Patent Application Titled "Binder Compositions and Method of Synthesis" Published Online (USPTO 20160075603)
By a News Reporter-Staff News Editor at Life Science Weekly -- According to news reporting originating from
Washington, D.C.
, by NewsRx journalists, a patent application by the inventors Neithalath, Narayanan (
Chandler, AZ
); Stone, David (
Tucson, AZ
), filed on September 16, 2015, was made available online on March 24, 2016 (see also
Patents).
No assignee for this patent application has been made.
Reporters obtained the following quote from the background information supplied by the inventors: "Anthropogenic emission of CO.sub.2 is accepted as being responsible for changes in global climate and potentially irreversible damaging impacts on ecosystems and societies. Various technologies designed to reduce the amount of greenhouse gases such as CO.sub.2 in the atmosphere is an active research area through the developed and developing world. The sequestration of CO.sub.2 offers the potential to prevent CO.sub.2 from entering the atmosphere (i.e., by removal of the CO2 from an industrial waste stream), or a potential route to extraction of CO.sub.2 that is already present in the atmosphere. Physical trapping of CO.sub.2, such as injection of CO.sub.2 into depleted natural gas reservoirs under the seabed or into the deep ocean has not yet been proven to be a leak-proof technology option. Chemical sequestration on the other hand offers the potential to trap the CO.sub.2 virtually permanently. The use of mineral rocks (especially alkaline-earth oxide bearing rocks) as a feedstock for reaction with CO.sub.2 is one of the promising routes for reduction of concentration of CO.sub.2 in the atmosphere. CO.sub.2 is passed through the rock, and chemically sequestered through mineral carbonation. See for example, Klein, E.; Lucia, M. D.; Kempka, T.; Kuhn, M. Evaluation of Long-term Mineral Trapping at the Ketzin Pilot Site for CO.sub.2 Storage: An Integrative Approach Using Geochemical Modeling and Reservoir Simulation. Int. J. Greenhouse Gas control 2013, 19, 720-730, and Xu, T.; Apps, J. A.; Pruess, K.; Yamamoto, H. Numerical Modeling of Injection and Mineral Trapping of CO.sub.2 with H2S and SO2 in a Sandstone Formation. Chem. Geol. 2007, 242, 319-346, and Naganuma, T.; Yukimura, K.; Todaka, N.; Ajima, S. Concept and Experimental Study for a New Enhanced Mineral Trapping System by Means of Microbially Mediated Processes. Energy Procedia 2011, 4, 5079-5084.
"Many industrial processes produce metal and metal oxide wastes that require disposal. For example, particulate waste that includes some metallic iron or steel powder can be generated in significant amounts as bag-house dust waste during the Electric Arc Furnace (EAF) manufacturing process of steel and from the shot-blasting operations of structural steel sections. The traditional means of disposing EAF and shot-blasting dust is landfilling as it is not economically feasible to recycle the iron from the dust. Several million tons of such waste material is being landfilled at great costs all over the world. It is known that secondary carbonate rocks formed during mineral trapping demonstrate mechanical strength, which suggests the possibility of using mineral trapping in conjunction with a binder for the development of a sustainable construction material.
"Several studies on iron carbonate formation by CO.sub.2 corrosion of steel have been reported (see for example, Wu, S. L.; Cui, Z. D.; He, F.; Bai, Z. Q.; Zhu, S. L.; Yang, X. J. Characterization of the Surface Film Formed from Carbon Dioxide Corrosion on N80 Steel. Mater. Lett. 2004, 58, 1076-1081, and Nordsveen, M.; Ne{hacek over (s)}i , S.; Nyborg, R.; Stangeland, A. A Mechanistic Model for Carbon Dioxide Corrosion of Mild Steel in the Presence of Protective Iron Carbonate Films--Part 1: Theory and Verification. Corros. Sci. 2003, 59, 443-456, and Nesic, S.; Postlethwaite, J.; Olsen, S. An Electrochemical Model for Prediction of Corrosion of Mild Steel in Aqueous Carbon Dioxide Solutions. Corros. Sci. 1996, 52, 280-294, and Sun, J. B.; Zhang, G. A.; Liu, W.; Lu, M. X. The Formation Mechanism of Corrosion Scale and Electrochemical Characteristic of Low Alloy Steel in Carbon Dioxide-saturated Solution. Corros. Sci. 2012, 57, 131-138. In addition to iron oxidation, dissolved CO.sub.2 is also capable of reacting with iron. A dense layer of iron carbonate can form which adheres strongly to the substrate. For example, CO.sub.2 can react with iron as outlined in the following reaction equations (1), (2):
"Fe+2CO.sub.2+2H.sub.2O.fwdarw.Fe.sup.2++2HCO.sub.3.sup.-+H.sub.2.uparw. (1)
"Fe.sup.2++2HCO.sub.3.sup.-.fwdarw.FeCO.sub.3+CO.sub.2+H.sub.2O (2)
"The net reaction then can be defined by the following reaction equation (3):
"Fe+CO.sub.2+H.sub.2O.fwdarw.FeCO.sub.3+H.sub.2.uparw. (3)
"However the kinetics of the reaction and the rate of product formation are often very slow. To be of any use for beneficial industrial applications, a promoter including one or more reducing agents can be added to increase the rate of reaction. However the handling and processing properties of the mixtures of powders can prevent optimal mixing of materials, thereby preventing homogeneous reaction and compositional development."
