Building Material Production via Carbonate Precipitate
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Solution Overview
Problem
The cement production industry is a significant source of carbon dioxide emissions, contributing to global warming and ocean acidification, and existing technologies have not effectively addressed this environmental impact.
Innovation Solution
The development of methods to produce building materials using a carbonate precipitate, specifically a carbonate slurry with an undifferentiated pluripotent polymorph precursor, which is processed to create a building material that can sequester CO2, thereby reducing atmospheric emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional cement production methods are used, then building materials with high load bearing capacity can be produced, but significant CO2 emissions are generated
Solution Approach 1:
The patent converts CO2, a harmful emission, into a useful building material component. The process captures CO2 and transforms it into calcium carbonate aggregates through chemical reaction with calcium hydroxide, thereby eliminating the harmful gas while producing construction material with load-bearing capacity.
Solution Approach 2:
The patent changes the chemical parameters of CO2 by transforming it from a gaseous emission into solid calcium carbonate particles. This parameter change from gas to solid material fundamentally alters the state and utility of the substance, converting an environmental hazard into a construction resource.
2Object-generated harmful factors
If CO2 emissions are reduced through sequestration, then environmental impact decreases, but production cost and process complexity increase
Solution Approach 1:
The patent merges the CO2 sequestration process with the building material production process into a single integrated system. The CO2 capture, chemical transformation, and aggregate production occur in one continuous process, eliminating the need for separate emission control infrastructure and reducing overall system complexity.
Solution Approach 2:
The process uses readily available materials (calcium hydroxide from lime kilns or agricultural waste) to capture and transform CO2, making the system self-sufficient. The byproducts of agricultural burning or industrial processes are directly utilized without requiring additional raw material inputs or complex purification systems.
3Object-generated harmful factors
If CO2 is captured and transformed into building materials, then atmospheric CO2 levels decrease, but energy consumption increases
Solution Approach 1:
The patent performs preliminary carbonization of biomass or uses pre-formed calcium hydroxide from lime kilns before the main CO2 capture process. This preliminary action prepares the chemical reactants in advance, reducing the energy required during the actual CO2 transformation process and making the overall system more energy-efficient.
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 enables the production of building materials that not only reduce CO2 emissions but also provide a sustainable alternative to traditional cement, addressing the environmental concerns associated with cement production.
Implementation Method 1
processing the carbonate precipitate, which may be a carbonate slurry, under conditions sufficient to produce the building material
Implementation Method 2
preparing a carbonate precipitate, which may be a carbonate slurry
Data Source
AI summary
Methods of producing a building material are provided. Methods of interest include preparing a carbonate precipitate comprising an undifferentiated pluripotent polymorph precursor (i.e., a polymorph precursor) and processing the carbonate precipitate under conditions sufficient to produce the building material. The disclosed polymorph precursors exist in an intermediate state between an disordered state (e.g., amorphous calcium carbonate (ACC)) and an ordered state (e.g., a polymorph of calcium carbonate or of calcium magnesium carbonate). Aspects of the invention also include building materials (e.g., aggregates) as well as compositions (e.g., concrete dry composites, settable compositions and built structures) that include building materials produced via the subject methods.