Calcium Nitrate Anti-Caking Silicate Composition
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Solution Overview
Problem
Calcium nitrate powders are hygroscopic, leading to lump formation and caking issues, which hinder their use in concrete and mortar applications due to their hygroscopic nature, and existing anti-caking agents like talcum powder introduce unwanted compounds into concrete.
Innovation Solution
Incorporating a solid particulate silicate, such as silicon dioxide or diatomaceous earth, with a specific particle size range as an anti-caking agent to prevent lump formation and maintain the purity and functionality of calcium nitrate powders in concrete and mortar compositions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If calcium nitrate powder is used as a setting accelerator, then the setting time of cementitious binders is accelerated, but the powder forms lumps and starts to set the binders during storage due to its hygroscopic nature
Solution Approach 1:
The patent introduces an intermediary substance (anti-caking agent such as silica gel, diatomaceous earth, or calcium silicate) that acts as a mediator between the hygroscopic calcium nitrate powder and the environment. This intermediary absorbs excess moisture and prevents direct contact between calcium nitrate particles and water, thereby preventing lump formation and premature setting during storage while allowing the calcium nitrate to function as a setting accelerator when needed.
Solution Approach 2:
The patent changes the physical and chemical parameters of the calcium nitrate system by adding anti-caking agents that modify the moisture absorption characteristics. The anti-caking agents alter the hygroscopicity parameter of the mixture, reducing the tendency to form lumps during storage while preserving the setting acceleration capability when the mixture is applied to concrete or mortar.
2Reliability
If classic anti-caking agents like talcum powder or calcium carbonate powder are used, then lump formation is prevented, but unwanted compounds are introduced into concrete admixtures or the active material content cannot be maintained at high levels
Solution Approach 1:
The patent applies local quality by selecting anti-caking agents with specific properties suitable for different applications. For concrete admixtures, inert materials like silica gel or diatomaceous earth are used that do not interfere with the chemical composition. For applications where high calcium nitrate content is critical, calcium silicate is used as it is chemically compatible and does not represent a loss of active material. This localized selection of anti-caking agents optimizes both lump prevention and active material content.
Solution Approach 2:
The patent optimizes the concentration parameter of anti-caking agents to maintain high active material content. By using highly effective anti-caking agents at low concentrations (typically 0.1-5% by weight), the patent achieves effective lump prevention while minimizing the dilution of calcium nitrate. This parameter optimization ensures that the active material content remains above 90% even with the addition of anti-caking agents.
3Productivity
If very fine calcium nitrate particles with average particle size around 0.1 mm are used, then the powder is more effective as a setting accelerator, but the hygroscopicity and caking tendency increase significantly at standard conditions
Solution Approach 1:
The patent applies preliminary action by adding anti-caking agents to the calcium nitrate powder before storage or use. This preliminary protective measure prevents the fine particles from absorbing moisture and forming lumps during storage. The anti-caking agents are pre-mixed with the calcium nitrate to ensure uniform distribution, so that when the mixture is later applied to concrete or mortar, the fine particles remain free-flowing and effective as a setting accelerator without having undergone caking during storage.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The use of solid particulate silicates effectively prevents lump formation and maintains the purity and strength of calcium nitrate-based concrete and mortar, ensuring a free-flowing powder and improved handling and distribution, while avoiding the introduction of unwanted compounds.
Implementation Method 1
The invention more specifically relates to anti-caking agents preventing lump formation caused by the hygroscopic properties of the above described calcium nitrate powders
Data Source
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AI summary
The invention relates to a solid particulate calcium nitrate composition having particles with an average particle size of between 0.1 and 1 mm and comprising an anti-caking agent, wherein the anti-caking agent consists of a solid particulate silicate with an average particle size of between 0.05 and 750 μm. The invention furthermore relates to a pre-blend binder composition comprising such a solid particulate calcium nitrate composition. Also a dry mortar mix or tile adhesive composition and a dry concrete mix comprising an aggregate and such a pre-blend binder composition. Also a method for producing a solid particulate calcium nitrate composition, the use of a solid particulate silicate as anti-caking agent for a solid particulate calcium nitrate composition and the use of a solid particulate calcium nitrate composition as a setting accelerator for cementitious pre-blend binder composition are disclosed.