blue indicator is added to the cone. The indicator is used to facilitate reading the cone by the color it imparts to the water. A 300 mL representative sample of the material being investigated is taken with a sampler. The exact volume (A mL) and mass (B g) of the sample are recorded and the sample is added to the cone. An additional 300 mL of deionized water is added to the sample in the cone, so that a total of 950 mL of water is in the Imhoff cone. The sample and water are stirred 20 times with a stirring rod. The upper wall and rod of the cone are rinsed with 50 mL of deionized water (so that a total of 1000 mL of water is in the cone) to wash any particles adhering to them into the cone. The cone and its contents are allowed to stand for 45 minutes. After this time, the volume of the cone (C mL) corresponding to the level of dark particles (i.e., "sediment") at the bottom of the cone (C mL) is recorded. The volume of the cone (D mL) corresponding to the level of total sediment at the bottom of the cone is also recorded. The "sediment," "debris," and "float" are then determined according to the following formulas:

[0191]

number

[0192] The expanded granular material may have a pH, measured according to PI 202-77, of about 8 or greater, e.g., about 9 or greater, or about 9.5 or greater. The expanded granular material may have a pH, measured according to PI 202-77, of about 12 or less, e.g., about 11 or less. The expanded granular material may have a pH, measured according to PI 202-77, of about 8 to about 12, e.g., about 9 to about 11, or about 9.5 to about 11. The pH of the expanded granular material may be determined by mixing 0.5 g of the granular material with 50 mL of deionized water and stirring for 30 minutes at room temperature. The pH value is measured (e.g., using a pH probe) and recorded during the last 2 minutes of stirring. The expanded granular material is approximately 0.4 g / cm 3More than, for example, about 0.5 g / cm 3 or more, or about 0.6 g / cm 3 The expanded particulate material may have a skeletal density of about 2 g / cm or more. 3 For example, about 1.8 g / cm 3 or less, or about 1.6 g / cm 3 The expanded granular material may have a skeletal density of about 0.4 g / cm 3 ~Approx. 2g / cm 3 , for example, about 0.5 g / cm 3 ~Approx. 1.8g / cm 3 , or about 0.6 g / cm 3 ~Approx. 1.6g / cm 3 The skeletal density of a porous material (i.e., the absolute density of a porous material determined using the volume of the porous material excluding both the volume of any pores and the volume of any voids between particles) can be measured using, for example, a stereopycnometer available from Quantachrome.

[0193] Purpose The expanded granular material may be used as or in an insulation product. The insulation product may be a cavity wall insulation material, such as a cavity wall bulk granular insulation material. The insulation product may be an insulation board or a filler for an insulation board. The insulation product may be an acoustical ceiling tile or a filler for an acoustical ceiling tile. The insulation product may be an insulating container, such as a cryogenic or cryogenic vessel, or a granular material for insulating an insulating container, such as a cryogenic or cryogenic vessel. For such applications, the expanded granular material should have (a) an average particle size (e.g., d) of less than about 1.25 mm. 50 ), and / or (b) approximately 30 kg / m 3 ~about 100kg / m 3 Expanded granular materials having a loose bulk density of 0.1 to 0.5 are particularly suitable.

[0194] The expanded granular material may be used as or in a building material. The building material may be a fiber cement sheet. The building material may be concrete. For example, the expanded granular material may be used as a lightweight aggregate material in concrete. For such applications, (a) an average particle size (e.g., d) of about 500 μm or more, e.g., about 500 μm to about 6 mm, e.g., about 2 mm to about 6 mm, is preferred. 50 ), and / or (b) approximately 10 kg / m 3 ~about 100kg / m 3 Expanded granular materials having a loose bulk density of 0.1 to 0.5 are particularly suitable. The building material may be a mortar or plaster, such as a cementitious, gypsum-based and / or acrylic-based mortar or plaster. For such applications, (a) an average particle size (e.g., d) of less than about 0.5 mm, e.g., less than about 0.2 mm, is preferred. 50 ), and / or (b) approximately 80 kg / m 3 ~about 450kg / m 3 , for example, about 80 kg / m 3 ~About 350kg / m 3 Expanded granular materials having a loose bulk density of 0.1 to 0.5 are particularly suitable. The expanded particulate material may be used in coatings such as paints. For such applications, (a) an average particle size (e.g., d) of less than about 0.5 mm, e.g., less than about 0.2 mm, is preferred. 50 ), and / or (b) approximately 80 kg / m 3 ~about 450kg / m 3 , for example, about 80 kg / m 3 ~About 350kg / m 3 Expanded granular materials having a loose bulk density of 0.1 to 0.5 are particularly suitable. The expanded granular material may be used as or in a horticultural or agricultural substrate. The horticultural or agricultural substrate may primarily comprise expanded granular material. For example, the horticultural or agricultural substrate may consist of expanded granular material. Alternatively, the horticultural or agricultural substrate may comprise expanded granular material and one or more other materials, such as organic matter or soil. The intumescent particulate material may be used as or in a flame retardant functional material. The flame retardant functional material may be a flame retardant filler material.

