Method of preparing supplementary cementitious materials, and supplementary cementitious materials prepared therefrom

Patent metadata

Field	Value
Publication number	US-2023110452-A1
Application number	US-202217961427-A
Country	US
Kind code	A1
Filing date	Oct 6, 2022
Priority date	Oct 7, 2021
Publication date	Apr 13, 2023
Grant date	—

Abstract

A method of preparing a carbonated supplementary cementitious materials, includes carbonating the carbonatable mixture to obtain a first carbonated cementitious material, milling the first carbonated cementitious material, and carbonating the milled mixture to obtain the carbonated supplementary cementitious material.

First claim

We claim:

1 . A method of preparing a carbonated supplementary cementitious material, the method comprising:
adding water to a carbonatable material to form a carbonatable mixture, wherein a moisture content of the mixture is from about 0.1% to about 99.99% by weight; agitating or stirring the carbonatable mixture for about 1 minute to about 24 hours; carbonating the carbonatable mixture to obtain a first carbonated cementitious material; milling the first carbonated cementitious material for about 0.1 minute to about 60 minutes to obtain a milled mixture; and carbonating the milled mixture for about 1 minute to about 24 hours to obtain the carbonated supplementary cementitious material, wherein carbonating the carbonatable mixture and the milled mixture comprises flowing a gas comprising about 5% to about 100% carbon dioxide, by volume, into the carbonatable mixture and the milled mixture, respectively, and maintaining a temperature of about 1° C. to about 99° C., to obtain the carbonated supplementary cementitious material.

2 . The method of claim 1 , wherein the moisture content of the carbonatable mixture is about 0.1% to about 90% by weight.

3 . The method of claim 1 , wherein the method comprises a plurality of carbonation cycles alternating with a plurality of milling and wetting cycles.

4 . The method of claim 1 , further comprising steaming the milled mixture prior to carbonating the milled mixture, wherein the steaming comprises exposing the milled mixture to water vapor or steam at a temperature of about 20° C. to about 200° C.

5 . The method of claim 1 , further comprising drying the carbonated supplementary cementitious material for about 1 minute to about 24 hours at a temperature of about 20° C. to about 500° C.

6 . The method of claim 1 , further comprising de-agglomerating the mixture.

7 . The method of claim 1 , further comprising obtaining the gas comprising carbon dioxide from a flue gas.

8 . The method of claim 1 , wherein the milling is carried out in a mill selected from a ball mill, a vertical roller mill, a belt roller mill, a granulator, a hammer mill, attrition mill, a milling roller, a peeling roller mill, an air-swept roller mill, or a combination thereof.

9 . The method of claim 1 , further comprising moistening the gas prior to carbonating, wherein moistening the gas comprises bubbling the gas through hot water.

10 . The method of claim 1 , wherein a flow rate of the gas comprising carbon dioxide is from about 1 L/min/Kg to about 6 L/min/Kg per kilogram of carbonatable material.

11 . The method of claim 1 , wherein the flowing of the gas comprising carbon dioxide is carried out for about 1 min to about 24 hours.

12 . The method of claim 1 , wherein a mean particle size (d50) of the carbonated supplementary cementitious material is from about 1 μm to about 25 μm.

13 . The method of claim 1 , wherein a BET surface area of the carbonated supplementary cementitious material is from about 5 m 2 /g to about 25 m 2 /g.

14 . The method of claim 1 , wherein a carbon dioxide uptake of the carbonated supplementary cementitious material is from about 5% to about 40%.

15 . The method of claim 1 , wherein the carbonatable material includes at least one synthetic formulation having the general formula M a Me b O c , M a Me b (OH) d , M a Me b O c (OH) d or M a Me b O c (OH) d ·(H 2 O) e , wherein M is at least one metal that can react to form a carbonate and Me is at least one element that can form an oxide during the carbonation reaction.

16 . The method of claim 15 , wherein M is calcium and/or magnesium.

17 . The method of claim 15 , wherein Me is silicon, titanium, aluminum, phosphorus, vanadium, tungsten, molybdenum, gallium, manganese, zirconium, germanium, copper, niobium, cobalt, lead, iron, indium, arsenic, sulfur and/or tantalum.

18 . The method of claim 15 , wherein a ratio of a:b is about 2.5:1 to about 0.167:1, c is 3 or greater, d is 1 or greater, e is 0 or greater.

19 . The method of claim 1 , wherein the carbonatable material comprises calcium silicate having a molar ratio of elemental Ca to elemental Si of about 0.8 to about 3.0.

20 . The method of claim 19 , wherein the carbonatable material comprises a blend of discrete, crystalline calcium silicate phases, selected from one or more of CS (wollastonite or pseudowollastonite), C 3 S 2 (rankinite) and C 2 S (belite or larnite or bredigite), at about 30% or more by mass of the total phases, and about 30% or less of metal oxides of Al, Fe and Mg by total oxide mass.

21 . The method of claim 19 , wherein the carbonatable material comprises a calcium silicate hydrate (C—S—H), recycled concrete, municipality waste, mine tailings, or a mixture thereof.

22 . The method of claim 15 , wherein the carbonatable material further comprises an amorphous calcium silicate phase.

23 . A method for forming cement or concrete, the method comprising:
forming a carbonated supplementary cementitious material according to the method of claim 1 ; combining the carbonated supplementary cementitious material with a hydraulic cement composition to form a cementitious material mixture, wherein the cementitious material mixture comprises about 1% to about 99%, by weight, of the carbonated supplementary cementitious material, based on the total weight of solids in the mixture; and reacting the cementitious material mixture with water to form the cement or concrete.

24 . The method of claim 23 , wherein the cementitious material mixture comprises about 20% to about 35% of the carbonated supplementary cementitious material by weight, based on the total weigh of solids in the mixture.

25 . The method of claim 23 , wherein the hydraulic cement composition comprises one or more of ordinary Portland cement (OPC), calcium sulfoaluminate cement (CSA), belitic cement, or other calcium based hydraulic material.

26 . The method of claim 23 , further comprising adding aggregate to the cementitious material mixture.

27 . The method of claim 23 , wherein:
a strength activity index of the cement or concrete is from about 75% to about 120%, and the strength activity index is a ratio of a compressive strength of the cement or concrete comprising about 20% by weight of the carbonated supplementary cementitious material to a compressive strength of the cement or concrete comprising about 0% by weight of the carbonated supplementary cementitious material, based on the total weight of solids in the mixture.

28 . The method of claim 23 , wherein:
the milling of the first carbonated cementitious material is carried out for about 5 minutes to about 60 minutes, a strength activity index of the cement or concrete obtained after milling the first carbonated cementitious material is about 7% to about 15% higher than the strength activity index of a cement or concrete obtained without milling, when measured at 7 days after formation of the respective cement or concrete, and the strength activity index is a ratio of a compressive strength of the cement or concrete comprising about 20% by weight of the carbonated supplementary cementitious material to a compressive strength of the cement or concrete comprising about 0% by weight of the carbonated supplementary cementitious material, based on the total weight of solids in the mixture.

29 . The me

Assignees

• Solidia Technologies Inc

Inventors

• Atakan Vahit
• Davidson Mario Jorge
• Sahu Sadananda

Classifications

• C04B2111/00019

  Carbon dioxide sequestration · CPC title

• C04B20/0232

  with carbon dioxide · CPC title

• C04B28/188 Primary

  the Ca-silicates being present in the starting mixture · CPC title

• Y02P40/18

  Carbon capture and storage [CCS] · CPC title

• C04B28/04

  Portland cements · CPC title