Recycled concrete preparation using sensors to characterize particles and control carbonation and densification process steps

A recycled concrete aggregate (RCA) preparation system comprising:

• a plurality of optical sensors arranged within the system to measure attributes of crushed RCA at different process stages;
• a carbonation sub-system;
• at least one processor in communication with the plurality of sensors and the carbonation sub-system;
• and
• a data store coupled to the at least one processor having instructions stored thereon which, when executed by the at least one processor, causes the at least one processor to perform operations comprising:
• obtaining, from first sensors, first measurements of RCA particles as the RCA particles are conveyed past the first sensors;
• determining, based on the first measurements, an initial characterization of the RCA particles and, from the initial characterization of the RCA particles, determining carbonation process parameters to achieve target carbonation characteristics for the RCA particles;
• and
• performing a carbonation process on the RCA particles to obtain carbonated RCA particles, wherein the carbonation process is controlled using the determined carbonation process parameters,
• obtaining second measurements of the carbonated RCA particles;
• determining, from the second measurements, a characterization of the carbonated RCA particles;
• and
• performing a densification process on the carbonated RCA particles to obtain upgraded-carbonated RCA particles, wherein the densification process is controlled based at least in part on the characterization of the carbonated RCA particles.

A non-transitory computer readable storage medium storing instructions that, when executed by at least one processor, cause the at least one processor to perform operations comprising:

• obtaining, from first sensors, first measurements of RCA particles as the RCA particles are conveyed past the first sensors;
• determining, based on the first measurements, an initial characterization of the RCA particles and, from the initial characterization of the RCA particles, determining carbonation process parameters to achieve target carbonation characteristics for the RCA particles;
• and
• performing a carbonation process on the RCA particles to obtain carbonated RCA particles, wherein the carbonation process is controlled using the determined carbonation process parameters.