Carbonated Concrete Composite Process for Chemical Resistance
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Solution Overview
Problem
The construction industry faces challenges in reducing carbon emissions, managing particulate waste, and creating durable concrete composites resistant to corrosive environments, with existing methods failing to effectively utilize carbon dioxide and incorporate waste materials sustainably.
Innovation Solution
A process involving a particulate material with high calcium, magnesium, aluminum, or iron content, combined with a primary additive like citric acid or sodium gluconate, and carbonation in the presence of carbon dioxide, to form a denser, more durable concrete composite that traps carbon dioxide and utilizes waste materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional concrete composites are used in corrosive environments, then initial structural integrity is achieved, but durability and chemical resistance deteriorate over time due to degradation from de-icing salt, rain, sunshine, heat, frost, natural carbonation, and seawater
Solution Approach 1:
The patent applies parameter changes by controlling the carbonation process through feedback mechanisms that adjust carbon dioxide delivery based on mix characteristics. The carbonation level is optimized to transform calcium hydroxide into calcium carbonate, which significantly improves chemical resistance and durability against corrosive environments while maintaining structural integrity
Solution Approach 2:
The patent converts harmful carbon dioxide emissions into a beneficial substance by using them as the carbonation agent. The CO2 that would otherwise contribute to climate change is utilized to carbonate the concrete mix, forming protective calcium carbonate that enhances durability and resistance to chemical degradation from seawater, de-icing salts, and atmospheric carbonation
2Productivity
If carbon dioxide emissions are released into the atmosphere, then industrial processes can proceed, but environmental impact and climate change worsen
Solution Approach 1:
The patent transforms carbon dioxide emissions from a harmful waste product into a valuable raw material for carbonating the concrete mix. By injecting CO2 during mixing and curing, the process captures emissions that would otherwise be released, converting them into calcium carbonate that strengthens the concrete and protects against chemical degradation
Solution Approach 2:
The concrete production process serves its own environmental need by using its own CO2 emissions as a carbonation agent. The system essentially recycles its waste output back into the production process, creating a more sustainable closed-loop system that reduces net emissions while improving product performance
3Ease of manufacture
If particulate waste is disposed of in landfill sites, then waste management is simplified, but landfill space is consumed and environmental pollution increases
Solution Approach 1:
The patent changes the chemical parameters of waste materials by incorporating them into the concrete mix as particulate matter. The waste materials undergo carbonation reactions that transform their chemical composition and properties, converting them from unwanted waste into functional components that contribute to the concrete's matrix and overall performance
Solution Approach 2:
The patent gives multi-functionality to waste materials by using them both as a carbonation substrate (consuming CO2) and as particulate matter that forms part of the concrete's structural matrix. This dual utilization maximizes the value extracted from waste materials while minimizing landfill requirements
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
The process reduces industrial carbon emissions, produces composites with higher compressive strength and chemical resistance, and provides a sustainable solution for corrosive environments, such as seawalls, by densifying the matrix and enhancing material strength.
Implementation Method 1
We believe that the primary additive complexes with metal ions present in the mixture to aid uniform distribution of, and to improve the reaction rate of, the metal ions throughout the mixture and at the surface of the binder particles
Implementation Method 2
The mixture is then carbonated in an atmosphere comprising carbon dioxide... the carbonation reaction forms carbonate minerals that bind the aggregate particles together and/or form a denser matrix in which the aggregate particles are embedded
Implementation Method 3
The resulting composite has a denser matrix and is therefore more resistant to chemical degradation from corrosive environments, such as de-icing salt, heat, frost, acid environments, natural carbonation and seawater
Data Source
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Figure 3
AI summary
The invention relates to a process for producing a composite comprising: a. providing a particulate material, wherein the particulate material comprises minerals having a content of at least 30% m/m of calcium, magnesium, aluminium, silicon, potassium or iron, or a combination of two or more thereof, b. providing an aggregate, c. providing a primary additive, wherein the primary additive comprises a sugar or derivative thereof, a polyol or derivative thereof, an organic acid, an organic acid salt or an inorganic acid, or any combination of two or more thereof, d. mixing the particulate material, the aggregate and the primary additive with water to form a mixture, and e. carbonating the mixture in the presence of carbon dioxide, wherein the concentration of carbon dioxide is greater than about 2 vol%.