Set forth herein are methods for producing low-carbon concrete components comprising a cementitious mixture of industrial solid wastes such as coal combustion residues, lime, kiln dust, and gypsum. These cementitious mixtures are a substantial replacement for Portland cement-based concrete mixtures. The methods herein include mixing materials, pressing, and shaping the mixed materials into a structural concrete component, and exposing the structural component to carbon dioxide. The CO2 may be sourced from CO2 emission sources (e.g., waste CO2-containing gas stream, dilute flue gas stream, a concentrated CO2 gas stream, a commercially available CO2 source, liquefied CO2, or from the atmosphere) to harden and thereby form structural concrete components. In some examples, the finished concrete components (e.g., concrete block) are compliant with industry-standard requirements for use in construction applications and feature significantly lower carbon intensity compared to traditional cement-based concrete components.
C04B 28/14 - Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements
C04B 40/02 - Selection of the hardening environment
C04B 111/10 - Compositions characterised by the absence of a specified material
2.
PROCESSES FOR USING REACTIVE LIME AND/OR MAGNESIA-CONTAINING MATERIALS IN CONCRETE BY LOW TEMPERATURE AND LOW-PRESSURE HYDROTHERMAL DENSIFICATION PROCESSES AND RELATED COMPOSITIONS AND APPARATUS
22 in the form of gaseous or liquid or a combination thereof are enforced in concrete pore space to form hydrated calcium carbonates (HCC) and/or hydrated magnesium carbonates and other hydration products to densify concrete microstructure. Certain processes and reagents are useful for adjusting the initial porosity of a concrete mixture. Certain processes and reagents are useful for regulating the rate of microstructure development of concrete during curing. Certain processes and reagents are useful for adjusting the initial porosity of a concrete mixture and also useful for regulating the rate of microstructure development of concrete during curing. The instant disclosure provides pathways for the utilization of lime/magnesia-containing industrial solid waste that otherwise cannot be generally used for concrete applications.
2333), and amorphous alumina-silica gel. The developed binder system is activated through hydration and/or concurrent hydration-carbonation reactions in concrete and it can be utilized in the form of slurry or dried powder for a wide range of precast and cast-in-place or ready-mix concrete applications. The binder system reacts with cement in concrete to form carbonate/calcium-silicate-hydrate (C-S-H) composite phases that result in enhanced mechanical properties.
C04B 28/02 - Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
4.
METHODS AND SYSTEMS FOR BIOMASS-DERIVED CO2 SEQUESTRATION IN CONCRETES AND AGGREGATES
Provided herein are integrated biomass combustion-carbonation gas conditioning systems to directly sequester carbon dioxide from biomass-derived CO2-containing flue gas. The CO2 is sequestered by mineral carbonation in concrete materials within a carbonation reactor. The mineral carbonation processes sequester CO2 in concrete materials, aqueous slurries, or aggregates without any additional carbon enrichment process. Contacting a CO2-containing gas stream from a biomass combustion apparatus with concrete, aggregate, or alkaline solutions, causes a carbonation reaction in which carbonation products such as calcium carbonate (CaCO3) and alumina silica gel are formed. The carbonation reactions set forth herein are useful for strengthening concrete and concrete components. Certain processes herein condition the biomass-derived flue gas. The conditioning includes condensing the gas to remove acidic gas, and to remove particulates and water. The conditioning includes adjusting the temperature, relative humidity, and gas flow rate of the biomass-derived flue gas without any carbon capture step before entering the carbonation reactor. The permanent storage of CO2 in concrete materials reduces carbon emissions from biomass combustion systems. The process does so, in certain embodiments, at low temperatures, ambient pressure, and even under dilute CO2 concentrations in CO2-containing flue gas streams. For example, the CO2 concentration in a CO2-containing flue gas stream from a biomass combustion system may be lower than 20 volume percent (vol %) and be used to produce low-carbon concrete materials.
22222-containing gas stream to precipitate additional calcium carbonate. The carbonated materials formed from these processes can be used in the form of a slurry, as a moist powder, as a dried powder, as a reactive filler or as a supplementary cementitious material in a mixture that is used to make concrete.
22223222222-containing flue gas stream from a biomass combustion system may be lower than 20 volume percent (vol%) and be used to produce low-carbon concrete materials.
The disclosure herein sets forth processes and compositions for producing carbonated materials comprising calcium carbonates through a mechanochemical process. The present disclosure concerns the production of calcium carbonate by sequestrating CO2. Certain processes herein include providing alkaline-rich mineral materials that include carbonatable solid wastes such as lime kiln dust, cement kiln dust, and coal combustion residues, and simultaneously fractioning the alkaline-rich mineral materials, while contacting the alkaline-rich mineral materials with a CO2-containing gas in carbonation reactor at low temperature and ambient pressure. In some embodiments, the alkaline-rich mineral materials are partially carbonated before being used in the processes disclosed herein. After contacting the alkaline-rich mineral materials with a CO2-containing gas in carbonation reactor at low temperature and ambient pressure, solid calcium carbonate is produced. In aqueous reactors, the solid calcium carbonate is filtered from a solution in which it precipitated, and the remaining solution includes hydroxide as well as alkaline metal ions. The solution filtered from the solid calcium carbonate can be sequentially contacted with a CO2-containing gas stream to precipitate additional calcium carbonate. The carbonated materials formed from these processes can be used in the form of a slurry, as a moist powder, as a dried powder, as a reactive filler or as a supplementary cementitious material in a mixture that is used to make concrete.
22e.g.2222e.g.e.g., concrete block) are compliant with industry-standard requirements for use in construction applications and feature significantly lower carbon intensity compared to traditional cement-based concrete components.
C04B 28/00 - Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
B01D 53/14 - Separation of gases or vapoursRecovering vapours of volatile solvents from gasesChemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases or aerosols by absorption
C04B 28/02 - Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
10.
METHODS FOR REACTIVATING PASSIVATED MINERAL RESIDUES
B01J 20/04 - Solid sorbent compositions or filter aid compositionsSorbents for chromatographyProcesses for preparing, regenerating or reactivating thereof comprising inorganic material comprising compounds of alkali metals, alkaline earth metals or magnesium
B01J 20/10 - Solid sorbent compositions or filter aid compositionsSorbents for chromatographyProcesses for preparing, regenerating or reactivating thereof comprising inorganic material comprising silica or silicate
B01J 20/28 - Solid sorbent compositions or filter aid compositionsSorbents for chromatographyProcesses for preparing, regenerating or reactivating thereof characterised by their form or physical properties
C04B 28/02 - Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
patents
