Sustainable cement and concrete

Abstract

Disclosed herein is a biomineral supplemental blend for the replacement of hydraulic cement to create sustainable cement and concrete with composition comprising a biomincralizcd algae, a silica source, pozzolan, biochar and / or bio- fly ash; and an aggregate; where the aggregate comprises a primary binder, a secondary binder, sand and / or rock, hydraulic cement, filler material(s), and admixtures. Also disclosed herein is a method of manufacturing a transportable dry biomineral supplemental blend composition comprising blending together a microorganism package, a biomineralized algae, biochar and / or bio-fly ash, and pozzolan; mixing the biomincral supplemental blend with hydraulic cement, cementitious materials, and liquid media to form a sustainable cement; and mixing the sustainable cement with an aggregate to form a sustainable concrete.

Description

SUSTAINABLE CEMENT AND CONCRETECROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This disclosure includes U.S. Provisional Application No. 63 / 641,703 filed on May 02, 2024, the entire contents of which are hereby incorporated by reference.BACKGROUND

[0002] This disclosure relates to sustainable cement and concrete production utilizing a biomineral supplemental blend for replacement of hydraulic cement in structural and non- structural cement and concrete applications.

[0003] Concrete is the most used construction material owing to ease of access to raw materials, low cost of production, versatility, durability, workability, and resistance to various failure modes relative to other construction materials. Currently, more than 10 billion tons of concrete are used globally per annum and experts have predicted that the concrete demand is likely to grow to 16 billion tons in 2050. Additionally, the recent and significant increases in demand for large data centers is likely to further increase the need for cement and concrete. The cun ent technology employed by the construction induslry generates a negative impact on the global environment and economy. For example, up to 80% of a data center’s embodied carbon emissions can come from the cement used alone. The industrial process involved in the production of cement from limestone accounts for 80% to 85% of concrete’s overall carbon footprint, while making up 10% to 25% of the overall mass of the concrete product. Furthermore, cement production consumes between 2 and 3% of the global energy demand, generating 0.73 to 0.99 tons of CCL / ton of cement produced, which accounts for about 8 to 10% of the global anthropogenic emissions of CO2 and 3.4% of the total CO2 global emissions.

[0004] Increases in concrete consumption are consequences of increased demand for newer technologies, such as data centers, growth in developing countries and the need to build new infrastructure to support that growth. The susceptibility of existing infrastructure to physical, chemical, and biological factors such as temperature variations, exposure to corrosive and radioactive substances, aggressive gases, natural disasters, andmicrobial activity further stress infrastructure demands. These exposure factors cause microcracking, which affect mechanical and durability properties of concrete such as compressive strength, flexural strength, and permeability and consequently reduce the useful life of concrete and increase the cost of the maintenance and repair of infrastructures. Although the global cost of concrete production ranges between 60 dollars / m3to 75 dollars / m3, the average cost for crack repair is about 130 dollars / m3, which reveals the high cost involved in the maintenance and repair of concrete structures.

[0005] It is therefore desirable to develop new forms of cement and concrete, as well as cement replacement technologies, that minimize the amount of carbon dioxide emitted into the atmosphere. It is also desirable to produce concrete that is less expensive than that currently produced.SUMMARY

[0006] Disclosed herein is a biomineral supplemental blend for the replacement of hydraulic cement, where the biomincral supplemental blend comprises a biomineralized algae, a silica source, pozzolan, biochar and / or bio-fly ash; and an aggregate; where the aggregate comprises a primary binder, a secondary binder, sand and / or rock. The disclosed biomineral supplemental blend serves as a substitute for Portland cement, modifying the paste-to-aggregate ratio in concrete mixtures. The paste comprises a mixture of ordinary Portland cement (OPC), biomincral supplemental blend, and water; whereas the aggregate comprises sands and rocks. The blend can replace up to 55% of OPC, offering a sustainable alternative for sustainable concrete applications.BRIEF DESCRIPTION OF THE FIGURES

[0007] FIG. 1 depicts the compressive strength (PSI) performance of a 4” x 8” cylinder over a 28-day curing period. The cylinder cement paste comprises 60 weight percent (wt%) hydraulic cement and 40 wt% biomineral supplemental blend at a paste-to- aggregate ratio of 0.23. The dotted line represents the end users targeted compressive strength specification at 28-days aging of the concrete. The paste -composition is described in Table 4;

[0008] FIG. 2 depicts the compressive strength (PSI) performance of 4” x 8” cylinders at 7-, 14-, and 28-day curing times. Each cylinder comprises a cement paste of 60 wt% hydraulic cement and 40 wt% biomincral supplemental blend at a pastc-to- aggregate weight ratio of 0.20. Each cylinder grouping represents a different biochar and / or bio-fly ash utilized in the biomineral supplemental blend. For each cylinder, biochar and / or bio-fly ash comprises 20 wt% of the total cement paste. The solid and dotted lines represent the ash content and residual organic content present in the biochar and / or bio-fly ash used, respectively; and

[0009] FIG. 3 depicts the inorganic analyses, based on X-ray fluorescence (XRF) and X-ray diffraction (XRD), of the biochar and / or bio-fly ash utilized in the formulation of the cylinders described and utilized in FIG 2. Each bar represents the weight percentage of the identified inorganic oxide detected by XRF and / or XRD.DETAILED DESCRIPTION

[0010] Disclosed herein is an environmentally friendly biomincral supplemental blend that can directly replace hydraulic cement in conventional concrete mix designs. This biomineral supplemental blend comprises bio-mineralized algae that can withdraw carbon dioxide from the atmosphere during the manufacturing of the biomineral supplemental blend, during the utility of the biomineral supplemental blend (in a construction project) or during both, the manufacturing of the biomincral supplemental blend as well as during the utility of the biomineral supplemental blend (in a construction project).

[0011] In an embodiment, the biomincral supplemental blend comprises biomineralized algae, residual algae, a supplemental carbonate filler (e.g., oolitic aragonite), a cementitious material, such as for example, a silica source (e.g., silica fume), and biochar or bio-fly ash. In an embodiment, the biomineral supplemental blend may be used to reduce the amount of hydraulic cement used in a concrete mix design to minimize the carbon footprint of the mix design while maintaining project specific requirements, such as compressive strength, chemical resistance, flexural strength, and / or other physical properties of importance to the customer, user, and / or specifier. The hydraulic cementreplaced mix design is generally mixed with sand, rock, and water to produce a lower global warming potential (GWP) containing concrete. Table 1 provides an exemplary composition for a biomincral supplemental blend for the replacement of hydraulic cement, while Table 2 provides an exemplary composition for a biomineral supplemental blend hydraulic cement replaced concrete. In Table 1, the weight percents are based on the total weight of the cement, while in Table 2, the weight percent is based on the total weight of the concrete.Table 1 (biomineral supplemental blend-paste)Table 2 (a mixture of aggregate and paste)

[0012] In an embodiment, the biomineral supplemental blend may be packaged and shipped to a manufacturing site at which additional materials such as aggregate (c.g. sand and rock), fillers (e.g. calcium carbonate), and cementitious or pozzolanic materials (such as slag, fly ash, coal ash, pozzolans, and the like). This biomineral supplemental blend may then be mixed with hydraulic cement to directly reduce the amount of hydraulic cement in a concrete mix design (i.e. a standard cement mix design contains 100 wt% hydraulic cement, while a biomincral supplemental blend replaced cement mix design contains 50 wt% hydraulic cement and 50 wt% of biomineral supplemental blend). A liquid medium may be added to the hydraulic cement reduced mix to form a significantly GWP reduced cement. The cement can be further converted into a concrete, which may be used in a variety of building and construction applications that require high sustainability, low GWP, with traditional concrete performance (strength, chemicalresistance, and the like). For example, a concrete mix design comprising a paste of 40 wt% of biomineral supplemental blend and 60 wt% hydraulic cement at a paste-to- aggrcgatc weight ratio of 0.16 will possess a GWP of approximately -7.6 kg CO2 per kg cement produced (i.e. in the final concrete embodiment, carbon has been sequestered from the atmosphere), whereas conventional hydraulic cement-based concrete possesses a GWP of approximately 1 .0 kg CO2 per kg cement produced. Tn an embodiment, an optional organic material such as a polymer may be added to the biomineral supplemental blend or to the concrete if desired. Additionally, other additional conventional cement modifiers, such as accelerators, retarders, air entrainers, etc. may be used in an embodiment.

