Methods of Producing Cured CO2 Sequestering Solid Compositions, Systems for Practicing the Same and Cured CO2 Sequestering Solid Compositions Produced Therefrom

1 . A method of producing a cured CO 2 sequestering solid, the method comprising:

a) preparing an initial CO 2 sequestering solid composition; and

b) contacting the initial CO 2 sequestering solid composition with a curing liquid sufficient to produce a cured CO 2 sequestering solid.

2 . The method according to claim 1 , wherein the curing liquid comprises a carbonate curing liquid, a bicarbonate curing liquid, a phosphate curing liquid, a divalent alkali earth metal curing liquid or tap water.

3 . The method according to claim 2 , wherein the curing liquid comprises a carbonate curing liquid.

4 . The method according to claim 3 , wherein the carbonate curing liquid comprises sodium carbonate (Na 2 CO 3 ) ammonium carbonate ((NH 4 ) 2 CO 3 ) or (K 2 CO 3 ).

5 . The method according to claim 2 , wherein the curing liquid comprises a bicarbonate curing liquid.

6 . The method according to claim 5 , wherein the bicarbonate curing liquid comprises sodium bicarbonate (NaHCO 3 ), ammonium bicarbonate (NH 4 HCO 3 ) or potassium bicarbonate (KHCO 3 ).

7 . The method according to any one of claims 1 - 6 , wherein the curing liquid has a dissolved inorganic carbon concentration ranging from 0.05 M to 5 M.

8 . The method according to claim 2 , wherein the curing liquid comprises a phosphate curing liquid.

9 . The method according to claim 8 , wherein the phosphate curing liquid comprises a phosphate anion selected from the group consisting of H 2 PO 4 − , HPO 4 2− and PO 4 3− .

10 . The method according to claim 2 , wherein the curing liquid comprises a divalent alkali earth metal curing liquid.

11 . The method according to claim 10 , wherein the divalent alkali earth metal curing liquid comprises a calcium curing liquid.

12 . The method according to claim 11 , wherein the calcium curing liquid comprises CaCl 2 .

13 . The method according to claim 2 , wherein the curing liquid comprises tap water.

14 . The method according to claim 2 , wherein the curing liquid comprises a composite of two or more curing liquids selected from the group consisting of a carbonate curing liquid, a bicarbonate curing liquid, a phosphate curing liquid, a divalent alkali earth metal curing liquid and tap water.

15 . The method according to any one of claims 1 - 14 , wherein the curing liquid has a pH ranging from 5 to 14.

16 . The method according to any one of claims 1 - 15 , wherein the curing liquid is at a temperature ranging from 20° C. to 50° C. for at least a portion of the contacting.

17 . The method according to any one of claims 1 - 16 , wherein the contacting is performed for between 1 minute and 30 days.

18 . The method according to any one of claims 1 - 17 , wherein the curing results in a carbonate compound changing from a first crystal structure in the initial CO 2 sequestering solid to a second crystal structure in the cured CO 2 sequestering solid.

19 . The method according to claim 18 , wherein the carbonate compound is calcium carbonate, the first crystal structure is vaterite or amorphous calcium carbonate, and the second crystal structure is aragonite or calcite.

20 . The method according to any one of claims 1 - 19 , wherein preparing the initial CO 2 sequestering solid comprises including:

(i) contacting an aqueous capture liquid with a gaseous source of CO 2 under conditions sufficient to produce a carbonate capture liquid; and

(ii) combining a cation source and the carbonate capture liquid under conditions sufficient to produce the initial CO 2 sequestering solid.

21 . The method according to any one of claims 1 - 19 , wherein preparing the initial CO 2 sequestering solid composition comprises contacting an aqueous capture liquid comprising a cation source with a gaseous source of CO 2 under conditions sufficient to produce the initial CO 2 sequestering solid.

22 . The method according to claim 20 or 21 , wherein the aqueous capture liquid comprises aqueous capture ammonia and preparing the initial CO 2 sequestering solid composition also results in production of an aqueous ammonium salt.

23 . The method according to claim 22 , further comprising regenerating aqueous capture ammonia from the aqueous ammonium salt.

24 . The method according to any one of claims 20 - 23 , wherein the cation source comprises a divalent alkali earth metal cation.

25 . The method according to claim 24 , wherein the divalent alkali earth metal cation is Ca 2+ or Mg 2+ .

26 . The method according to any one of claims 20 - 23 , wherein the cation source comprises transition metal cation.

27 . The method according to claim 26 , wherein the transition metal cation is a Mn, Fe, Ni, Cu, Co, Zn cation.

