Pre- and post-treatment methods for producing carbon-negative supplementary cementitious materials by direct air capture and sequestration of carbon dioxide

Patent metadata

Field	Value
Publication number	US-2025042812-A1
Application number	US-202418793164-A
Country	US
Kind code	A1
Filing date	Aug 2, 2024
Priority date	Aug 3, 2023
Publication date	Feb 6, 2025
Grant date	—

Abstract

A method for producing carbon negative supplementary cementitious materials utilizing a carbon mineralization-based direct air capture process. One version of the method comprises pre-treating a mineral feedstock with an alkaline solution, resulting in a pre-treated feedstock and an alkaline solution comprising dissolved alumina or silica. The pre-treated feedstock has enhanced carbonation reactivity in the subsequent carbon mineralization-based direct air capture process. Another version of the method comprises post-treating precipitates yielded from carbon mineralization-based direct air capture process of a mineral feedstock with an alkaline solution, resulting in a residue and an alkaline solution comprising dissolved alumina or silica. The alkaline solutions resulted from the pre- and post-treatments can be directly used as supplementary cementitious materials, or as a sorbent solution for carbon capture.

First claim

What is claimed is:

1 . A method of sequestering gaseous carbon dioxide, the method comprising:
(a) contacting a solid feedstock comprising an oxide or a hydroxide with a first alkaline solution for a time and at a temperature wherein at least a portion of alumina or silica present in the solid feedstock is dissolved from the solid feedstock, thereby yielding a pre-treated feedstock and a second alkaline solution comprising dissolved alumina or silica; (b) contacting the pre-treated feedstock with a first aqueous carbonate solution for a time, at a temperature, and under conditions wherein:
(i) at least a portion of the oxide or hydroxide in the pre-treated feedstock is converted into a carbonate and wherein at least a portion of the carbonate so formed precipitates from the aqueous carbonate solution, to yield a precipitate; and
(ii) an aqueous hydroxide solution is formed; and
(c) contacting the aqueous hydroxide solution of step (b)(ii) with gaseous carbon dioxide for a time, at a temperature, and under conditions wherein at least a portion of the gaseous carbon dioxide is sequestered into a second aqueous carbonate solution.

2 . The method of claim 1 , further comprising using at least a portion of the second aqueous carbonate solution of step (c) as at least a portion of the first aqueous carbonate solution of step (b).

3 . The method of claim 1 , wherein in step (a) the first alkaline solution is a hydroxide solution.

4 . The method of claim 1 , wherein in step (a) the first alkaline solution has an OH − concentration of from about 0.1 M to about 2.0 M.

5 . The method of claim 1 , further comprising precipitating at least a portion of the dissolved alumina or silica from the second alkaline solution and using the precipitated alumina or silica as a supplementary cementitious material.

6 . The method of claim 5 , wherein the precipitating comprises contacting the second alkaline solution with gaseous carbon dioxide for a time, at a temperature, and under conditions wherein at least a portion of the gaseous carbon dioxide is sequestered into a third aqueous carbonate solution.

7 . The method of claim 6 , further comprising using at least a portion of the third aqueous carbonate solution as at least a portion of the first aqueous carbonate solution of step (b).

8 . The method of claim 5 , wherein the precipitating comprises contacting the second alkaline solution with a mineral acid.

9 . The method of claim 1 , further comprising contacting the precipitate of step (b)(i) with a third alkaline solution for a time and at a temperature to extract from the precipitate at least a portion of any silica or alumina present therein, thereby yielding a fourth alkali solution comprising dissolved alumina or silica.

10 . The method of claim 1 , wherein the solid feedstock in step (a) comprises a material selected from the group consisting of solid industrial waste, mafic rock, and ultramafic rock.

11 . The method of claim 10 , wherein the industrial waste is selected from the group consisting of mine tailings, fly ash, bottom ash, slag, and crushed concrete.

12 . A method of sequestering gaseous carbon dioxide, the method comprising:
(a) contacting a solid feedstock comprising an oxide or a hydroxide with a first aqueous carbonate solution for a time, at a temperature, and under conditions wherein:
(i) at least a portion of the oxide or hydroxide in the feedstock is converted into a carbonate and wherein at least a portion of the carbonate so formed precipitates from the aqueous carbonate solution, to yield a precipitate; and
(ii) an aqueous hydroxide solution is formed;
(b) contacting the aqueous hydroxide solution of step (a)(ii) with gaseous carbon dioxide for a time, at a temperature, and under conditions wherein at least a portion of the gaseous carbon dioxide is sequestered into a second aqueous carbonate solution; and (c) contacting the precipitate of step (a)(i) with a first alkaline solution for a time and at a temperature wherein at least a portion of silica or alumina present in the precipitate is dissolved from the precipitate, thereby yielding a residue and a second alkaline solution comprising dissolved alumina or silica.

13 . The method of claim 12 , further comprising using at least a portion of the second aqueous carbonate solution of step (b) as at least a portion of the first aqueous carbonate solution of step (a).

14 . The method of claim 12 , wherein in step (c) the first alkaline solution is a hydroxide solution.

15 . The method of claim 12 , wherein in step (c) the first alkaline solution has an OH − concentration of from about 0.1 M to about 2.0 M.

16 . The method of claim 12 , further comprising precipitating at least a portion of the dissolved alumina or silica from the second alkaline solution and using the precipitated alumina or silica as a supplementary cementitious material.

17 . The method of claim 16 , wherein the precipitating comprises contacting the second alkaline solution with gaseous carbon dioxide for a time, at a temperature, and under conditions wherein at least a portion of the gaseous carbon dioxide is sequestered into a third aqueous carbonate solution.

18 . The method of claim 17 , further comprising using at least a portion of the third aqueous carbonate solution as at least a portion of the first aqueous carbonate solution of step (a).

19 . The method of claim 16 , wherein the precipitating comprises contacting the second alkaline solution with a mineral acid.

20 . The method of claim 12 , wherein the solid feedstock in step (a) comprises a material selected from the group consisting of solid industrial waste, mafic rock, and ultramafic rock.

21 . The method of claim 20 , wherein the industrial waste is selected from the group consisting of mine tailings, fly ash, bottom ash, slag, and crushed concrete.

Assignees

• Wisconsin Alumni Res Found

Inventors

• Wang Bu
• Anex Robert
• Hang Zhai

Classifications

• C04B12/005

  Geopolymer cements, e.g. reaction products of aluminosilicates with alkali metal hydroxides or silicates · CPC title

• C04B7/424

  Oxides, Hydroxides · CPC title

• B01D2258/06

  Polluted air · CPC title

• B01D2257/504

  Carbon dioxide · CPC title

• B01D2251/604

  Hydroxides · CPC title