[0013] In an embodiment, the bio-mineralized algae in an amount of up to 100 wt% may be transferred from a first site (at which it is manufactured) to a second site. The remainder of the ingredients (other than the bio-mineralized algae and biochar / bio- fly ash) in Table 1 (i.e., the primary binder, the hydraulic cement, and the cementitious material) and Table 2 (i.e., the secondary binder, the hydraulic cement, the cementitious or pozzolanic materials) may be added at the first site or at the second site, or may be added partially at the first site and partially at the second site to form the biomineral supplemental blend as detailed below. The first site is different from the second site. In some embodiments, the first site is generally the manufacturing site while the second site is typically the site at which the biomineral supplemental blend is used. In some embodiments, the first site is a bio-mineralization production site and the second site as a biomineral supplemental blending site, and optionally a third site for a batch plant where the final mixture is combined in a silo or another suitable location.

[0014] Bio-mineralized algae refer to algae that have the ability to produce and deposit minerals (also called a “primary binder”) within their cellular structures. An example of such a primary binder is calcium carbonate (CaCOa). In an embodiment, the primary binder is produced during the bio-mineralization. The calcium carbonate used as the primary binder may be in one of three crystalline forms, which are vaterite, aragonite and calcite, when produced initially during bio-mineralization. Additionally, amorphous calcium carbonate (ACC) may also be generated during the bio-mineralization process. It is desirable to have the calcite and vaterite form the majority of the primary binder.

[0015] In an embodiment, the primary binder is a densifier and it can have cementitious properties- it displays an ability to bind, harden, and gain strength upon setting. Additionally, in an embodiment hydraulic cements arc materials that have the ability to react with water under ambient conditions to form a hardened and water- resistant product. These properties are useful for materials used in construction and structural applications.

[0016] A secondary densifier (or binder) may also be added during the manufacturing of the biomineral supplemental blend for hydraulic cement replacement mix design. This secondary densifier (or binder) may constitute a biochar, bio-fly ash, pozzolan, slag, fly ash, coal ash, or a combination thereof.

[0017] The algae used to produce the first binder is preferably one that withdraws carbon dioxide from the atmosphere and produces a first binder comprising calcium carbonate. However, other microorganisms may also be used in a microorganism package that may produce one or more first binders. In some embodiments, a microorganism package may comprise a microorganism that has not been biomincralizcd. In an embodiment, the microorganism package may comprise two or more different types of microorganisms that can produce the first binder. When two or more microorganisms are used to produce the first binder, the first binder may comprise an additional binder in addition to calcium carbonate. The first microorganisms are preferably those that consume carbon dioxide from the atmosphere to produce a carbonate salt that serves as the first precipitate in the binder. The microorganisms may be photosynthetic prokaryotic or eukaryotic, in particular bacteria, yeast, or algae, or a combination thereof.

