Hydraulic Cements Comprising Carbonate Compound Compositions

• US 20100132591A1
• Filed: 02/04/2010
• Published: 06/03/2010
• Est. Priority Date: 05/24/2007
• Status: Active Grant

• Current Assignee: Arelac, Inc.
• Original Assignee: Calera Corporation
• Inventors: Ryan, Cecily, Clodic, Laurence, Constantz, Brent R.
• Granted Patent: US 7,906,028 B2
• Time in Patent Office: Days
• US Class Current: 106/705
• CPC Class Codes: C04B 14/26 Carbonates
• CPC Class Codes: C04B 28/04 Portland cements
• CPC Class Codes: Y02W 10/33 using wind energy
• CPC Class Codes: Y02W 10/37 using solar energy
• CPC Class Codes: Y10T 428/2982 Particulate matter [e.g., sphere, flake, etc.]

Abstract

Hydraulic cement compositions that include a carbonate compound composition, e.g., a salt-water derived carbonate compound composition containing crystalline and/or amorphous carbonate compounds, are provided. Also provided are methods of making and using the hydraulic cements, as well as settable compositions, such as concretes and mortars, prepared therefrom. The cements and compositions produced therefrom find use in a variety of applications, including use in a variety of building materials and building applications.

Claims

1. A method comprising:

contacting an alkaline-earth-metal-containing water with an industrial waste stream CO₂ source, wherein said alkaline-earth-metal-containing water comprises strontium;

subjecting said alkaline-earth-metal-containing water to carbonate compound precipitation conditions sufficient to produce a precipitated metastable carbonate compound composition comprising CO₂ from said CO₂ source and strontium present in the carbonate composition in an amount ranging from 3 to 10,000 ppm, wherein said metastable carbonate compound composition is characterized by being more stable in salt water than in fresh water; and

using said carbonate compound composition to produce a hydraulic cement composition.

2. The method according to claim 1, wherein said industrial waste stream is a waste stream or product from an industrial plant comprising a flue gas from combustion;

a flue gas from a chemical processing plant;

a flue gas from another industrial plant that produces CO₂ as a byproduct;

or any combination thereof.

3. The method according to claim 2, wherein said method further produces a mother liquor, and further comprises separating said precipitated carbonate compound composition from said mother liquor and further processing the separated carbonate compound composition wherein further processing comprises storage;

drying;

preparation for use in a building material;

or any combination thereof.

4. The method according to claim 1, wherein said alkaline-earth-containing water contains calcium and magnesium in a ratio of from 10/1 to 1/5 Ca/Mg.

5. The method according to claim 1, further comprising using the hydraulic cement composition as a component of a settable composition.

6. The method according to claim 1, wherein said subjecting step comprises contacting said alkaline-earth-metal-containing water with a pH raising agent.

7. The method according to claim 6, wherein said pH raising agent comprises a component selected from the group consisting of:

oxides, hydroxides, carbonate, coal ash, and naturally occurring minerals.

8. The method according to claim 1, wherein said subjecting step comprises subjecting said water to electrolysis conditions.

9. The method according to claim 1, wherein said alkaline-earth-metal-containing water comprises sea water, a brine, or any combination thereof.

10. A method comprising:

combining a hydraulic cement composition according to claim 1 with water to produce a hydrated hydraulic cement; and

allowing said hydrated hydraulic cement to set into a solid product.

11. A hydraulic cement composition comprising a carbonate compound composition comprising carbon from gaseous source of carbon dioxide, wherein the carbonate compound composition is a metastable carbonate compound composition characterized by being more stable in salt water than in fresh water, wherein strontium is present in the carbonate composition in an amount ranging from 3 to 10,000 ppm.

12. The hydraulic cement composition of claim 11 that is a dry particulate composition comprising particles having an average particle size of 0.1 to 100 microns.

13. The hydraulic cement composition of claim 11 where the metastable carbonate composition comprises magnesium and calcium.

14. The hydraulic cement composition of claim 11 wherein, upon combination with water, the setting time of the composition is from 30 minutes to 48 hours.

15. The hydraulic cement composition of claim 11 wherein said composition has an average surface area from 0.5 m²/gm to 50 m²/gm.

16. A settable composition comprising the hydraulic cement composition of claim 12.

17. The settable composition according to claim 16, wherein said settable composition further comprises a portland cement clinker, an aggregate, or a combination thereof.

18. A building or construction material comprising a hydraulic cement composition according to claim 11.

19. The building material according to claim 18, wherein said building or construction material is a pavement or architectural structure selected from:

building, foundation, motorway, road, overpass, parking structure, brick, block, wall, and footing for a gate, fence or pole.

20. A system for producing a hydraulic cement, said system comprising:

an input for a salt water wherein said salt water comprises an alkaline-earth-metal-containing water comprising strontium;

a CO₂ gaseous stream source;

a CO₂ charger and precipitation reactor that subjects said water to carbonate compound precipitation conditions sufficient to produce a precipitated metastable carbonate compound composition characterized by being more stable in salt water than in fresh water that finds use as a hydraulic cement, wherein strontium is present in the carbonate composition in an amount ranging from 3 to 10,000 ppm; and

a refining station where the precipitated carbonate compound composition may be mechanically processed and/or one or more components may be added to the precipitate to produce a final product.