Integrated CO2 Capture in Cement Production
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Solution Overview
Problem
The cement and lime production processes release significant amounts of carbon dioxide, which is typically vented into the atmosphere, contributing to greenhouse gas emissions.
Innovation Solution
The integration of carbon dioxide capture and utilization methods, where CO2 is concentrated from flue gases and reintegrated into cement and concrete manufacturing processes, forming stable carbonate products and reducing overall emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If carbon dioxide is captured from flue gases and reintegrated into cement manufacturing processes, then carbon dioxide emissions are reduced and stable carbonate products are formed, but the process complexity and equipment requirements increase
Solution Approach 1:
The patent converts the harmful carbon dioxide emissions from cement manufacturing into a beneficial resource by reintroducing it into the manufacturing process. The CO2 reacts with calcium-containing materials to form stable carbonate products, effectively sequestering the emissions while creating valuable building materials. This transforms the waste stream into a useful component of the production process.
Solution Approach 2:
The patent implements a multi-functional system where the same cement manufacturing facility serves both as a source of CO2 emissions and as a location for CO2 utilization. The captured CO2 is used both for carbonation reactions to form carbonates and for cooling concrete mixes, allowing one process to fulfill multiple functions and reducing the need for separate facilities.
2Productivity
If carbon dioxide is transported from cement facilities to building material production facilities, then CO2 utilization efficiency increases, but transportation costs and energy consumption increase
Solution Approach 1:
The patent merges the CO2 capture process with the building material production process by locating both operations at the same facility. The cement manufacturing facility that generates CO2 emissions also houses the building material production line that utilizes the CO2, eliminating the need for external transportation infrastructure and reducing energy costs associated with moving CO2 between separate locations.
3Object-generated harmful factors
If higher concentrations of carbon dioxide are used in building material production, then the effectiveness of carbon sequestration increases, but the cost of CO2 concentration and separation increases
Solution Approach 1:
The patent implements a self-service system where the cement manufacturing process itself provides the concentrated CO2 stream needed for carbonation. The flue gas from the kiln, which naturally contains high concentrations of CO2 (14-33% by volume), is directly utilized without requiring external concentration or purification facilities. The process uses its own waste stream as the feedstock, eliminating the need for additional separation equipment or external CO2 sources.
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 effectively sequesters carbon dioxide, reduces transportation and energy costs, and enhances the efficiency of carbon dioxide utilization in building materials production.
Implementation Method 1
incorporating the carbon dioxide into building products and other products that incorporate a mineral binder, e.g., a cement binder such as Portland cement, that provides minerals, e.g. calcium, magnesium, sodium, and/or potassium minerals such as CaO, MgO, Na2O, and/or K2O that react with the carbon dioxide to form carbonate (CO2) bonded products
Implementation Method 2
Alternative or additional uses of the carbon dioxide include cooling concrete mixes, e.g., with liquid carbon dioxide
Implementation Method 3
treating process water, for example, to adjust pH to an acceptable level
Data Source
AI summary
A method/system for sequestering carbon dioxide from cement and lime production facilities wherein carbon dioxide from flue gases originating from cement or lime production facilities is recovered and transported to a building materials production facility where it is sequestered.