[0018] Examples of algae include:CyanobacteriaGreen Sulfur Bacteria (Chlorobi)Green Non-Sulfur Bacteria (Chloroflcxi) HeliobacteriaAcidobacteria (some are photosynthetic) ProteobacteriaPurple Sulfur Bacteria (Chromatiaceae)Purple Nonsulfur BacteriaGreen Bacteria (Chloroflexi and Chloracidobacterium)Chloroflcxi bacteriumPurple Sulfur Bacteria (Ectothiorhodospiraceae)Purple Bacteria (Rhodospirillaceae)Purple Nonsulfur Bacteria (Rhodospirillaceae)Purple Sulfur Bacteria (Chromatiaceae)Purple Bacteria (Rhodospirillaceae)Purple Sulfur Bacteria (Ectothiorhodospiraceae)Green Sulfur Bacteria (Chlorobi)Green Nonsulfur Bacteria (Chloroflexi)HeliobacteriaAcidobacteria (some are photosynthetic)ProteobacteriaPurple Sulfur Bacteria (Chromatiaceae)Purple Nonsulfur BacteriaGreen Bacteria (Chloroflcxi and Chloracidobacterium)Chloroflexi bacteriumPurple Sulfur Bacteria (Ectothiorhodospiraceae)Purple Bacteria (Rhodospirillaceae)Purple Nonsulfur Bacteria (Rhodospirillaceae)Purple Sulfur Bacteria (Chromatiaceae)Purple Bacteria (Rhodospirillaceae)Purple Sulfur Bacteria (Ectothiorhodospiraceae)Green Sulfur Bacteria (Chlorobi)Green Nonsulfur Bacteria (Chloroflexi)HcliobactcriaAcidobacteria (some are photosynthetic)ProteobacteriaPurple Sulfur Bacteria (Chromatiaceae)Purple Nonsulfur BacteriaGreen Bacteria (Chloroflcxi and Chloracidobacterium)Chloroflexi bacteriumPurple Sulfur Bacteria (Ectothiorhodospiraceae)Purple Bacteria (Rhodospirillaccac)Purple Nonsulfur Bacteria (Rhodospirillaceae)Purple Sulfur Bacteria (Chromatiaceae)Purple Bacteria (Rhodospirillaceae)Purple Sulfur Bacteria (Ectothiorhodospiraceae)Green Sulfur Bacteria (Chlorobi)Green Nonsulfur Bacteria (Chloroflexi)HeliobacteriaAcidobacteria (some are photosynthetic)ProteobacteriaPurple Sulfur Bacteria (Chromatiaceae)Purple Nonsulfur BacteriaGreen Bacteria (Chloroflexi and Chloracidobacterium)Chloroflexi bacteriumPurple Sulfur Bacteria (Ectothiorhodospiraceae)Purple Bacteria (Rhodospirillaceae)Purple Nonsulfur Bacteria (Rhodospirillaceae)Purple Sulfur Bacteria (Chromatiaceae)Purple Bacteria (Rhodospirillaceae)Purple Sulfur Bacteria (Ectothiorhodospiraceae)Green Sulfur Bacteria (Chlorobi)Green Nonsulfur Bacteria (Chloroflexi)HeliobacteriaAcidobacteria (some are photosynthetic)ProteobacteriaPurple Sulfur Bacteria (Chromatiaceae)Purple Nonsulfur BacteriaGreen Bacteria (Chloroflexi and Chloracidobacterium)Chloroflexi bacteriumPurple Sulfur Bacteria (Ectothiorhodospiraceae)Purple Bacteria (Rhodospirillaceae)Purple Nonsulfur Bacteria (Rhodospirillaceae)Purple Sulfur Bacteria (Chromatiaceae)Purple Bacteria (Rhodospirillaceae)Purple Sulfur Bacteria (Ectothiorhodospiraceae)Green Sulfur Bacteria (Chlorobi)Green Nonsulfur Bacteria (Chloroflexi)HcliobactcriaAcidobacteria (some are photosynthetic)ProteobacteriaPurple Sulfur Bacteria (Chromatiaceae)Purple Nonsulfur BacteriaGreen Bacteria (Chloroflexi and Chloracidobacterium)Chloroflexi bacteriumPurple Sulfur Bacteria (Ectothiorhodospiraceae)Purple Bacteria (Rhodospirillaceae)Purple Nonsulfur Bacteria (Rhodospirillaceae)Purple Sulfur Bacteria (Chromatiaceae)Purple Bacteria (Rhodospirillaceae)Purple Sulfur Bacteria (Ectothiorhodospiraceae)Green Sulfur Bacteria (Chlorobi)Green Nonsulfur Bacteria (Chloroflexi)HeliobacteriaAcidobacteria (some are photosynthetic)ProteobacteriaPurple Sulfur Bacteria (Chromatiaceae)Purple Nonsulfur BacteriaGreen Bacteria (Chloroflexi and Chloracidobacterium)Chloroflexi bacteriumAnabaena cylindricaNostoc communeSpirulina platcnsisSynechococcus elongatusProchlorococcus marinusMicrocystis aeruginosaOscillatoria tenuisGloeocapsa magmaTrichodesmium erythraeumCyanothece sp.Chlorobium limicolaChlorobaculum tepidumChlorobium phaeobacteroidesChloroflexus aurantiacusRoseiflexus castenholziiHeliobacterium modesticaldumHeliobacterium chlorumAcidobacterium capsulatumRhodopseudomonas palustrisRhodobactcr sphacroidcsRhodocyclus tenuisChromatium okeniiThiocapsa roseopersicinaRhodospirillum centenumChloracidobactcrium thermophilumChlorollexus aggregansOscillochloris trichoidesHerpetosiphon aurantiacusThiocystis violascensAllochromatium vinosumMarichromatium purpuratumNitrosococcus oceaniNitrosopumilus maritimusEctothiorhodospira shaposhnikoviiEctothiorhodospira halochlorisEctothiorhodospira mobilis Lamprocystis purpurea Rubrivivax gclatinosus Rhodopseudomonas viridis Rhodopseudomonas acidophilaRhodopseudomonas palustris CGA009 Rhodobacter capsulatus BIO Rhodobactcr sphacroidcs 2.4.1 Rhodopseudomonas palustris BisB5 Roseiflexus castenholziiChlorobaculum parvum Roseiflexus sp.Chloroflexi bacterium MS-G Chloroflexi bacterium GNS-1 Chloroflexus sp.Thiodictyon sp. KC- 1 Thiodictyon sp. CLB1001 Rhodobacter capsulatus SB 1003 Rhodobacter sphaeroides ATCC 17029 Rhodobacter sphaeroides ATCC 17096 Rhodobacter sphaeroides ATCC 17925Hcliophilum prolipovicii Chlorobaculum parvum Chlorobaculum tepidum Oscillatoria limosaNostoc punctiforme Syncchocystis sp. Chloracidobacterium aurantiacum Synechocystis aquatilis Thiocapsa roseaThiodictyon sp. KC-1 Thiodictyon sp. CLB1001Marichromatium purpuratumNitrosococcus oceaniNitrosopumilus maritimusEctothiorhodospira shaposhnikoviiEctothiorhodospira halochlorisEctothiorhodospira mobilisLamprocystis purpureaRubrivivax gclatinosusRhodopseudomonas viridisRhodopseudomonas acidophilaRhodopseudomonas palustris CGA009Rhodobacter capsulatus BIORoseillexus sp.Chlorobaculum parvumChloroflexus sp.Oscillatoria limosaNostoc punctiformcChlorobium limicolaChlorobium phaeobacteroidesChloroflexus aurantiacusGloeocapsa magmaTrichodcsmium crythracumCyanothece sp.Microcoleus chthonoplastesPhormidium sp.Chloroflexi bacterium MS-GChlorollcxi bacterium GNS-1Aphanocapsa sp.Geitlerinema sp.Anabaenopsis sp.Leptolyngbya sp.Moorca produccnsChroococcidiopsis sp., or a combination thereof.

[0019] Preferred examples of photosynthetic prokaryotic microorganisms include:Anabaena cylindricaNostoc communeSpirulina platcnsisSynechococcus elongatusProchlorococcus marinusMicrocystis aeruginosaOscillatoria tenuisGlococapsa magmaTrichodesmium erythraeumCyanothece sp.Chlorobium limicolaChlorobaculum tepidumChlorobium phacobactcroidcsChloroflexus aurantiacusRoseiflexus castenholziiHeliobacterium modesticaldumHeliobacterium chlorumAcidobacterium capsulatumRhodopseudomonas palustrisRhodobacter sphaeroidesRhodocyclus tenuisChromatium okcniiThiocapsa roseopersicinaRhodo spirillum centenumChloracidobacterium thermophilumChloroflexus aggregansOscillochloris trichoidcsHerpetosiphon aurantiacusThiocystis violascensAllochromatium vinosum Marichromatium purpuratum Nitrosococcus occaniNitrosopumilus maritimus Ectothiorhodospira shaposhnikovii Ectothiorhodospira halochloris Ectothiorhodospira mobilis Lamprocystis purpurea Rubrivivax gelatinosus Rhodopseudomonas viridis Rhodopseudomonas acidophila Rhodopseudomonas palustris CGA009 Rhodobacter capsulatus BIO Rhodobacter sphaeroides 2.4.1Rhodopseudomonas palustris BisB5 Roseiflexus castenholzii Chlorobaculum parvum Roseiflexus sp.Chloroflexi bacterium MS-G Chloroflexi bacterium GNS- 1 Chloroflexus sp.Thiodictyon sp. KC-1 Thiodictyon sp. CLB1001 Rhodobacter capsulatus SB 1003 Rhodobacter sphaeroides ATCC 17029 Rhodobacter sphaeroides ATCC 17096 Rhodobacter sphaeroides ATCC 17925 Heliophilum prolipovicii Chlorobaculum parvum Chlorobaculum tepidumOscillatoria limosa Nostoc punctiformcSynechocystis sp.Chloracidobacterium aurantiacumSynechocystis aquatilis Thiocapsa roseaThiodictyon sp. KC-1 Thiodictyon sp. CLB 1001 Marichromatium purpuratum Nitrosococcus occani Nitrosopumilus maritimus Ectothiorhodospira shaposhnikovii Ectothiorhodospira halochloris Ectothiorhodospira mobilis Lamprocystis purpurea Rubrivivax gelatinosus Rhodopseudomonas viridis Rhodopseudomonas acidophila Rhodopseudomonas palustris CGA009 Rhodobacter capsulatus BIO Roseiflexus sp.Chlorobaculum parvum Chloroflexus sp.Oscillatoria limosaNostoc punctiforme Chlorobium limicolaChlorobium phaeobacteroides Chloroflexus aurantiacusGlococapsa magma Trichodesmium erythraeum Cyanothece sp.Microcoleus chthonoplastes Phormidium sp.Chloroflcxi bacterium MS-GChloroflexi bacterium GNS- 1Aphanocapsa sp.Gcitlcrincma sp.Anabaenopsis sp.Leptolyngbya sp.Moorea producersChroococcidiopsis sp., or a combination thereof.

