CO2-sequestering formed building materials

• US 8,006,446 B2
• Filed: 06/29/2010
• Issued: 08/30/2011
• 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:
  US12/826,209
• Publication Number:
  US 20100326328A1
• Time in Patent Office: 427 Days
• Field of Search: 106/461, 106/462, 106/713, 106/738, 106/739, 106811-819, 106/640, 106/643, 106/644, 106/719, 106/720, 106/724, 106/728, 106/729, 106/463, 106/464, 106/638, 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, 522/94, 522/231, 522/236, 522/238, 522/231.4, 522/234, 522/92, 523/091.7, 525/96, 404/17, 404/44
• US Class Current: 52/223.1
• 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 formed building material comprising a CO₂-sequestering component, wherein the CO₂-sequestering component comprises 75% (w/w) or more calcium carbonate comprising a metastable carbonate selected form the group consisting of amorphous calcium carbonate, vaterite, aragonite, and combinations thereof,

wherein the CO₂-sequestering has a δ

¹³C less than −

15%, and

wherein the formed building material is selected from the group consisting of

a) a brick having a compressive strength ranging from 5 to 100 MPa;

b) a block having a compressive strength ranging from 5 to 100 MPa;

c) a tile having a compressive strength ranging from 5 to 75 MPa;

d) a cement board having a compressive strength ranging from 5 to 50 MPa;

e) a drywall having a compressive strength ranging from 1 to 20 MPa;

f) a conduit having a compressive strength ranging from 5 to 75 MPa;

g) a beams having a compressive strength ranging from 35 to 150 MPa;

h) a basin having a compressive strength ranging from 5 to 60 MPa;

i) a column having a compressive strength ranging from 25 to 200 MPa;

j) a fiber-cement siding having a compressive strength ranging from 2 to 25 MPa; and

k) a slab having a compressive strength ranging from 10 to 100 MPa.

2. The formed building material of claim 1, wherein the CO₂-sequestering component comprises carbonates, bicarbonates, or a combination thereof.

3. The formed building material of claim 2, wherein the CO₂-sequestering component further comprises calcium, magnesium, or a combination thereof.

4. The formed building material of claim 3, wherein the CO₂-sequestering component further comprises strontium.

5. The formed building material of claim 1, wherein the CO₂-sequestering component further comprises calcite, ikaite, magnesite, barringtonite, nesquehonite, landfordite, amorphous magnesium carbonate, or a combination thereof.

6. The formed building material of claim 1, wherein the CO₂-sequestering component further comprises co-products from NOx, SOx, VOCs, particulates, mercury, or a combination thereof.

7. The formed building material of claim 6, wherein the CO₂-sequestering component further comprises sulfates.

8. The formed building material of claim 1, wherein the formed building material does not release more than 5% of its sequestered CO₂ when exposed to a temperature of 100°

C for 100 days at 50% relative humidity.

9. A formed building material produced by a method comprising:

a) producing a CO₂-sequestering component comprising a metastable carbonate selected from the group consisting of amorphous calcium carbonate, aragonite, vaterite, and combinations thereof from a saltwater solution of divalent cations and a gaseous waste stream comprising CO₂,

wherein the CO₂-sequestering component has a δ

¹³C less than −

15%; and

b) forming the formed building material from the CO₂-sequestering component in a process comprising contacting the CO₂-sequestering component with freshwater, wherein the formed building material comprises 75% (w/w) or more of the CO₂-sequestering component, and wherein the formed building material is selected from the group consisting of

a) a brick having a compressive strength ranging from 5 to 100 MPa;

b) a block having a compressive strength ranging from 5 to 100 MPa;

c) a tile having a compressive strength ranging from 5 to 75 MPa;

d) a cement board having a compressive strength ranging from 5 to 50 MPa;

e) a drywall having a compressive strength ranging from 1 to 20 MPa;

f) a conduit having a compressive strength ranging from 5 to 75 MPa;

g) a beams having a compressive strength ranging from 35 to 150 MPa;

h) a basin having a compressive strength ranging from 5 to 60 MPa;

i) a column having a compressive strength ranging from 25 to 200 MPa;

j) a fiber-cement siding having a compressive strength ranging from 2 to 25 MPa; and

k) a slab having a compressive strength ranging from 10 to 100 MPa.