Cement Clinker Carbonation for Low-Cost Flue Gas CO2 Sequestration
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Solution Overview
Problem
Current CO2 capture and storage technologies for the cement industry are costly and inefficient, limiting their large-scale industrial application, and there is a need for methods that can effectively capture and utilize carbon dioxide waste at low cost and high efficiency.
Innovation Solution
A method involving the reaction of cement clinker with flue gas in the presence of a reaction accelerator and surfactant to sequester carbon dioxide, followed by solid-liquid separation and drying to produce calcium carbonate microfibers, which are then mixed with gypsum and mineral admixtures to create microfiber-reinforced cement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional CO2 capture technologies (deep saline layer storage, geological storage, chemical method capture) are used, then CO2 can be captured and stored, but the process requires multiple steps (capture, transportation, utilization, storage) resulting in high energy consumption and high cost (300-900 RMB/ton)
Solution Approach 1:
The patent combines CO2 capture and cement production into a single integrated process. The flue gas containing CO2 is directly introduced into the cement kiln where it undergoes carbonation reaction with calcium-based materials during the clinkering process, eliminating the need for separate capture, transportation, and storage steps. This merging of processes dramatically reduces energy consumption and operational complexity while achieving effective CO2 sequestration.
Solution Approach 2:
The cement kiln serves multiple functions simultaneously: it produces cement clinker while also acting as a CO2 capture and storage facility. The calcium-based raw materials in the kiln serve dual purposes as both cement ingredients and CO2 absorbents. This multi-functionality allows the system to achieve both industrial production and carbon mitigation goals without requiring additional dedicated infrastructure.
2Quantity of substance
If conventional CO2 capture technologies are used, then CO2 can be captured, but the cost is high (300-900 RMB/ton) which seriously limits the promotion and application of capture technologies
Solution Approach 1:
The patent combines CO2 capture and cement production into a single integrated process. The flue gas containing CO2 is directly introduced into the cement kiln where it undergoes carbonation reaction with calcium-based materials during the clinkering process, eliminating the need for separate capture, transportation, and storage steps. This merging of processes dramatically reduces energy consumption and operational complexity while achieving effective CO2 sequestration.
Solution Approach 2:
The cement production process itself provides the CO2 capture function. The calcium-based raw materials required for cement manufacturing naturally absorb CO2 during the high-temperature processing, converting it into stable calcium carbonate in the final cement product. This self-service mechanism eliminates the need for external capture facilities and reduces operational costs significantly.
3Object-generated harmful factors
If calcium alternative raw materials (calcium carbide slag, blast furnace slag, steel slag, fly ash) are used to reduce CO2 emissions from raw material decomposition, then CO2 emissions can be reduced, but the blending amount is limited and these materials have insufficient sources and unstable composition which could generate potential bottlenecks
Solution Approach 1:
The patent converts the harmful CO2 emissions from flue gas into a beneficial resource by using it as a carbonation agent during cement production. The CO2 that would otherwise be wasted is transformed into stable calcium carbonate within the cement matrix, effectively sequestering it while enhancing the cement's carbonation resistance and durability. This approach eliminates the reliability issues associated with alternative raw materials by using a consistent, controllable process rather than depending on variable external materials.
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 achieves high-efficiency carbon sequestration, reducing CO2 emissions by 8% to 75% and enhancing mechanical properties of cement, such as increased strength and reduced shrinkage, while being cost-effective and applicable to cement kiln flue gas and other carbon dioxide-emitting enterprises.
Implementation Method 1
reacting the flue gas with a cement clinker thereby sequestering at least a portion of the carbon dioxide from the flue gas in the cement clinker
Implementation Method 2
reacting the flue gas with a cement clinker in the presence of at least one of a reaction accelerator and a surfactant
Implementation Method 3
carrying out solid-liquid separation after the reaction between the flue gas and the solid-liquid suspension slurry thereby forming a solid and a liquid
Implementation Method 4
drying the solid to obtain a separated fibrous solid comprising calcium carbonate microfibers
Data Source
AI summary
A method for sequestating carbon dioxide from flue gas by using a cement clinker. The products of this method can also be used to prepare microfiber-reinforced cement. The method of the present disclosure is capable of capturing and storing carbon dioxide in flue gas, such as cement kiln flue gas.