[0020] Examples of photosynthetic eukaryotic microorganisms include:Chlamydomonas rcinhardtiiEuglena gracilisSpirogyraDiatoms (e.g., Thalassiosira)ChlorellaVolvoxDesmidsCyanophora paradoxa (a cryptomonad)Dinoflagellates (e.g., Karenia brevis)Cryptophytes (e.g., Rhodomonas)Brown algae (Phaeophyta)Red algae (Rhodophyta)Green algae (e.g., Ulva, Spirogyra)MicrasteriasClostcriumOedogoniumCoccolithophores (e.g., Emiliania huxleyi)SynuraPrymnesium parvumAphanizomcnonChlamydomonas reinhardtiiEuglena gracilisSpirogyra sp.Thalassiosira pseudonanaChlorclla vulgarisVolvox carteriMicrasterias denticulataClosterium sp.Oedogonium sp.Emiliania huxlcyiPrymnesium parvumChara vulgarisCladophora glomerataEctocarpus siliculosus Phacus sp.Vaucheria sp.Dictyostelium discoideumOchromonas danicaNannochloropsis sp.Gymnodinium sp.Peridinium sp.Phaeocystis pouchetiiOstreococcus tauriGonyaulax spinifcraDinobryon divergensActinophrys solSymbiodinium microadriaticumLaminaria digitataEuglcna longaPandorina morumZygnema sp.Mesotaenium sp.Dinophysis acuminataNoctiluca scintillansPorphyra purpurea Porphyridium cruentum Griffithsia sp.Corallina officinalis Theileria parva Chromera velia Dasya sp.Chactoccros sp. Coscinodiscus sp. Trichodesmium erythraeum Chrysochromulina sp. Bathycoccus prasinos Scenedesmus obliquus Selenastrum capricomutumPediastrum boryanum Synura petersenii Botryococcus braunii Bulbochaete sp.Sarcodina sp.Chattonella marina Tetraselmis chuii Eutrcpticlla gymnastica Myrmecia ingens Haematococcus pluvialis Monoraphidium minutum Ankistrodesmus falcatusSphacrocystis schroctcri Chlorogonium elongatum Nannochloris atomus Fragilariopsis cylindrus Chaetoceros muelleri Scytoncma sp.Aphanochaete repens Clostridium perfringens Microcolcus vaginatus Navicula gregaria Rhizosolenia calc ar- avisParaphysomonas imperforata Neochloris oleoabundans Isochrysis galbana Cyanidium caldarium Tribonema sp.Dinobryon sertularia Botrydium granulatum Penium margaritaceum Desmodesmus quadricauda Staurastrum brachiatum Pteridium sp.Klcbsormidium flaccidum Phaeodactylum tricomutum Nannochloris maculata Navicula radiosaProchlorococcus marinusAcgagropila linnaci Rhizoclonium hieroglyphicum Acetabularia acetabulum Chrysochromulina parva Ochrosphaera neapolitana Tetrastrum cambridgci Cephaleuros parasiticus Micromonas pusiliaPyramimonas tetrarhynchus Heterocapsa pygmaea Amphidinium cartcracAmphora coffeaeformisScherffelia dubia, or a combination thereof.

[0021] Preferred examples of photosynthetic eukaryotic microorganisms include:Chlamydomonas rcinhardtiiEuglena gracilisSpirogyra sp.Thalassiosira pseudonanaChlorella vulgarisVolvox cartcriMicrasterias denticulataClosterium sp.Oedogonium sp.Emiliania huxleyiPrymncsium parvumChara vulgarisCladophora glomerataEctocarpus siliculosusPhacus sp.Vauchcria sp.Dictyostelium discoideumOchromonas danicaNannochloropsis sp.Gymnodinium sp.Peridinium sp.Phaeocystis pouchetiiOstreococcus tauriGonyaulax spiniferaDinobryon divcrgcnsActinophrys solSymbiodinium microadriaticumLaminaria digitataEuglena longa Pandorina morumZygncma sp.Mesotaenium sp. Dinophysis acuminataNoctiluca scintillans Porphyra purpurea Porphyridium crucntum Griffithsia sp.Corallina officinalis Theileria parva Chromera veliaDasya sp.Chaetoceros sp. Coscinodiscus sp. Trichodesmium erythraeum Chrysochromulina sp. Bathycoccus prasinos Scenedesmus obliquus Selenastrum capricomutum Pediastrum boryanum Synura pctcrscnii Botryococcus braunii Bulbochaete sp. Sarcodina sp.Chattonella marina Tctrasclmis chuii Eutreptiella gymnastica Myrmecia ingens Haematococcus pluvialisMonoraphidium minutum Ankistrodcsmus falcatusSphaerocystis schroeteri Chlorogonium elongatum Nannochloris atomus Fragilariopsis cylindrus Chaetoceros muelleri Scytonema sp.Aphanochaete repens Clostridium pcrfringcns Microcoleus vaginatus Navicula gregaria Rhizosolenia calcar-avis Paraphysomonas imperforata Neochloris oleoabundans Isochrysis galbana Cyanidium caldarium Tribonema sp.Dinobryon scrtularia Botrydium granulatum Penium margaritaceum Desmodesmus quadricauda Staurastrum brachiatum Ptcridium sp.Klebsormidium llaccidum Phaeodactylum tricomutum Nannochloris maculata Navicula radiosa Prochlorococcus marinus Aegagropila linnaei Rhizoclonium hieroglyphicum Acetabularia acetabulum Chrysochromulina parva Ochrosphacra ncapolitanaTetrastrum Cambridge!Cephaleuros parasiticus Micromonas pusilia Pyramimonas tetrarhynchus Heterocapsa pygmaea Amphidinium carterae Amphora coffeaeformis Schcrffclia dubia, or a combination thereof.Nutrients

[0022] The nutrients arc consumed by the microorganisms along with gases from the atmosphere (carbon dioxide, nitrogen, and the like) to produce the first binder during the biomineralization process. The term “nutrient” as used herein refers to any chemical compound or composition which provides for microorganism growth or function. For example, for calcium-precipitating bacteria, a source of calcium is a nutrient. Co-factors which support bacteria viability (c.g., trace elements) arc considered nutrients. The disclosed nutrient media comprise ingredients which provide for microorganism growth, as well as, the flowability of the bio-cement. Microorganism growth materials include inorganic salts and sources of carbon for microorganism metabolism. Some of the nutrients can serve as the binder and some of the binder can function as nutrients.

[0023] The nutrients that are added to facilitate biomineralization include macronutrients and / or micronutrients. Macronutrients refer to elements that are used by organisms in relatively large quantities for their growth and development.

[0024] Micronutrients, also known as trace elements or trace metals, are elements used by living organisms in smaller quantities compared to macronutrients. While micronutrients are needed in smaller amounts, they play useful roles in various biological processes, including biomineralization. Macronutrients may include primary nutrients and secondary nutrients. Primary nutrients include nitrogen- containing compounds, phosphorus-containing compounds, potassium containing compounds, or a combination thereof. Nitrogen containing compounds include urea, ammonium nitrate, ammoniumsulfate, calcium ammonium nitrate, sodium nitrate, or a combination thereof. Phosphorus-containing compounds include triple superphosphate, di-ammonium phosphate, mono-ammonium phosphate, rock phosphate, sodium phosphate, potassium phosphate, or a combination thereof.

