Methods and systems for utilizing waste sources of metal oxides

• US 9,260,314 B2
• Filed: 05/06/2013
• Issued: 02/16/2016
• Est. Priority Date: 12/28/2007
• Status: Active Grant

• Current Assignee: Arelac, Inc.
• Original Assignee: Calera Corporation
• Inventors: Constantz, Brent, Monteiro, Paulo J. M., Omelon, Sidney, Fernandez, Miguel, Farsad, Kasra, Geramita, Katharine, Yaccato, Karin
• Primary Examiner(s): DRODGE, JOSEPH W
• Application Number:
  US13/887,986
• Publication Number:
  US 20130243674A1
• Time in Patent Office: 1,016 Days
• Field of Search: 210/702, 210/710, 210/714, 210/717, 210/718, 210/721, 210/723, 210/724, 210/738, 210768-774, 210/806, 423/155, 423/160, 423/165, 423/173, 423/220, 423/232, 423/170, 423/184, 423/430, 423/431, 423/437, 423/438, 423/439, 423/441, 423/432
• US Class Current: 1/1
• CPC Class Codes: B01D 2257/504 Carbon dioxide
• CPC Class Codes: C01F 11/181 Preparation of calcium carbonate by carbonation of aqueous solutions and characterised by control of the carbonation conditions
• 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 2004/61 Micrometer sized, i.e. from 1-100 micrometer
• CPC Class Codes: C01P 2006/12 Surface area
• CPC Class Codes: C04B 14/28 of calcium
• CPC Class Codes: C04B 2290/20 Integrated combined plants or devices, e.g. combined foundry and concrete plant
• CPC Class Codes: C04B 7/436 Special arrangements for treating part or all of the cement kiln dust
• CPC Class Codes: Y02P 40/121 Energy efficiency measures, e.g. improving or optimising the production methods
• CPC Class Codes: Y02P 40/18 Carbon capture and storage [CCS]

Abstract

Methods are provided for producing a composition comprising carbonates, wherein the methods comprise utilizing waste sources of metal oxides. An aqueous solution of divalent cations, some or all of which are derived from a waste source of metal oxides, may be contacted with CO2 and subjected to precipitation conditions to provide compositions comprising carbonates. In some embodiments, a combustion ash is the waste source of metal oxides for the aqueous solution containing divalent cations. In some embodiments, a combustion ash is used to provide a source of proton-removing agents, divalent cations, silica, metal oxides, or other desired constituents or a combination thereof.

Claims

1. A method comprising:

a) contacting an aqueous solution with metal oxide comprising CaO wherein the metal oxide provides proton-removing agent upon hydration of the CaO in the aqueous solution, wherein the metal oxide is slag, and wherein the aqueous solution further comprises a supplemental proton removing agent comprising ammonia;

b) charging the aqueous solution with carbon dioxide from an industrial process; and

c) subjecting the aqueous solution to precipitation conditions favoring precipitation of precipitation material comprising aragonite, vaterite, or mixture thereof.

2. The method of claim 1, wherein the metal oxide and the carbon dioxide are from the same industrial process.

3. The method of claim 1, wherein contacting the aqueous solution with the metal oxide occurs prior to charging the aqueous solution with the carbon dioxide.

4. The method of claim 1, wherein the carbon dioxide further comprises SO_x, NO_x, mercury, or any combinations thereof.

5. The method of claim 1, wherein the carbon dioxide is flue gas from a coal fired power plant or flue gas from cement plant.

6. The method of claim 1, wherein the slag is blast furnace slag, electric arc slag, steel slag, copper slag, nickel slag, phosphorus slag, or combinations thereof.

7. The method of claim 1, wherein the slag is steel slag.

8. The method of claim 1, wherein the metal oxide provides divalent cations comprising calcium ions, magnesium ions, or combinations thereof, for producing the precipitation material.

9. The method of claim 1, wherein the metal oxide further provides silica, alumina, ferric oxide, or a combination thereof.

10. The method of claim 1, wherein the aqueous solution comprises brine, seawater, or freshwater.

11. The method of claim 1, wherein the precipitation material further comprises MgCO₃.

12. The method of claim 1, wherein the precipitation material further comprises bicarbonate.

13. The method of claim 1, further comprising processing the precipitation material to form a building material selected from the group consisting of hydraulic cement, pozzolanic cement, and aggregate.

14. The method of claim 1, wherein the precipitation conditions are selected from the group consisting of temperature, pH, additive, ion ratio, rate of precipitation, mixing rate, form of agitation, presence of seed crystal, catalyst, membrane, or substrate, and combinations thereof.

15. The method of claim 1, further comprising separating the precipitation material from the supernatant.

16. The method of claim 1, further comprising drying the precipitation material.