Granted Patent B2

US 12,246,993 · App. 18/172,087 · Granted Mar 11, 2025

Inventor: Iman Mehdipour (Los Angeles, CA)

Assignee: CarbonBuilt

C04B40/0236C04B14/28F23K1/00B01D47/00B01D53/265C04B2111/00017F23J15/02F23K2201/20

Abstract

Claims (31)

1. A process for sequestering carbon dioxide from a biomass combustion apparatus in carbonated concrete, comprising

providing a CO 2 -containing flue gas from a biomass combustion apparatus having a biomass discharge outlet;

conditioning the CO 2 -containing flue gas to provide a conditioned gas by:

removing particulate matter; and

adjusting the temperature, flow rate, or a combination thereof, of the CO 2 -containing flue gas;

wherein the conditioned gas has a different temperature, flow rate, or a combination thereof, than the CO 2 -containing flue gas at the biomass discharge outlet; and

wherein the conditioned gas has the same concentration of CO 2 as the CO 2 -containing flue gas at the biomass discharge outlet;

wherein the concentration of CO 2 in the CO 2 -containing flue gas is less than 20% by volume;

contacting, in a carbonation chamber, the conditioned gas with at least one block of concrete or concrete precursor until the at least one block of concrete or concrete precursor is carbonated 1.45 weight % to 2.2 weight % CO 2 by total solid mass; and

making calcium carbonate in carbonated concrete that has a compressive strength of at least 1,600 pounds-per-square inch (PSI) at ambient pressure and temperatures ranging from, and including, 20° C. to 100° C.;

wherein the process comprises recirculating the conditioned gas out of and back into the carbonation chamber;

wherein the carbonation chamber is a flow-through reactor.

2. The process of claim 1 , wherein the conditioned gas is directly transferred to the carbonation chamber without using an additional CO 2 capture or enrichment process step.

3. The process of claim 1 , wherein the average CO 2 conversion efficiency via mineral carbonation from biomass CO 2 emission ranges from about 30% to 95%.

4. The process of claim 1 , wherein the concrete comprises hydrated lime, cement kiln dust, lime kiln dust, carbide lime, lime residues, portland cement, coal combustion residues, recycled concrete aggregates, natural pozzolans, other industrial solid wastes, a combination thereof, the carbonation products thereof, or the hydration products thereof.

5. The process of claim 1 , wherein the at least one block further comprises aggregates selected from coal combustion residues, recycled concrete aggregates, slag, lime, lime kiln dust, natural alkaline rocks, other industrial alkaline solid wastes, or combinations thereof.

6. The process of claim 1 , comprising conditioning the CO 2 -containing flue gas in a gas processing apparatus that comprises:

at least one gas cleaning system,

at least one condenser,

at least one heat exchanger,

at least one blower; and

at least one air cooler or water chiller.

7. The process of claim 1 , wherein heat from the biomass combustion apparatus is conducted to the CO 2 -containing flue gas by hot air, hot water, steam, heat recovery from flue gas cooling, or a combination thereof.

8. The process of claim 1 , further comprising:

providing a biomass feedstock in the biomass combustion apparatus; and

drying the feedstock if the feedstock has a moisture content greater than, or equal to, 30% by weight (w/w) to reduce carbon monoxide (CO), volatile organic compounds (VOC), or a combination thereof.

9. The process of claim 1 , comprising providing a conditioned gas which increases the rate of carbonation in the carbonation chamber.

10. The process of claim 1 , wherein the conditioned gas has a temperature, CO 2 amount, gas stream flow rate, or a combination thereof to provide a carbonation rate constant that is at or above 0.005.

11. The process of claim 1 , comprising flowing the CO 2 -containing flue gas through a gas cleaning system selected from a cyclone, baghouse filter, wet scrubber, or electrostatic precipitator, to reduce particulate matter present in the CO 2 -containing flue gas.

12. The process of claim 1 , further comprising making alumina-silica gel and calcium carbonate in carbonated concrete, further wherein at least 50% of the combination of alumina-silica gel and calcium carbonate is calcium carbonate.

13. The process of claim 1 , wherein the conditioned gas that is recirculated out of and back into the carbonation chamber has the same or lower concentration of CO 2 as the CO 2 -containing flue gas at the biomass discharge outlet.

Assignments (1)

Continuity (2)

References Cited (294)