Reduced-carbon footprint concrete compositions

• US 8,470,275 B2
• Filed: 07/19/2010
• Issued: 06/25/2013
• Est. Priority Date: 09/30/2008
• Status: Active Grant

• Current Assignee: Arelac, Inc.
• Original Assignee: Calera Corporation
• Inventors: Constantz, Brent R., Youngs, Andrew, Holland, Terence C.
• Primary Examiner(s): DRODGE, JOSEPH W
• Application Number:
  US12/838,794
• Publication Number:
  US 20100313793A1
• Time in Patent Office: 1,072 Days
• Field of Search: 522/201, 522/236, 522/94, 523/06, 523/091.2, 523/091.7, 527/450.5, 951/29, 951/34, 951/35, 95141-143, 106/461, 106/462, 106/638, 106/705, 106/708, 106713-715, 106/718, 106/723, 106/738, 106/739, 106811-818, 210/702, 210/710, 210/714, 210/717, 210/718, 210/724, 210/726, 210/749, 210768-774, 210/748.01, 210/806, 404/17, 404/34, 404/44, 423/155, 423/165, 423/173, 423/220, 423/230, 423/232, 423/158, 423/242.1, 423/243.01, 423/245.1, 423/419.1, 423430-432, 588251-2522, 588/256, 588/257, 588/400
• US Class Current: 423/220
• 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: C04B 2103/0086 Chelating or complexing agents
• CPC Class Codes: C04B 7/02 Portland cement
• CPC Class Codes: C04B 7/367 Avoiding or minimising carbon dioxide emissions
• CPC Class Codes: Y02P 40/18 Carbon capture and storage [CCS]

Abstract

Reduced-carbon footprint concrete compositions, and methods for making and using the same, are provided. Aspects of the reduced-carbon footprint concrete compositions include CO₂-sequestering carbonate compounds, which may be present in the hydraulic cement and/or aggregate components of the concrete. The reduced-carbon footprint concrete compositions find use in a variety of applications, including use in a variety of building materials and building applications.

Claims

1. A method comprising:

a) precipitating synthetic carbonates and/or bicarbonates from a solution comprising divalent cations and dissolved CO₂ from an industrial waste gas comprising CO₂ under set of precipitation conditions that favor precipitation of vaterite in the synthetic carbonate wherein the synthetic carbonate and/or bicarbonate has a δ

¹³C less than −

10‰

; and

b) producing one or more concrete components from the synthetic carbonates and/or bicarbonates wherein the one or more concrete components are selected from the group consisting of cement, supplementary cementitious material, aggregate, and combination thereof.

2. The method of claim 1, further comprising incorporating at least a portion of the one or more concrete components into a reduced-carbon footprint concrete composition and adding water to the reduced-carbon footprint concrete composition to form a settable composition.

3. The method of claim 2, wherein the reduced-carbon footprint concrete composition comprises residual water from precipitating the synthetic carbonates, producing the one or more concrete components, or a combination thereof.

4. The method of claim 3, wherein the residual water provides at least 5% of the water needed for the settable composition.

5. The method of claim 1 or 2, wherein the synthetic carbonates further comprise calcite, monohydrocalcite, aragonite, ikaite, amorphous calcium carbonate, magnesite, barringtonite, nesquehonite, lanfordite, amorphous magnesium carbonate, hydromagnesite, dolomite, huntite, and sergeevite, or a combination thereof.

6. The method of claim 2, wherein the reduced-carbon footprint concrete composition comprises Portland Cement.

7. The method of claim 6, further comprising adding to the reduced-carbon footprint concrete composition a component selected from the group consisting of blast furnace slag, fly ash, diatomaceous earth, natural or artificial pozzolans, silica fumes, limestone, gypsum, and hydrated lime.

8. The method of claim 2, wherein the reduced-carbon footprint concrete composition has a carbon footprint that is neutral.

9. The method of claim 2, wherein the reduced-carbon footprint concrete composition has a carbon footprint that is negative.

10. The method of claim 9, wherein the negative carbon footprint is −

250 lbs CO₂/yd³ or less.

11. The method of claim 10, wherein the negative carbon footprint is −

500 lbs CO₂/yd³ or less.

12. A reduced-carbon footprint concrete composition produced by the method of claim 2.

13. The method of claim 1, wherein the divalent cation is obtained from industrial waste, freshwater, brackish water, seawater, brine, hard water, rock or mineral.

14. The method of claim 1, wherein the industrial waste gas comprising CO₂ is from a plant selected from the group consisting of power plants, chemical processing plants, mechanical processing plants, refineries, cement plants, steel plants, and other industrial plants that produce CO₂ as a by-product of fuel combustion or another processing step.

15. The method of claim 1, wherein the synthetic carbonates are metastable.

16. The method of claim 1, wherein the synthetic carbonates have a δ

¹³C less than −

20‰

.

17. The method of claim 1, wherein the precipitating step comprises using a proton removing agent.

18. The method of claim 1, wherein the precipitation conditions are selected from the group consisting of temperature, pH, additives, ion ratio, rate of precipitation, mixing rate, form of agitation, presence of seed crystals, catalysts, membranes, or substrates, drying, refining, and combinations thereof.