Process for producing calcined mineral binder material with reduced carbon footprint

Patent metadata

Field	Value
Publication number	US-2025171353-A1
Application number	US-202318841799-A
Country	US
Kind code	A1
Filing date	Apr 19, 2023
Priority date	Apr 21, 2022
Publication date	May 29, 2025
Grant date	—

Abstract

A method to produce a calcined mineral binder material includes the steps of: a) providing a source material including a mineral binder material, carbonating the source material with carbon dioxide such that the mineral binder material is at least partially, in particular essentially completely, carbonated to produce a carbonated product; b) calcining a carbonate-containing material to produce a calcined mineral binder material and carbon dioxide as side product; whereby in step a) the carbon dioxide side product of step b), optionally in combination with further carbon dioxide from a different source, is used as the carbon dioxide for carbonation of the source material; and in step b) the carbonate-containing material includes the carbonated product of step a), and optionally other material.

First claim

1 . A method to produce a calcined mineral binder material comprising the steps of:
a) providing a source material comprising a mineral binder material, carbonating the source material with carbon dioxide such that the mineral binder material is at least partially carbonated to produce a carbonated product; b) calcining a carbonate-containing material to produce a calcined mineral binder material and carbon dioxide as side product;
whereby in step a) the carbon dioxide side product of step b), optionally in combination with further carbon dioxide from a different source, is used as the carbon dioxide for carbonation of the source material; and in step b) the carbonate-containing material comprises the carbonated product of step a), and optionally other material.

2 . The method according to claim 1 , whereby the carbonate-containing material additionally comprises a clay mineral.

3 . The method according to claim 2 , whereby a ratio of clay mineral to carbonated product is from 5:1-1:1.

4 . The method according to claim 2 , whereby the clay mineral is selected from crude clay, low-temperature calcined clay, and/or high-temperature calcined clay.

5 . The method according to claim 2 , whereby the clay mineral comprises kaolinite, montmorillonite and/or illite, especially kaolinite.

6 . The method according to claim 1 , whereby in step a) the source material comprises hardened mineral binder and aggregates and whereby during carbonation the hardened mineral binder is at least partially removed from the surface of the aggregates.

7 . The method according to claim 5 , whereby the treated source material is separated at a predefined cut-off grain size in order to retrieve treated aggregates with a grain size of at least the predefined cut-off grain size and in order to retrieve a powdery mineral material with a grain size below the predefined cut-off grain size.

8 . The method according to claim 1 , whereby the source material comprises hardened mortar and/or concrete.

9 . The method according to claim 1 , whereby the source material comprises uncured mineral binder.

10 . The method according to claim 1 , whereby the carbonated product produced in step a) comprises or consist of calcium, silicate and/or aluminium carbonates.

11 . The method according to claim 1 , whereby calcination in step b) is effected at a temperature of 550-1,100° C.

12 . The method according to claim 1 , whereby the calcined mineral binder material comprises or consist of:
calcium oxide; optionally calcined clay; optionally aggregates.

13 . The method according to claim 1 , whereby the calcined mineral binder material is partially hydrated to convert calcium oxide to calcium hydroxide.

14 . The method according to claim 1 , whereby the calcined mineral binder material is subjected to a grinding procedure to obtain a powder with a Blaine fineness measured according to DIN EN 196-6:2018 of at least 1,000 m 2 /g.

15 . A method for producing a settable mineral binder composition comprising the steps of (i) providing a mineral binder material obtained in a method according to claim 1 and (ii) mixing it with one or more representatives of the group consisting of aggregates, a further mineral binder, water and additives.

Assignees

• Sika Tech Ag

Inventors

• Juilland Patrick
• Gallucci Emmanuel
• Frunz Lukas

Classifications

• C04B7/52

  Grinding {; After-treatment of ground cement} · CPC title

• C04B7/44

  Burning; Melting · CPC title

• C04B28/10

  Lime cements or magnesium oxide cements · CPC title

• C04B2/005

  obtained from an industrial by-product · CPC title

• C04B7/38 Primary

  Preparing or treating the raw materials individually or as batches {, e.g. mixing with fuel; (C04B7/362 takes precedence)} · CPC title