In addition to obtaining background information on this patent application, NewsRx editors also obtained the inventors' summary information for this patent application: "Some embodiments of the invention include a method of producing iron carbonate binder compositions comprising providing a plurality of binder precursors including a powdered iron or steel, a first powdered additive comprising silica, a second powdered additive comprising calcium carbonate, and a powdered clay. The method includes providing a curing chamber including a first fluid coupling between a first end of the curing chamber and a first end of a CO.sub.2 source, and a second fluid coupling between a second end of the curing chamber and a second end of the CO.sub.2 source. The method further includes mixing the plurality of binder precursors and a water additive to form an uncured product, and feeding at least a portion of the uncured product into a curing chamber. Further, the method includes using CO.sub.2 at least partially from the CO.sub.2 source, curing at least a portion of the uncured product to form a cured iron carbonate containing product and at least one reaction byproduct.
"In some embodiments, the first powdered additive further comprises alumina. In some further embodiments, the powdered clay comprises at least one of kaolinite and metakaolin. In some embodiments, the water additive comprises at least one of effluent water and seawater. In some further embodiments of the invention, the plurality of binder precursors includes at least one organic reducing agent comprising at least one carboxylic acid additive. In some other embodiments, the at least one carboxylic acid additive comprises oxalic acid.
"Some embodiments include a second powdered additive that comprises limestone. In some further embodiments, the first powdered additive is derived from fly ash. In some embodiments, the powdered iron or steel comprises powdered iron or steel recycled from at least one industrial process.
"In some embodiments of the invention, the curing chamber is coupled to or integrated with an existing industrial process comprising the CO.sub.2 source. In some further embodiments, the CO.sub.2 source comprises a furnace of the existing industrial process. In some further embodiments, the CO.sub.2 source comprises at least one of a furnace, a boiler, a reactor or process vessel, a power station or generator, an oil or gas well or field, a natural or synthetic CO.sub.2 aquifer, a CO.sub.2 sequestration apparatus, and the atmosphere or environment.
"In some embodiments, the CO.sub.2 from the CO.sub.2 source is fed to the curing chamber by the second fluid coupling. In some embodiments, the flow rate of the CO.sub.2 is determined by at least one meter and is controlled by at least one valve. In some embodiments, the at least one reaction byproduct is fed from the curing chamber to the CO.sub.2 source by the first fluid coupling.
"In some embodiments of the invention, at least one reaction byproduct is hydrogen gas. In some further embodiments, the at least one reaction byproduct is CHxOy, where x=0-4 and y=0-2.
"In some embodiments, the flow rate of the at least one byproduct is determined by at least one meter and is controlled by at least one valve. In some embodiments, at least some of the carbonate of the iron carbonate containing product is formed from CO.sub.2 from the CO.sub.2 source. In some embodiments, the CO.sub.2 from the CO.sub.2 source is produced by an exothermic reaction driven at least in part by the at least one reaction byproduct.
DESCRIPTION OF THE DRAWINGS
"FIG. 1 illustrates a schematic of a method of synthesis and processing of binder compositions using a recycled reaction products integrated within a conventional furnace process in accordance with some embodiments of the invention.
"FIG. 2 provides an illustrative view of a scanning electron micrograph of iron particles according to one embodiment of the invention.
"FIG. 3A shows a plot of particle size distribution of metallic iron powder, OPC, fly ash, metakaolin, which is the clay source and limestone powder in accordance with at least one embodiment of the invention.
"FIG. 3B illustrates a table of compositions comprising mixtures of iron powder, fly ash, limestone and a clay source such as metakaolin and/or kaolinite in accordance with at least one embodiment of the invention.
"FIG. 4A illustrates a plot of compressive strength values of mixtures after 3 days in CO.sub.2 and 2 days in air in accordance with various embodiments of the invention.
"FIG. 4B illustrates a plot of compressive strength values of mixtures showing 7-day compressive strengths of plain and modified OPC mixtures for comparison with 4-day carbonated iron-carbonate (mixture 2: 60% iron powder, 20% fly ash, 8% limestone, 10% metakaolin) in accordance with various embodiments of the invention.
"FIG. 5A illustrates a plot of the effect of fly ash content on the compressive strength of iron carbonate binders in accordance with some embodiments of the invention.
