CO2 Curing of Calcium Silicate Precast Concrete
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Solution Overview
Problem
The cement industry faces challenges with high energy consumption and significant greenhouse gas emissions due to traditional Portland cement manufacturing, and existing precast concrete production technologies are not optimal in terms of economics and environmental impact, particularly regarding energy use and carbon footprint.
Innovation Solution
The development of novel apparatus and processes for gas flow and conditioning to achieve optimal CO2 curing of composite materials with solid or hollow interior structures, using carbonatable calcium silicate cements that react with carbon dioxide to reduce emissions and energy consumption, and improve product quality and scalability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional Portland cement manufacturing is used, then concrete products can be produced with established strength and durability, but energy consumption and greenhouse gas emissions increase significantly
Solution Approach 1:
The patent changes the chemical composition parameters of cement by using carbonatable calcium silicate materials (such as calcium silicate, calcium aluminate, or calcium aluminosilicate) instead of traditional Portland cement. This parameter change enables the curing process to occur at lower temperatures through CO2 reaction, significantly reducing energy consumption while maintaining concrete strength and durability through the formation of calcium carbonate and calcium silicate hydrate phases.
2Reliability
If traditional Portland cement manufacturing is used, then concrete products can be produced with established strength and durability, but greenhouse gas emissions increase significantly
Solution Approach 1:
The patent converts CO2, traditionally a harmful greenhouse gas, into a beneficial curing agent for concrete. By introducing CO2 during the curing process, it reacts with carbonatable calcium silicate materials to form calcium carbonate, thereby sequestering CO2 and reducing greenhouse gas emissions while simultaneously achieving concrete strength development through the carbonation reaction.
3Manufacturing precision
If uniform CO2 curing is achieved throughout the precast object, then product quality and properties are improved, but gas flow control system complexity increases
Solution Approach 1:
The patent segments the gas flow control system into multiple independent circulation loops, each equipped with its own gas source and circulation capabilities. This segmentation allows each loop to independently control CO2 distribution in different regions of the precast object, achieving uniform curing throughout the entire object while maintaining manageable system complexity through modular design.
4Manufacturing precision
If gas circulation systems are used to achieve uniform curing, then product quality improves, but equipment complexity and cost increase
Solution Approach 1:
The patent designs gas circulation systems that can handle multiple functions: CO2 injection, gas circulation, temperature control, and humidity management. By creating multi-functional equipment that performs several operations simultaneously, the system achieves uniform curing and improved product quality without proportionally increasing equipment complexity and cost.
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 more efficient and cost-effective production of precast concrete products with a reduced carbon footprint, achieving uniform curing and improved properties through controlled gas circulation systems, allowing for longer production lengths and flexible equipment use.
Implementation Method 1
CO2 is needed to react with the carbonatable calcium silicate materials during the curing process to form concrete products
Implementation Method 2
control over rate limiting steps in water removal
Implementation Method 3
passing the gas at the second condition through a primary gas conditioning system to restore the gas to its first condition
Implementation Method 4
passing the gas at a first flow rate over a heating unit to increase the temperature of the gas
Implementation Method 5
flowing the gas through a dehumidification unit, at a second flow rate to reduce the relative humidity
Implementation Method 6
flowing the gas over a surface of the precast object inside the envelope
Data Source
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AI summary
The invention provides novel apparatus and processes for gas flow and conditioning to achieve optimal CO2 curing of articles of composite materials (e.g., precast objects made of carbonatable calcium silicate-based cements), with solid interior or having hollow interior ducts, channels and chambers or otherwise being hollowed out, as well as the precast objects so made, which are suitable for a variety of applications in construction, pavements and landscaping, and infrastructure.