Efficient integration of manufacturing of upcycled concrete product into power plants
A manufacturing process of a concrete product includes: (1) extracting calcium from solids as portlandite; (2) forming a cementitious slurry including the portlandite; (3) shaping the cementitious slurry into a structural component; and (4) exposing the structural component to carbon dioxide sourced from a flue gas stream, thereby forming the concrete product.
1. A system for manufacturing a concrete product, comprising:
a leaching reactor;
a precipitation reactor connected to the leaching reactor;
a set of heat exchangers thermally connected to the leaching reactor and the precipitation reactor and configured to source heat from a flue gas stream and transfer residual heat from the flue gas to liquid water feeding the leaching and precipitation reactors.
2. The system of claim 1 , wherein the set of heat exchangers includes a set of finned-tube heat exchangers.
3. The system of claim 1 , further comprising a capacitive concentrator for controlled concentration of calcium ions and/or magnesium ions connected between the leaching reactor and the precipitation reactor.
4. The system of claim 3 , wherein the capacitive concentrator includes a set of electrodes and an electrical source connected to the set of electrodes.
5. The system of claim 1 , further comprising a carbonation reactor that may be connected to the leaching reactor and the precipitation reactor and configured to source carbon dioxide from the flue gas stream.
6. The system of claim 5 , further comprising a mixer connected between the leaching reactor, the precipitation reactor, and the carbonation reactor.
7. The system of claim 6 , further comprising an extruder or a pressing, molding, or forming device connected between the mixer and the carbonation reactor.
8. The system of claim 5 , wherein the carbonation reactor includes:
a reaction chamber; and
a gas exchange mechanism connected to the reaction chamber and configured to:
expose, during an initial time period, contents of the reaction chamber to a first gas reactant having a first carbon dioxide concentration; and
expose, during a subsequent time period, the contents to a second gas reactant having a second carbon dioxide concentration that is greater than the first carbon dioxide concentration.
9. A system for manufacturing a concrete product, comprising:
a leaching reactor;
a precipitation reactor connected to the leaching reactor;
a set of heat exchangers thermally connected to the leaching reactor and the precipitation reactor and configured to source heat from a flue gas stream; and
a capacitive concentrator for controlled concentration of calcium ions and/or magnesium ions connected between the leaching reactor and the precipitation reactor.
10. The system of claim 9 , wherein the set of heat exchangers includes a set of finned-tube heat exchangers.
11. The system of claim 9 , wherein the capacitive concentrator includes a set of electrodes and an electrical source connected to the set of electrodes.
12. The system of claim 9 , wherein the capacitive concentrator for controlled concentration of calcium ions and/or magnesium ions includes a membrane filtration device.
13. The system of claim 12 , wherein the membrane filtration device comprises at least one nanofiltration membrane or reverse osmosis membrane.
14. The system of claim 9 , further comprising a carbonation reactor that may be connected to the leaching reactor and the precipitation reactor and configured to source carbon dioxide from the flue gas stream.
15. The system of claim 14 , further comprising a mixer connected between the leaching reactor, the precipitation reactor, and the carbonation reactor.
16. The system of claim 15 , further comprising an extruder or a pressing, molding, or forming device connected between the mixer and the carbonation reactor.
17. The system of claim 14 , wherein the carbonation reactor includes:
a reaction chamber; and
a gas exchange mechanism connected to the reaction chamber and configured to:
expose, during an initial time period, contents of the reaction chamber to a first gas reactant having a first carbon dioxide concentration; and
expose, during a subsequent time period, the contents to a second gas reactant having a second carbon dioxide concentration that is greater than the first carbon dioxide concentration.
18. The system of claim 3 , wherein the capacitive concentrator for controlled concentration of calcium ions and/or magnesium ions includes a membrane filtration device.
19. The system of claim 18 , wherein the membrane filtration device comprises at least one nanofiltration membrane or reverse osmosis membrane.
20. A method of manufacturing a carbonated concrete product using the system of claim 1 , wherein the method comprises:
subjecting the solids to dissolution in the leaching reactor to yield an solution comprising calcium ions and/or magnesium ions;
concentrating the calcium and/or magnesium-ion solution;
transferring at least a portion of the concentrated calcium and/or magnesium-ion solution to the precipitation reactor;
inducing precipitation of the calcium and/or magnesium-ion solution in the precipitation reactor to yield portlandite;
forming a cementitious slurry including the portlandite;
shaping the cementitious slurry into a structural component;
placing the structural component in a carbonation reactor; and
exposing the structural component to carbon dioxide sourced from the flue gas stream, thereby forming the carbonated concrete product.