CO2-Emulsified Concrete for Faster Carbonation Curing
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Solution Overview
Problem
Conventional cement curing processes are diffusion-limited and inefficient, leading to slow reaction rates and low CO2 utilization in forming CaCO3, which is crucial for reducing atmospheric CO2.
Innovation Solution
A concrete emulsion composition is formed by mixing cement, aggregate, and water, then emulsified with liquid or supercritical CO2, maintaining pressure and temperature to enhance CO2 dispersion and reaction, potentially incorporating additives for improved properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If conventional steam curing is used, then cement hydration proceeds, but the process is diffusion-limited and slow
Solution Approach 1:
The patent changes the physical state of CO2 from gas to liquid or supercritical phase, which fundamentally alters the transport mechanism from diffusion-limited to convection-enhanced, thereby accelerating the curing rate and reducing curing time
Solution Approach 2:
The patent uses liquid or supercritical CO2 under pressure to penetrate the cement matrix, utilizing fluid dynamics and pressure-driven flow to overcome the diffusion limitation of gaseous CO2, thus speeding up the carbonation curing process
2Productivity
If gaseous CO2 is used for curing, then CO2 is provided to cement, but only a small percentage is reacted due to diffusion limitations
Solution Approach 1:
The patent changes CO2 from gaseous to liquid or supercritical state, increasing its density and solubility, which enables much higher CO2 uptake by the cement matrix and improves overall utilization efficiency while reducing waste
Solution Approach 2:
The patent uses liquid or supercritical CO2 as an intermediary medium that facilitates enhanced mass transfer into the cement pores, acting as a carrier that delivers CO2 more effectively than gaseous CO2, thereby improving reaction efficiency
3Productivity
If liquid or supercritical CO2 is emulsified into concrete, then CO2 dispersion and reaction are enhanced, but process complexity increases
Solution Approach 1:
The patent utilizes phase transitions of CO2 (between liquid, supercritical, and gaseous states) controlled by pressure and temperature changes to achieve enhanced dispersion and reaction, leveraging the natural properties of CO2 rather than requiring complex external equipment
Solution Approach 2:
The patent allows the CO2-emulsion composition to self-disperse and self-react within the cement matrix through controlled phase behavior, reducing the need for complex external processing equipment while maintaining high reaction rates
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 accelerates cement curing, achieving high compressive strength within hours and days, with enhanced CO2 uptake and utilization, suitable for wellbore treatment and 3D printing applications.
Implementation Method 1
emulsifying the hydrated concrete composition with liquid or supercritical CO2
Implementation Method 2
dispersed in the cement emulsion composition
Implementation Method 3
curing concrete in a CO2 environment to make use of the cement hydration byproduct Ca(OH)2 to form CaCO3
Data Source
AI summary
A concrete emulsion comprising a cement, aggregate, water, and carbon dioxide is provided. The carbon dioxide may be liquid or supercritical and is dispersed in the concrete emulsion composition. A method of producing a concrete emulsion composition is also provided. The method includes mixing a cement, aggregate, and water to form a hydrated concrete composition, and emulsifying the hydrated concrete composition with liquid or supercritical CO2. An article comprising the concrete emulsion composition is provided. Further, a method of treating a wellbore comprising producing a concrete emulsion composition and pumping the concrete emulsion composition into a wellbore, and a method of manufacturing an article comprising producing a concrete emulsion composition and 3D printing the concrete emulsion composition are also provided.