"FIG. 5B illustrates a plot of the effect of limestone content on the compressive strength of iron carbonate binders in accordance with some embodiments of the invention.
"FIG. 5C illustrates a plot of the effect of metakaolin content on the compressive strength of iron carbonate binders in accordance with some embodiments of the invention.
"FIG. 6A illustrates a response surface plot showing the statistical influence of amounts of fly ash and metakaolin in accordance with some embodiments of the invention.
"FIG. 6B illustrates a response surface plot showing the statistical influence of amounts of fly ash and limestone in accordance with some embodiments of the invention.
"FIG. 6C illustrates a response surface plot showing the statistical influence of amounts of limestone and metakaolin in accordance with some embodiments of the invention.
"FIG. 7 shows a bar graph of the comparison of compressive strength of mixture 1 (comprising 64% iron powder, 20% fly ash, 8% limestone, 6% metakaolin) and mixture 2 (comprising 60% iron powder, 20% fly ash, 8% limestone, 10% metakaolin) under different curing conditions in accordance with some embodiments of the invention.
"FIG. 8A illustrates a surface plot of the effect of curing procedure and curing duration in accordance with some embodiments of the invention.
"FIG. 8B shows a bar graph of the effect of air-curing duration on compressive strength of mixture 2 (comprising 60% iron powder, 20% fly ash, 8% limestone, 10% metakaolin), and carbonated for 4 days in accordance with some embodiments of the invention.
"FIG. 9 illustrates a graph showing variations in average pore diameter with varying carbonation durations for mixture 2 (comprising 60% iron powder, 20% fly ash, 8% limestone, 10% metakaolin) in accordance with some embodiments of the invention.
"FIG. 10A illustrates a plot showing a logarithmic increase of flexural strength with increase in carbonation duration, where mixture 1 comprises 64% iron powder, 20% fly ash, 8% limestone, 6% metakaolin, and mixture 2 comprises 60% iron powder, 20% fly ash, 8% limestone, 10% metakaolin in accordance with some embodiments of the invention.
"FIG. 10B illustrates a plot showing the interaction between bulk density and flexural strength for the mixtures of FIG. 10A in accordance with some embodiments of the invention.
"FIG. 11A shows a plot including thermogravimetric and differential thermogravimetric curves corresponding to the core and surface of mixture 2 (comprising 60% iron powder, 20% fly ash, 8% limestone, 10% metakaolin), carbonated for 3 days in accordance with some embodiments of the invention.
"FIG. 11B shows a plot including thermogravimetric and differential thermogravimetric curves corresponding to the core and surface of mixture 6 (comprising 65% iron powder, 15% fly ash, 8% limestone, 10% metakaolin), carbonated for 3 days in accordance with some embodiments of the invention.
"FIG. 12A illustrates thermal analysis results of samples from mixture 2 (comprising 60% iron powder, 20% fly ash, 8% limestone, 10% metakaolin) carbonated for 1 day, where samples were exposed to air for 3 days after carbonation in accordance with some embodiments of the invention.
"FIG. 12B illustrates thermal analysis results of samples from mixture 2 (comprising 60% iron powder, 20% fly ash, 8% limestone, 10% metakaolin) carbonated for 2 days, where samples were exposed to air for 3 days after carbonation in accordance with some embodiments of the invention.
"FIG. 12C illustrates thermal analysis results of samples from mixture 2 (comprising 60% iron powder, 20% fly ash, 8% limestone, 10% metakaolin) carbonated for 3 days, where samples were exposed to air for 3 days after carbonation in accordance with some embodiments of the invention.
"FIG. 12D illustrates thermal analysis results of samples from mixture 2 (comprising 60% iron powder, 20% fly ash, 8% limestone, 10% metakaolin) carbonated for 4 days, where samples were exposed to air for 3 days after carbonation in accordance with some embodiments of the invention.
"FIG. 13A illustrates a plot of the effect of carbonation duration on mass loss in the 250-400.degree. C. range in thermogravimetric analysis in accordance with some embodiments of the invention.
"FIG. 13B illustrates a plot of the effect of carbonation duration on the amount of CaCO.sub.3 remaining in the 250-400.degree. C. range in thermogravimetric analysis in accordance with some embodiments of the invention."
For more information, see this patent application: Neithalath, Narayanan; Stone, David. Binder Compositions and Method of Synthesis. Filed September 16, 2015 and posted March 24, 2016. Patent URL: http://appft.uspto.gov/netacgi/nph-Parser?Sect1=PTO2&Sect2=HITOFF&u=%2Fnetahtml%2FPTO%2Fsearch-adv.html&r=5651&p=114&f=G&l=50&d=PG01&S1=20160317.PD.&OS=PD/20160317&RS=PD/20160317
Keywords for this news article include: Anions, Patents, Alkalies, Chemistry, Carbonates, Carbonic Acid, Carbon Dioxide, Electrochemical, Inorganic Carbon Compounds.
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