[0195] Numbered paragraphs For the avoidance of doubt, this application relates to the subject matter described in the following numbered paragraphs: 1. A method for producing an expanded granular material, the method comprising: forming a mixture including a silicate material, an alkali compound, and water; hardening the mixture to form a solid precursor; crushing and / or milling the solid precursor to form an expandable granular material; and heating the expandable granular material to form the expanded granular material. 2. The method of numbered paragraph 1, wherein the mixture comprises glass network formers, glass network intermediates, and / or glass network modifiers other than silicon, wherein the glass network formers other than silicon may be selected from boron, germanium, and phosphorus; the glass network intermediates may be selected from titanium, aluminum, zirconium, beryllium, magnesium, and zinc; and / or the glass network modifiers may be selected from calcium, lead, lithium, sodium, and potassium. 3. The method of numbered paragraph 1 or numbered paragraph 2, wherein the mixture further comprises reactive silica, such as silica fume and / or fumed silica. 4. The method of any of numbered paragraphs 1-3, wherein the mixture comprises two different silicate materials, e.g., the mixture comprises a silicate glass, such as an aluminosilicate glass, and a silicate mineral, e.g., an aluminosilicate mineral; or the mixture comprises a first silicate glass, such as a first aluminosilicate glass; and a second silicate glass, such as a second aluminosilicate glass. 5. The method of numbered paragraph 4, wherein one of the two different silicate materials is selected from a volcanic glass, e.g., a perlitic material, e.g., unexpanded natural perlite ore having a water content greater than about 2% by weight; a phyllosilicate mineral, e.g., bentonite, kaolin, or calcined kaolin; diatomaceous earth; or a combination thereof. 6. The method of numbered paragraph 4 or numbered paragraph 5, wherein one of the two different silicate materials is a silicate glass selected from fused silica glass, soda-lime glass, borosilicate glass, lead oxide glass, aluminosilicate glass, and silica-germania glass. 7. The method of numbered paragraph 6, wherein the silicate glass is recycled glass, for example in the form of recycled glass cullet. 8. The method of any of numbered paragraphs 1-7, wherein the alkaline compound is an alkaline salt, such as an alkaline hydroxide, for example, sodium hydroxide, lithium hydroxide, or potassium hydroxide; an alkaline carbonate, for example, sodium carbonate, lithium carbonate, or potassium carbonate; or an alkaline silicate, for example, sodium silicate, lithium silicate, or potassium silicate; or a mixed alkaline salt, for example, sodium / lithium silicate or sodium / potassium silicate. 9. The method of any of numbered paragraphs 1-8, wherein the mixture comprises about 10% to about 90% by weight, e.g., about 15% to about 80% by weight, or about 20% to about 70% by weight, of the silicate material; about 5% to about 25% by weight, about 10% to about 20% by weight, of the alkali compound; and about 15% to about 50% by weight, e.g., about 20% to about 40% by weight, of water. 10. The method of numbered paragraph 9, wherein the mixture comprises from about 5% to about 75% by weight, e.g., from about 5% to about 50% by weight, or from about 5% to about 40% by weight, of reactive silica. 11. The method of numbered paragraph 9 or numbered paragraph 10, wherein the mixture comprises about 5% to about 50% by weight, e.g., about 10% to about 40% by weight, of the first silicate material; and about 5% to about 50% by weight, e.g., about 10% to about 40% by weight, of the second silicate material. 12. The method of numbered paragraph 11, wherein the first silicate material is a silicate glass, e.g., an aluminosilicate glass, and the second silicate material is a silicate mineral, e.g., an aluminosilicate mineral; or wherein the first silicate material is a first silicate glass, e.g., a first aluminosilicate glass, and the second silicate material is a second silicate glass, e.g., a second aluminosilicate glass. 13. The method of numbered paragraph 9, wherein the silicate material comprises about 50% to about 95%, by weight, e.g., about 60% to about 85%, by weight, of SiO2; about 1% to about 30%, by weight, e.g., about 2% to about 15%, by weight, of Na2O; about 0% to about 15%, by weight, e.g., about 0.01% to about 6%, by weight, of KO2; about 0% to about 20%, by weight, e.g., about 0.05% to about 15%, by weight, of CaO; about 0% to about 20%, by weight, e.g., about 0.1% to about 15%, by weight, of Al2O3; about 20% or less, e.g., less than about 15%, by weight, of B2O3; about 20% or less, e.g., less than about 15%, by weight, of PbO; about 10% or less, e.g., less than about 5%, by weight, of MgO; and about 10% or less, e.g., less than about 5%, by weight, of BaO. 14. The method of any of numbered paragraphs 1-13, wherein the mixture includes boron in an amount such that the expanded particulate material includes less than about 5.0% by weight, e.g., less than about 3.5% by weight, B2O3. 