[0025] Triple superphosphate (TSP) is a highly concentrated phosphorus fertilizer. It is produced by reacting rock phosphate with phosphoric acid. The process involves treating phosphate rock with an excess of phosphoric acid, resulting in a fertilizer with a high concentration of soluble phosphorus. Rock phosphate is a natural mineral deposit that is mined for its phosphorus content. The main component of rock phosphate is the mineral apatite, which contains various forms of calcium phosphate.

[0026] Potassium containing compounds include potassium chloride, potassium sulfate, potassium nitrate, potassium phosphate, dipotassium phosphate, or a combination thereof.

[0027] Secondary nutrients include calcium-containing compounds, magnesium- containing compounds, sulfur in elemental form or sulfur-containing compounds, or a combination thereof.

[0028] Calcium-containing compounds include calcium carbonate, calcium sulfate, calcium nitrate, or a combination thereof. Magnesium-containing compounds include magnesium sulfate (Epsom salt), magnesium oxide, or a combination thereof. Sulfur- containing compounds include ammonium sulfate.

[0029] Micronutrients include ferrous sulfate, iron chelates, ferric sulfate (Fe.SO 1.7H2O). manganese sulfate, manganese chelates, zinc sulfate, zinc chelates, copper sulfate, copper chelates, borax, boric acid, boron chelates, sodium molybdate, potassium chloride, cobalt nitrate, cobalt chloride, sodium nitrate, calcium chloride hydrate (CaCh.2H2O), boric acid, ethylenediaminetetraacetic acid, or a combination thereof.

[0030] In a preferred embodiment, suitable nutrients include nitrogen, potassium and phosphorus containing compounds. Suitable nutrients that may be used forfacilitating algal growth include sodium nitrate, calcium chloride hydrate (CaCh.2H2O), magnesium sulfate (MgSCC fCO), dipotassium phosphate, sodium chloride, sodium bicarbonate, potassium hydroxide, ferric sulfate (FCSO4.7H2O), ethylenediaminetetraacetic acid, boric acid, zinc sulfate (ZnSOi. / HiO). or the like, or a combination thereof.

[0031] The nutrients are added in an amount of 0.0000001 to 10 weight percent based on the weight of the liquid media, the nutrients and the algae.

[0032] The aggregate may contain a pozzolan (such as an amorphous aluminum silicate), a silica fume, three-quarter minus rock or smaller, oolitic aragonite, sand, or a combination thereof. The aggregate is mixed with the biomincral supplemental blend, Portland-cement, and liquid media to form the sustainable concrete.

[0033] The pozzolan comprises silicon dioxide and aluminum oxide. Silicon dioxide is present in an amount of 40 to 80 wt%, based on a total weight of the pozzolan. Aluminum oxide is present in an amount of 5 to 40 wt%, based on a total weight of the pozzolan. Iron oxide may be present in an amount of 0.05 to 10 wt%, based on a total weight of the pozzolan. The pozzolan may also contain water in an amount of 1 to 8 wt%, based on a total weight of the pozzolan. Additionally, a standard specification for raw or calcined natural pozzolan for use in concrete may be found in ASTM C618. The pozzolan is present in the aggregate in an amount of 5 to 40 wt%, preferably 10 to 30 wt%, based on the weight of the biomineral supplemental blend and the desired hydraulic cement replacement level.

[0034] In some embodiments, the pozzolan comprises silicon dioxide, aluminum oxide and iron oxide, and is pursuant to pozzolans as described in ASTM C618 (standard specification for coal fly ash and raw or calcined natural pozzolan), ASTM C1697 (standard specification for blended supplementary cementitious materials), and / or ASTM C311 (standard test methods for sampling and testing fly ash or natural pozzolans for use in Portland-ccmcnt concrete), and where the pozzolan is present in the biomincral supplemental blend composition in an amount of 5 to 40 wt%. In some embodiments, the hydraulic cement comprises a Portland cement, an ASTM Cl 50 Portland Cement, anASTM C 150-07 Portland Cement, an ASTM C595 blended hydraulic cement, an ASTM Cl 157 blended hydraulic cement, C109 / C109M hydraulic cement mortar’, Cl 14 hydraulic cement, C151 / C151M hydraulic cement, C183 / C183M hydraulic cement, C185 hydraulic cement, C191 hydraulic cement, C204 hydraulic cement, C 19 hydraulic cement, C226 hydraulic cement, C266 hydraulic cement, C451 hydraulic cement, C452 hydraulic cement, C465 hydraulic cement, C563 hydraulic cement, C 1038 / C 1038M hydraulic cement, C1702 hydraulic cement, C1778 hydraulic cement and mixtures thereof.

[0035] The dried biomineral referred to herein for purposes of determining the weight percent contribution is obtained by the removal of water (which is primarily the liquid media used in the mixing of the cement with the aggregate to produce the concrete).

[0036] Biochar is a product generated through the pyrolysis of organic materials, such as agricultural waste, wood chips, or another biomass. Pyrolysis is a process where organic materials arc heated in the absence of oxygen, which permanently fixes carbonaceous compounds into a stable char. As a result, biochar is created along with other byproducts like gases and liquids. Biochar is considered a form of carbon sequestration, as the carbon captured during the growth of the biomass is retained in the biochar. Biochar production can be a way to utilize organic waste materials that might otherwise be disposed of such as agricultural residues or forestry' byproducts. Biochar is characterized by its porous carbon content (that has a high surface area) with possible inorganic oxide inclusions. Biochar may act as a densifier as well as a binder when it contains inorganic oxides that react with water and cement hydration byproducts, such as calcium hydroxide. It can also act as a carbon sink. Biochar and / or bio-fly ash may be classified into sub-categories based on the residual organic content present within the material: low ash content (greater than70 wt% residual organic carbon organic content), moderate ash content (between 30 wt% and 70 wt% residual organic content), and high ash content of less than 30 wt% residual organic content). The weight percent of residual organic content can impact the performance dynamics of the biomincral supplemental blend, as shown in FIG. 2.

[0037] The pyrolytic products (such as biochars and bio-fly ashes) may comprise about 5 to 97 wt% carbon with the rest comprising a variety of different inorganic oxides. The inorganic oxides that make up the balance of the ash content for various biochars and / or bio-fly ashes may comprise calcium oxide (CaO), silicon dioxide (SiCh), aluminum oxide (AI2O3), ferric oxide ( cjOs). and may be present in either, or both, crystalline and amorphous crystal states within the biochar. In some embodiments, the amount of total ash is 30 to 70 percent by weight of the biochar composition. In some embodiments, the ash comprises 95 wt% organic residue, 5 wt% inorganic oxides (where the inorganic oxide composition is shown in Table 3); 50 wt% organic residue with 50 wt% inorganic oxides (where the inorganic oxide composition is shown in Table 3); 10 wt% organic residue with 90 wt% inorganic oxides (where the inorganic oxide composition is shown in Table 3). Table 3 provides an exemplary composition of inorganic oxides present in the ash content of a pyrolytic product produced from organic materials, as described above.Table 3 (inorganic oxides present within pyrolytic product ashes)

[0038] In some embodiments, the amount of total ash is 15 to 65 wt% of the biochar composition; the amount of SiO? from ash is 55 to 65 wt% of the biochar composition; the amount of AI2O3 from ash is 3 to 15 wt% of the biochar composition; the amount of CaO from ash is 10 to 20 wt% of the biochar composition; the amount of Fe2O3 is 1 to 10 wt% of the biochar composition; the amount of P2O5 is 0.5 to 10 wt% of the biochar composition; the amount of MgO from ash is 0.5 to 10 wt% of the biocharcomposition; the amount of K2O from ash is 0.5 to 10 wt% of the biochar composition; the amount of SO3 from ash is 0.5 to 10 wt% of the biochar composition; the amount of Cl from ash is 1 to 10 wt% of the biochar composition.