28 . The method according to any one of claims 20 - 27 , further comprising preparing the aqueous capture liquid by at least partially dissolving in an initial aqueous liquid a material selected from the group consisting of cement, concrete, fly ash, rock, and steel slag.

29 . The method according to claim 28 , wherein the initial aqueous liquid comprises aqueous ammonia.

30 . The method according to any one of claims 1 to 29 , wherein the initial CO 2 sequestering solid composition comprises a precipitate and the method produces a cured precipitate composition.

31 . The method according to claim 30 , wherein the method further comprises producing an aggregate from the cured precipitate composition.

32 . The method according to any one of claims 1 to 29 , wherein the initial CO 2 sequestering solid composition comprising an initial aggregate.

33 . The method according to any one of claims 1 - 32 , further comprising forming the cured CO 2 sequestering solid into a plurality of cured formed aggregates each having a diameter ranging from 75 μm to 100,000 μm.

34 . The method according to any one of claims 1 - 33 , wherein the method further comprises contacting the cured CO 2 sequestering solid with steam in a manner sufficient to remove an impurity from the CO 2 sequestering solid.

35 . The method according to claim 34 , wherein the CO 2 sequestering solid is contacted with the steam for a time period ranging from 1 to 60 minutes.

36 . The method according to any one of claims 34 - 35 , wherein the CO 2 sequestering solid is contacted with the steam at 0 psig and 100° C.

37 . The method according to claim 36 , wherein the CO 2 sequestering solid is contacted with the steam in an open system.

38 . The method according to any one of claims 34 - 36 , wherein the CO 2 sequestering solid is contacted with the steam in a closed system.

39 . The method according to claim 38 , wherein the CO 2 sequestering solid is contacted with the steam at a contact pressure greater than atmospheric pressure.

40 . A cured CO 2 sequestering solid prepared by a process comprising the steps of:

a) preparing an initial CO 2 sequestering solid composition; and

b) contacting the initial CO 2 sequestering solid composition with a carbonate curing liquid to produce a cured CO 2 sequestering solid.

41 . The solid according to claim 40 , wherein the cured CO 2 sequestering solid has a hardness of 2 or greater according to the Mohs Hardness Scale.

42 . The solid according to any one of claims 40 - 41 , wherein concrete specimens containing the cured CO 2 sequestering solid have average 28-day compressive strength and calculated equilibrium density ranging from 2,500 psi to 4,000 psi and 100 lb/ft to 115 lb/ft 3 , respectively, according to ASTM C330.

43 . The solid according to any one of claims 40 - 42 , wherein the cured CO 2 sequestering solid has a crystalline structure.

44 . The solid according to claim 43 , wherein the cured CO 2 sequestering solid comprises aragonite, calcite, or a combination thereof.

45 . The solid according to any one of claims 40 - 44 , wherein the cured CO 2 sequestering solid has a diameter ranging from 75 μm to 100,000 μm.

46 . A system for producing a cured CO 2 sequestering solid, the system comprising:

an initial CO 2 sequestering solid composition preparation module; and

a curing module.

47 . The system according to claim 46 , wherein the curing module comprises a curing liquid comprising a carbonate curing liquid, a bicarbonate curing liquid, a phosphate curing liquid, a divalent alkali earth metal curing liquid, or tap water.

48 . The system according to claim 47 , wherein the curing liquid comprises sodium carbonate (Na 2 CO 3 ), ammonium carbonate ((NH 4 ) 2 CO 3 ), potassium carbonate (K 2 CO 3 ), sodium bicarbonate (NaHCO 3 ), ammonium bicarbonate (NH 4 HCO 3 ), potassium bicarbonate (KHCO 3 ), a combination thereof.

49 . The system according to any one of claims 46 - 48 , further comprising an aqueous capture ammonia regeneration module configured to supply aqueous capture ammonia to the aggregate composition preparation module.

50 . The system according to claim 49 , wherein the aqueous capture ammonia regeneration module is configured to produce aqueous capture ammonia by distillation.

51 . The system according to any one of claims 49 - 50 , wherein the aqueous capture ammonia regeneration module is configured to produce aqueous capture ammonia by contacting an ammonium salt with an alkalinity source.

52 . The system according to any one of claims 46 - 51 , wherein the initial CO 2 sequestering solid composition preparation module comprises:

a CO 2 gas/aqueous liquid contactor module; and

a solid carbonate production module.

53 . The system according to any one of claims 46 - 51 , wherein the initial CO 2 sequestering solid composition preparation module comprises a CO 2 gas/aqueous liquid contactor module configured to contact CO 2 gas with an aqueous liquid comprising a cation source and produce a solid carbonate.

54 . The system according to any one of claims 46 - 53 , wherein the initial CO 2 sequestering solid composition preparation module is operably coupled to a source of a flue gas.