Active Flow-Through Carbonation Chamber for Concrete CO2 Sequestration
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Solution Overview
Problem
Current carbonation curing systems for concrete manufacturing are energy-intensive and require extended curing cycles due to their reliance on closed loop processes and external heating, which hampers CO2 sequestration efficiency and concrete performance.
Innovation Solution
An active flow-through carbonation chamber system with self-sensing instrumentation that adjusts gas processing conditions in real-time, using a gas conditioning apparatus with heat exchangers, blowers, and chillers to optimize CO2 sequestration efficiency and concrete performance by controlling temperature, humidity, and gas flow rate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If closed loop process control with external heating systems is used to enhance carbonation kinetics, then CO2 sequestration efficiency is improved, but energy demand and curing cycle duration increase
Solution Approach 1:
The system uses the concrete's own thermal mass and the exothermic heat from carbonation reactions to maintain optimal curing conditions. The self-sensing instrumentation detects internal temperature and humidity, allowing the system to harness the concrete's inherent properties rather than relying on external heating systems, thereby reducing energy demand while maintaining CO2 sequestration efficiency.
Solution Approach 2:
The system dynamically adjusts gas flow rate, temperature, and humidity parameters based on real-time sensor feedback from the concrete's internal conditions. By changing these parameters adaptively rather than maintaining constant conditions, the system optimizes carbonation kinetics while minimizing energy consumption, resolving the contradiction between productivity and energy use.
2Productivity
If closed loop process control with external heating systems is used to enhance carbonation kinetics, then CO2 sequestration efficiency is improved, but curing cycle duration increases
Solution Approach 1:
The system leverages the concrete's own thermal properties and the heat generated during carbonation to maintain optimal curing conditions without external heating. This self-sustaining approach accelerates the carbonation process and shortens curing cycle duration while maintaining high CO2 sequestration efficiency.
Solution Approach 2:
The flow-through chamber system maintains continuous CO2 gas flow and optimal environmental conditions throughout the curing process, eliminating the need for extended drying steps. This continuous action ensures uninterrupted carbonation reactions, thereby reducing overall curing cycle duration while maintaining productivity.
3Device complexity
If constant processing conditions are maintained during curing time, then system simplicity is preserved, but CO2 sequestration efficiency and concrete performance are suboptimal
Solution Approach 1:
The self-sensing instrumentation system continuously monitors temperature, humidity, and other critical parameters within the concrete, providing real-time feedback to the control system. This feedback mechanism enables dynamic adjustment of processing conditions to optimize CO2 sequestration efficiency and concrete performance, while the automated nature of the system keeps the overall complexity manageable.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces energy demand, shortens carbonation curing cycles, and enhances material performance by optimizing processing conditions, thereby improving CO2 uptake and concrete strength while minimizing energy consumption.
Implementation Method 1
a gas conditioning apparatus comprising at least one heat exchanger, at least one blower, and at least one chiller; wherein: the gas conditioning apparatus is configured to condition a CO2-containing gas stream
Implementation Method 2
contacting the conditioned gas with the at least one green body or at least one concrete component, or both, in the flow-through chamber
Data Source
AI summary
Provided herein are active flow-through carbonation curing systems useful for contacting carbon dioxide (CO2) gas streams with concrete materials under ambient pressure. This contacting causes a carbonation reaction in which CO2 forms materials, such as, but not limited to, calcium carbonate (CaCO3). The methods include, but are not limited to, contacting a conditioned flue gas containing CO2 inside of a carbonation chamber with green bodies or concrete components in which flue gas properties such as temperature, relative humidity, flow rate, and flow direction, are self-adjusted during the curing process based on a self-sensing instrumentation system inside a curing chamber and carbonation kinetic regression model. This system improves CO2 capture efficiency and material performance while reducing processing energy.