Concrete compositions and methods

• US 9,061,940 B2
• Filed: 10/03/2012
• Issued: 06/23/2015
• Est. Priority Date: 09/30/2008
• Status: Active Grant

• Current Assignee: Arelac, Inc.
• Original Assignee: Calera Corporation
• Inventors: Chen, Irvin, Patterson, Joshua, Lee, Patricia Tung
• Primary Examiner(s): DRODGE, JOSEPH W
• Application Number:
  US13/573,786
• Publication Number:
  US 20130167756A1
• Time in Patent Office: 993 Days
• Field of Search: 522/201, 522/94, 523/06, 523/091.2, 523/091.7, 527/450.5, 522/236, 951/29, 951/34, 951/35, 951/39, 95141-143, 106/461, 106/462, 106/638, 106/705, 106/708, 106713-715, 106/718, 106/723, 106/738, 106/739, 106811-818, 423/220, 423/230, 423/232, 423/158, 423/242.1, 423/243.01, 423/245.1, 423/419.1, 423430-432, 423/441, 423/155, 423/165, 423/173, 423/594.18, 423/437.1, 404/17, 404/34, 404/44, 210/702, 210/710, 210/714, 210/717, 210/718, 210/72, 210/724, 210/726, 210728-774, 210/748.01, 210/806, 588/252.2, 588/256, 588/257, 588/251, 588/400, 204/157.47, 204/515
• US Class Current: 1/1
• 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 14/06 Quartz; Sand
• CPC Class Codes: C04B 14/106 Kaolin
• CPC Class Codes: C04B 14/28 of calcium
• CPC Class Codes: C04B 18/062 Purification products of smoke, fume or exhaust-gases
• CPC Class Codes: C04B 18/08 Flue dust , i.e. fly ash
• CPC Class Codes: C04B 18/141 Slags
• CPC Class Codes: C04B 20/008 Micro- or nanosized fillers, e.g. micronised fillers with particle size smaller than that of the hydraulic binder colloidal silica C04B14/062 ; silica fume C04B18/146
• CPC Class Codes: C04B 2111/1037 Cement free compositions, e.g. hydraulically hardening mixtures based on waste materials, not containing cement as such
• CPC Class Codes: C04B 28/021 Ash cements, e.g. fly ash cements fly ash as filler C04B18/08; Cements based on incineration residues, e.g. alkali-activated slags from waste incineration alkali-activated combustion residues as such C04B7/243; mixtures of the lime-pozzuolane type C04B28/18; Kiln dust cements
• CPC Class Codes: C04B 28/10 Lime cements or magnesium oxide cements
• CPC Class Codes: C04B 38/0074 expressed as porosity percentage
• CPC Class Codes: C04B 7/34 Hydraulic lime cements; Roman cements ; natural cements
• CPC Class Codes: C04B 7/364 Avoiding environmental pollution during cement-manufacturing
• CPC Class Codes: C04B 7/421 Inorganic materials
• CPC Class Codes: C04B 7/424 Oxides, Hydroxides
• CPC Class Codes: Y02P 40/18 Carbon capture and storage [CCS]
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete

Abstract

Provided herein are compositions, methods, and systems for cementitious compositions containing calcium carbonate compositions and aggregate. The compositions find use in a variety of applications, including use in a variety of building materials and building applications.

Claims

1. A cementitious composition, comprising:

between 10-55 wt % of a composition comprising calcium carbonate, wherein between 50-100 wt % of the calcium carbonate is in a metastable polymorphic form comprising vaterite, and wherein the calcium carbonate has a δ

¹³C value of between −

12 to −

30‰

; and

between 45-90 wt % of aggregate,

wherein the cementitious composition after combination with water sets and hardens into cement wherein the calcium carbonate binds to the aggregate.

2. The cementitious composition of claim 1, comprising between 10-25 wt % of the composition comprising calcium carbonate and between 75-90 wt % of the aggregate.

3. The cementitious composition of claim 1, wherein the calcium carbonate comprises other polymorphic forms selected from the group consisting of amorphous calcium carbonate, aragonite, calcite, and combinations thereof.

