CO2-sequestering formed building materials

• US 7,771,684 B2
• Filed: 09/30/2009
• Issued: 08/10/2010
• Est. Priority Date: 09/30/2008
• Status: Active Grant

• Current Assignee: Arelac, Inc.
• Original Assignee: Calera Corporation
• Inventors: Youngs, Andrew, Holland, Terence C., Constantz, Brent R.
• Primary Examiner(s): Drodge; Joseph W
• Application Number:
  US12/571,398
• Publication Number:
  US 20100077691A1
• Time in Patent Office: 314 Days
• Field of Search: 522/20, 522/94, 523/06, 523/091.2, 523/09, 52/17, 527/450.5, 522/236, 522/201, 951/29, 951/34, 951/35, 951/39, 951/41, 951/43, 106/705, 106/708, 106/713, 106/738, 106/739, 106/745, 106811-819, 404/17, 404/34, 404/44, 423/220, 423/230, 423/232, 423/235, 423/242.1, 423/243.01, 423/245.1, 423/419.1, 423430-432, 423/594.18, 423/437.1, 588/252, 588/256, 588/257, 210/702, 210/710, 210/717, 210/718, 210/749
• US Class Current: 423/220
• CPC Class Codes: B01D 2257/504 Carbon dioxide
• CPC Class Codes: C04B 2103/0086 Chelating or complexing agents
• CPC Class Codes: C04B 2111/00017 Aspects relating to the protection of the environment
• CPC Class Codes: C04B 22/10 containing carbon in the anion
• CPC Class Codes: C04B 22/106 Bicarbonates
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 28/04 Portland cements
• CPC Class Codes: Y02A 50/20 Air quality improvement or preservation, e.g. vehicle emission control or emission reduction by using catalytic converters
• CPC Class Codes: Y02C 20/40 of CO2

Abstract

CO₂-sequestering formed building materials are provided. The building materials of the invention include a composition comprising a carbonate/bicarbonate component. Additional aspects of the invention include methods of making and using the CO₂-sequestering formed building material.

Claims

1. A method for producing a formed building material comprising:

a) producing a metastable CO²-sequestering component from a saltwater water solution of divalent cations and a gaseous waste stream comprising CO²;

wherein the metastable CO²-sequestering component, upon contact with freshwater, re-precipitates into a freshwater stable compound; and

b) forming the formed building material from the metastable CO²-sequestering component in a process comprising contacting the CO²-sequestering component with freshwater, wherein the formed building material has a defined physical shape.

2. The method of claim 1, wherein the formed building material comprises 5% to 50% (w/w) CO₂-sequestering component.

3. The method of claim 1, wherein the CO₂-sequestering component comprises carbonates.

4. The method of claim 3, wherein the CO₂-sequestering component further comprises co-products of NOx, SOx, VOCs, particulates, mercury, or a combination thereof resulting from conditions used to convert carbon dioxide to carbonates.

5. The method of claim 1, wherein the gaseous waste stream further comprises NOx, SOx, VOCs, particulates, mercury, or a combination thereof.

6. The method of claim 1, wherein the formed building material has a carbon footprint that is neutral or negative.

7. The method of claim 6, wherein water for forming the formed building material is provided by the CO₂-sequestering component.

8. The method of claim 7, wherein the CO₂-sequestering component provides at least 50% of the water for forming the formed building material.

9. The method of claim 6, wherein the formed building material continuously reduces carbon emission via reduced lighting demands due to the high albedo of the formed building material.