[0039] In some embodiments, the amount of total ash is 15 to 25 wt% of the biochar composition; the amount of SiCh from ash is 50 to 60 wt% of the biochar composition; the amount of AI2O3 from ash is 3 to 10 wt% of the biochar composition; the amount of CaO from ash is 15 to 25 wt% of the biochar composition; the amount of FeiCh is 1 to 10 wt% of the biochar composition; the amount of P2O5 is 0.5 to 10 wt% of the biochar composition; the amount of MgO from ash is 1 to 10 wt% of the biochar composition; the amount of K2O from ash is 0.5 to 10 wt% of the biochar composition; the amount of SO3 from ash is 0.5 to 10 wt% of the biochar composition; the amount of Cl from ash is 1 to 10 wt% of the biochar composition.

[0040] Tn some embodiments, the amount of total ash is 30 to 45 wt% of the biochar composition; the amount of SiC>2 from ash is 15 to 25 wt% of the biochar composition; the amount of AI2O3 from ash is 3 to 10 wt% of the biochar composition; the amount of CaO from ash is 15 to 25 wt% of the biochar composition; the amount of Fe2O3 is 15 to 25 wt% of the biochar composition; the amount of P2O5 is 15 to 25 wt% of the biochar composition; the amount of MgO from ash is 1 to 10 wt% of the biochar composition; the amount of K2O from ash is 0.5 to 10 wt% of the biochar composition; the amount of SO3 from ash is 0.5 to 10 wt% of the biochar composition; the amount of Cl from ash is 0.1 to 10 wt% of the biochar composition.

[0041] Tn some embodiments, the amount of total ash is 30 to 45 wt% of the biochar composition; the amount of SiO2 from ash is 15 to 25 wt% of the biochar composition; the amount of AI2O3 from ash is 3 to 10 wt% of the biochar composition; the amount of CaO from ash is 15 to 25 wt% of the biochar composition; the amount of Fe2O3 is 15 to 25 wt% of the biochar composition; the amount of P2O5 is 15 to 25 wt% of the biochar composition; the amount of MgO from ash is 1 to 10 wt% of the biochar composition; the amount of K2O from ash is 1 to 10 wt% of the biochar composition; the amount of SO3 from ash is 0.5 to 10 wt% of the biochar composition; the amount of Cl from ash is 0.1 to 10 wt% of the biochar composition.

[0042] In some embodiments, the amount of total ash is 40 to 50 wt% of the biochar composition; the amount of SiC>2 from ash is 15 to 25 wt% of the biochar composition; the amount of AI2O3 from ash is 3 to 15 wt% of the biochar composition; the amount of CaO from ash is 15 to 25 wt% of the biochar composition; the amount of Fe Ch is 15 to 25 wt% of the biochar composition; the amount of P2O5 is 5 to 15 wt% of the biochar composition; the amount of MgO from ash is 1 to 10 wt% of the biochar composition; the amount of K2O from ash is 0.1 to 10 wt% of the biochar composition; the amount of SO; from ash is 5 to 15 wt% of the biochar composition; the amount of Cl from ash is 0.1 to 10 wt% of the biochar composition.

[0043] Tn some embodiments, the amount of total ash is 44 to 55 wt% of the biochar composition; the amount of SiO2 from ash is 30 to 40 wt% of the biochar composition; the amount of AI2O3 from ash is 3 to 15 wt% of the biochar composition; the amount of CaO from ash is 10 to 20 wt% of the biochar composition; the amount of Fe20s is 15 to 25 wt% of the biochar composition; the amount of P2O5 is 5 to 15 wt% of the biochar composition; the amount of MgO from ash is 1 to 10 wt% of the biochar composition; the amount of K2O from ash is 0.1 to 10 wt% of the biochar composition; the amount of SO3 from ash is 1 to 10 wt% of the biochar composition; the amount of Cl from ash is 0.1 to 10 wt% of the biochar composition.

[0044] FIG. 3 shows the inorganic analyses of the various biochar and bio-fly ash types discussed above and depicted in FIG. 2. The variations in carbon content, ash content, and inorganic oxide(s) are determined by the precursor starting materials (i.e. agricultural waste, wood chips, other biomass, etc.), the pyrolytic processing a material undergoes to create the pyrolytic products, and other factors such as moisture content, seasonal variability, etc.

[0045] The biochar may be used in the biomineral supplemental blend in an amount of 0.01 to 49 wt%, 10 to 25 wt%, based on a total weight of the dried biomineral replacement blend.

[0046] Three-quarter minus rock refers to a specific size of crushed rock or gravel particles. The term is commonly used in the construction and landscaping industry todescribe the size of the material. The “three-quarter minus” designation usually indicates that the crushed rock particles are small and will pass through a screen or sieve with openings that arc approximately three-quarter inch in diameter. This means that the material is relatively fine, with particles smaller than 3 / 4 inch. The term “minus” implies that the material includes particles smaller than the specified size. In the case of “three- quarter minus,” this means that the majority of the material will pass through a three- quarter-inch sieve, but it may also contain smaller particles, such as fines, which contribute to the compaction of the material. The rock selected for use herein will be three-quarter minus rock or smaller, such as, for example, quarter minus rock. In the case of “quarter minus,” this means that the majority of the material will pass through a quarter-inch sieve, but it may also contain smaller particles, such as fines, which contribute to the compaction of the material.

[0047] The three-quarter minus rock (or smaller sizes) is used in an amount of 50 to 95 wt%, 65 to 85 wt%, based on a total weight of the concrete. In other embodiments, three-quarter minus rock (or smaller sizes) and sand may be omitted, and the biomineral supplemental blend cement-paste, as described in Table 2, may be used directly.

[0048] Oolitic aragonite refers to a form of aragonite, which is a crystal form of calcium carbonate (CaCOa), a mineral commonly found in nature. The term “oolitic” refers to the characteristic small, rounded structures called ooids that make up the material. The oolitic aragonite may be referred to as the second binder. In an embodiment, the first binder is the same as the second binder. As noted above, the calcium carbonate generated during bio-mineralization is the first binder.

[0049] The secondary binder is present in an amount of 0.01 to 5 wt%, based on the total weight of the concrete.

[0050] The sand is used as the substrate (also referred to herein as the scaffold). The sand is generally used in the concrete in an amount of 50 to 95 wt%, based on a total weight of the concrete.

