Source: http://www.google.com/patents/US7815880?dq=6721967
Timestamp: 2015-11-28 22:13:02
Document Index: 122227255

Matched Legal Cases: ['Application No. 61', 'Application No. 61', 'Application No. 61', 'Application No. 61', 'Application No. 61', 'Application No. 61', 'Application No. 61', 'Application No. 61', 'Application No. 61', 'Application No. 61', 'Application No. 61']

Patent US7815880 - Reduced-carbon footprint concrete compositions - Google PatentsSearch Images Maps Play YouTube News Gmail Drive More »Sign inAdvanced Patent SearchPatentsReduced-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....http://www.google.com/patents/US7815880?utm_source=gb-gplus-sharePatent US7815880 - Reduced-carbon footprint concrete compositionsAdvanced Patent SearchPublication numberUS7815880 B2Publication typeGrantApplication numberUS 12/604,383Publication dateOct 19, 2010Filing dateOct 22, 2009Priority dateSep 30, 2008Fee statusPaidAlso published asUS8470275, US20100083880, US20100313793, US20120000396Publication number12604383, 604383, US 7815880 B2, US 7815880B2, US-B2-7815880, US7815880 B2, US7815880B2InventorsBrent R. Constantz, Andrew Youngs, Terence C. HollandOriginal AssigneeCalera CorporationExport CitationBiBTeX, EndNote, RefManPatent Citations (300), Non-Patent Citations (101), Referenced by (63), Classifications (17), Legal Events (3) External Links: USPTO, USPTO Assignment, EspacenetReduced-carbon footprint concrete compositions
US 7815880 B2Abstract
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.
a) producing synthetic carbonates from a divalent cation-containing solution and an industrial waste gas comprising CO2;
b) producing from the synthetic carbonates
i) a first material comprising a supplementary cementitious material comprising carbonates, bicarbonates, or a combination thereof, wherein the supplementary cementitious material reacts with a hydraulic cement composition, and additionally
ii) a second material comprising a concrete component comprising carbonates, bicarbonates, or a combination thereof selected from the group consisting of cement, aggregate, and pozzolanic material; and
c) incorporating the supplementary cementitious material into a concrete composition.
2. The method of claim 1, wherein at least one of the synthetic carbonates comprise aragonite, hydromagnesite, monohydrocalcite, or a combination thereof.
3. The method of claim 1, wherein the synthetic carbonates have a δ13C less than −10‰.
4. The method of claim 1, wherein the synthetic carbonates have a δ13C less than −20‰.
5. The method of claim 1, wherein the synthetic carbonates have a δ13C less than −30‰.
6. The method of claim 1, further comprising incorporating the concrete component into the concrete composition.
7. The method of claim 6, wherein the concrete component comprises aggregate.
8. The method of claim 1 or claim 6, further comprising determining a carbon footprint for the concrete composition, wherein determining the carbon footprint consists essentially of the steps of
i) multiplying the number of pounds of a concrete component per cubic yard of the concrete component by the number of pounds of carbon dioxide per pound of the concrete component to obtain a multiplication product;
ii) repeating step i) for each concrete component in the concrete composition;
iii) summing the one or more multiplication products corresponding to the concrete composition to obtain the carbon footprint for the concrete composition.
9. The method of claim 8 wherein the concrete composition is a reduced-carbon concrete composition, such that a cubic yard of the reduced-carbon footprint concrete composition has a carbon footprint that is less than a carbon footprint of a cubic yard of an ordinary Portland concrete composition consisting essentially of ordinary Portland cement produced by a process of calcining a carbonate source, water, fine aggregate, and coarse aggregate, the carbon footprint for the ordinary Portland concrete composition being as determined in steps i)-iii) of claim 8.
10. The method of claim 9, wherein the reduced-carbon footprint concrete composition has a carbon footprint that is at least 25% less than the carbon footprint of the ordinary Portland concrete composition.
11. The method of claim 9, wherein the reduced-carbon footprint concrete composition has a carbon footprint that is at least 50% less than the carbon footprint of the ordinary Portland concrete composition.
12. The method of claim 9, wherein the reduced-carbon footprint concrete composition has a carbon footprint that is at least 75% less than the carbon footprint of the ordinary Portland concrete composition.
13. The method of claim 8, wherein the reduced-carbon footprint concrete composition has a carbon footprint that is neutral.
14. The method of claim 8, wherein the reduced-carbon footprint concrete composition has a carbon footprint that is negative.
