Abstract: This disclosure relates to inorganic coatings suitable for fire protection, fire retardancy, and articles comprising same. Specifically, the disclosure relates to the manufacture and use of inorganic phosphate-based coating formulations for fire protection, preventing or reducing fire propagation, and for heat management.

Abstract: A sealant having a specific gravity in the range of from about 0.7 to about 1.6 for heavy oil and/or coal bed methane fields is disclosed. The sealant has a binder including an oxide or hydroxide of Al or of Fe and a phosphoric acid solution. The binder may have MgO or an oxide of Fe and/or an acid phosphate. The binder is present from about 20 to about 50% by weight of the sealant with a lightweight additive present in the range of from about 1 to about 10% by weight of said sealant, a filler, and water sufficient to provide chemically bound water present in the range of from about 9 to about 36% by weight of the sealant when set. A porous ceramic is also disclosed.

Abstract: A method is provided for making inexpensive synthetic inorganic resins that are stable, mix easily with water and may be conveniently diluted to form an easy-to-use paste for commercial applications. The method uses environmentally friendly techniques to provide improved efficiencies in the commercial production of these resins. The resins are produced by the partial reaction of phosphoric acid with sparsely-soluble oxides, or sparsely-soluble oxide minerals, that are added to the phosphoric acid under controlled conditions. In certain specific embodiments, methods are provided for modifying synthetic inorganic resins so as to produce rapid-setting phosphate cements and ceramics having high flexural strength. Unique synthetic inorganic resin formulations are also disclosed.

Abstract: A sealant for an oil or geothermal well capable of setting within about 3 to about 6 hours at temperatures less than about 250° F. for shallow wells less than about 10,000 feet and deep wells greater than about 10,000 feet having MgO present in the range of from about 9.9 to about 14.5%, KH2PO4 present in the range of from about 29.7 to about 27.2%, class C fly ash present in the range of from about 19.8 to about 36.3%, class F fly ash present in the range of from about 19.8 to about 0%, boric acid or borax present in the range of from about 0.39 to about 1.45%, and water present in the range of from about 20.3 to about 21.86% by weight of the sealant. A method of sealing wells is disclosed as are compositions for very high temperature wells is disclosed as is a composition for treating oil field wastes.

Abstract: A structural material of a polystyrene base and the reaction product of the polystyrene base and a solid phosphate ceramic is applied as a slurry which includes one or more of a metal oxide or a metal hydroxide with a source of phosphate to produce a phosphate ceramic and a poly (acrylic acid or acrylate) or combinations or salts thereof and polystyrene or MgO applied to the polystyrene base and allowed to cure so that the dried aqueous slurry chemically bonds to the polystyrene base. A method is also disclosed of applying the slurry to the polystyrene base.

Abstract: A structural material of a polystyrene base and the reaction product of the polystyrene base and a solid phosphate ceramic. The ceramic is applied as a slurry which includes one or more of a metal oxide or a metal hydroxide with a source of phosphate to produce a phosphate ceramic and a poly (acrylic acid or acrylate) or combinations or salts thereof and polystyrene or MgO applied to the polystyrene base and allowed to cure so that the dried aqueous slurry chemically bonds to the polystyrene base. A method is also disclosed of applying the slurry to the polystyrene base.

Abstract: A method of stabilizing nuclear material is disclosed. Oxides or halides of actinides and/or transuranics (TRUs) and/or hydrocarbons and/or acids contaminated with actinides and/or TRUs are treated by adjusting the pH of the nuclear material to not less than about 5 and adding sufficient MgO to convert fluorides present to MgF2; alumina is added in an amount sufficient to absorb substantially all hydrocarbon liquid present, after which a binder including MgO and KH2PO4 is added to the treated nuclear material to form a slurry. Additional MgO may be added. A crystalline radioactive material is also disclosed having a binder of the reaction product of calcined MgO and KH2PO4 and a radioactive material of the oxides and/or halides of actinides and/or transuranics (TRUs). Acids contaminated with actinides and/or TRUs, and/or actinides and/or TRUs with or without oils and/or greases may be encapsulated and stabilized by the binder.

Abstract: A dry mix particulate composition of a calcined oxide of Mg and/or Ca, an acid phosphate, and fly ash or equivalent, wherein the calcined oxide is present in the range of from about 17% to about 40% by weight and the acid phosphate is present in the range of from about 29% to about 52% by weight and the fly ash or equivalent is present in the range of from about 24% to about 39% by weight when sand is added to the dry mix, it is present in the range of from about 39% to about 61% by weight of the combined dry mix and sand. A method of forming a structural member is also disclosed wherein an aqueous slurry of about 8–12 pounds of water is added to dry mix and sand.

Abstract: The present invention is directed to magnesium phosphate ceramics and their methods of manufacture. The composition of the invention is produced by combining a mixture of a substantially dry powder component with a liquid component. The substantially dry powder component comprises a sparsely soluble oxide powder, an alkali metal phosphate powder, a sparsely soluble silicate powder, with the balance of the substantially dry powder component comprising at least one powder selected from the group consisting of bioactive powders, biocompatible powders, fluorescent powders, fluoride releasing powders, and radiopaque powders. The liquid component comprises a pH modifying agent, a monovalent alkali metal phosphate in aqueous solution, the balance of the liquid component being water. The use of calcined magnesium oxide as the oxide powder and hydroxylapatite as the bioactive powder produces a self-setting ceramic that is particularly suited for use in dental and orthopedic applications.

