Methods of forming cured composite materials with optimized pH and related compositions and systems

Patent metadata

Field	Value
Publication number	US-11618714-B2
Application number	US-202017067149-A
Country	US
Kind code	B2
Filing date	Oct 9, 2020
Priority date	Oct 9, 2019
Publication date	Apr 4, 2023
Grant date	Apr 4, 2023

Abstract

A method of producing a carbonated composite material includes: providing a carbonatable cementitious material in particulate form; mixing the carbonatable cementitious material with water to produce a mix; forming a predetermined shape with the mix, wherein the predetermined shape has an initial pore structure containing an initial pore solution having a first pH; pre-conditioning the predetermined shape to remove a predetermined amount of the water from the predetermined shape to produce a pre-conditioned shape; carbonating the pre-conditioned shape in an environment comprising carbon dioxide to produce a modified pore structure containing a modified pore solution having and a second pH, wherein the difference between the first pH and the second pH is represented by a ΔpH, and the ΔpH is 1.0 or less.

First claim

We claim:

1. A method of producing a carbonated composite material, comprising:
providing a carbonatable cementitious material in particulate form;
mixing the carbonatable cementitious material with water to produce a mix;
forming a predetermined shape with the mix, wherein the predetermined shape has an initial pore structure containing an initial pore solution having a first pH;
pre-conditioning the predetermined shape in an environment comprising ambient air or carbon dioxide to remove a predetermined amount of the water from the predetermined shape to produce a pre-conditioned shape;
carbonating the pre-conditioned shape in an environment comprising carbon dioxide to produce a modified pore structure containing a modified pore solution having a second pH, wherein the difference between the first pH and the second pH is represented by a ΔpH, and the ΔpH is 1.0 or less.

2. The method of claim 1 , wherein the first pH is 11.5 or greater.

3. The method of claim 1 , wherein the second pH is at least about 9.5 to about 11.5.

4. The method of claim 1 , wherein the carbonation of the pre-conditioned shape forms one or more bonding elements, wherein each bonding element comprises;
a core, wherein the core has a first chemical composition that includes one or more chemical elements;
a silica-rich first layer at least partially covering a peripheral portion of the core; and
a calcium carbonate and/or magnesium carbonate-rich second layer at least partially covering a peripheral portion of the first layer.

5. The method of claim 1 , wherein the predetermined amount of water removed from the predetermined shape during the pre-conditioning is 20 to 70%.

6. The method of claim 5 , wherein the predetermined amount of water removed from the predetermined shape during the pre-conditioning is 40 to 50%.

7. The method of claim 1 , wherein the pre-conditioning is performed in an environment comprising carbon dioxide, and the concentration of carbon dioxide is greater than 0% to 50%.

8. The method of claim 1 , wherein the concentration of carbon dioxide during carbonation of the pre-conditioned shape is 10% to 100%.

9. The method of claim 1 , wherein the concentration of carbon dioxide during carbonation of the pre-conditioned shape is 50% to 99%.

10. The method of claim 1 , further comprising:
forming the predetermined shape with the mix by pouring the mix into a mold; and
pre-curing the mix while in the mold to at least a hardness sufficient to allow removal of the mold.

11. The method of claim 1 , wherein the mix comprises aggregates.

12. The method of claim 11 , wherein the aggregates have a particle size ranging from 0.25 mm to about 25 mm.

13. The method of claim 11 , wherein the aggregates comprise sand.

14. The method of claim 11 , wherein the aggregates comprise gravel, trap rock or granite stone.

15. The method of claim 13 , wherein the sand is dolomitic.

16. The method of claim 13 , wherein the sand is silica-based.

17. The method of claim 1 , wherein the mix further comprises at least one pH enhancing additive in an amount of about 1% to about 30%, by mass, based on the total amount of cementitious materials.

18. The method of claim 17 , wherein the at least one pH enhancing additive is chosen from: calcium nitrate tetrahydrate, calcium nitrite, NaOH, sodium bicarbonate, ordinary portland cement, sodium silicate, deadburned CaO, deadburned MgO, concrete recycled material (CRM), slag aggregate, and combinations thereof.

Assignees

• Solidia Technologies Inc

Inventors

• Seth Anuj
• Jain Jitendra Arunchandra
• Ali Yussuf Sultan
• Sulik Matthew David
• Patel Dishen
• Ibrahim Makar Makram

Classifications

• C04B2111/00019

  Carbon dioxide sequestration · CPC title

• C04B40/0231

  Carbon dioxide hardening · CPC title

• C04B14/26

  Carbonates · CPC title

• C04B2111/26

  Corrosion of reinforcement resistance · CPC title

• C04B2103/22

  Set retarders · CPC title