[0051] The biomineral supplemental blend is added to the hydraulic cement to form a sustainable, low GWP, cement. The biomineral supplemental blend is present inthe dry cement mix in an amount of I to 55 wt%, preferably 20 to 45 wt%, and more preferably 30 to 40 wt%, based on a total weight of the dry cement mix. In some embodiments, the disclosed biomincral supplemental blend may be added to the hydraulic cement and aggregate mix during concrete manufacturing (i.e. at a concrete batch plant or other concrete manufacturing facility) such that the biomineral supplemental blend replaces 1 to 55 wt% of the cement paste, preferably 20 to 45 wt%, and more preferably 30 to 40 wt% based on total weight of the dry cement mix. The dry cement mix is a combination of the biomincral supplemental blend, hydraulic cement and / or an aggregate mix. Water (in desirable quantities) may be added to the dry cement mix to form the cement paste.

[0052] In some embodiments, the disclosed biomineral supplemental blend may be added to the hydraulic cement and aggregate mix by pre-blending with hydraulic cement before packaging. The biomineral supplemental blend replaces 1 to 55 wt% of the cement paste, preferably 20 to 45 wt%, and more preferably 30 to 40 wt% based on total weight of the dry cement mix

[0053] In some embodiments, the disclosed biomineral supplemental blend may be added to the hydraulic cement and aggregate mix by adding it directly at the concrete batch plant during concrete production. The biomineral supplemental blend replaces 1 to 55 wt% of the cement paste, preferably 20 to 45 wt%, and more preferably 30 to 40 wt% based on total weight of the dry cement mix. In an embodiment, in one manner of manufacturing the biomineral supplemental blend, the biomineralized algae, biochar, biofly ash, oolitic aragonite, and pozzolan are taken in the desired proportions and mixed in a blender (e.g., Waring blender, Henschel mixer, and the like) at room temperature for 1 to 10 minutes to form a first mixture.

[0054] The sand, rock, and hydraulic cement are added to a blender (e.g., Waring blender, Henschel mixer, and the like) that contains the first mixture. The mixing is conducted at room temperature for 1 to 10 minutes to form a second mixture.

[0055] The liquid medium (e.g., water) is then added to the blender and mixed for5 to 15 minutes to form a sustainable concrete. The sustainable concrete may be pouredinto a mold having the shape of a desired article and is then subjected to curing. The sustainable concrete is then cured at a temperature of 10 to 125°C and 25 to 95 % relative humidity for 1 to 72 hours followed by storage at ambient conditions for 1 to 56 days.

[0056] During the formation of the article, the liquid added may optionally reactivate the microorganisms, which can consume some of the binder or nutrients. The microorganism(s) upon reactivation produce the binder (calcium carbonate, reaction products thereof, or the like) to bond the substrates and reinforcing agents into a shapeable solid. The sustainable concrete may then be placed in a mold or injected into a mold to form bricks, cinder blocks, columns, tiles, and so on.

[0057] In an embodiment, once the sustainable concrete has cured, the bacteria no longer produce the binder. The formulator or user, however, can restore the microbiological activity of the building material by adding sufficient moisture and / or physical conditions to promote activity. In this way any surface imperfections formed during casting of the material, for example, into bricks, can be repaired after curing. This allows for reinforcement of the material to achieve the added strength that the cured material possesses. In this way cracks or fissures which have formed can be filled by the existing microorganisms using the existing matrix elements and nutrient medium.

[0058] Another embodiment of the disclosure is directed to compositions and structures that do not require formworks (c.g., framclcss manufacturing) wherein structures are formed by compressing the dry composition after the addition of water (which functions as an activating agent). Preferred compression devices include hydraulic presses, and preferred pressures are 100 psi or greater, 250 psi or greater, 500 psi or greater, 1000 psi or greater, 2000 psi or greater, 3000 psi or greater, 4000 psi or greater, 5000 psi or greater.

[0059] Sustainable cement and concrete production utilizing a biomineral supplemental blend for replacement of hydraulic cement are exemplified by the following non-limiting examples.Example # 1

[0060] This example was conducted to demonstrate one exemplary embodiment of a method to manufacture the sustainable concrete described herein.

[0061] The biomineral supplemental blend manufactured as detailed above mixed with a hydraulic cement and aggregate to form a sustainable concrete. The sustainable concrete composition is shown in Table 4 below.Table 4

[0062] As noted above, the biomineralized algae, biochar, pozzolan, and secondary binder are first mixed together to form a first mixture. The hydraulic cement and water (the liquid media) are added to the first mixture and blended to form a second mixture. This second mixture constitutes the sustainable cement which can then be mixed with aggregate (sand and / or rock) and additional pozzolans to create a sustainable concrete. A typical embodiment of traditional concrete is prepared in 10 cubic yards batches and comprises 511 lbs of hydraulic cement per cubic yard of concrete and possesses a GWP of 21 1 kg CO2 per cubic yard of concrete. The exemplary embodiment represents a sustainable concrete mix design prepared for a 10 cubic yard batch of concrete in which 40 wt%, of hydraulic cement has been replaced with the biomincral supplemental blend with no changes to any other typical mix design parameters (i.e. paste-to-aggregate ratio, water-to-cement ratio, etc.), and possesses a GWP of -3 kg CO2 per cubic yard of concrete. The biomineral supplemental blend represents a carbonsequestering, or carbon removal, pathway to offset more than 100% of the embodied carbon produced in a traditional concrete mix design produced at commercial batch scales. As disclosed herein, the term ‘pastc-to- aggregate ratio’ (P:A) refers to the ratio of the weight of the cementitious paste (including but not limited to cement, supplementary cementitious materials, OPC, biochar, pozzolan, biomineralized algae, oolitic aragonite, water, and any additives or admixtures) to the total volume or weight of aggregate in a concrete mixture. The aggregate may include coarse aggregates such as gravel, crushed stone, recycled concrete aggregate, or expanded clay, as well as fine aggregates such as natural sand, manufactured sand, and silica sand. The P:A ratio can be determined by the user based on the desired properties of the concrete and generally ranges from 0.1 to 0.4.

[0063] The wet sustainable concrete can then be poured into a mold, form, or other conventional concrete framework, and cured to form the dried sustainable concrete. If a concrete masonry unit (CMU), paver, or other precast or concrete manufactured good is produced utilizing the biomineral supplemental blend, the produced unit is cured at 10 to 125 °C and 25 to 95 % relative humidity for 1 to 72 hours then stored under ambient conditions for 1 to 56 days.Example #2

[0064] This example was conducted to demonstrate one exemplary embodiment of a method to manufacture the sustainable concrete described herein.

[0065] The compressive strength (PSI) performance of a 4” x 8” cylinder over a 28-day period of performance was tested and described in FIG 1. The cylinder cement paste comprises 60% hydraulic cement and 40% biomincral supplemental blend at a paste-to-aggregate ratio of approximately 0.20. The dotted line represents the end users targeted compressive strength specification at 28-days aging of the concrete for use as in floor slab applications.Example #3

[0066] The resulting compressive strength (PSI) performance of 4” x 8” cylinders at 7-, 14-, and 28-day curing times was tested and described in FIG 2. Each cylindercomprises a cement paste of 60% hydraulic cement and 40% biomineral supplemental blend at a paste-to-aggregate ratio of 0.20. Each cylinder grouping represents a different biochar and / or bio-fly ash utilized in the biomincral supplemental blend, while holding all other blend constituents constant. The dotted and square lines represent the ash content and residual organic content present in the biochar and / or bio-fly ash used, respectively.Example #4

[0067] Inorganic analyses, based on X-ray fluorescence (XRF) and X-ray diffraction (XRD), of the biochar and / or bio-fly ash utilized in the formulation of the cylinders described and utilized in FIG 2, arc described in FIG. 3. Each bar represents the weight percent of the identified inorganic oxide present in the inorganic ash content of the biochar and / or bio-fly ash, also described in FIG 3.

