(169j) Magnesium Oxychloride Composites: Design, Synthesis and Scaled-up Manufacturing for Next Generation Building Materials

Magnesium oxychloride (MOC) is a ceramic material with significant fire resistant properties and growing potential as a light-weight, structurally strong alternative building material. Despite many advantages, MOC has limitations as a construction material, particularly water stability. This talk will explore the opportunities that MOC has to completely disrupt the construction and building products landscape. We will examine the fundamentals of the formation cure reaction, mechanisms of composite reinforcement to optimize mechanical performance, and methods of enhancing the material water stability. The formation cure reaction kinetics for magnesium oxychloride 5-phase was monitored from 35 to 55°C using time-resolved quantitative x-ray diffraction and differential scanning calorimetry (DSC). The reaction was characterized as a two-step process: dissolution of magnesium oxide into a gel state followed by crystallization of magnesium oxychloride. Assuming first-order kinetics for both MgO dissolution and MOC crystallization, a kinetic model predicts 42.4 kJ/mol and 26.1 kJ/mol for dissolution and crystallization activation energies respectively. Alternatively, the Avrami nucleation and growth model was fit to DSC measurements predicting diffusion controlled, one-dimensional growth with an activation energy of 72.4 kJ/mol, accounting for both dissolution and crystallization.

For the water stability enhancement, two methods of water stability enhancement have been explored: chlorartinite formation from CO₂ exposure and phosphoric acid addition. The conversion of magnesium oxychloride to chlorartinite by CO2 forms a protective, semi-insoluble chlorartinite layer on the surface of the magnesium oxychloride crystals, which improves water stability. Phosphoric acid (2.5 to 10 wt. %) was added to the MOC slurry before the cure reaction. Additions of 2.5 wt. % and above had positive impacts on the water stability, preserving ~50 wt. % crystalline MOC after the water stability test, but has a significant impact on the MOC formation kinetics. This is achieved via. the formation of an amorphous phase on the MOC crystal surface that contains structural motifs related to insoluble MgHPO4·3H2O (newberyte) and Mg2P2O7·3.5H2O (magnesium pyrophosphate) phases. Results from this work have been significantly impactful in our work with MiTek Inc. as we are building a first of its kind in the world manufacturing facility in Houston Texas. This talk will also highlight the path from fundamental research in the lab to full scale manufacturing of a new commercial product as a sustainable alternatives for conventional materials in residential and commercial building applications.