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Direct Carbon Dioxide Utilization from Flue Gas to Produce Concrete Components

Technology Overview

The technology provider converts carbon dioxide (CO2) emissions from industrial flue gas streams (e.g., emissions from power plants, petrochemical plants, etc.) into concrete (construction) components with a much lower CO2 footprint than conventional materials. This disruptive approach to carbon capture and utilization (CCU) demonstrates unprecedented energy efficiency and scalability, because it (1) utilizes CO­2 directly from flue gases without needing an expensive and energy-intensive CO2 capture system and (2) makes use of low cost and abundant material inputs. The technology is based on the concept of “CO2 mineralization,” whereby the binder materials (e.g., hydrated lime and inorganic industrial wastes) take up CO2 from the flue gas and form stable carbonate minerals. The patent-pending CO2 mineralization process is energy efficient and cost effective, as it can be operated at ambient temperature and pressure, using low grade waste heat from flue gases. The concrete products manufactured demonstrate equivalent or superior performance to conventional concrete, without a need for CO2-intensive cement. This technology is of interest to companies that need to economically reduce their CO2 emissions, and to construction companies looking for green building materials.

Technology Features & Specifications

The technology comprises a modular reactor system for utilization/uptake of CO2 from flue gas streams to form carbonate binding agents; procedures for optimal operation of this system, and mixture formulations required for efficient production of concrete components that exceed industry performance standards. The reactor system is designed for simple “bolt-on” integration into emissions streams at the stack to facilitate system operations. The technology features include:

  • Permanent CO2 sequestration into construction products
  • Low cost of CO2 utilization by direct uptake from flue gases
  • Process flexibility to utilize diverse flue gas streams and reactant formulations to exceed customer specifications
  • Inexpensive material inputs, including low-value industrial wastes
  • Utilization of abundant materials and existing CAPEX to minimize implementation costs

Potential Applications

This technology can be employed by any industry that operates facilities that emit CO2 and is looking to economically reduce its emissions profile. Common examples include petrochemical refining and manufacturing facilities, fossil fuel power plants (coal or natural gas-fired), waste incinerators, and cement kilns. The concrete products produced by this technology are also of interest to engineers, architects, contractors, and end-users looking for green, low-carbon construction materials.

Market Trends and Opportunities

This process fulfills an urgent market need for technologies that convert CO2 into construction products (i.e., via carbon capture and utilization, CCU), which is expected to grow into a USD500 billion market by 2030. The current global market for concrete products is approximately USD1 trillion, and a majority of this market can be fulfilled by CCU technologies for concrete production. This market need is made more urgent by the quickening pace of climate change, and financial and policy incentives aimed towards engendering global CO2 emissions reductions. This technology describes the process and production methods required for CO2 removal and production of low carbon construction products to meet this tremendous market need.

Customer Benefits

  • Impactfully reduce greenhouse gas (GHG) emissions with quantifiable progress towards meeting emissions reduction goals, while requiring far lower costs than other technologies
  • Serves as the cornerstone of a company’s sustainability program which will illustrate a company’s commitment to the reduction of CO2 emissions
  • Reduces risk profile and demonstrates a commitment to continuous improvement
  • Efficiently produces valuable “low-carbon” concrete products to meet the growing global demand for green construction materials

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