15. The method of any of numbered paragraphs 1-14, wherein the step of curing the mixture to form a solid precursor comprises curing the mixture at a temperature of about 250°C or less, e.g., about 120°C or less, or from about 20°C to about 250°C, or from about 20°C to about 120°C, or from about 50°C to about 110°C, or from about 70°C to about 100°C. 16. The method of any of numbered paragraphs 1-15, wherein the step of heating the granular material to form the expanded granular material comprises heating the granular material to a temperature of about 1100°C or less, e.g., about 700°C or less, or about 300°C to about 900°C, or about 300°C to about 700°C, or about 400°C to about 600°C. 17. The method of any of numbered paragraphs 1-16, wherein the step of heating the granular material to form the expanded granular material includes heating the granular material in an infrared furnace, an electrically heated furnace, a natural gas or LPG expansion furnace, a muffle furnace, or a fluidized bed reactor. 18. Expanded granular material has a density of approximately 15 kg / m 3 ~about 450kg / m 3 , for example, about 20 kg / m 3 ~about 100kg / m 3 , or approximately 20 kg / m 3 ~about 30kg / m 3 , or approximately 20 kg / m 3 ~about 40kg / m 3 , or approximately 55 kg / m 3 ~about 100kg / m 3 , or approximately 70 kg / m 3 ~about 100kg / m 3 a loose bulk density measured in accordance with PI 200-77 of from about 3 PSI to about 350 PSI at 2", e.g., from about 3 PSI to about 200 PSI at 2", or from about 3 PSI to about 100 PSI at 2", or from about 3 PSI to about 10 PSI at 2", or from about 30 PSI to about 80 PSI at 2", or from about 40 PSI to about 75 PSI at 2", or from about 5 PSI to about 20 PSI at 2", and / or a resistance to compaction measured in accordance with PI 306-80 of from about 0.0300 W / mK to about 0.0700 W / m 18. The method of any of numbered paragraphs 1 to 17, wherein the thermal conductivity (λ, lambda value) measured in accordance with EN 12667 is from about 0.0320 W / mK to about 0.0420 W / mK, from about 0.0350 W / mK to about 0.0400 W / mK, or from about 0.0360 W / mK to about 0.0410 W / mK, or from about 0.0320 W / mK to about 0.0340 W / mK, or from about 0.042 W / mK to about 0.055 W / mK, or from about 0.055 W / mK to about 0.070 W / mK. 19. An expanded granular material produced by the method described in any of numbered paragraphs 1 to 18. 20.About 15kg / m 3 ~about 450kg / m 3 , for example, about 20 kg / m 3 ~about 100kg / m 3, or approximately 20 kg / m 3 ~about 30kg / m 3 , or approximately 20 kg / m 3 ~about 40kg / m 3 , or approximately 55 kg / m 3 ~about 100kg / m 3 , or approximately 70 kg / m 3 ~about 100kg / m 3 a loose bulk density measured in accordance with PI 200-77 of from about 3 PSI to about 350 PSI at 2", e.g., from about 3 PSI to about 200 PSI at 2", or from about 3 PSI to about 100 PSI at 2", or from about 3 PSI to about 10 PSI at 2", or from about 30 PSI to about 80 PSI at 2", or from about 40 PSI to about 75 PSI at 2", or from about 5 PSI to about 20 PSI at 2", and / or a resistance to consolidation measured in accordance with PI 306-80 of from about 0.0300 W / m an expanded granular material having a thermal conductivity measured in accordance with EN 12667 of from about 0.0320 W / mK to about 0.0420 W / mK, for example, from about 0.0350 W / mK to about 0.0400 W / mK, or from about 0.0360 W / mK to about 0.0410 W / mK, or from about 0.0320 W / mK to about 0.0340 W / mK, or from about 0.042 W / mK to about 0.055 W / mK, or from about 0.055 W / mK to about 0.070 W / mK. 21. The expanded granular material according to numbered paragraph 20, comprising about 8% to about 30%, e.g., about 13% to about 22%, by weight, of X2O (X is an alkali metal such as Na or Li); about 0% to about 15%, by weight, for example, about 5% to about 9%, by weight of Al2O3; and about 50% to about 80%, by weight, for example, about 60% to about 75%, by weight of SiO2, and optionally about 0% to about 10%, by weight, for example, about 0.5% to about 5%, by weight of HO. 22. The expanded granular material of numbered paragraph 21, comprising less than about 5% by weight, e.g., less than about 3.5% by weight, B2O3. 