Methods and compositions using calcium carbonate

• US 20110067603A1
• Filed: 08/16/2010
• Published: 03/24/2011
• Est. Priority Date: 12/31/2009
• Status: Active Grant

• Current Assignee: Arelac, Inc.
• Original Assignee: Calera Corporation
• Inventors: Omelon, Sidney, Thatcher, Ryan, Hodson, Keith, Holland, Terence C., Chen, Irvin, Fernandez, Miguel, Geramita, Katharine, Patterson, Joshua, Yaccato, Karin, Farsad, Kasra, Camire, Chris, Clodic, Laurence, Stagnaro, John, Constantz, Brent R.
• Granted Patent: US 8,114,214 B2
• Time in Patent Office: Days
• US Class Current: 106/739
• CPC Class Codes: B01D 2251/404 of calcium
• CPC Class Codes: B01D 2257/504 Carbon dioxide
• CPC Class Codes: B01D 2258/0233 from cement factories
• CPC Class Codes: B01D 53/62 Carbon oxides
• CPC Class Codes: C04B 14/28 of calcium
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 28/04 Portland cements
• CPC Class Codes: Y02C 20/40 of CO2
• CPC Class Codes: Y02P 40/10 Production of cement, e.g. improving or optimising the production methods; Cement grinding
• CPC Class Codes: Y10S 264/43 Processes of curing clay and concrete materials

Abstract

Provided herein are compositions and methods including hydraulic cement, supplementary cementitious material, and/or self-cementing material. Methods for making the compositions and using the compositions are provided.

Claims

1. A composition, comprising a supplementary cementitious material (SCM), the SCM comprising at least 47% w/w vaterite, wherein the composition upon combination with water, setting, and hardening, has a compressive strength of at least 14 MPa.

3. The composition of claim 1, wherein the composition has a compressive strength in a range of 20-40 MPa.

4. The composition of claim 1, wherein the composition has a carbon isotopic fractionation value (δ

¹³C) of between −

12‰

to −

25‰

.

5. The composition of claim 1, wherein the vaterite is in a range of 47% w/w to 99% w/w.

7. The composition of claim 1, further comprising a polymorph selected from the group consisting of amorphous calcium carbonate, aragonite, calcite, ikaite, a precursor phase of vaterite, a precursor phase of aragonite, an intermediary phase that is less stable than calcite, polymorphic forms in between these polymorphs, and combination thereof.

9. The composition of claim 1, further comprising strontium (Sr) in an amount of 1-50,000 parts per million (ppm).

11. The composition of claim 1, wherein the composition is a particulate composition with an average particle size of 0.1-100 microns.

13. The composition of claim 1, further comprising nitrogen oxide, sulfur oxide, mercury, metal, derivative of any of nitrogen oxide, sulfur oxide, mercury, and/or metal, or combination thereof.

14. The composition of claim 1, further comprising Portland cement clinker, aggregate, supplementary cementitious material (SCM), or combination thereof.

22. A method for making a composition of claim 1, comprising:

(a) contacting an alkaline earth-metal containing water with a CO₂ source; and

(b) subjecting the alkaline earth-metal containing water of step (a) to one or more conditions to make the composition of claim 1.

23. The method of claim 22, wherein the CO₂ source is an industrial waste stream comprising flue gas from combustion;

a flue gas from a chemical processing plant;

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

or combination thereof.

24. The method of claim 22, wherein the alkaline earth-metal containing water is sea water, brine, or combination thereof.

26. The method of claim 22, wherein the one or more conditions comprise contacting the alkaline earth-metal containing water with a proton removing agent.

27. The method of claim 26, wherein the proton removing agent is selected from the group consisting of oxide, hydroxide, carbonate, coal ash, naturally occurring mineral, and combination thereof.

29. A system for making a composition of claim 1, comprising:

(a) an input for an alkaline earth-metal containing water;

(b) an input for a CO₂ source; and

(c) a reactor connected to the inputs of step (a) and step (b) that is configured to make the composition of claim 1.

40. A method for making a formed building material from the composition of claim 1, comprising:

combining the composition of claim 1 with an aqueous medium under one or more suitable conditions; and

allowing the composition to set and harden into the formed building material.

2. A composition, comprising a SCM, the SCM comprising at least 10% w/w vaterite and at least 1% w/w amorphous calcium carbonate (ACC), wherein the composition upon combination with water, setting, and hardening has a compressive strength of at least 14 MPa.

6. The composition of claim 2, wherein the composition comprises ACC in a range of 1% w/w to 53% w/w.

8. (canceled)

10. (canceled)

12. (canceled)

15-16. -16. (canceled)

17. A composition, comprising a SCM, wherein at least 16% by wt of SCM mixed with OPC results in no more than 10% reduction in a compressive strength of OPC at 28 days when compared to OPC alone.

18. The composition of claim 17, wherein the compressive strength of OPC is in a range of 17-45 MPa.

19-21. -21. (canceled)

25. (canceled)

28. (canceled)

30-39. -39. (canceled)