Patents by Inventor Maciej Zajac
Maciej Zajac has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Patent number: 12338172Abstract: A method for manufacturing hydraulically hardening building materials, includes the steps of: providing concrete demolition waste with a maximum particle size of up to 150 mm as a starting material, mixing the starting material with water to form a feedstock slurry, introducing carbon dioxide or a precursor thereof into the feedstock slurry to form carbonated concrete fines in an amount from 1 to 100 wt.-% of the hardened binder contained in the starting material and to detach the concrete fines from the aggregate contained in the starting material to form a product slurry, and mixing the product slurry with a cement forming the building material, and use of the obtainable building material for manufacturing building structures as well as method for manufacturing a supplementary cementitious material slurry.Type: GrantFiled: October 8, 2020Date of Patent: June 24, 2025Assignee: HSustainability GmbHInventors: Jan Skocek, Maciej Zajac, Wolfgang Dienemann, Mohsen Ben Haha
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Publication number: 20250154063Abstract: A method for improving the reactivity of carbonated recycled concrete paste including sulfur in an oxidation state lower than 6+ as supplementary cementitious material includes the steps: providing a starting material including recycled concrete paste; carbonation of the starting material with carbon dioxide contained in an exhaust gas containing from 2 to 15 Vol.-% oxygen and/or from 35 to 400 vppm sulfur dioxide to provide carbonated recycled concrete paste; and oxidation of the carbonated recycled concrete paste simultaneously or subsequently to the carbonation with an added oxidizing agent to provide the supplementary cementitious material, and method for making composite cements.Type: ApplicationFiled: March 9, 2023Publication date: May 15, 2025Applicant: HSustainability GmbHInventors: Maciej ZAJAC, Jan SKOCEK, Nicolas PATO
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Publication number: 20250144565Abstract: Carbon capture method for an industrial plant off-gas involves removing mercury and/or other heavy metals from the off-gas by contacting the off-gas with an at least partially hydrated cement paste as sorbent in a scrubber before a concentration step of the off-gas to concentrate CO2. The at least partially hydrated cement paste is simultaneously carbonated and loaded with the mercury and/or other heavy metals during contacting with the off-gas and is used as supplementary cementitious material in composite cement. The at least partially hydrated cement paste is used as sorbent in a scrubber before a concentration step of the off-gas to concentrate CO2.Type: ApplicationFiled: March 9, 2023Publication date: May 8, 2025Applicant: HSustainability GmbHInventors: Francisco CARRASCO MALDONADO, Maciej ZAJAC, Nicolas PATO
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Publication number: 20240425411Abstract: A method for manufacturing a supplementary cementitious material has improved reactivity from waste concrete, wherein a starting material including waste concrete is provided, subjected to carbonation to provide a carbonated product having a carbonation degree of at least 50%, and the carbonated product is heat treated at a temperature ranging from 120 to 350° C. until constant mass to provide the supplementary cementitious material with improved reactivity. The obtained supplementary cementitious material can be used to manufacture composite cements.Type: ApplicationFiled: September 8, 2022Publication date: December 26, 2024Applicant: HConnect 2 GmbHInventors: Maciej ZAJAC, Jan SKOCEK
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Publication number: 20240383807Abstract: A method for sequestering carbon dioxide includes providing a starting material having calcium ions, sulfate and/or sulfite ions, and alkali metal ions with a molar ratio ? Alk:? SO3>2.00, reacting the starting material with carbon dioxide at a pressure in the range from ambient up to 3.5 bar overpressure and/or a temperature in the range from 10 to 145° C. to obtain a carbonated product comprising calcium carbonate and alkali sulfate. The obtained product is used as a set regulator or accelerator for cement and/or as a minor or main cement component.Type: ApplicationFiled: February 3, 2022Publication date: November 21, 2024Applicants: HConnect 2 GmbH, HEIDELBERGCEMENT AGInventors: Maciej ZAJAC, Jan SKOCEK, Gerd BOLTE, Mohsen BEN HAHA
