Rocks and aggregate, and methods of making and using the same

• US 7,914,685 B2
• Filed: 06/04/2010
• Issued: 03/29/2011
• Est. Priority Date: 06/28/2007
• Status: Active Grant

• Current Assignee: Arelac, Inc.
• Original Assignee: Calera Corporation
• Inventors: Constantz, Brent, O'Neil, James, Stagnaro, John, Patterson, Joshua, Farsad, Kasra, Thatcher, Ryan, Youngs, Andrew, Camire, Chris
• Primary Examiner(s): Drodge; Joseph W
• Application Number:
  US12/794,198
• Publication Number:
  US 20100247410A1
• Time in Patent Office: 298 Days
• Field of Search: 106/461, 106/462, 106/713, 106/738, 106/739, 106811-819, 106/463, 106/464, 423/220, 423/223, 423/232, 423/419.1, 423/420.2, 423/430, 423/431, 423/437.1, 423/438, 423/439, 423/441, 588/249, 588/252, 588/313, 588/400, 588/404, 210/652, 210/702, 210/710, 210/714, 210/717, 210/718, 210/723, 210/724, 210/726, 210/737, 210/749, 951/49, 951/56, 952/41
• US Class Current: 210/702
• CPC Class Codes: B01D 2251/402 of magnesium
• CPC Class Codes: B01D 2251/404 of calcium
• CPC Class Codes: B01D 2257/302 Sulfur oxides
• CPC Class Codes: B01D 2257/404 Nitrogen oxides other than dinitrogen oxide
• CPC Class Codes: B01D 2257/504 Carbon dioxide
• CPC Class Codes: B01D 2257/602 Mercury or mercury compounds
• CPC Class Codes: B01D 53/1425 Regeneration of liquid absorbents
• CPC Class Codes: B01D 53/1475 Removing carbon dioxide
• CPC Class Codes: B01D 53/1493 Selection of liquid materials for use as absorbents
• CPC Class Codes: B01D 53/62 Carbon oxides
• CPC Class Codes: B01D 53/77 Liquid phase processes
• CPC Class Codes: C01B 32/60 Preparation of carbonates or bicarbonates in general of percarbonates C01B15/10; of specific carbonates or bicarbonates according to the cation C01B-C01G
• CPC Class Codes: C01F 11/18 Carbonates
• CPC Class Codes: C01F 5/24 Magnesium carbonates
• CPC Class Codes: C01P 2002/72 by d-values or two theta-values, e.g. as X-ray diagram
• CPC Class Codes: C01P 2002/82 by IR- or Raman-data
• CPC Class Codes: C01P 2002/88 by thermal analysis data, e.g. TGA, DTA, DSC
• CPC Class Codes: C01P 2004/03 obtained by SEM
• CPC Class Codes: C01P 2004/50 Agglomerated particles
• CPC Class Codes: C01P 2006/88 Isotope composition differing from the natural occurrence
• CPC Class Codes: C02F 1/66 : by neutralisation; pH adjustment for degassing C02F1/20; using ion-exchange C02F1/42; for flocculation or precipitation of suspended impurities C02F1/52; for removing dissolved compounds C02F1/58
• CPC Class Codes: C02F 1/683 : by addition of complex-forming compounds
• CPC Class Codes: C04B 7/367 : Avoiding or minimising carbon dioxide emissions
• CPC Class Codes: Y02C 20/40 : of CO2
• CPC Class Codes: Y02P 20/151 : Reduction of greenhouse gas [GHG] emissions, e.g. CO2
• CPC Class Codes: Y02P 40/18 : Carbon capture and storage [CCS]
• CPC Class Codes: Y02W 10/33 : using wind energy
• CPC Class Codes: Y02W 10/37 : using solar energy
• CPC Class Codes: Y10T 436/235 : In an aqueous solution [e.g., TOC, etc.]

Abstract

Compositions comprising synthetic rock, e.g., aggregate, and methods of producing and using them are provided. The rock, e.g., aggregate, contains CO₂ and/or other components of an industrial waste stream. The CO₂ may be in the form of divalent cation carbonates, e.g., magnesium and calcium carbonates. Aspects of the invention include contacting a CO₂ containing gaseous stream with a water to dissolve CO₂, and placing the water under precipitation conditions sufficient to produce a carbonate containing precipitate product, e.g., a divalent cation carbonate.

Claims

1. A method of sequestering CO₂ comprising:

(i) precipitating a CO₂-sequestering carbonate compound composition from a divalent cation-containing water that has contacted or is contacting a CO₂ source comprising at least one of;

an industrial waste stream;

a flue gas from a power plant;

a flue gas from a cement plant;

CO₂ from the combustion of a fossil fuel;

or

CO₂ dissolved in a liquid

to form a precipitate; and

(ii) producing aggregate comprising 80% or more by weight of the CO₂-sequestering carbonate compound composition wherein the aggregate has a hardness of at least 3 on the Mohs hardness scale and wherein the aggregate is suitable for use in a building material.

2. The method of claim 1 wherein producing the aggregate comprises subjecting the precipitate of claim 1 to elevated temperature, elevated pressure, or a combination thereof.

3. The method of claim 1, wherein the divalent cation-containing water has contacted or is contacting CO₂ from an industrial waste gas stream.

4. The method of claim 1 wherein the divalent cation-containing has contacted or is contacting with CO₂ from the combustion of a fossil fuel.

5. The method of claim 1 wherein the divalent cation-containing has contacted or is contacting a flue gas from a power plant or a cement plant.

6. The method of claim 1 wherein the divalent cations of the divalent cation-containing water come at least partially from a saltwater.

7. The method of claim 6 wherein the saltwater comprises seawater or brine.

8. The method of claim 1 wherein the producing of the aggregate comprises producing aggregate of a predetermined size and shape.

9. The method of claim 1,

wherein the divalent cation-containing water has contacted or is contacting a CO₂ source comprising CO₂ dissolved in a liquid.

10. The method of claim 1 wherein the precipitating comprises subjecting the divalent cation-containing water to carbonate and/or bicarbonate compound precipitation conditions.

11. The method of claim 1 wherein the precipitating comprises adjusting the magnesium to calcium ratio (Mg:

Ca) of the divalent cation-containing water to be between 10/1 to 1/10.

12. The method of claim 1, further comprising adding siliceous materials during the precipitating.

13. The method of claim 12, wherein the siliceous materials comprise diatomaceous earth, fly ash, silica fume and metal silicates.

14. The method of claim 1, wherein the processing conditions comprise:

a) separation of the precipitate from the water; and

b) producing a set product, wherein the aggregate comprises the set product.

15. The method of claim 14, wherein the processing conditions further comprise adding fresh water with or without drying the precipitate first to produce the set product.

16. The method of claim 15, wherein the processing conditions further comprise washing the precipitate.

17. The method of any of claims 14 to 16, wherein the processing conditions further comprise mechanical processing of the set product.

18. The method of claim 1, wherein producing the aggregate comprises subjecting the precipitate to exposure to the open environment and mechanically processing.

19. The method of claim 1, wherein the temperature of the water is maintained between 5 to 70°

C. during precipitation.

20. The method of claim 1, wherein the carbonate compound composition forms a settable composition upon combination with water and wherein producing the aggregate comprises:

a) generating a settable composition consisting essentially of the CO₂-sequestering carbonate compound composition and water;

b) allowing the settable composition to form a solid product having a hardness of at least 3 on the Mohs hardness scale; and

c) forming the aggregate from the solid product.