Methods and compositions for low-carbon concrete production using carbon dioxide and solid waste streams

Abstract

Set forth herein are methods for producing low-carbon concrete components comprising a cementitious mixture of industrial solid wastes such as coal combustion residues, lime, kiln dust, and gypsum. These cementitious mixtures are a substantial replacement for Portland cement-based concrete mixtures. The methods herein include mixing materials, pressing, and shaping the mixed materials into a structural concrete component, and exposing the structural component to carbon dioxide. The CO2 may be sourced from CO2 emission sources (e.g., waste CO2-containing gas stream, dilute flue gas stream, a concentrated CO2 gas stream, a commercially available CO2 source, liquefied CO2, or from the atmosphere) to harden and thereby form structural concrete components. In some examples, the finished concrete components (e.g., concrete block) are compliant with industry-standard requirements for use in construction applications and feature significantly lower carbon intensity compared to traditional cement-based concrete components.

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