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Publication number: 20240375998Abstract: A method for producing a pozzolanic product by hydrothermal treatment of a feedstock including silicate, aluminate, and/or aluminosilicate materials, and a source of calcium ions, wherein the feedstock has a molar ratio of Ca:(Si+Al) from 0.4 to 1.2 and a maximum content of hydrated cement paste of 10 wt.-%, to provide a hydrate product, and subsequent carbonation of the hydrate product to provide a pozzolanic product including calcium carbonate and silica gel, alumina gel and/or silica-alumina gel. A pozzolanic product is obtainable by the method. The pozzolanic product is used as a supplementary cementitious material for manufacturing a composite cement including the pozzolanic product and a hydraulic cement.Type: ApplicationFiled: September 8, 2022Publication date: November 14, 2024Applicant: HSustainability GmbHInventors: Jan SKOCEK, Maciej ZAJAC
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Publication number: 20240376004Abstract: Composition comprising a polyphosphate, an amine and an inorganic sulfate compound for enhancing the workability and/or the strength development of hydraulic binders comprising a cement and a high water demand supplementary cementitious material and/or a high water demand filler.Type: ApplicationFiled: June 28, 2022Publication date: November 14, 2024Applicant: HConnect 2 GmbHInventors: Mohsen BEN HAHA, Arnaud MULLER, Maciej ZAJAC
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Publication number: 20240351947Abstract: A method for producing a supplementary cementitious material from concrete waste and similar materials includes the steps of i) providing a starting material comprising hydrated cement and aggregate comprising silicate and/or alumino-silicate, ii) hydrothermal treatment of the starting material provided in step i) to obtain a hydrothermally activated material, and iii) carbonation of the hydrothermally activated material of step ii) to provide the supplementary cementitious material, as well as supplementary cementitious material obtainable by the method, hydraulic binder comprising the supplementary cementitious material and use of the supplementary cementitious material and of the hydraulic binder for making hydraulic building materials.Type: ApplicationFiled: May 4, 2022Publication date: October 24, 2024Applicant: HConnect 2 GmbHInventors: Maciej ZAJAC, Jan SKOCEK, Frank BULLERJAHN, Gerd BOLTE
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Publication number: 20240262743Abstract: A method for separating hydrated concrete paste from aggregate includes the steps of providing a feedstock comprising waste concrete with a D10?0.1 mm and a D90?100 mm, passing the feedstock, a water containing liquid and carbon dioxide into a fragmentation vessel, where the wet feedstock is subjected to electric-pulse fragmentation, withdrawing fragmented solid material from the fragmentation vessel, separating the fragmented solid material from admixed liquid phase, separating the fragmented solid material into a fine fraction with a maximum particle size of 250 ?m to provide the carbonated recycled concrete paste and a coarse fraction, recycling the coarse fraction into the fragmentation vessel and/or discharging the coarse fraction as clean aggregate, use of the recycled concrete paste obtained thereby as supplementary cementitious material or filler.Type: ApplicationFiled: July 22, 2022Publication date: August 8, 2024Applicant: HConnect 2 GmbHInventors: Nicolas PATO, Maciej ZAJAC, Jan SKOCEK, Eckhard WAGNER
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Publication number: 20240067565Abstract: A method for converting a starting material containing at least 40 wt.-% of calcium silicon (hydr)oxide phases and calcium aluminum (hydr)oxide phases into an SiO2 rich SCM and a calcium carbonate additive includes the steps: providing the starting material with a D90 of ?1 mm, mixing the starting material with water or adjusting the water content to provide a starting material slurry having a solid:liquid weight ratio from 2:1 to 1:100, passing the starting material slurry together with carbon dioxide into a gravity separation reactor, subjecting the starting material slurry and carbon dioxide to centrifugal motion inside the reactor, and removing a heavy slurry from a first outlet of the reactor, removing a light slurry of lower density particles from a second outlet of the reactor, and removing liquid at a third outlet of the reactor.Type: ApplicationFiled: March 2, 2022Publication date: February 29, 2024Applicant: HConnect 2 GmbHInventors: Maciej ZAJAC, Nicolas PATO, Jan SKOCEK
