Carbonated Supplementary Cementitious Material for Lower-Clinker Cement
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Solution Overview
Problem
There is a need for more sustainable industrial processes with reduced carbon emissions, efficient carbon dioxide capture, enhanced cement hydration reaction, improved compressive strength development, reduced use of clinker, and faster setting times in concrete, mortar, and cement production, while utilizing waste flue gas from industrial activities.
Innovation Solution
A method involving the production of a supplementary cementitious material (SCM) by mixing particulate mineral material with water, milling the mixture in the presence of carbon dioxide at concentrations greater than 8 vol%, and drying the slurry to form SCM, which captures and stores carbon dioxide, enhancing cement hydration and reducing clinker use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If carbon dioxide is captured during SCM production, then carbon emissions are reduced, but the process complexity increases
Solution Approach 1:
The patent combines the carbonation process with the existing SCM production process by introducing CO2 during the milling operation. This merges two functions (SCM production and carbon capture) into a single integrated process flow, reducing overall system complexity while achieving dual objectives of material production and emissions reduction.
Solution Approach 2:
The process uses waste CO2 from industrial flue gases as a raw material input for SCM production. This self-service approach converts harmful emissions into a useful resource, eliminating the need for separate carbon capture infrastructure and reducing process complexity through resource utilization.
2Productivity
If CO2 concentration is increased during milling to enhance carbon capture, then carbon dioxide capture efficiency improves, but energy consumption increases
Solution Approach 1:
The patent optimizes the CO2 concentration parameter during milling to achieve effective carbonation at practical energy levels. By carefully controlling the CO2 concentration (greater than 8 vol%) and milling conditions, the process achieves high carbon capture efficiency without excessive energy input, balancing productivity and energy consumption.
3Object-affected harmful factors
If clinker usage is reduced to improve sustainability, then carbon emissions decrease, but compressive strength development may be compromised
Solution Approach 1:
The patent creates a composite SCM product by combining mineral material with carbonated phases formed during milling. This composite structure provides both the sustainability benefits of reduced clinker usage and the mechanical strength required for construction applications, achieving dual performance targets through material composition rather than quantity alone.
4Productivity
If setting time is reduced to increase production cycles per day, then productivity improves, but the quality of cement hydration may be compromised
Solution Approach 1:
The carbonation process performs preliminary chemical modification of the mineral material during milling, creating pre-reacted phases that accelerate subsequent hydration. This preliminary action reduces setting time and increases production cycles while maintaining hydration quality, as the pre-carbonated material provides ready-to-react sites for cement hydration without compromising the overall hydration process.
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 method effectively captures carbon dioxide, enhances cement hydration, increases compressive strength, reduces setting time, and decreases clinker usage, while utilizing waste flue gas, resulting in a more efficient and sustainable construction material production process.
Implementation Method 1
milling the mixture in the presence of carbon dioxide to form a slurry, wherein the concentration of carbon dioxide is greater than about 8 vol %
Implementation Method 2
The method effectively captures carbon dioxide, enhances cement hydration, increases compressive strength, reduces setting time, and decreases clinker usage
Implementation Method 3
drying the slurry to form the SCM
Implementation Method 4
enhances the cement hydration reaction in concrete, mortar or cement
Data Source
AI summary
The invention relates to a method of producing a supplementary cementitious material (SCM) comprising:a) providing a particulate mineral material;b) mixing the mineral material with water to form a mixture;c) milling the mixture in the presence of carbon dioxide to form a slurry, wherein the concentration of carbon dioxide is greater than about 8 vol %; and;d) drying the slurry to form the SCM.