# US 2023/0265019 A1 · Methods and systems for biomass-derived co2 sequestration in concretes and aggregates

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- Number: US 2023/0265019 A1
- Document ID: US20230265019A1
- Status: Published application
- Kind: A1
- Application number: 18/172,087
- Filed: 2023-02-21
- Published: 2023-08-24
- Earliest claimed: 2022-02-21
- Assignees: CarbonBuilt
- Applicants: CarbonBuilt
- Inventors: Iman Mehdipour
- Web page: https://patentgrep.com/patent/US20230265019A1

## CPC

- C01F 11/18: Carbonates
- C04B 40/0236: {Carbon dioxide post-treatment of already hardened material}
- B01D 53/002: {by condensation}
- C01F 11/02: Oxides or hydroxides (production of lime C04B2/00)
- C01F 11/182: {Preparation of calcium carbonate by carbonation of aqueous solutions and characterised by an additive other than CaCO3-seeds}
- C04B 14/28: of calcium
- C04B 40/0231: {Carbon dioxide hardening}
- F23K 1/00: Preparation of lump or pulverulent fuel in readiness for delivery to combustion apparatus
- B01D 47/00: Separating dispersed particles from gases, air or vapours by liquid as separating agent (B01D45/10 takes precedence; fractionating columns or parts thereof B01D3/16)
- B01D 53/26: Drying gases or vapours
- B01D 53/265: {by refrigeration (condensation)}
- B01D 53/323: {by electrostatic effects or by high-voltage electric fields}
- B01D 2257/504: Carbon dioxide
- B01D 2258/0283: Flue gases
- C01P 2002/88: by thermal analysis data, e.g. TGA, DTA, DSC
- C04B 2111/00017: {Aspects relating to the protection of the environment}
- C04B 2111/00019: {Carbon dioxide sequestration}
- F23J 15/02: of purifiers, e.g. for removing noxious material (traps for solid residues F23J3/04)
- F23K 2201/20: Drying
- Y02C 20/40: of CO2
- C01F: COMPOUNDS OF THE METALS BERYLLIUM, MAGNESIUM, ALUMINIUM, CALCIUM, STRONTIUM, BARIUM, RADIUM, THORIUM, OR OF THE RARE-EARTH METALS (metal hydrides {monoborane, diborane or addition complexes thereof} C01B6/00; salts of oxyacids of halogens C01B11/00; peroxides, salts of peroxyacids C01B15/00; sulfides or polysulfides of magnesium, calcium, strontium, or barium C01B17/42; thiosulfates, dithionites, polythionates C01B17/64; compounds containing selenium or tellurium C01B19/00; binary compounds of nitrogen with metals C01B21/06; azides C01B21/08; {compounds other than ammonia or cyanogen containing nitrogen and non-metals and optionally metals C01B21/082; amides or imides of silicon C01B21/087}; metal {imides or} amides C01B21/092, {C01B21/0923}; nitrites C01B21/50; {compounds of noble gases C01B23/0005}; phosphides C01B25/08; salts of oxyacids of phosphorus C01B25/16; carbides C01B32/90; compounds containing silicon C01B33/00; compounds containing boron C01B35/00; compounds having molecular sieve properties but not having base-exchange properties C01B37/00; compounds having molecular sieve and base-exchange properties, e.g. crystalline zeolites, C01B39/00; cyanides C01C3/08; salts of cyanic acid C01C3/14; salts of cyanamide C01C3/16; thiocyanates C01C3/20; {double sulfates of magnesium with sodium or potassium C01D5/12; with other alkali metals C01D15/00, C01D17/00})
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE
- B01D: SEPARATION (separating solids from solids by wet methods B03B, B03D; by pneumatic jigs or tables B03B; by other dry methods B07; magnetic or electrostatic separation of solid materials from solid materials or fluids, separation by high-voltage electric fields B03C; centrifuges, vortex apparatus B04; presses per se for squeezing-out liquid from liquid-containing material B30B9/02; treatment of water C02F, e.g. softening by ion-exchange C02F1/42; {arrangements of air intake cleaners in gas turbine plants F02C7/05} ; arrangements or mounting of filters in air-conditioning, air-humidification or ventilation F24F13/28)
- F23K: FEEDING FUEL TO COMBUSTION APPARATUS (fuel feeders specially adapted for fluidised bed combustion apparatus F23C10/22)
- C01P: INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
- F23J: REMOVAL OR TREATMENT OF COMBUSTION PRODUCTS OR COMBUSTION RESIDUES; FLUES (combustion apparatus for consuming smoke or fumes, e.g. exhaust gases, F23G7/06)
- Y02C: CAPTURE, STORAGE, SEQUESTRATION OR DISPOSAL OF GREENHOUSE GASES [GHG]

## Abstract

Provided herein are integrated biomass combustion-carbonation gas conditioning systems to directly sequester carbon dioxide from biomass-derived CO2-containing flue gas. The CO2 is sequestered by mineral carbonation in concrete materials within a carbonation reactor. The mineral carbonation processes sequester CO2 in concrete materials, aqueous slurries, or aggregates without any additional carbon enrichment process. Contacting a CO2-containing gas stream from a biomass combustion apparatus with concrete, aggregate, or alkaline solutions, causes a carbonation reaction in which carbonation products such as calcium carbonate (CaCO3) and alumina silica gel are formed. The carbonation reactions set forth herein are useful for strengthening concrete and concrete components. Certain processes herein condition the biomass-derived flue gas. The conditioning includes condensing the gas to remove acidic gas, and to remove particulates and water. The conditioning includes adjusting the temperature, relative humidity, and gas flow rate of the biomass-derived flue gas without any carbon capture step before entering the carbonation reactor. The permanent storage of CO2 in concrete materials reduces carbon emissions from biomass combustion systems. The process does so, in certain embodiments, at low temperatures, ambient pressure, and even under dilute CO2 concentrations in CO2-containing flue gas streams. For example, the CO2 concentration in a CO2-containing flue gas stream from a biomass combustion system may be lower than 20 volume percent (vol %) and be used to produce low-carbon concrete materials.