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Publication number: 20230357084Abstract: A method for manufacturing concrete parts has the steps of: providing a hydraulic cement and aggregate; mixing the cement and aggregate with water to provide a fresh concrete; introducing CO2 into the fresh concrete in an amount resulting in a carbonation degree of more than 0.5 wt.-% and less than 5 wt.-% of the total carbonatable Ca and Mg phases for a first carbonation step; curing the fresh concrete until at least 15 wt.-% of the calcium aluminates are hydrated to provide a green concrete part; subjecting the green concrete part to CO2 in an amount resulting in a carbonation degree of more than 10 wt.-% of the total carbonatable Ca and Mg phases for a final carbonation step; and storing the part for 0.5 hours to 28 days for further hydration of not-yet carbonated, not-yet hydrated cement to provide the concrete part. and concrete parts obtainable with the method.Type: ApplicationFiled: July 28, 2021Publication date: November 9, 2023Applicant: HConnect 2 GmbHInventors: Maciej ZAJAC, Jan SKOCEK, Mohsen BEN HAHA
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Publication number: 20230348330Abstract: The present invention relates to a supplementary cementitious material, a method for producing the supplementary cementitious material, the use of the supplementary cementitious material, a binder comprising the supplementary cementitious material, a method for the preparation of the binder and use of the binder to make hydraulic building materials like concrete.Type: ApplicationFiled: October 4, 2021Publication date: November 2, 2023Applicant: HConnect 2 GmbHInventors: Mohsen BEN HAHA, Gerd BOLTE, Frank BULLERJAHN, Wolfgang DIENEMANN, Jan SKOCEK, Maciej ZAJAC
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Patent number: 11753340Abstract: A method for manufacturing supplementary cementitious material and sequestering CO2 by carbonating concrete fines has the following steps: grinding the concrete fines obtained from crushed concrete demolition waste in a mill at a temperature from 1 to 10° C. above the water dew point in a carbonating atmosphere provided by a gas containing from 10 to 99 Vol.-% CO2, circulating the ground and partially carbonated concrete fines in a fluidized bed reactor in contact with the carbonating atmosphere, and withdrawing decarbonated gas and carbonated concrete fines.Type: GrantFiled: May 25, 2020Date of Patent: September 12, 2023Assignee: HConnect 2 GmbHInventors: Jan Skocek, Maciej Zajac, Mohsen Ben Haha, Stefan Federhen, Marek Majchrowicz
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Patent number: 11642625Abstract: A method of exhaust gas scrubbing includes providing recycled concrete fines as a waste material rich in carbonatable Ca and/or Mg phases and with d90?1000 ?m and a Rosin-Rammler slope n from 0.6 to 1.4 , injecting the waste material into an exhaust gas stream containing CO2 and/or SOx for reaction with CO2 and/or SOx at a relative humidity of 50 to 100 Vol.-% and a temperature from 40 to 130° C. in an amount of dry waste material ranging from 5 to 30 kg/m3, withdrawing a partly carbonated and/or sulphurized waste material and purified exhaust gas, and recycling a part of the partly carbonated and sulphurized waste material while the remainder is discharged, as well as use of a waste material slurry for exhaust gas cleaning of CO2 and/or SOx.Type: GrantFiled: June 4, 2020Date of Patent: May 9, 2023Assignee: HConnect 2 GmbHInventors: Jan Skocek, Maciej Zajac, Mohsen Ben Haha, Stefan Federhen
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Publication number: 20230036356Abstract: A method for manufacturing hydraulically hardening building materials, includes the steps of: providing concrete demolition waste with a maximum particle size of up to 150 mm as a starting material, mixing the starting material with water to form a feedstock slurry, introducing carbon dioxide or a precursor thereof into the feedstock slurry to form carbonated concrete fines in an amount from 1 to 100 wt.-% of the hardened binder contained in the starting material and to detach the concrete fines from the aggregate contained in the starting material to form a product slurry, and mixing the product slurry with a cement forming the building material, and use of the obtainable building material for manufacturing building structures as well as method for manufacturing a supplementary cementitious material slurry.Type: ApplicationFiled: October 8, 2020Publication date: February 2, 2023Applicant: HConnect 2 GmbHInventors: Jan SKOCEK, Maciej ZAJAC, Wolfgang DIENEMANN, Mohsen BEN HAHA
