Systems and methods of sequestering carbon dioxide in concrete

Inventors: Barry John Diggins (Elora, CA); Clive Michael Diggins (Kitchener, CA); Brian Robert Reid (Kitchener, CA)

Assignee: Innovative Carbon Technologies Inc.

C04B38/103 B01D53/62 B28C5/388 B28C5/4272 B28C5/462 C04B40/0032 B01D2251/404 B01D2251/604 B01D2257/504 B01D2258/05 C04B2201/50

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Quick Facts

Patent No.: US 12679779
App. No.: 17/430,824
Granted: Jul 14, 2026
Kind: B2

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Abstract

Systems and methods of sequestering carbon dioxide in concrete are described herein. The methods include combining water and a foaming agent to form a foaming agent mixture, adding a gas comprising carbon dioxide to the foaming agent mixture in a first mixing chamber, mixing the water, the gas comprising carbon dioxide and the foaming agent to form a foam mixture in the first mixing chamber, the foam mixture comprising a plurality of foam bubbles containing the at least a portion of the carbon dioxide, combining the foam mixture with concrete materials in a second mixing chamber so that the foam mixture contacts the concrete materials, the concrete materials comprising cement, and mixing the foam mixture and the concrete materials in the second mixing chamber to form the concrete having the carbon dioxide sequestered therein.

Claims (16)

1 . A method of sequestering carbon dioxide in concrete, the method comprising:

combining water and a foaming agent to form a foaming agent mixture;

adding a gas comprising carbon dioxide to the foaming agent mixture in a first mixing chamber to form a foam mixture in the first mixing chamber, the foam mixture comprising a plurality of foam bubbles containing at least a portion of the carbon dioxide, the foam bubbles have an average diameter in a range of about 1 μm to about 1 mm;

combining the foam mixture with concrete materials in a second mixing chamber so that the foam mixture contacts the concrete materials, the step of combining the foam mixture with the concrete materials including adding a volume of the foam mixture to the second mixing chamber such that 1 m 3 of concrete formed in the second mixing chamber has about 1000 L of the gas comprising carbon dioxide sequestered therein, the concrete materials comprising cement; and

mixing the foam mixture and the concrete materials in the second mixing chamber to form the concrete having the carbon dioxide sequestered therein.

2 . The method of claim 1 , wherein during the step of combining the water and the foaming agent, the water has a pressure in a range of about 10 psi to about 150 psi.

3 . The method of claim 1 , wherein the foaming agent mixture has a concentration in a range of about 3 vol % to about 10 vol % foaming agent.

4 . The method of claim 1 , wherein during the step of adding the gas comprising carbon dioxide to the foaming agent mixture, the gas comprising carbon dioxide is added to the first mixing chamber from a carbon dioxide reservoir, the gas comprising carbon dioxide having a pressure in a range of about 1 psi to about 250 psi upon exiting the carbon dioxide reservoir.

5 . The method of claim 1 , wherein during the step of adding the gas comprising carbon dioxide to the foaming agent mixture, the gas comprising carbon dioxide is added to the first mixing chamber from a carbon dioxide reservoir, the gas comprising carbon dioxide having a pressure in a range of about 5 psi to about 60 psi upon exiting carbon dioxide reservoir.

6 . The method of claim 1 , wherein during the step of adding the gas comprising carbon dioxide to the foaming agent mixture, the gas comprising carbon dioxide is added to the first mixing chamber from a carbon dioxide reservoir, the gas comprising carbon dioxide having a pressure in a range of about 20 psi to about 30 psi upon exiting the carbon dioxide reservoir.

7 . The method of claim 4 , wherein adding the gas comprising carbon dioxide to the first mixing chamber from the carbon dioxide reservoir includes the gas comprising carbon dioxide through a compressor, the gas comprising carbon dioxide having a pressure in a range of about 100 psi to about 150 psi at an outlet of the compressor.

8 . The method of claim 4 , wherein adding the gas comprising carbon dioxide to the first mixing chamber from the carbon dioxide reservoir includes passing the gas comprising carbon dioxide through a compressor, the gas comprising carbon dioxide having a pressure in a range of about 125 psi to about 150 psi at an outlet of the compressor.

9 . The method of claim 1 , wherein adding the gas comprising carbon dioxide to the foaming agent mixture in the first mixing chamber includes blowing the gas comprising carbon dioxide into the foaming agent mixture to form the plurality of foam bubbles containing at least a portion of the carbon dioxide, the gas comprising carbon dioxide having a pressure in a range of about 100 psi to about 150 psi when blown into the foaming agent mixture.

10 . The method of claim 1 , wherein adding the gas comprising carbon dioxide to the foaming agent mixture in the first mixing chamber includes blowing the gas comprising carbon dioxide into the foaming agent mixture to form the plurality of foam bubbles containing at least a portion of the carbon dioxide, the gas comprising carbon dioxide having a pressure in a range of about 125 psi to about 150 psi when blown into the foaming agent mixture.

11 . The method of claim 1 , wherein the foaming agent is a protein-based foaming agent or a synthetic foaming agent.

12 . The method of claim 1 , wherein the concrete is a high strength concrete having a compressive strength of at least 30 MPa.