NRG COSIA Carbon XPRIZE: carbon-dioxide mineralization in recycled concrete wash water

Abstract

Wash water is generated as a waste stream from ready-mixed-concrete production. Reuse of the water as mixture water is limited, in practice, by the negative material performance impacts associated with the water chemistry and properties; the effects are intensified with increasing content of suspended solids and age. However, this waste material can be used as a beneficial additive to concrete by profiting from the cementitious properties of the suspended solids, if variability can be reduced. A method of stabilizing this material is through CO₂ treatment. The added CO₂ is mineralized through a reaction with the calcium from the cement particles. This provides a calcium-carbonate coating that prevents further cement hydration, making the material predictable. This has been shown to alleviate concerns with set acceleration and inconsistencies in compressive strength. A method of CO₂ treatment was tested as part of the NRG COSIA Carbon XPRIZE at a site in Calgary, Alberta. The slurry for the treatment was provided by a local concrete plant and had a specific gravity of 1.15. The simulated wash water was treated in 1000-L quantities with each treatment mineralizing an average of 40 kg of CO₂. The system ran for 1600 hours of operation over 127 treatment cycles and converted 14.5 tonnes of CO₂ at an average mineralization efficiency of 80%. The treated slurry was used as an additive in >300 batches of concrete where the concrete met the necessary requirements for fresh properties and setting time, while achieving a strength benefit. Replacement of 5% and 10% of batch water with treated slurry (9.4 and 18.8 kg slurry/m³ concrete) showed a strength benefit of 3% and 6% compared to a reference. The technology was selected as the winner of the NRG COSIA Carbon XPRIZE (Track B: Natural Gas) in April 2021.