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Patent number: 11384017Abstract: A method for manufacturing a binder of a hydratable material includes providing a starting material from one or more raw materials convertible by tempering at 600 to 1200° C. into the hydratable material, tempering the starting material to provide the hydratable material containing not more than 10% by weight monocalcium silicate and at least 15% by weight hydratable phases in the form of lime and dicalcium silicate, wherein the residence time and the tempering temperature are adapted to obtain the hydratable material by converting not more than 80% by weight of the starting material, and cooling the hydratable material to provide the binder comprising the hydratable material. The binder can be mixed with water and optionally one or more of aggregate, additives, admixtures to obtain a binder paste that is placed, hydrated and carbonated to produce a building product.Type: GrantFiled: October 2, 2018Date of Patent: July 12, 2022Assignee: HConnect 2 GmbHInventors: Jan Skocek, Maciej Zajac, Gerd Bolte, Mohsen Ben Haha
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Publication number: 20220212992Abstract: A method for manufacturing supplementary cementitious material and sequestering CO2 by carbonating concrete fines has the following steps: grinding the concrete fines obtained from crushed concrete demolition waste in a mill at a temperature from 1 to 10° C. above the water dew point in a carbonating atmosphere provided by a gas containing from 10 to 99 Vol.-% CO2, circulating the ground and partially carbonated concrete fines in a fluidized bed reactor in contact with the carbonating atmosphere, and withdrawing decarbonated gas and carbonated concrete fines.Type: ApplicationFiled: May 25, 2020Publication date: July 7, 2022Applicant: HConnect 2 GmbHInventors: Jan SKOCEK, Maciej ZAJAC, Mohsen BEN HAHA, Stefan FEDERHEN, Marek MAJCHROWICZ
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Publication number: 20220152554Abstract: A method of exhaust gas scrubbing includes providing recycled concrete fines as a waste material rich in carbonatable Ca and/or Mg phases and with d90?1000 ?m and a Rosin-Rammler slope n from 0.6 to 1.4 , injecting the waste material into an exhaust gas stream containing CO2 and/or SOx for reaction with CO2 and/or SOx at a relative humidity of 50 to 100 Vol.-% and a temperature from 40 to 130° C. in an amount of dry waste material ranging from 5 to 30 kg/m3, withdrawing a partly carbonated and/or sulphurized waste material and purified exhaust gas, and recycling a part of the partly carbonated and sulphurized waste material while the remainder is discharged, as well as use of a waste material slurry for exhaust gas cleaning of CO2 and/or SOx.Type: ApplicationFiled: June 4, 2020Publication date: May 19, 2022Applicant: HConnect 2 GmbHInventors: Jan SKOCEK, Maciej ZAJAC, Mohsen BEN HAHA, Stefan FEDERHEN
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Method for simultaneous exhaust gas cleaning and manufacturing of supplementary cementitous material
Patent number: 11208350Abstract: A method for manufacturing a binder of a hydratable material includes providing a starting material from one or more raw materials convertible by tempering at 600 to 1200° C. into the hydratable material and tempering the starting material to provide the hydratable material containing not more than 10% by weight monocalcium silicate and at least 15% by weight hydratable phases in the form of lime and dicalcium silicate. The residence time and the tempering temperature are adapted to obtain the hydratable material by converting not more than 80% by weight of the starting material, and the hydratable material is then cooled to provide the binder comprising the hydratable material. The binder can be mixed with water and optionally one or more of aggregate, additives, admixtures to obtain a binder paste that is placed, hydrated and carbonated to produce a building product.Type: GrantFiled: December 13, 2018Date of Patent: December 28, 2021Assignee: HConnect 2 GmbHInventors: Jan Skocek, Maciej Zajac, Mohsen Ben Haha, Gerd Bolte -
Patent number: 11111180Abstract: A method of manufacturing building elements has the steps: providing a binder comprising at least 8% by weight ternesite, at least 15% by weight dicalcium silicate and at least 5% by weight ye'elimite, each with respect to the total binder, as hydraulically reactive phases; mixing the binder with water to form a paste; casting the paste into a desired shape for the building element; reacting the paste hydraulically to form calcium-silicate-hydrates, calcium-aluminium-silicate-hydrates, portlandite, brucite, strätlingite, hydrotalcite-like phases and ettringite/AFm and capillary pores, and carbonation hardening to provide the building element and to building elements obtainable by the method.Type: GrantFiled: September 18, 2018Date of Patent: September 7, 2021Assignee: HConnect 2 GmbHInventors: Jan Skocek, Maciej Zajac, Mohsen Ben Haha, Frank Bullerjahn