4. The cementitious composition of claim 1, wherein the aggregate comprises fine aggregate, coarse aggregate, or a combination thereof.

5. The cementitious composition of claim 4, wherein the fine aggregate is sand.

6. The cementitious composition of claim 4, wherein the coarse aggregate is rock.

7. The cementitious composition of claim 1, wherein the cement has a compressive strength of at least 2000 psi after at least 1 day, 7 days, or 28 days.

8. The cementitious composition of claim 7, wherein the cement has a compressive strength of at least 3000 psi or between 2000-6000 psi.

9. The cementitious composition of claim 1, wherein the cement has a porosity of between 10-90 vol %.

10. The cementitious composition of claim 1, wherein the cementitious composition further comprises fly ash, slag, metakaolin, admixture, or combinations thereof.

11. A method for forming a cementitious composition of claim 1, comprising:

mixing between 10-55 wt % of a composition comprising calcium carbonate, wherein between 50-100 wt % of the calcium carbonate is in a metastable polymorphic form comprising vaterite, and wherein the calcium carbonate has a δ

¹³C value of between −

12 to −

30‰

, with between 45-90 wt % of aggregate to form a cementitious composition of claim 1, and

contacting the cementitious composition with water when the cementitious composition sets and hardens into cement where the calcium carbonate binds to the aggregate.

12. The method of claim 11, further comprising before the mixing step a) making the composition comprising calcium carbonate by contacting an industrial waste gas stream comprising carbon dioxide with a proton removing agent to form a carbon dioxide charged water;

and b) contacting the carbon dioxide charged water with divalent cations to form the composition comprising calcium carbonate.

13. The method of claim 12, wherein the contacting of the carbon dioxide charged water with the divalent cations is under precipitation conditions that favor the formation of the composition comprising calcium carbonate that has between 50-100 wt % of the calcium carbonate in a metastable polymorphic form comprising vaterite.

14. The method of claim 13, wherein the precipitation conditions are selected from temperature, pH, residence time, proton removing agent, additive, ion ratio, rate of precipitation, mixing rate, form of agitation, presence of seed crystal, catalyst, membrane, substrate, separation, drying, refining, and combinations thereof.

15. The method of claim 12, wherein the industrial waste gas stream is from an industrial plant selected from power plant, chemical processing plant, steel mill, paper mill, cement plant, other industrial plant that produces CO₂ as a byproduct, and combinations thereof.

16. The method of claim 12, wherein the proton removing agent is NaOH, Na₂CO₃, KOH, K₂CO₃, NH₄OH, Ca(OH)₂, Mg(OH)₂, or combinations thereof.

17. The method of claim 11, wherein the calcium carbonate binds to the aggregate when the vaterite transforms to aragonite.

18. The method of claim 11, wherein the calcium carbonate comprises other polymorphic forms selected from the group consisting of amorphous calcium carbonate, aragonite, calcite, and combinations thereof.

19. The method of claim 11, wherein the aggregate comprises fine aggregate, coarse aggregate, or a combination thereof.

20. The composition of claim 1, wherein the cementitious composition after combination with water sets and hardens into cement and forms building or construction materials.

21. The composition of claim 1, wherein the cementitious composition after combination with water sets and hardens into cement and forms pavement, architectural structure, foundation, motorway/road, overpass, parking structure, brick, block, wall, footing for gate, fence and pole, bridge, foundation, levee, dam, or combinations thereof.

23. The method of claim 11, wherein the cementitious composition sets and hardens into cement with a compressive strength of at least 2000 psi.

22. A cementitious composition, comprising:

between 10-55 wt % of a composition comprising calcium carbonate, wherein between 50-100 wt % of the calcium carbonate is in a metastable polymorphic form comprising vaterite, and wherein the calcium carbonate has a δ

¹³C value of between −

12 to −

30‰

; and

between 45-90 wt % of aggregate,

wherein the cementitious composition after combination with water sets and hardens into brick or block wherein the calcium carbonate binds to the aggregate.