23. The expanded granular material of any of numbered paragraphs 20-22, wherein the expanded granular material is formed by expanding a precursor obtained by curing a mixture comprising a silicate material, an alkali compound, and water, wherein (a) the mixture may include glass network formers, glass network intermediates, and / or glass network modifiers other than silicon; (b) the mixture may further include reactive silica; and / or (c) the mixture may include two different silicate materials. 24. The expanded granular material according to part (c) of numbered paragraph 23, wherein (i) one of the two different silicate materials is selected from a volcanic glass, such as a perlitic material, such as unexpanded natural perlite ore having a water content of more than about 2% by weight; a phyllosilicate mineral, such as bentonite, kaolin or calcined kaolin; diatomaceous earth; or any combination thereof; and / or (ii) one of the two different silicate materials is a silicate glass selected from fused silica glass, soda-lime glass, borosilicate glass, lead oxide glass, aluminosilicate glass, silica-germania glass. 25. An intumescent material comprising about 0.1% to about 25%, e.g., about 0.2% to about 5%, by weight of X2O (wherein X is an alkali metal such as Na or Li); about 0.1% to about 30%, e.g., about 0.2% to about 20%, by weight of Al2O3; about 30% to about 80%, e.g., about 40% to about 60%, by weight of SiO2; and about 10% to about 30%, e.g., about 15% to about 30%, by weight of HO, which may contain less than about 5%, e.g., less than about 3.5%, by weight of B2O3. 26. The expandable material of numbered paragraph 25, which is substantially amorphous. 27. The expandable material described in numbered paragraph 25 or numbered paragraph 26, which may be granular and have a particle size of about 10 μm to about 2 cm. 28. A method of making an intumescent material, the method comprising: (a) forming a mixture comprising a silicate material, an alkali compound, and water; (i) the mixture may include glass network formers, glass network intermediates, and / or glass network modifiers other than silicon; (ii) the mixture may further include reactive silica; and / or (iii) the mixture may include two different silicate materials; and (b) curing the mixture to form the intumescent material. 29. The method of numbered paragraph 28, further comprising the step of fracturing the expandable material. 30. An intumescent material produced in accordance with the method set forth in numbered paragraph 28 or numbered paragraph 29. 31. An insulation product comprising an expanded granular material described in any of numbered paragraphs 19 to 24, or an expanded granular material formed by expanding an intumescent material described in any of numbered paragraphs 25 to 27 or 30, such as a bulk material for insulating cavity walls, a filler for insulation board, an insulation board, a filler for ceiling tiles such as acoustical ceiling tiles, a ceiling tile such as acoustical ceiling tiles, a granular material for insulating cryogenic or cryogenic vessels, or an insulated cryogenic or cryogenic vessel. 30. A building material, such as a sheet such as a fiber cement sheet, a mortar or plaster such as a cementitious gypsum-based and / or acrylic-based mortar or plaster, or concrete, comprising an expanded granular material as described in any of numbered paragraphs 19 to 24, or an expanded granular material formed by expanding an expansive material as described in any of numbered paragraphs 25 to 27 or 30. 31. A horticultural or agricultural substrate or substrate component comprising an expanded granular material as set forth in any of numbered paragraphs 19 to 24, or an expanded granular material formed by expanding an intumescent material as set forth in any of numbered paragraphs 25 to 27 or 30. 32. A flame-retardant functional material comprising an intumescent granular material as set forth in any of numbered paragraphs 25 to 27, or an intumescent granular material produced according to the method set forth in any of numbered paragraphs 28 to 30. 33. Use of an expanded granular material as set forth in any of numbered paragraphs 19 to 24, or an expanded granular material formed by expanding an intumescent material as set forth in any of numbered paragraphs 25 to 27 or 30, in an insulation product, such as a bulk material for insulating cavity walls, a filler for insulation boards, a filler for acoustical ceiling tiles, a granular material for insulating cryogenic or cryogenic vessels, or a building material, such as a sheet such as a fiber cement sheet, a mortar or plaster such as a cementitious gypsum-based and / or acrylic-based mortar or plaster, or concrete, or a horticultural or agricultural substrate or substrate component. [Example]

