Manufacturing of Ultra-Lightweight Composites Through Accelerated CO2 Mineralization

Abstract

A method for producing ultra-lightweight concrete (ULWC), includes: generating CO2 foam including nanobubbles; forming a brine paste including nanocrystals and nanopores by mixing the nanobubbles with a brine solution; generating the CO2 foam including microbubbles, where pore sizes of the microbubbles are larger than pore sizes of the nanobubbles; mixing the microbubbles into the brine paste, where the nanocrystals comprised in the brine paste distributes along a surface of each microbubble; and mixing fiber hairs into the brine paste and the microbubbles. Ultra-lightweight aggregate (ULWA) may be formed using the ULWC. A method for producing ULWC panels, includes: printing creases on alkali-resistant fiber paper sheets; folding the fiber paper sheets along the creases; affixing the folded fiber paper sheets into a 3D structure with open channels; injecting atomized brine water into surfaces of the open channels; and injecting CO2 gas into the open channels until filled with carbonate crystals.

Dependencies are inferred from the claim text.