CO2-Sequestering Carbonate Drywall via Segmented Processing
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Solution Overview
Problem
Carbon dioxide emissions contribute significantly to global warming and ocean acidification, necessitating effective methods for CO2 sequestration in building materials to mitigate climate change impacts.
Innovation Solution
A method for producing drywall and paver products that incorporate a sequestered-CO2 component, where CO2 is processed with water to form carbonates and bicarbonates, which are then concentrated and integrated into the material composition, along with additional additives for enhanced properties, to create building materials with reduced carbon footprints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If CO2 is processed with water to form carbonates and bicarbonates for sequestration in building materials, then CO2 emissions are reduced and environmental benefits are achieved, but the manufacturing process complexity increases
Solution Approach 1:
The manufacturing process is divided into distinct stages: (1) processing waste gas stream with process water to produce original composition, (2) removing process water to produce concentrated composition, (3) producing drywall slurry mixture, and (4) depositing between backing material sheets. This segmentation allows each stage to be optimized independently while managing overall process complexity.
Solution Approach 2:
The patent uses an intermediary concentrated composition as a bridge between the original composition and the final drywall product. This intermediary form facilitates controlled incorporation of CO2-derived carbonates into the building material matrix, enabling sequestration while maintaining manufacturing feasibility.
2Quantity of substance
If process water is removed from the original composition to produce concentrated composition, then CO2 sequestration efficiency is improved, but energy consumption for water removal increases
Solution Approach 1:
The patent employs parameter changes in the water removal process, concentrating the original composition to produce a concentrated composition with at least 25% solids, preferably at least 50% solids. By adjusting the concentration parameter, the process achieves effective CO2 sequestration while managing energy requirements through controlled evaporation or drying.
3Quantity of substance
If high concentration of carbonates and bicarbonates is achieved in the drywall slurry mixture, then CO2 sequestration capacity is enhanced, but the difficulty of processing and forming the material increases
Solution Approach 1:
The patent performs preliminary concentration of the carbonate-containing composition before forming the final drywall product. By removing process water in advance to produce a concentrated composition, the subsequent slurry formation and deposition steps become more manageable, reducing processing difficulty while maintaining high CO2 sequestration capacity.
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 resulting building materials effectively sequester CO2, reducing atmospheric CO2 levels and offering improved physical properties such as increased compressive strength and reduced carbon footprints, while maintaining long-term stability and minimizing CO2 release over their lifespan.
Implementation Method 1
processing a waste gas stream comprising carbon dioxide with a process water to produce an original composition comprising carbonates, bicarbonates, or a combination of carbonates and bicarbonates
Implementation Method 2
removing at least a portion of the process water from the original composition to produce a concentrated composition
Implementation Method 3
concentrating the original composition to dryness to produce a dry composition
Data Source
AI summary
Formed building materials comprising a sequestered CO2 are provided. The building materials of the invention include a composition comprising a carbonate/bicarbonate component. Additional aspects of the invention include methods of making and using the formed building materials.