[0068] As defined herein, hydraulic cement comprises calcium (from limestone), silica, alumina, and iron (from clay / shalc) and added gypsum to control setting. It forms complex hydrates when mixed with water that give it strength and durability, even in wet environments.

[0069] While the invention has been described with reference to some embodiments, it will be understood by those skilled in the art that various changes may be made, and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiments disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.

Claims

CLAIMSWhat is claimed is:

1. A sustainable concrete composition comprising: a biomineral supplemental blend capable of replacing hydraulic cement in a concrete mix design, where the biomineral supplemental blend comprises a biomincralizcd algae, a pozzolan, biochar and / or bio-fly ash; hydraulic cement, where mixing the hydraulic cement with the biomineral supplemental blend and liquid media creates a sustainable cement; and an aggregate, where the aggregate comprises sand and / or rock.

2. The biomincral supplemental blend composition of Claim 1, where the aggregate further comprises a secondary binder; where the secondary binder comprises a biochar, bio-fly ash, pozzolan, slag, fly ash, coal ash, or a combination thereof.

3. The biomineral supplemental blend composition of Claim 1, where the biomineral supplemental blend further comprises a three-quarter minus rock or smaller, calcium carbonate, oolitic aragonite, or other aggregate mineral filler.

4. The biomineral supplemental blend composition of Claim 1 , where the biomineralized algae comprises a primary binder; where the primary binder has the same chemical composition as the secondary binder.

5. The biomineral supplemental blend composition of Claim 4, where the primary binder and the secondary binder each comprise calcium carbonate.

6. The biomineral supplemental blend composition of Claim 1, where the pozzolan comprises silicon dioxide, aluminum oxide and iron oxide, and is pursuant to pozzolans as described in ASTM C618 (standard specification for coal fly ash and raw or calcined natural pozzolan), ASTM Cl 697 (standard specification for blended supplementary cementitious materials), and / or ASTM C311 (standard test methods forsampling and testing fly ash or natural pozzolans for use in Portland-cement concrete), and where the pozzolan is present in the biomineral supplemental blend composition in an amount of 5 to 40 wt%.

7. The biomineral supplemental blend composition of Claim 6, where the silicon dioxide is present in an amount of 40 to 80 wt%, the aluminum oxide is present in an amount of 5 to 45 wt%, and the iron oxide is present in an amount of 0.05 to20 wt%, based on a total weight of the pozzolan.

8. The sustainable concrete composition of Claim 3, where the three-quarter minus rock or smaller is present in an amount of 50 to 95 wt%, based on a total weight of the sustainable concrete composition.

9. The sustainable concrete composition of Claim 1, where the sand is present in an amount of 50 to 95 wt%, based on a total weight of the sustainable concrete composition.

10. The biomincral supplemental blend composition of Claim 1, where the biochar and / or bio-fly ash is present in an amount of 0.01 to 49 wt%, based on a total weight of the biomineral supplemental blend composition.

11. The sustainable cement composition of Claim 1, where the hydraulic cement comprises a Portland cement, an ASTM C150 Portland Cement, an ASTM C150- 07 Portland Cement, an ASTM C595 blended hydraulic cement, an ASTM Cl 157 blended hydraulic cement, C109 / C109M hydraulic cement mortar, Cl 14 hydraulic cement, C151 / C 15 IM hydraulic cement, C 183 / C 183M hydraulic cement, C l 85 hydraulic cement, C191 hydraulic cement, C204 hydraulic cement, C219 hydraulic cement, C226 hydraulic cement, C266 hydraulic cement, C451 hydraulic cement, C452 hydraulic cement, C465 hydraulic cement, C563 hydraulic cement, C 1038 / C 1O38M hydraulic cement, C1702 hydraulic cement, C1778 hydraulic cement and mixtures thereof.

12. A method of manufacturing a transportable dry composition comprising: blending a microorganism package; mixing a biomineralized algae with a silica source, pozzolan, biochar and / or bio-fly ash, a cementitious material, and inert filler to form a biomineral supplemental blend; mixing the biomineral supplemental blend with a hydraulic cement and / or liquid media to form a sustainable cement, and mixing the sustainable cement with an aggregate, liquid media, cementitious material(s), filler material(s), admixtures, and / or hydraulic cement to form a sustainable concrete.

13. The method of Claim 12, wherein the biomineral supplemental blend is formed at a first site and where the sustainable cement and / or sustainable concrete are formed at a second site different from the first site.

14. The method of Claim 12, further comprising pouring the sustainable cement and / or sustainable concrete into a mold to form an article.

15. The method of Claim 12, further comprising curing the sustainable cement and / or sustainable concrete, where the curing of the bio-concrete is conducted at a temperature of 10 to 125°C and 25 to 95 % relative humidity for 1 to 72 hours.

16. The method of Claim 12, wherein the cementitious material comprises slag, coal ash, fly ash, pozzolan, calcined clays, metakaolin, kaolin, silica fume, vaterite calcined clays, limestone calcined clays, burnt clays, concrete waste materials, recycled cement materials, recycled concrete materials, hydrated lime, calcium hydroxide, magnesium hydroxide, polymeric materials, and mixtures thereof.

17. The method of Claim 12, wherein the filler material comprises manufactured limestone, dolomite, and magnesite, harvested limestone, dolomite, and magnesite, mined and / or quarried limestone, dolomite, and magnesite, silicon dioxide,sodium bicarbonate, sodium carbonate, olivine, magnesium silicates, carbonaceous materials (such as carbon black, single walled nanotubes (SWNTs), graphene, carbon nanotubes, etc.), polymeric materials, and mixtures thereof.

18. The method of Claim 12, wherein the biochar and / or bio-fly ash comprises low ash content having >70% residual organic content within the material, medium ash content having between 30% and 70% residual organic content within the material, high ash content having < 30% residual organic content within the material, and mixtures thereof; wherein inorganic oxides of the ash content of the biochar and / or bio-fly ash may comprise calcium oxide, silicon dioxide, aluminum oxide, and / or ferric oxide in crystalline or amorphous phases, as well as other inorganic oxides, such as magnesium oxide, potassium oxide, phosphates, sulfates, titanium dioxide, and chlorides.

19. The method of Claim 12, wherein the biochar and / or bio-fly ash is produced from sources comprising wood, rice husk, sunflower, wastewater sludge, biosolids, sewage sludge, municipal solid waste (MSW), agricultural solid waste, agrowaste, algae, algae waste, plants, plant waste, and mixtures thereof.

20. The method of Claim 12, wherein the biochar and / or bio-lly ash further comprises volcanic ash, tephra, and mixtures thereof.

21. The method of Claim 12, wherein the biomineral supplemental blend is cultivated, extracted from, or otherwise generated from coccolithophores, electrolysis of sea and / or ocean water, harvesting of oolitic aragonite, residual algae waste streams, and / or the biomineral supplemental blend further comprises microalgae, cyanobacteria, and / or other organisms.

22. The method of Claim 12, wherein the transportable dry composition comprises cement and concrete admixtures, such as accelerators, hardeners, pore reducers, air entraining admixtures, water reducers, superplasticizers, gas forming agents,shrinkage reducers, bonding admixtures, retarders, dyes, pigments, other commonly employed chemical and physical admixtures, and mixtures thereof.

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