CO2-Activated Clinker Binder from MSW Incineration Residues
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Solution Overview
Problem
The production of concrete is energy-intensive and environmentally taxing, contributing significantly to carbon emissions and resource depletion, necessitating the development of sustainable alternatives using municipal solid waste incinerator residues.
Innovation Solution
A process to synthesize a CO2-activated clinker binder from municipal solid waste incinerator residues using a tubular kiln at 1000-1100°C, powered by locally-sourced energy, and combining it with primed bottom ash aggregates to produce building products with rapid binding strength through carbonation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional concrete production is used, then building construction is supported, but carbon emissions and energy consumption increase significantly
Solution Approach 1:
The patent changes the chemical parameters of the binder by using MSW incineration residues instead of conventional cement, and activates the binding strength through carbonation (CO2 treatment) rather than traditional hydraulic curing. This parameter change enables the system to achieve required binding strength while reducing energy consumption in the clinkering process to 1000-1100°C.
Solution Approach 2:
The patent converts the harmful CO2 emissions from incineration into a beneficial activation mechanism for the clinker binder. The CO2 generated during MSW incineration is captured and used to carbonate the clinker, activating binding strength and simultaneously mitigating carbon emissions. This transforms a harmful by-product into a useful resource.
2Strength
If conventional concrete production is used, then building construction is supported, but carbon emissions increase significantly
Solution Approach 1:
The patent converts the harmful CO2 emissions from MSW incineration into a beneficial carbonation process that activates the clinker binder. By capturing and utilizing the CO2 generated during incineration for carbonation, the system transforms a harmful emission into a useful chemical reaction that strengthens the binder while reducing net carbon emissions.
Solution Approach 2:
The patent recovers and reuses the CO2 that would otherwise be discarded as an emission. The carbonation process captures CO2 from the incineration atmosphere and incorporates it into the clinker structure, thereby recovering a valuable resource and reducing the net carbon footprint of the construction process.
3Ease of manufacture
If natural raw materials are extracted for concrete production, then concrete can be manufactured, but natural resources are depleted
Solution Approach 1:
The patent recovers and reuses MSW incineration residues that would otherwise be discarded as waste. These residues, consisting of ash and other by-products from MSW combustion, are converted into the clinker binder, thereby recovering valuable materials and eliminating the need to extract natural raw materials for concrete production.
Solution Approach 2:
The patent creates a composite binder system using MSW incineration residues as the primary raw material. This composite approach replaces traditional homogeneous cement production with a multi-component system that utilizes waste materials, achieving manufacturability while conserving natural resources.
4Object-generated harmful factors
If MSW incineration residues are used to produce clinker, then carbon emissions are reduced, but the binding strength must be activated through carbonation
Solution Approach 1:
The patent converts the harmful CO2 emissions from MSW incineration into a beneficial carbonation process. The CO2 generated during incineration is captured and used to activate the clinker binder, transforming a harmful emission into a useful chemical reaction that strengthens the binder while reducing net carbon emissions.
Solution Approach 2:
The system uses its own CO2 emissions to activate the clinker binder, making the process self-sufficient. The carbonation process utilizes the CO2 generated during MSW incineration, eliminating the need for external carbon sources and simplifying the overall process requirements.
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 reduces carbon emissions, conserves resources, and transforms waste into value-added building products with zero embodied carbon and energy footprints, offering a near-zero-waste operation and potential revenue stream for incinerator operators.
Implementation Method 1
a raw clinker composition from municipal solid waste (MSW) incinerator residues activated by carbonation
Implementation Method 2
processing is achieved by an embedded or stand-alone tubular kiln-like device operating between 1000-1100° C.
Data Source
AI summary
A process for synthesis of a waste-derived CO2-activated clinker, which comprises firing nodules at temperatures between 1000-1100° C. for a time sufficient to obtain CO2-reactive clinker phases within the nodules, cooling the clinker nodules, and reducing to powder to obtain a clinker powder; wherein the nodules are agglomerates of a stoichiometric mix of uniformly-sized powders of municipal solid waste (MSW) incineration residues; wherein the stoichiometric mix respects the primary compositional requisite of containing Ca, Al, and Si in their oxide forms within the ranges of 35-45 wt. % CaO, 2-8 wt. % AI2O3, and 12-20 wt. % SiO2; wherein the final stoichiometric mix has a total-sulfur content of 1 to 10 wt. %, total-carbon content of 2 to 20 wt. %, and a total-chlorine content of 2 to 15 wt. %.