[0196] In the following examples, intumescent and expandable materials were prepared using silicate raw materials whose chemical compositions, expressed in mass % as equivalent oxide content, are shown in Table 1. 50 The particle size as is also shown for each of the silicate raw materials. [Table 1] *Values ​​expressed as % by mass **Values ​​expressed in μm

[0197] Generally, expandable materials were prepared by inorganic polymerization of silicate precursors in an aqueous alkaline solution. Pellets of an alkali salt (e.g., sodium hydroxide or lithium hydroxide) were dissolved in water. The solid silicate precursor was quickly added to the resulting solution so that the heat generated during dissolution of the alkali salt could aid in dissolving the silicate material. The mixture was stirred for several minutes to form a paste. After stirring, the paste was cured in an oven at temperatures between 70°C and 100°C for several hours to several days to form the expandable precursor material. The precursor was crushed and sieved to the desired particle size distribution.

[0198] Expanded materials were produced by expanding crushed precursor material. Unless otherwise specified, crushed precursors were expanded by heating in an infrared (IR) expansion furnace equipped with a stainless steel vibration table, eight Elstein HTS ceramic infrared panel radiators (125 x 125 mm, 64 kW / m output, and a maximum operating temperature of 860 °C), and Italvibras G. Silingardi vibration elements (Model: M3 / 45-S02, Series: AA, CFKN 0.44 / 0.64, RPM 3000 / 3800). The feed into the furnace was regulated using an electromagnetic automatic feeder. The infrared lamps were operated at temperatures between 500 °C and 750 °C so that the temperature of the granular precursor reached approximately 300 °C to approximately 350 °C. Finely crushed precursors with particle sizes less than 500 μm were expanded by heating in a vertical electric furnace (VEF) or a vertical LPG furnace. Fine particles with particle sizes below 100 μm were expanded in a laboratory-scale fluidized bed (FB) reactor.

[0199] Example 1 Four different intumescent materials were formed using borosilicate glass, sodium hydroxide, and water as starting materials. Table 2 shows the composition of the four different starting mixtures, the concentration of sodium hydroxide in the initial alkaline solution, the silicon to sodium ratio in the mixture, the measured "loss on ignition" for the materials before expansion, and the measured loose bulk density of the materials after expansion at 700°C in a laboratory muffle furnace.

[0200] [Table 2]

[0201] Example 2 Six different intumescent materials were formed using borosilicate glass, soda-lime glass, sodium hydroxide, and water as starting materials. Table 3 shows the composition of the six different starting mixtures, the ratio of borosilicate glass to soda-lime glass in the mixtures ("B / S ratio"), the concentration of sodium hydroxide in the initial alkaline solution, the ratio of silicon to sodium in the mixtures, the measured "loss on ignition" for the materials before expansion, and the measured loose bulk density of the materials after expansion at 600°C, 650°C, or 750°C in a laboratory muffle furnace. Mixes B4, B5, and B6 did not yield intumescent materials.

[0202] [Table 3]

[0203] Example 3 13.5 wt% borosilicate glass, 40.5 wt% silica fume, 18 wt% sodium hydroxide, and 27.9 wt% water were used as starting materials to form the intumescent material. Prior to expansion, the intumescent material was crushed into two different particle size ranges. The measured loose bulk density, compaction resistance, and thermal conductivity of the two different intumescent materials are shown in Table 4.

[0204] [Table 4]

[0205] Example 4 An intumescent material was formed using 15% by weight borosilicate glass, 45% by weight perlite tailings, 10% by weight sodium hydroxide, and 30% by weight water as starting materials. Prior to expansion, the intumescent material was crushed to a particle size range of 0.5 mm to 1 mm. The measured loose bulk density and thermal conductivity of the intumescent material are shown in Table 5.

[0206] [Table 5]

[0207] Example 5 Different combinations of borosilicate glass, silica fume, perlite tailings, sodium hydroxide, lithium hydroxide, water, and a water repellent were used as starting materials to form 51 different expanded materials. Tables 6-16 show the compositions of the 40 starting mixtures, as well as the ratio of the sum of the total amount of silica fume and perlite tailings to the total amount of borosilicate glass (the "(SF+P) / BG" ratio), the ratio of the total amount of silica fume to the total amount of perlite tailings (the "SF / P" ratio), the silicon to sodium ratio, the particle size of the unexpanded precursor material, the temperature at which the expansion was performed, the measured loose bulk density of the expanded material, the particle size of the expanded material, and the d of the expanded material. 50 , the water absorption of the expanded material, the water repellency of the expanded material, the percentage of expanded particles that were suspended, the resistance to compaction of the expanded material at 1" or 2", the thermal conductivity of the expanded material, the pH of the expanded material, and the skeletal density of the expanded material. Unless otherwise specified, expansion was performed in an IR oven.