15. The method of claim 14, wherein the negative carbon footprint is −250 lbs CO2/yd3 or less.
16. The method of claim 14, wherein the negative carbon footprint is −500 lbs CO2/yd3 or less.
This application is a continuation-in-part application of U.S. patent application Ser. No. 12/571,398, filed 30 Sep. 2009, titled “CO2-Sequestering Formed Building Materials,” which claims the benefit of U.S. Provisional Patent Application No. 61/101,631, filed 30 Sep. 2008, titled “CO2 Sequestration”; U.S. Provisional Patent Application No. 61/110,489, filed 31 Oct. 2008, titled “CO2-Sequestering Formed Building Materials”; U.S. Provisional Patent Application No. 61/149,610, filed 3 Feb. 2009, titled “CO2-Sequestering Formed Building Materials”; and U.S. Provisional Patent Application No. 61/246,042, filed 25 Sep. 2009, titled “CO2-Sequestering Formed Building Materials,” each of is incorporated herein by reference, and to each of which we claim priority. This application also claims the benefit of U.S. Provisional Patent Application No. 61/107,645, filed 22 Oct. 2008, titled “Low-Carbon Footprint Carbon Compositions”; U.S. Provisional Patent Application No. 61/116,141, filed 19 Nov. 2008, titled “Low-Carbon Footprint Carbon Compositions”; U.S. Provisional Patent Application No. 61/117,542, filed 24 Nov. 2008, titled “Low-Carbon Footprint Carbon Compositions”; U.S. Provisional Patent Application No. 61/148,353, filed 29 Jan. 2009, titled “Low-Carbon Footprint Carbon Compositions”; U.S. Provisional Patent Application No. 61/149,640, filed 3 Feb. 2009, titled “Low-Carbon Footprint Carbon Compositions”; U.S. Provisional Patent Application No. 61/225,880, filed 15 Jul. 2009, titled “Low-Carbon Footprint Carbon Compositions”; U.S. Provisional Patent Application No. 61/234,251, filed 14 Aug. 2009, titled “Methods and Systems for Treating Industrial Waste,” each of which is incorporated herein by reference, and to each of which we claim priority.
Fossil fuels that are employed in cement plants include coal, natural gas, oil, used tires, municipal waste, petroleum coke and biofuels. Fuels are also derived from tar sands, oil shale, coal liquids, and coal gasification and biofuels that are made via syngas. Cement plants are a major source of CO2 emissions, from both the burning of fossil fuels and the CO2 released from the calcination which changes the limestone, shale and other ingredients to Portland cement. Cement plants also produce wasted heat. Additionally, cement plants produce other pollutants like NOx, SOx, VOCs, particulates and mercury. Cement plants also produce cement kiln dust (CKD), which must sometimes be land filled, often in hazardous materials landfill sites.
Carbon dioxide (CO2) emissions have been identified as a major contributor to the phenomenon of global warming and ocean acidification. CO2 is a by-product of combustion and it creates operational, economic, and environmental problems. It is expected that elevated atmospheric concentrations of CO2 and other greenhouse gases will facilitate greater storage of heat within the atmosphere leading to enhanced surface temperatures and rapid climate change. CO2 has also been interacting with the oceans driving down the pH toward 8.0. CO2 monitoring has shown atmospheric CO2 has risen from approximately 280 parts per million (ppm) in the 1950s to approximately 380 ppm today, and is expect to exceed 400 ppm in the next decade. The impact of climate change will likely be economically expensive and environmentally hazardous. Reducing potential risks of climate change will require sequestration of CO2.
