Carbonatable calcium silicate compositions and methods thereof

• US 10,611,690 B2
• Filed: 11/19/2018
• Issued: 04/07/2020
• Est. Priority Date: 08/04/2014
• Status: Active Grant

• Current Assignee: Solidia Technologies, Inc.
• Original Assignee: Solidia Technologies, Inc.
• Inventors: Atakan, Vahit, Quinn, Sean, Sahu, Sadananda, Ravikumar, Deepak, DeCristofaro, Nicholas
• Primary Examiner(s): Green, Anthony J
• Application Number:
  US16/194,685
• Publication Number:
  US 20190152856A1
• Time in Patent Office: 505 Days
• CPC Class Codes: C04B 28/10 Lime cements or magnesium oxide cements
• CPC Class Codes: C04B 28/188 the Ca-silicates being present in the starting mixture
• CPC Class Codes: C04B 40/0231 Carbon dioxide hardening
• CPC Class Codes: C04B 7/345 Hydraulic cements not provided for in one of the groups C04B7/02 - C04B7/34
• CPC Class Codes: C04B 7/3453 Belite cements, e.g. self-disintegrating cements based on dicalciumsilicate
• CPC Class Codes: Y02P 40/10 Production of cement, e.g. improving or optimising the production methods; Cement grinding
• CPC Class Codes: Y02P 40/18 Carbon capture and storage [CCS]

Abstract

The invention provides novel carbonatable calcium silicate compositions and carbonatable calcium silicate phases that are made from widely available, low cost raw materials by a process suitable for large-scale production. The method of the invention is flexible in equipment and production requirements and is readily adaptable to manufacturing facilities of conventional cement. The invention offers an exceptional capability to permanently and safely sequesters CO₂.

Claims

1. A carbonatable calcium silicate composition in powder form having a mean particle size (d50) of about 8 μ

m to about 25 μ

m, with 10% of particles (d10) sized below about 0.1 μ

m to about 3 μ

m, and 90% of particles (d90) sized above about 35 μ

m to about 100 μ

m, wherein the composition comprises;

calcium silicate in the form of one or more discrete crystalline calcium silicate phases selected from CS (wollastonite or pseudowollastonite), C3S2(rankinite), and C2S (belite, larnite, bredigite), and

calcium silicate in the form of an amorphous calcium silicate phase,

wherein the one or more discrete crystalline calcium silicate phases are present at about 30% or more by mass of the total phases;

elemental Ca and elemental Si are present in the composition at a molar ratio from about 0.8 to about 1.2; and

metal oxides of Al, Fe and Mg are present in the composition at about 30% or less by mass,

wherein the composition is carbonatable with CO₂ at a temperature of about 30°

C. to about 90°

C. to form CaCO₃ with a mass gain of about 10% or more.

2. The carbonatable composition of claim 1, wherein the ratio of d90:

d10 is about 5 to about 1,000.

3. The carbonatable composition of claim 1, wherein the ratio of d50:

d10 is about 2 to about 250.

4. The carbonatable composition of claim 1, wherein the ratio of d90:

d50 is about 2 to about 15.

5. The carbonatable composition of claim 1, comprising one or more residual SiO₂ and CaO phases.

6. The carbonatable composition of claim 1, comprising one or more melilite phases having the general formula (Ca,Na,K)₂[(Mg, Fe²⁺,Fe³⁺,Al,Si)₃O₇] or ferrite phases having the general formula Ca₂(Al,Fe³⁺)₂O₅.

7. The carbonatable composition of claim 1, wherein the composition comprises calcium silicate phases existing in an amorphous state and calcium silicate phases existing in a crystalline state.

8. The carbonatable composition of claim 1, wherein the molar ratio of elemental Ca to elemental Si is from about 0.90 to about 1.10.

9. The carbonatable composition of claim 1, comprising about 25% or less of metal oxides of Al, Fe and Mg by total oxide mass.

10. The carbonatable composition of claim 1, wherein CS is present at about 10 wt % to about 60 wt %, C3S2 in about 5 wt % to 50 wt %, C2S in about 5 wt % to 60 wt %, and CaO in about 0 wt % to 3 wt %.

11. The carbonatable composition of claim 10, wherein CS is present at about 20 wt % to about 60 wt %, C3S2 in about 10 wt % to 50 wt %, C2S in about 10 wt % to 50 wt % and CaO in about 0 wt % to 3 wt %.

12. A carbonated material produced from the carbonatable calcium silicate composition of claim 1 via carbonation at a temperature of about 30°

C. to about 90°

C.