[0208] [Table 6]

[0209] [Table 7]

[0210] [Table 8]

[0211] [Table 9]

[0212] [Table 10]

[0213] [Table 11]

[0214] [Table 12]

[0215] [Table 13]

[0216] [Table 14]

[0217] [Table 15]

[0218] [Table 16]

[0219] Example 6 Nine different expanded materials were formed using different combinations of borosilicate glass, silica fume, perlite tailings, soda-lime glass, sodium hydroxide, water, and a water repellent as starting materials. Tables 17 and 18 show the composition of the nine starting mixtures, the ratio of the sum of the total amount of silica fume and perlite tailings to the total amount of borosilicate glass (the "(SF+P) / BG" ratio), the ratio of the total amount of silica fume to the total amount of perlite tailings (the "SF / P" ratio), the ratio of borosilicate glass to soda-lime glass (the "B / S" ratio), the silicon to sodium ratio, the particle size of the unexpanded precursor material, the temperature at which the expansion was performed, the measured loose bulk density of the expanded material, and the water absorption (i.e., water loading) of the expanded material. Unless otherwise specified, the samples were expanded in an IR furnace.

[0220] The water absorption (water load) of each granular material was measured by first weighing 400 ml of the granular material. The sample was transferred to a 500 ml cylinder with a very fine sieve at the bottom, sufficient to retain the granular material within the cylinder while allowing water to pass through. This was then tapped 50 times using an automatic tapping device. An additional 30 ml of granular material was weighed and added to the cylinder, which was then tapped an additional 30 times. Finally, several ml of material were added as the sample accumulated, and the tapped sample was repeated 20 times to produce a tapped sample in a 400 ml cylinder, the mass of which was recorded. The cylinder was then connected to a water pump. The water pump was used to first fill the cylinder with water, then drain the water from the cylinder. The new wet mass was measured. The water absorption of the granular material was then calculated as the mass of water retained by the sample (i.e., the mass of water absorbed) per mass of granular material in the cylinder (expressed in g / g).

[0221] [Table 17]

[0222] [Table 18]

[0223] Example 7 Five different intumescent materials (E1-E5) were formed using different mixtures of borosilicate glass, silica fume, perlite tailings, sodium hydroxide, lithium hydroxide, and water as starting materials. The compositions of the five starting mixtures are listed in Table 19. The applicability of intumescent materials as non-expanding, foaming flame retardant additives for polymer compositions was examined. Foaming agents are substances that swell upon exposure to heat, thus increasing volume and decreasing density. Foaming additives are typically used in passive fire protection.

[0224] The functionality of these new flame retardant formulations is based on their (i) ability to endothermically release up to 30% by weight of bound water; (ii) ability to expand to form an insulating barrier that inhibits heat transfer and destabilization of the surrounding polymer matrix (i.e., avoiding burning droplets); and (iii) ability to melt at temperatures above 700°C without collapsing and retaining at least part of their original shape. All formulations were found to: 1. Chemically bound water is released within the temperature range of 200 to 500°C. 2.Expands and foams within the range of 400 to 600°C. 3.It starts to melt at temperatures above 700℃.

[0225] The test was carried out in accordance with DIN EN 45545 (fire test). For all the different polymers charged with flame retardant additives, the softening point, melting point, and pour point were successfully adjusted to meet specific target narrow temperature ranges. Adjustments were achieved by varying the starting mixture as shown in Table 19.

[0226] Two different polymers were loaded with the highest melting point flame retardant additive: (1) PVC containing 10% by weight of D2; (2) PVC containing 10% by weight of D4; (3) polypropylene containing 5% and 10% by weight of D2 (i.e., two different loading levels); and (4) polypropylene containing 5% and 10% by weight of D4 (i.e., two different loading levels). Polyurethane (PU) foam was also loaded with 8% by weight of each flame retardant additive. Before loading, the softening point, melting point, and flow point of the flame retardant additive were successfully adjusted (relative to the baseline material, material D5) to maximize fire resistance. The adjustment was achieved by changing the starting mixture as shown in Table 19.

