Ejector-Based Carbonation Curing of Pre-Cast Cement

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Solution Overview

Problem

Existing accelerated carbonation curing systems for pre-cast cementitious structures require costly compressors and pumps to compress lesser-pressure carbon dioxide streams to match the pressure of greater-pressure steam, introducing energy consumption and maintenance needs.

Innovation Solution

Incorporating an ejector that utilizes the Venturi effect to combine lesser-pressure carbon dioxide streams with greater-pressure steam, eliminating the need for compression by creating a vacuum that draws the carbon dioxide stream into the steam stream, thus forming a high-pressure mixed stream without additional components or moving parts.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If compressors or pumps are used to compress carbon dioxide streams to match steam pressure, then the carbon dioxide can be combined with steam for curing, but the system becomes costly, energy-consuming, and requires maintenance of moving parts

Engineering Contradiction:

Improveability to combine carbon dioxide and steam streamsVSAvoidpresence of compressors and pumps with moving parts

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent removes the compressors and pumps from the system entirely, extracting the problematic moving parts that required maintenance. Instead, it uses a stationary ejector device that relies on fluid dynamics (Venturi effect) to achieve stream combination without mechanical compression components.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the mechanical compression system (compressors/pumps with moving parts) with a fluid dynamics-based system (ejector using Venturi effect). The high-pressure steam itself performs the work of drawing in and mixing with the low-pressure carbon dioxide stream through pressure differential and fluid entrainment, eliminating the need for mechanical compression devices.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Stress or pressure

If compressors or pumps are used to compress carbon dioxide streams, then the required pressure for curing is achieved, but large amounts of energy are consumed

Engineering Contradiction:

Improvepressure of carbon dioxide streamVSAvoidenergy consumption of compressors

Core Design Contradiction:

Stress or pressureVSUse of energy by moving object

Solution Approach 1:

The system uses the high-pressure steam stream itself to perform the work of pressurizing and mixing the carbon dioxide. The steam's own pressure energy is utilized to create the vacuum that draws in the CO2 and to pressurize the mixed stream, eliminating the need for external energy input through compressors.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent uses pneumatic principles (Venturi effect) where the high-velocity steam flow creates a pressure differential that automatically draws in and pressurizes the carbon dioxide stream. This fluid-based pressure transmission replaces mechanical compression, significantly reducing energy consumption.

Inventive Principle:

Principle #29Pneumatics and hydraulics

3Stress or pressure

If compressors are used to compress carbon dioxide streams, then the streams can be combined at matching pressures, but costly equipment is required

Engineering Contradiction:

Improvepressure matching between carbon dioxide and steamVSAvoidcost of compressors and pumps

Core Design Contradiction:

Stress or pressureVSEase of manufacture

Solution Approach 1:

The patent replaces expensive, maintenance-prone compressors with a simple, stationary ejector device that has no moving parts. The ejector is a much cheaper component that achieves the same pressure-matching function through fluid dynamics rather than mechanical compression.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 enhances the efficiency of accelerated carbonation curing by eliminating the need for compressors and pumps, reducing energy consumption and maintenance, while maintaining effective curing pressures and carbon dioxide concentrations for pre-cast cementitious structures.

Implementation Method 1

the ejector relies on the Venturi effect in which a vacuum is created by the passing of the greater-pressure steam through the ejector

Methodology Applied

Scientific EffectVenturi effect: Venturi Effect

Implementation Method 2

The vacuum produced by the greater-pressure steam passing through the ejector may be sufficient to draw the lesser-pressure carbon dioxide containing stream into the greater-pressure steam

Methodology Applied

Scientific EffectPressure differential-driven mixing:

Data Source

PatentUS11254028B2Systems and processes for accelerated carbonation curing of pre-cast cementitious structures

Publication Date: 2022.02.22 SAUDI ARABIAN OIL CO

AI summary

Systems for accelerated carbonation curing of a pre-cast cementitious structure may include an ejector and a curing chamber downstream of the ejector. The ejector may be operable to combine a lesser-pressure carbon dioxide containing stream from a carbon dioxide source with a greater-pressure steam to produce a mixed stream including at least steam and carbon dioxide. The mixed stream may have a pressure greater than the pressure of the lesser-pressure carbon dioxide containing stream. The curing chamber may be operable to receive the mixed stream from the ejector and contact the mixed stream with the pre-cast cementitious structure to cure the pre-cast cementitious structure. Processes for accelerated carbonation curing of pre-cast cementitious structures using the systems are also disclosed.