IP Library Granted Patent US 8,006,446
Granted Patent B2
US 8,006,446 · App. 12/826,209 · Granted Aug 30, 2011

CO2-sequestering formed building materials

Assignee: Calera Corporation
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Quick Facts
Patent No.
US 8,006,446
App. No.
12/826,209
Granted
Aug 30, 2011
Kind
B2
Abstract

CO 2 -sequestering formed building materials are provided. The building materials of the invention include a composition comprising a carbonate/bicarbonate component. Additional aspects of the invention include methods of making and using the CO 2 -sequestering formed building material.

Claims (36)

1. A formed building material comprising a CO 2 -sequestering component, wherein the CO 2 -sequestering component comprises 75% (w/w) or more calcium carbonate comprising a metastable carbonate selected form the group consisting of amorphous calcium carbonate, vaterite, aragonite, and combinations thereof,

wherein the CO 2 -sequestering has a δ 13 C less than −15%, and

wherein the formed building material is selected from the group consisting of

a) a brick having a compressive strength ranging from 5 to 100 MPa;

b) a block having a compressive strength ranging from 5 to 100 MPa;

c) a tile having a compressive strength ranging from 5 to 75 MPa;

d) a cement board having a compressive strength ranging from 5 to 50 MPa;

e) a drywall having a compressive strength ranging from 1 to 20 MPa;

f) a conduit having a compressive strength ranging from 5 to 75 MPa;

g) a beams having a compressive strength ranging from 35 to 150 MPa;

h) a basin having a compressive strength ranging from 5 to 60 MPa;

i) a column having a compressive strength ranging from 25 to 200 MPa;

j) a fiber-cement siding having a compressive strength ranging from 2 to 25 MPa; and

k) a slab having a compressive strength ranging from 10 to 100 MPa.

2. The formed building material of claim 1 , wherein the CO 2 -sequestering component comprises carbonates, bicarbonates, or a combination thereof.

3. The formed building material of claim 2 , wherein the CO 2 -sequestering component further comprises calcium, magnesium, or a combination thereof.

4. The formed building material of claim 3 , wherein the CO 2 -sequestering component further comprises strontium.

5. The formed building material of claim 1 , wherein the CO 2 -sequestering component further comprises calcite, ikaite, magnesite, barringtonite, nesquehonite, landfordite, amorphous magnesium carbonate, or a combination thereof.

6. The formed building material of claim 1 , wherein the CO 2 -sequestering component further comprises co-products from NOx, SOx, VOCs, particulates, mercury, or a combination thereof.

7. The formed building material of claim 6 , wherein the CO 2 -sequestering component further comprises sulfates.

8. The formed building material of claim 1 , wherein the formed building material does not release more than 5% of its sequestered CO 2 when exposed to a temperature of 100° C for 100 days at 50% relative humidity.

9. A formed building material produced by a method comprising:

a) producing a CO 2 -sequestering component comprising a metastable carbonate selected from the group consisting of amorphous calcium carbonate, aragonite, vaterite, and combinations thereof from a saltwater solution of divalent cations and a gaseous waste stream comprising CO 2 ,

wherein the CO 2 -sequestering component has a δ 13 C less than −15%; and

b) forming the formed building material from the CO 2 -sequestering component in a process comprising contacting the CO 2 -sequestering component with freshwater, wherein the formed building material comprises 75% (w/w) or more of the CO 2 -sequestering component, and wherein the formed building material is selected from the group consisting of

a) a brick having a compressive strength ranging from 5 to 100 MPa;

b) a block having a compressive strength ranging from 5 to 100 MPa;

c) a tile having a compressive strength ranging from 5 to 75 MPa;

d) a cement board having a compressive strength ranging from 5 to 50 MPa;

e) a drywall having a compressive strength ranging from 1 to 20 MPa;

f) a conduit having a compressive strength ranging from 5 to 75 MPa;

g) a beams having a compressive strength ranging from 35 to 150 MPa;

h) a basin having a compressive strength ranging from 5 to 60 MPa;

i) a column having a compressive strength ranging from 25 to 200 MPa;

j) a fiber-cement siding having a compressive strength ranging from 2 to 25 MPa; and

k) a slab having a compressive strength ranging from 10 to 100 MPa.

Assignments (2)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Sep 17, 2019
From: CALERA CORPORATION
To: ARELAC, INC.
Reel/Frame 050398/0562 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Jun 29, 2010
From: CONSTANTZ, BRENT R.; YOUNGS, ANDREW; HOLLAND, TERENCE C.
To: CALERA CORPORATION
Reel/Frame 024613/0355 →
Continuity (6)
Continuation 12571398 · Sep 30, 2009
Provisional Application 61110489 · Oct 31, 2008
Provisional Application 61149610 · Feb 3, 2009
Provisional Application 61246042 · Sep 25, 2009
Provisional Application 61101631 · Sep 30, 2008
Related Publication 20100326328A1 · Dec 30, 2010