[0227] [Table 19]

[0228] Depending on the particle size distribution, different particle size distributions listed in Table 20 were tested in various polymers. [Table 20]

Claims

1. 1. A method for producing an expanded granular material, comprising: silicate materials; alkaline compounds; and water forming a mixture comprising: curing the mixture to form a solid precursor; crushing and / or milling the solid precursor to form an expandable particulate material; heating the expandable granular material to form an expandable granular material; A method comprising:

2. the mixture contains glass network formers, glass network intermediates and / or glass network modifiers other than silicon; The glass network former elements other than silicon may be selected from boron, germanium, and phosphorus; The glass network intermediate elements may be selected from titanium, aluminum, zirconium, beryllium, magnesium and zinc; and / or 10. The method of claim 1, wherein the glass network modifying element may be selected from calcium, lead, lithium, sodium and potassium.

3. 3. The method of claim 1 or claim 2, wherein the mixture further comprises reactive silica, such as silica fume and / or fumed silica.

4. The mixture may comprise two different silicate materials, e.g. the mixture comprises a silicate glass, such as an aluminosilicate glass; and a silicate mineral, such as an aluminosilicate mineral; or The method of any one of claims 1 to 3, wherein the mixture comprises a first silicate glass, such as a first aluminosilicate glass; and a second silicate glass, such as a second aluminosilicate glass.

5. one of the two different silicate materials is selected from a volcanic glass, e.g., a perlitic material, e.g., unexpanded natural perlite ore having a water content of greater than about 2% by weight; a phyllosilicate mineral, e.g., bentonite, kaolin, or calcined kaolin; diatomaceous earth; or a combination thereof; and / or 5. The method of claim 4, wherein one of the two different silicate materials is a silicate glass selected from fused silica glass, soda-lime glass, borosilicate glass, lead oxide glass, aluminosilicate glass, silica-germania glass, and the silicate glass may be recycled glass, for example in the form of recycled glass cullet.

6. The mixture is about 10% to about 90% by weight, e.g., about 15% to about 80% by weight, or about 20% to about 70% by weight, of a silicate material; about 5% to about 25% by weight, about 10% to about 20% by weight of an alkaline compound; and About 15% to about 50% by weight, for example about 20% to about 40% by weight, of water Including, 6. The method of any one of claims 1 to 5, wherein the mixture may comprise from about 5% to about 75% by weight, such as from about 5% to about 50% by weight, or from about 5% to about 40% by weight, of reactive silica.

7. The silicate material is About 50% to about 95% by weight, for example about 60% to about 85% by weight, of SiO 2 ; About 1% to about 30% by weight, for example about 2% to about 15% by weight, of Na 2 O; about 0% to about 15% by weight, for example about 0.01% to about 6% by weight of K 2 O; about 0% to about 20% by weight, e.g., about 0.05% to about 15% by weight, of CaO; about 0% to about 20% by weight, for example about 0.1% to about 15% by weight, of Al 2 O 3 ; about 20% by weight or less, for example, less than about 15% by weight B 2 O 3 ; about 20% by weight or less, e.g., less than about 15% by weight PbO; about 10% by weight or less, e.g., less than about 5% by weight, MgO; and BaO of about 10% by weight or less, for example, less than about 5% by weight The method of claim 6, comprising:

8. The mixture may contain less than about 5.0% by weight, e.g., less than about 3.5% by weight, of expanded particulate material. 2 O 3 The method of any one of claims 1 to 7, wherein the boron is present in an amount such that the boron content is in the range of 0.1 to 1.0%.

9. and / or curing the mixture to form a solid precursor comprises curing the mixture at a temperature of about 250°C or less, e.g., about 120°C or less, or from about 20°C to about 250°C, or from about 20°C to about 120°C, or from about 50°C to about 110°C, or from about 70°C to about 100°C; and / or 9. The method of any one of claims 1 to 8, wherein the step of heating the granular material to form the expanded granular material comprises heating the granular material to a temperature of about 1100°C or less, such as about 700°C or less, or from about 300°C to about 900°C, or from about 300°C to about 700°C, or from about 400°C to about 600°C.