In some embodiments, the invention provides a method comprising a) producing a synthetic carbonate component from a divalent cation-containing solution and an industrial waste gas comprising CO2 and b) incorporating the synthetic carbonate component into a reduced-carbon footprint concrete composition, wherein the reduced-carbon footprint concrete composition has a reduced carbon footprint relative to an ordinary concrete composition. In some embodiments, the reduced-carbon footprint concrete composition has a smaller carbon footprint relative to an ordinary concrete composition. In some embodiments, the reduced-carbon footprint concrete composition has less than 75% of the carbon footprint as the ordinary concrete composition. In some embodiments, the reduced-carbon footprint concrete composition has less than 50% of the carbon footprint as the ordinary concrete composition. In some embodiments, the reduced-carbon footprint concrete composition has less than 25% of the carbon footprint as the ordinary concrete composition. In some embodiments, the reduced-carbon footprint concrete composition has a neutral carbon footprint. In some embodiments, the reduced-carbon footprint concrete composition has a negative carbon footprint. In some embodiments, the carbon footprint of the reduced-carbon footprint concrete composition results from both carbon dioxide that is sequestered and carbon dioxide that is avoided. In some embodiments, the negative carbon footprint is less than 0 lbs CO2/yd3 of the reduced concrete composition. In some embodiments, the negative carbon footprint is less than 250 lbs CO2/yd3 of the reduced concrete composition. In some embodiments, the negative carbon footprint is less than 500 lbs CO2/yd3 of the reduced concrete composition. In some embodiments, the negative carbon footprint is less than 1000 lbs CO2/yd3 of the reduced concrete composition. In some embodiments, the synthetic carbonate component is supplementary cementitious material, fine aggregate, coarse aggregate, or reactive pozzolanic material. In some embodiments, the synthetic carbonate component is aragonite, nesquehonite, hydromagnesite, monohydrocalcite, or a combination thereof. In some embodiments, the synthetic carbonate component is a combination of aragonite and hydromagnesite. In some embodiments, the synthetic carbonate component is a combination of aragonite and nesquehonite. In some embodiments, the synthetic carbonate component is a combination of nesquehonite and monohydrocalcite. In some embodiments, the synthetic carbonate component has a δ13C less than −10‰. In some embodiments, the synthetic carbonate component has a δ13C less than −20‰. In some embodiments, the synthetic carbonate component has a δ13C less than −30‰.
In some embodiments, the invention provides a reduced-carbon footprint composition produced by a method comprising a) producing a synthetic carbonate component from a divalent cation-containing solution and an industrial waste gas comprising CO2 and b) incorporating the synthetic carbonate component into a reduced-carbon footprint concrete composition, wherein the reduced-carbon footprint concrete composition has a reduced carbon footprint relative to an ordinary concrete composition.
In some embodiments, the invention provides a composition comprising between 2.5% and 50% calcium; between 2.5% and 50% magnesium; and at least 25% carbonates, bicarbonates, or a mixture thereof. In some embodiments, the composition comprises between 2.5% and 25% calcium. In some embodiments, the composition comprises between 5% and 10% calcium. In some embodiments, the composition comprises between 5% and 30% magnesium. In some embodiments, the composition comprises between 10% and 30% magnesium. In some embodiments, the composition comprises at least 50% carbonates, bicarbonates, or a mixture thereof. In some embodiments, the composition comprises at least 75% carbonates, bicarbonates, or a mixture thereof. In some embodiments, the composition comprises aragonite, nesquehonite, hydromagnesite, monohydrocalcite, or a combination thereof. In some embodiments, the composition comprises a combination of aragonite and hydromagnesite. In some embodiments, the composition comprises a combination of aragonite and nesquehonite. In some embodiments, the composition comprises a combination of nesquehonite and monohydrocalcite.
In some embodiments, the invention provides a reduced-carbon footprint concrete composition comprising a CO2-sequestering component. The CO2-sequestering component may be a supplementary cementitious material or an aggregate such as a coarse aggregate or a fine aggregate. In some embodiments, the reduced-carbon footprint concrete composition comprises a CO2-sequestering supplementary cementitious material and a CO2-sequestering aggregate. In some embodiments, the reduced-carbon footprint concrete composition comprises a Portland cement clinker.
In some embodiments, the invention provides a settable composition comprising water and a reduced-carbon footprint concrete composition comprising a CO2-sequestering component. The CO2-sequestering component may be a supplementary cementitious material or an aggregate such as a coarse aggregate or a fine aggregate. In some embodiments, the reduced-carbon footprint concrete composition comprises a CO2-sequestering supplementary cementitious material and a CO2-sequestering aggregate. In some embodiments, the reduced-carbon footprint concrete composition comprises a Portland cement clinker.
In some embodiments, the invention provides a method of making a concrete, the method comprising combining a hydraulic cement with a CO2-sequestering component. The CO2-sequestering component may be a supplementary cementitious material or an aggregate such as a coarse aggregate or a fine aggregate. In some embodiments, the reduced-carbon footprint concrete composition comprises a CO2-sequestering supplementary cementitious material and a CO2-sequestering aggregate. In some embodiments, the reduced-carbon footprint concrete composition comprises a Portland cement clinker.
