Search

US-12617717-B2 - Compositions and methods relating to increased carbon dioxide uptake in mixing and curing of concrete

US12617717B2US 12617717 B2US12617717 B2US 12617717B2US-12617717-B2

Abstract

Cementitious compositions comprising lime, which may be foamed or non-foamed compositions, may increase carbon dioxide uptake of the cementitious compositions. Said cementitious compositions may be used in various cementing methods including pre-casting methods, cast-in-place methods, and primary or secondary cementing operations in a wellbore. The carbon dioxide may be added to the cementitious compositions during mixing, during pre-conditioning, during curing, or any combination thereof. Further, the carbon dioxide may be delivered as a gas (e.g., a gas that includes 1 vol % to 100 vol % carbon dioxide) or as a gas-entrained admixture that includes the gas, water, and a foaming agent.

Inventors

  • Mohammed AL MEHTHEL
  • Sami A. AL ABDULJABBAR
  • Waseem Rahim KHATRI

Assignees

  • SAUDI ARABIAN OIL COMPANY

Dates

Publication Date
20260505
Application Date
20230315

Claims (6)

  1. 1 . A method comprising: mixing a cementitious composition comprising: lime at 0.1 kg/m 3 to 500 kg/m 3 based on the dry weight of the cementitious composition; a cement binder at 0.1 kg/m 3 to 500 kg/m 3 based on a dry weight of the cementitious composition; optionally, a secondary cementitious material at 0.1 kg/m 3 to 350 kg/m 3 based on the dry weight of the cementitious composition; fine aggregates at 300 kg/m 3 to 1500 kg/m 3 based on the dry weight of the cementitious composition; coarse aggregates at 300 kg/m 3 to 1200 kg/m 3 based on the dry weight of the cementitious composition; water in a weight ratio to the cement binder, the secondary cementitious material, and the lime cumulatively of 0.2:1 to 0.8:1; and a foaming agent at 0.01 wt % to 1 wt % based on a weight of the water; and wherein the cementitious composition has a maximum dry weight of 2000 kg/m 3 ; wherein the cementitious composition except a gas is mixed for at least 1 minute to 30 minutes, the gas comprising carbon dioxide; subsequently, injecting the gas into the cementitious composition and mixing at least 5 seconds to 5 minutes; subsequently, placing the cementitious composition having the gas therein in a desired location; and allowing the cementitious composition having the gas therein to cure to a concrete composition.
  2. 2 . The method of claim 1 further comprising: mixing of the cementitious composition having the gas therein for at least 30 seconds to 3 minutes.
  3. 3 . The method of claim 1 , wherein the gas is a first gas, and wherein the method further comprises: exposing the cementitious composition after being placed in the desired location to a second gas that comprises carbon dioxide.
  4. 4 . The method of claim 1 , wherein the carbon dioxide is present in the gas at 1 vol % to 100 vol %.
  5. 5 . The method of claim 1 , wherein the cementitious composition further comprises one or more additives at 0.1 wt % to 1 wt % based on a total weight of cementitious components in the cementitious composition.
  6. 6 . The method of claim 1 , wherein the cementitious composition further comprises 0.1 wt % to 2 wt % of an admixture of a water reducer additive and a retarder additive based on the weight of the cement binder.