## Claims

### Claim 1

A process for sequestering carbon dioxide from a biomass combustion apparatus, comprising
providing a CO2-containing flue gas from a biomass combustion apparatus having a biomass discharge outlet;
conditioning the CO2-containing flue gas to provide a conditioned gas;
wherein the conditioning comprises:
removing a member selected from the group consisting of particulate matter, acidic gas, alkali chlorides, alkali sulfates, and combinations thereof; and
adjusting the temperature, relative humidity, flow rate, or a combination thereof, of the CO2-containing flue gas;
wherein the conditioned gas has a different temperature, relative humidity, flow rate, or a combination thereof, than the CO2-containing flue gas at the biomass discharge outlet; and
wherein the conditioned gas has the same concentration of CO2 as the CO2-containing flue gas at the biomass discharge outlet;
contacting, in a carbonation chamber, the conditioned gas with a component selected from the group consisting of a green body, concrete, an aqueous solution of alkaline solids, an aqueous solution of aggregates, or a combination thereof; and
precipitating calcium carbonate at ambient pressure and temperatures ranging from, and including, 20° C. to 100° C.

### Claim 2 (depends on 1)

The process of claim 1, wherein the conditioned gas is directly transferred to the carbonation chamber without using an additional CO2 capture or enrichment process step.

### Claim 3 (depends on 1)

The process of claim 1 , wherein the concentration of CO2 in the CO2-containing flue gas is less than 20% by volume.

### Claim 4

(canceled)

### Claim 5

(canceled)

### Claim 6 (depends on 3)

The process of claim 3 FM wherein the average CO2 conversion efficiency via mineral carbonation from biomass CO2 emission ranges from about 30% to 95%.

### Claim 7

(canceled)

### Claim 8 (depends on 1)

The process of claim 1, wherein the carbonation chamber is a flow-through reactor, an aqueous reactor, a slurry reactor, or a stirring reactor.

### Claim 9

(canceled)

### Claim 10 (depends on 1)

The process of claim 1, wherein the carbonation chamber is at ambient pressure and a temperature in a range from about 20° C. to about 100° C.

### Claim at position 11

-13. (canceled)

### Claim 14 (depends on 1)

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.

### Claim 15 (depends on 1)

The process of claim 1, comprising contacting, in the carbonation chamber, the conditioned gas with an aqueous solution of alkaline solids, wherein the aqueous solution of alkaline solids comprises coal combustion residues, recycled concrete aggregates, slag, portland cement, hydrated lime, lime kiln dust, cement kiln dust, other industrial alkaline solid wastes, or a combination thereof.

### Claim 16 (depends on 15)

The process of claim 15, wherein the aggregates are selected from coal combustion residues, recycled concrete aggregates, slag, lime, lime kiln dust, natural alkaline rocks, other industrial alkaline solid wastes, or combinations thereof.

### Claim 17

(canceled)

### Claim 18 (depends on 1)

The process of claim 1, wherein the gas processing apparatus 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.

### Claim 19

(canceled)

### Claim 20 (depends on 1)

The process of claim 1, wherein heat from the biomass combustion apparatus is conducted to the CO2-containing flue gas by hot air, hot water, steam, heat recovery from flue gas cooling, or a combination thereof.

### Claim at position 19

-13. (canceled)

### Claim 24 (depends on 1)

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) and volatile organic compounds (VOC), or a combination.

### Claim at position 21

25-18. (canceled)

### Claim 29 (depends on 1)

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

### Claim 30 (depends on 1)

The process of claim 1, wherein the conditioned gas has a temperature, relative humidity, CO2 amount, gas stream flow rate, or a combination thereof to provide a carbonation rate constant of the precursor that is at or above 0.005.

### Claim 31 (depends on 1)

The process of claim 1, comprising recirculating the conditioned gas out of and back into the carbonation chamber.

### Claim at position 25

-34. (canceled)

### Claim 35 (depends on 1)

The process of claim 1, comprising flowing the CO2-containing flue gas through a gas cleaning systems such as cyclone, baghouse filter, wet scrubber, or electrostatic precipitator to reduce particulate matter and acidic gases present in the CO2-containing flue gas.

### Claim 36 (depends on 1)

The process of claim 1, wherein the carbonation products are mainly calcium carbonate and alumina-silica gel, or a combination thereof.

### Claim at position 28

-38. (canceled)

### Claim 39 (depends on 1)

The process of claim 1, wherein the process occurs in a flow-through reactor.

### Claim 40

(canceled)

### Claim 41

(canceled)

### Claim 42 (depends on 1)

The process of claim 1, wherein the process occurs in a stirring reactor.

### Claim at position 33

-59. (canceled)

### Claim 60

An apparatus comprising:
a biomass combustion apparatus coupled to a gas processing apparatus;
wherein the gas processing apparatus is coupled to at least one or more carbonation chambers;
where the gas process apparatus is configured to condition CO2-containing flue gas from the biomass combustion apparatus to produce a conditioned gas;
wherein the conditioned gas has a different temperature, relative humidity, flow rate, or a combination thereof, than the CO2-containing flue gas; and
wherein the conditioned gas has the same concentration of CO2 as the CO2-containing flue gas without any carbon capture step.

### Claim at position 35

-67. (canceled)