In some embodiments, the invention provides a method of combining water with a reduced-carbon footprint concrete composition comprising a CO2-sequestering component to produce a hydrated concrete composition and allowing the hydrated concrete composition to set into a solid product. The CO2-sequestering component may be a supplementary cementitious material or an aggregate such as a coarse aggregate or a fine aggregate. In some embodiments, the reduced-carbon footprint concrete composition comprises a CO2-sequestering supplementary cementitious material and a CO2-sequestering aggregate. In some embodiments, the reduced-carbon footprint concrete composition comprises a Portland cement clinker. In some embodiments, the solid product a structural product.
FIG. 1 provides a method of the invention for producing precipitation material.
FIG. 2 illustrates a system of the invention for producing a precipitation material.
FIG. 3 provides a plot of strength vs. days for a composition of the invention.
FIG. 4 illustrates production of a precipitation material and/or cement of the invention.
FIG. 5 provides a system of the invention for producing a precipitation material and/or cement.
FIG. 6 illustrates production of a precipitation material, cement, and/or concrete of the invention from power plant flue gas comprising CO2.
FIG. 7 provides an Fourier transform-infrared (FT-IR) plot for ordinary Portland cement (OPC), unhydrated supplementary cementitious admixture (SCMA), and a hydrated blend comprising 20% SCMA and 80% OPC at 7 days.
FIG. 8 provides an X-ray diffractogram (XRD) for OPC and a hydrated blend comprising 20% SCMA and 80% OPC at 7 days.
FIG. 9 provides an X-ray diffractogram (XRD) for hydrated OPC, unhydrated OPC, unhydrated SCMA, and a hydrated blend comprising 20% SCMA and 80% OPC.
FIG. 10 provides scanning electron microscopy (SEM) images for hydrated OPC and a hydrated blend comprising 20% SCMA and 80% OPC.
FIG. 11 indicates SCMA of the invention is reactive.
FIG. 12 provides different morphologies for supplementary cementitious material of the invention.
In some embodiments, the invention provides reduced-carbon footprint concrete compositions. The reduced-carbon footprint concrete of the invention include a component (e.g., a CO2-sequestering component), which comprises carbonates, bicarbonates, or a combination thereof. Additional aspects of the invention include methods of making and using the reduced-carbon footprint concrete.
Before the invention is described in greater detail, it is to be understood that the invention is not limited to particular embodiments described herein as such embodiments may vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and the terminology is not intended to be limiting. The scope of the invention will be limited only by the appended claims. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs.
Certain ranges are presented herein with numerical values being preceded by the term “about.” The term “about” is used herein to provide literal support for the exact number that it precedes, as well as a number that is near to or approximately the number that the term precedes. In determining whether a number is near to or approximately a specifically recited number, the near or approximating unrecited number may be a number, which, in the context in which it is presented, provides the substantial equivalent of the specifically recited number.
It is noted that, as used herein and in the appended claims, the singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise. It is further noted that the claims may be drafted to exclude any optional element. As such, this statement is intended to serve as antecedent basis for use of such exclusive terminology as “solely,” “only,” and the like in connection with the recitation of claim elements, or use of a “negative” limitation.
As will be apparent to those of skill in the art upon reading this disclosure, each of the individual embodiments described and illustrated herein has discrete components and features which may be readily separated from or combined with the features of any of the other several embodiments without departing from the scope or spirit of the invention. Any recited method may be carried out in the order of events recited or in any other order that is logically possible. Although any methods and materials similar or equivalent to those described herein may also be used in the practice or testing of the invention, representative illustrative methods and materials are now described.
In further describing the invention, the reduced-carbon footprint concrete compositions, as well as methods and systems for their production, will be described first in greater detail. Next, methods of using the reduced-carbon footprint concrete compositions will be reviewed further.
In some embodiments, the invention provides reduced-carbon footprint concrete compositions. Reduced-carbon footprint concrete compositions are concrete compositions that may include, for example, an ordinary Portland cement (OPC) component but have a reduced carbon footprint as compared to a concrete that only includes, for example, OPC as the cement component. In some embodiments, the reduced-carbon footprint concrete compositions comprise carbon derived from a fuel used by humans (e.g., a fossil fuel). For example, reduced-carbon footprint concrete compositions according to aspects of the invention comprise carbon that was released in the form of CO2 from combustion of a fossil fuel. In certain embodiments, the carbon sequestered in a composition of the invention (e.g., a reduced-carbon footprint concrete composition) comprises a carbonate, bicarbonate, or a mixture thereof. Therefore, in certain embodiments, reduced-carbon footprint c