10. Approximately 15kg / m 3 ~Approx. 450kg / m 3 , for example, about 20 kg / m 3 ~Approx. 100kg / m 3 , or about 20 kg / m 3 ~Approx. 30kg / m 3 , or about 20 kg / m 3 ~About 40kg / m 3 , or about 55 kg / m 3 ~Approx. 100kg / m 3 , or about 70 kg / m 3 ~Approx. 100kg / m 3 loose bulk density measured in accordance with PI 200-77 of the and / or a resistance to consolidation measured according to PI 306-80 of from about 3 PSI to about 350 PSI at 2", e.g., from about 3 PSI to about 200 PSI at 2", or from about 3 PSI to about 100 PSI at 2", or from about 3 PSI to about 10 PSI at 2", or from about 30 PSI to about 80 PSI at 2", or from about 40 PSI to about 75 PSI at 2", or from about 5 PSI to about 20 PSI at 2"; and / or a thermal conductivity measured according to EN 12667 of from about 0.0300 W / mK to about 0.0700 W / mK, e.g., from about 0.0320 W / mK to about 0.0420 W / mK, from about 0.0350 W / mK to about 0.0400 W / mK, or from about 0.0360 W / mK to about 0.0410 W / mK, or from about 0.0320 W / mK to about 0.0340 W / mK, or from about 0.042 W / mK to about 0.055 W / mK, or from about 0.055 W / mK to about 0.070 W / mK 1. An expanded granular material having:

11. The expanded granular material about 8% to about 30% by weight, for example about 13% to about 22% by weight of X 2 O (X is an alkali metal such as Na or Li); about 0% to about 15% by weight, for example about 5% to about 9% by weight, of Al 2 O 3 and About 50% to about 80% by weight, for example about 60% to about 75% by weight, of SiO 2 Including; About 0% to about 10% by weight, for example about 0.5% to about 5% by weight H 2 may contain O; The expanded particulate material has less than about 5% by weight, e.g., less than about 3.5% by weight B 2 O 3 11. The expanded granular material of claim 10, comprising:

12. The expanded granular material silicate materials; alkaline compounds; and water and forming the precursor by expanding the precursor obtained by curing a mixture comprising: (a) the mixture may contain glass network formers, glass network intermediates and / or glass network modifiers other than silicon; (b) the mixture may further comprise reactive silica; and / or (c) the mixture may include two different silicate materials; moreover, (i) one of the two different silicate materials may be selected from a volcanic glass, e.g., a perlitic material, e.g., unexpanded natural perlite ore having a water content of greater than about 2% by weight; a phyllosilicate mineral, e.g., bentonite, kaolin, or calcined kaolin; diatomaceous earth; or any combination thereof; and / or (ii) The expanded granular material according to claim 10 or claim 11, wherein one of the two different silicate materials may be a silicate glass selected from fused silica glass, soda-lime glass, borosilicate glass, lead oxide glass, aluminosilicate glass, and silica-germania glass.

13. about 0.1% to about 25% by weight, for example about 0.2% to about 5% by weight of X 2 O, where X is an alkali metal such as Na or Li; about 0.1% to about 30% by weight, for example about 0.2% to about 20% by weight, of Al 2 O 3 ; About 30% to about 80% by weight, for example about 40% to about 60% by weight, of SiO 2 and About 10% to about 30% by weight, for example about 15% to about 30% by weight H 2 O An expandable material comprising: Less than about 5% by weight, for example less than about 3.5% by weight, of B 2 O 3 The expandable material may include

14. 14. The expandable material of claim 13, which is substantially amorphous and / or granular and may have a particle size of from about 10 μm to about 2 cm.

15. 1. A method for producing an expandable material, comprising: (a) silicate materials; alkaline compounds; and water forming a mixture comprising: (i) the mixture may contain glass network formers, glass network intermediates and / or glass network modifiers other than silicon; (ii) the mixture may further comprise reactive silica; and / or (iii) the mixture may include two different silicate materials; (b) curing the mixture to form an expandable material; Including; (c) The method may include the step of fracturing the intumescent material.

16. 16. An insulating product comprising the expanded granular material of any one of claims 10 to 12, or expanded granular material formed by expanding the intumescent material of claims 13 or 14, or by expanding the intumescent material produced according to the method of claim 15, such as a bulk material for insulating cavity walls, a filler for insulation boards, insulation boards, a filler for ceiling tiles such as acoustical ceiling tiles, a granular material for insulating cryogenic or cryogenic vessels, or an insulated cryogenic or cryogenic vessel.

17. 16. A building material, for example a sheet such as a fibre cement sheet, a mortar or plaster such as a cementitious gypsum-based and / or acrylic-based mortar or plaster, or concrete, comprising an expanded granular material according to any one of claims 10 to 12, or formed by expanding an expansive material according to claims 13 or 14, or by expanding an expansive material produced according to the method of claim 15.

18. 16. A horticultural or agricultural substrate or substrate component comprising an expanded granular material according to any one of claims 10 to 12, or an expanded granular material formed by expanding an intumescent material according to claim 13 or claim 14, or by expanding an intumescent material produced according to the method of claim 15.

19. A flame-retardant functional material comprising the intumescent granular material according to claim 13 or claim 14 or the intumescent granular material produced according to the method according to claim 15.

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