Abstract: A structural material of a polystyrene base and the reaction product of the polystyrene base and a solid phosphate ceramic. The ceramic is applied as a slurry which includes one or more of a metal oxide or a metal hydroxide with a source of phosphate to produce a phosphate ceramic and a poly (acrylic acid or acrylate) or combinations or salts thereof and polystyrene or MgO applied to the polystyrene base and allowed to cure so that the dried aqueous slurry chemically bonds to the polystyrene base. A method is also disclosed of applying the slurry to the polystyrene base.

Abstract: Method and composition for sealing a borehole. A chemically bonded phosphate ceramic sealant for sealing, stabilizing, or plugging boreholes is prepared by combining an oxide or hydroxide and a phosphate with water to form slurry. The slurry is introduced into the borehole where the seal, stabilization or plug is desired, and then allowed to set up to form the high strength, minimally porous sealant, which binds strongly to itself and to underground formations, steel and ceramics.

Abstract: A new method for combining magnesium oxide, MgO, and magnesium dihydrogen phosphate to form an inexpensive compactible ceramic to stabilize very low solubility metal oxides, ashes, swarfs, and other iron or metal-based additives, to create products and waste forms which can be poured or dye cast, and to reinforce and strengthen the ceramics formed by the addition of fibers to the initial ceramic mixture.

Abstract: Method and composition for sealing a borehole. A chemically bonded phosphate ceramic sealant for sealing, stabilizing, or plugging boreholes is prepared by combining an oxide or hydroxide and a phosphate with water to form slurry. The slurry is introduced into the borehole where the seal, stabilization or plug is desired, and then allowed to set up to form the high strength, minimally porous sealant, which binds strongly to itself and to underground formations, steel and ceramics.

Abstract: There has been invented a chemically bonded phosphate corrosion protection material and process for application of the corrosion protection material for corrosion prevention. A slurry of iron oxide and phosphoric acid is used to contact a warm surface of iron, steel or other metal to be treated. In the presence of ferrous ions from the iron, steel or other metal, the slurry reacts to form iron phosphates which form grains chemically bonded onto the surface of the steel.

Abstract: A new method for combining magnesium oxide, MgO, and magnesium dihydrogen phosphate to form an inexpensive compactible ceramic to stabilize very low solubility metal oxides, ashes, swarfs, and other iron or metal-based additives, to create products and waste forms which can be poured or dye cast, and to reinforce and strengthen the ceramics formed by the addition of fibers to the initial ceramic mixture.

Abstract: Canister, sealing method and composition for sealing a borehole. The canister includes a container with slurry inside the container, one or more slurry exits at one end of the container, a pump at the other end of the container, and a piston inside that pushes the slurry though the slurry exit(s), out of the container, and into a borehole. An inflatable packer outside the container provides stabilization in the borehole. A borehole sealing material is made by combining an oxide or hydroxide and a phosphate with water to form a slurry which then sets to form a high strength, minimally porous material which binds well to itself, underground formations, steel and ceramics.

Abstract: A chemically bonded phospho-silicate ceramic formed by chemically reacting a monovalent alkali metal phosphate (or ammonium hydrogen phosphate) and a sparsely soluble oxide, with a sparsely soluble silicate in an aqueous solution. The monovalent alkali metal phosphate (or ammonium hydrogen phosphate) and sparsely soluble oxide are both in powder form and combined in a stochiometric molar ratio range of (0.5-1.5):1 to form a binder powder. Similarly, the sparsely soluble silicate is also in powder form and mixed with the binder powder to form a mixture. Water is added to the mixture to form a slurry. The water comprises 50% by weight of the powder mixture in said slurry. The slurry is allowed to harden. The resulting chemically bonded phospho-silicate ceramic exhibits high flexural strength, high compression strength, low porosity and permeability to water, has a definable and bio-compatible chemical composition, and is readily and easily colored to almost any desired shade or hue.

Abstract: A new method for combining elemental iron and other metals to form an inexpensive ceramic to stabilize arsenic, alkaline red mud wastes, swarfs, and other iron or metal-based additives, to create products and waste forms which can be poured or dye cast.

Abstract: There has been invented a chemically bonded phosphate corrosion protection material and process for application of the corrosion protection material for corrosion prevention. A slurry of iron oxide and phosphoric acid is used to contact a warm surface of iron, steel or other metal to be treated. In the presence of ferrous ions from the iron, steel or other metal, the slurry reacts to form iron phosphates which form grains chemically bonded onto the surface of the steel.

Abstract: A new method for combining elemental iron and other metals to form an inexpensive ceramic to stabilize arsenic, alkaline red mud wastes, swarfs, and other iron or metal-based additives, to create products and waste forms which can be poured or dye cast.