Description

FIELD OF THE DISCLOSURE The present disclosure relates generally to compositions and methods that increase carbon dioxide uptake in mixing and curing of concrete. BACKGROUND OF THE DISCLOSURE Carbonation of cements hydration products uses carbon dioxide to convert calcium-containing minerals into concrete. For example, calcium hydroxide (CH) and calcium silicate hydrate (C—S—H) reacts with carbon dioxide to produce CaCO3. This process typically has a faster curing time than traditional hydration curing. SUMMARY OF THE DISCLOSURE Various details of the present disclosure are hereinafter summarized to provide a basic understanding. This summary is not an exhaustive overview of the disclosure and is neither intended to identify certain elements of the disclosure, nor to delineate the scope thereof. Rather, the primary purpose of this summary is to present some concepts of the disclosure in a simplified form prior to the more detailed description that is presented hereinafter. An embodiment consistent with the present disclosure includes a method comprising: mixing the cementitious composition of Embodiment A; injecting a gas into the cementitious composition, the gas comprising carbon dioxide; placing the cementitious composition having the gas therein in a desired location; and allowing the cementitious composition having the gas therein to cure to a concrete composition. Another embodiment consistent with the present disclosure includes a method comprising: mixing a cementitious composition comprising: a cement binder at 0 kg/m3 to 500 kg/m3 based on a dry weight of a cementitious composition; optionally, a secondary cementitious material at 0.1 kg/m3 to 350 kg/m3 based on the dry weight of the cementitious composition; lime at 0.1 kg/m3 to 500 kg/m3 based on the dry weight of the cementitious composition; fine aggregates at 300 kg/m3 to 1500 kg/m3 based on the dry weight of the cementitious composition; and coarse aggregates at 300 kg/m3 to 1200 kg/m3 based on the dry weight of the cementitious composition; and wherein the cementitious composition has a maximum dry weight of 2000 kg/m3; injecting a gas-entrained admixture into the cementitious composition, the gas-entrained mixture comprising carbon dioxide, water in a weight ratio to the cement binder, the secondary cementitious material, and the lime cumulatively of 0.2:1 to 0.8:1, and a foaming agent at 0.01 wt % to 1 wt % based on a weight of the water; placing the cementitious composition having the gas-entrained mixture therein in a desired location; and allowing the cementitious composition to cure to a concrete composition. Yet another embodiment consistent with the present disclosure includes a method comprising: placing a cementitious composition in a mold, the cementitious composition comprising: a cement at 0 kg/m3 to 500 kg/m3 based on a dry weight of the cementitious composition; optionally, a secondary cementitious material at 0.1 kg/m3 to 350 kg/m3 based on the dry weight of the cementitious composition; lime at 0.1 kg/m3 to 500 kg/m3 based on the dry weight of the cementitious composition; fine aggregates at 300 kg/m3 to 1500 kg/m3 based on the dry weight of the cementitious composition; coarse aggregates at 300 kg/m3 to 1200 kg/m3 based on the dry weight of the cementitious composition; and wherein the cementitious composition has a dry weight of 2000 kg/m3 to 4000 kg/m3; exposing the cementitious composition in the mold to air for a pre-conditioning period to produce a pre-conditioned member; placing the pre-conditioned member in an enclosure; and curing the pre-conditioned member by exposing the pre-conditioned member to a gas comprising carbon dioxide to produce a concrete member. Another embodiment consistent with the present disclosure includes a method comprising: placing a cementitious composition in a mold, the cementitious composition comprising a cement at 0 kg/m3 to 500 kg/m3 based on a dry weight of the cementitious composition; lime at 0.1 kg/m3 to 500 kg/m3 based on the dry weight of the cementitious composition; fine aggregates at 300 kg/m3 to 1500 kg/m3 based on the dry weight of the cementitious composition; coarse aggregates at 300 kg/m3 to 1200 kg/m3 based on the dry weight of the cementitious composition; and wherein the cementitious composition has a dry weight of 2000 kg/m3 to 4000 kg/m3; exposing the cementitious composition in the mold to water and a gas comprising carbon dioxide to produce a pre-conditioned member; removing a portion of the mold from the pre-conditioned member; further exposing the pre-conditioned member to the water and/or the gas comprising carbon dioxide; and allowing the pre-conditioned member to set to a concrete member. According to an embodiment consistent with the present disclosure includes a cementitious composition (e.g., for producing a foamed concrete composition) that comprises: a cement binder at 0 kg/m3 to 500 kg/m3 based on a dry weight of the cementitious composition; optionally,