Concrete Mix Carbonation With Feedback-Controlled CO₂ Delivery
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Solution Overview
Problem
There is a need for methods and compositions to contact cement mixes with carbon dioxide and for cement mixes containing incorporated carbon dioxide and carbonation products, addressing the growing concern of greenhouse gases such as carbon dioxide.
Innovation Solution
A method and apparatus for carbonating cement mixes by monitoring characteristics such as mass, location, carbon dioxide content, temperature, and rheology during mixing, and modulating the exposure to carbon dioxide using sensors and controllers to achieve an efficiency of carbonation of at least 60%, with the use of pure carbon dioxide in gas, liquid, or solid forms, including dry ice, to form stable or metastable carbon dioxide products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If carbon dioxide is contacted with cement mix during mixing, then carbonation efficiency is improved, but control precision of carbonation process deteriorates
Solution Approach 1:
The patent implements a feedback control system that monitors carbon dioxide content, temperature, and other parameters during mixing, and automatically adjusts carbon dioxide flow rate and mixing speed to maintain optimal carbonation efficiency while preventing overshoot and ensuring precise control of the carbonation process
Solution Approach 2:
The patent employs dynamic adjustment of mixing speed and carbon dioxide flow rate based on real-time sensor feedback, allowing the system to adapt to changing mix composition and carbonation progress, thereby achieving both high efficiency and precise control throughout the mixing process
2Manufacturing precision
If multiple characteristics are monitored during mixing, then control precision is improved, but device complexity increases
Solution Approach 1:
The patent employs a multi-functional control system that integrates sensors for monitoring carbon dioxide content, temperature, humidity, and mix composition into a single centralized control unit, which processes all inputs and coordinates adjustments of carbon dioxide flow and mixing speed, thereby achieving precise multi-parameter control without proportionally increasing system complexity
Solution Approach 2:
The patent combines multiple monitoring functions and control actions into an integrated system where sensors, controllers, and actuators work together as a unified carbonation control system, reducing overall system complexity while maintaining the ability to precisely monitor and adjust multiple characteristics simultaneously
3Productivity
If carbon dioxide flow rate is increased, then carbonation efficiency is improved, but energy consumption increases
Solution Approach 1:
The patent employs periodic or pulsed delivery of carbon dioxide during the mixing process, coordinated with variations in mixing speed, which enhances carbonation efficiency by ensuring adequate contact time and reaction conditions while reducing overall energy consumption compared to continuous high-flow rate delivery
Solution Approach 2:
The patent dynamically adjusts carbon dioxide flow rate and mixing speed based on real-time monitoring of carbonation progress and mix conditions, optimizing the balance between carbonation efficiency and energy consumption by applying higher flow rates only when and where needed rather than maintaining constant high flow throughout the process
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 efficient carbonation of cement mixes, retaining carbon dioxide and forming stable carbon dioxide products, enhancing the strength and stability of cement mixes while sequestering carbon dioxide.
Implementation Method 1
contacting a cement mix comprising cement binder and aggregate in a mixer with carbon dioxide
Implementation Method 2
monitoring a characteristic of the cement binder, the cement mix, a gas mixture in contact with the cement mix or the mixer, or a component of the cement mix apparatus
Implementation Method 3
contacting a cement mix comprising cement binder and aggregate in a mixer with carbon dioxide
Data Source
AI summary
The invention provides compositions and methods directed to carbonation of a cement mix during mixing. The carbonation may be controlled by one or more feedback mechanisms to adjust carbon dioxide delivery based on one or more characteristics of the mix or other aspects of the mixing operation.