Abstract: A thermoresponsive suspension composition for use in additive manufacturing includes an aqueous suspension of a thermosetting resin, a crosslinking agent configured to react with the thermosetting resin, and a mineral particulate, wherein the thermosetting resin and crosslinking agent react at or above a trigger temperature.

Abstract: The instant disclosure sets forth a process for re-activating a mineral residue. The process includes providing a mineral residue, which includes a core and a shell around the core. In certain examples, the core comprises calcium (Ca), magnesium (Mg), or a combination thereof. The Ca and Mg is not present as elemental Ca or Mg but rather as a compound of Ca or of Mg, such as but not limited to Ca(OH)2 or Mg(OH)2. In certain examples, the shell comprises an oxide, a hydroxide, a carbonate, a silicate, a sulfite, a sulfate, a chloride, a nitrate, or nitrite, of calcium (Ca) or of magnesium (Mg), or a combination thereof. The process includes (a) fractionating the mineral residue; (b) contacting the mineral residue with an acid and fractionating the mineral residue; or (c) contacting the mineral residue with a base and fractionating the mineral residue. As a result, the mineral residue's core is exposed.

Abstract: Described herein are processes for synthesizing hydraulic-carbonating binder systems through mechanochemical process, including providing a blend of material stream one of aluminosilicate or calcium aluminosilicate mineral material and material stream two of alkaline-rich mineral material; and simultaneously fractioning the blended minerals while contacting the blended minerals with a CO2-containing in the mechanochemical reactor. This binder system is useful for cementation functions in concrete. The precipitated carbonation products are mainly calcium carbonates (CaCO3), magnesium carbonates (MgCO3), and amorphous alumina-silica gel. The developed binder system is activated through hydration and/or concurrent hydration-carbonation reactions in concrete and it can be utilized in the form of slurry or dried powder for a wide range of precast and cast-in-place or ready-mix concrete applications.

Abstract: Provided herein are compositions and methods of carbonation processing for the fabrication of cementitious materials and concrete products. Embodiments include manufacturing processes of a low-carbon concrete product comprising: forming a cementitious slurry including portlandite; shaping the cementitious slurry into a structural component; and exposing the structural component to a CO2 waste stream, thereby enabling manufacture of the low-carbon concrete product.

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.

Abstract: The disclosure herein sets forth processes and compositions for producing carbonated materials comprising calcium carbonates through a mechanochemical process. The present disclosure concerns the production of calcium carbonate by sequestrating CO2. Certain processes herein include providing alkaline-rich mineral materials that include carbonatable solid wastes such as lime kiln dust, cement kiln dust, and coal combustion residues, and simultaneously fractioning the alkaline-rich mineral materials, while contacting the alkaline-rich mineral materials with a CO2-containing gas in carbonation reactor at low temperature and ambient pressure. In some embodiments, the alkaline-rich mineral materials are partially carbonated before being used in the processes disclosed herein. After contacting the alkaline-rich mineral materials with a CO2-containing gas in carbonation reactor at low temperature and ambient pressure, solid calcium carbonate is produced.

Abstract: A thermoresponsive suspension composition for use in additive manufacturing includes an aqueous suspension of a thermosetting resin, a crosslinking agent configured to react with the thermosetting resin, and a mineral particulate, wherein the thermosetting resin and crosslinking agent react at or above a trigger temperature.

Abstract: A method of forming a concrete product includes directly capturing CO2 from a gas source, the capturing comprising contacting the gas source with an absorption solution having a solvent and a solute, wherein the solvent and/or the solute are capable of reacting with CO2 to form an anionic compound, adjusting the pH of the absorption solution electrochemically to less than about 7 to release the CO2 as a concentrated vapor containing CO2, collecting the concentrated vapor containing CO2, regenerating the solvent and/or the solute, and optionally collecting the regenerated solvent and/or solute; flowing the concentrated vapor containing CO2 through a gas processing unit to adjust at least one of a temperature, a relative humidity, or a flow rate of the concentrated vapor containing CO2; and contacting the concentrated vapor containing CO2 with a concrete component.

Abstract: Provided herein are compositions and methods of carbonation processing for the fabrication of cementitious materials and concrete products. Embodiments include manufacturing processes of a low-carbon concrete product comprising: forming a cementitious slurry including portlandite; shaping the cementitious slurry into a structural component; and exposing the structural component to a CO2 waste stream, thereby enabling manufacture of the low-carbon concrete product.

Abstract: Provided herein are systems for carbonation curing and CO2 mineralization of concrete composites and methods of manufacturing a carbonated concrete composite. A method of manufacturing a carbonated concrete composites includes contacting concrete with CO2-containing gas streams in the carbonation reactor having a gas stream inlet and an outlet to provide optimal gas flow distribution and gas velocity. The concrete precursor includes a binder, one or more aggregates, and water. A gas stream is received at the carbonation reactor. The gas stream includes carbon dioxide. The concrete precursor is maintained at a suitable temperature in the carbonation reactor to thereby react the concrete precursor with the gas stream to produce carbonate minerals in the carbonated concrete composite.

Abstract: Provided herein are compositions and methods of carbonation processing for the fabrication of cementitious materials and concrete products. Embodiments include manufacturing processes of a low-carbon concrete product comprising: forming a cementitious slurry including portlandite; shaping the cementitious slurry into a structural component; and exposing the structural component to a CO2 waste stream, thereby enabling manufacture of the low-carbon concrete product.

Abstract: Provided herein are compositions and methods of carbonation processing for the fabrication of cementitious materials and concrete products. Embodiments include manufacturing processes of a low-carbon concrete product comprising: forming a cementitious slurry including portlandite; shaping the cementitious slurry into a structural component; and exposing the structural component to a CO2 waste stream, thereby enabling manufacture of the low-carbon concrete product.