System and method of applying carbon dioxide during the production of concrete

Abstract

The present disclosure involves systems and methods for applying CO2 to concrete, which may be performed in-situ or through a separate, stand-alone process. According to another embodiment disclosed herein, a system and method for applying CO2 to one or more materials used in the production of concrete is also provided.

What is claimed is: 
     
         1 . An apparatus for applying carbon dioxide to concrete or concrete materials, the apparatus comprising:
 a storage container for storing liquid carbon dioxide;   at least one load cell for determining a weight of the storage container and the carbon dioxide stored therein, the at least one load cell in communication with a system controller, the at least one load cell operable to transmit information related to the weight to the system controller;   piping interconnecting the storage container to an injection assembly, the piping operable to transport carbon dioxide to the injection assembly, the piping adapted to maintain the carbon dioxide in a liquid state;   a control valve proximate to the storage container, the control valve operable to prevent carbon dioxide from entering the piping when provided in a closed configuration, the control valve operable to enable carbon dioxide to enter the piping when provided in an open configuration, and the control valve provided in communication with the system controller;   a liquid-gas separator in fluid communication with the piping, the liquid-gas separator operable to separate gaseous carbon dioxide from liquid carbon dioxide before the injection assembly receives the carbon dioxide, the liquid-gas separator having a vent to release the gaseous carbon dioxide;   the injection assembly operable to receive carbon dioxide from the piping and operable to inject carbon dioxide into a concrete mixer or a concrete material container; and   the system controller operable to control the control valve and the injection assembly.   
     
     
         2 . The apparatus of  claim 1 , wherein the system controller is operable to send a signal to move the control valve to the closed configuration when the system controller determines that the weight of the storage container and the carbon dioxide stored therein has decreased by a predetermined amount. 
     
     
         3 . The apparatus of  claim 1 , wherein the system controller is operable to send a signal to move the control valve to the closed configuration after a predetermined amount of time. 
     
     
         4 . The apparatus of  claim 1 , further comprising a mass flow controller in fluid communication with the piping, the mass flow controller operable to measure a mass of carbon dioxide that flows through the mass flow controller, the mass flow controller in communication with the system controller, the mass flow controller operable to transmit information related to the mass to the system controller. 
     
     
         5 . The apparatus of  claim 4 , wherein the system controller is operable to send a signal to move the control valve to the closed configuration when the system controller determines that a predetermined mass of carbon dioxide has flowed through the mass flow controller. 
     
     
         6 . The apparatus of  claim 1 , wherein the interconnection of the piping to the storage container is adapted to extract only liquid carbon dioxide from the storage container. 
     
     
         7 . The apparatus of  claim 1 , further comprising a liquid carbon dioxide sensor operable to determine when gaseous carbon dioxide is in contact with the control valve of the piping, wherein the liquid carbon dioxide sensor is in communication with the system controller and operable to transmit information related to the contact to the system controller, wherein the system controller is operable to send a signal to move the control valve to the closed configuration when the liquid carbon dioxide sensor determines that gaseous carbon dioxide is in contact with the control valve. 
     
     
         8 . The apparatus of  claim 1 , wherein gaseous carbon dioxide separated from liquid carbon dioxide by the liquid-gas separator is returned to the storage container by second piping interconnecting the storage container to the vent of the liquid-gas separator. 
     
     
         9 . The apparatus of  claim 1 , wherein the injection assembly is operable to cause a temperature of carbon dioxide to decrease to no more than about −109° F. when carbon dioxide passes through the injection assembly. 
     
     
         10 . The apparatus of  claim 1 , wherein the injection assembly is operable to inject between about 1 and about 27 pounds of carbon dioxide into the mixer or material container for each cubic yard of concrete mix in the mixer or the material container. 
     
     
         11 . The apparatus of  claim 1 , wherein the injection assembly is operable to cause carbon dioxide to change state to a mixture of solid carbon dioxide and gaseous carbon dioxide and to inject the mixture of solid and gaseous carbon dioxide into the mixer. 
     
     
         12 . The apparatus of  claim 1 , further comprising the material container, wherein the material container has a plurality of injectors with outlets facing an interior chamber of the material container, wherein inlets of the plurality of injectors are interconnected to the injection assembly, and wherein the system controller is operable to control each of the plurality of injectors. 
     
     
         13 . The apparatus of  claim 1 , further comprising the mixer, wherein the mixer has a mixing chamber with an aperture, wherein the mixing chamber is operable to receive carbon dioxide from the injection assembly, wherein the mixing chamber is operable to receive a predetermined amount of concrete materials, and wherein the mixing chamber is operable to mix the carbon dioxide and the predetermined amount of concrete materials. 
     
     
         14 . The apparatus of  claim 13 , further comprising a closure interconnected to the mixer operable to seal the aperture of the mixing chamber, wherein the mixing chamber is pressurized after the closure seals the aperture, and wherein the mixing chamber is operable to mix the carbon dioxide and the predetermined amount of concrete materials in the pressurized mixing chamber. 
     
     
         15 . The apparatus of  claim 13 , wherein the controller is operable to send signals to start and stop the mixer, and wherein the controller is operable to send signals to open and close one or more pressure release valves interconnected to the mixing chamber of the mixer. 
     
     
         16 . A method of applying carbon dioxide to concrete during the production of the concrete, the method comprising:
 determining if there is sufficient carbon dioxide in a storage container;   after determining there is sufficient carbon dioxide in the storage container, starting a mixer;   placing a predetermined amount of concrete materials in a mixing chamber of the mixer, wherein the mixing chamber has an aperture;   determining if an injection assembly is in a position to inject carbon dioxide into the mixing chamber of the mixer, wherein the injection assembly is in fluid communication with the storage container by piping interconnected to the storage container, a control valve, a liquid-gas separator, and the injection assembly;   after determining the injection assembly is in the position to inject carbon dioxide into the mixing chamber, moving the control valve to an open configuration to allow liquid carbon dioxide to leave the storage container and enter the piping;   separating gaseous carbon dioxide from liquid carbon dioxide in the piping by the liquid-gas separator, wherein gaseous carbon dioxide is released from the piping through a vent to the atmosphere, and wherein liquid carbon dioxide continues through the piping to the injection assembly;   injecting carbon dioxide into the mixing chamber of the mixer by the injection assembly, wherein the injection assembly is operable to cause liquid carbon dioxide to change state to a mixture of solid carbon dioxide and gaseous carbon dioxide;   determining that a predetermined amount of carbon dioxide has been injected into the mixing chamber of the mixer;   after determining that the predetermined amount of carbon dioxide has been injected into the mixing chamber, moving the control valve to a closed configuration to prevent liquid carbon dioxide from leaving the storage container;   mixing the concrete materials and the carbon dioxide until a chemical reaction between the concrete materials and the carbon dioxide is complete; and   discharging the concrete from the mixing chamber of the mixer.   
     
     
         17 . The method of  claim 16 , further comprising:
 sealing the aperture of the mixing chamber with a closure after placing the concrete materials and carbon dioxide in the mixing chamber; and   increasing the pressure in the mixing chamber after sealing the aperture of the mixing chamber.   
     
     
         18 . The method of  claim 16 , further comprising adding at least one of a water reducer and an air entrainment agent to the concrete materials in the mixing chamber of the mixer. 
     
     
         19 . The method of  claim 16 , wherein determining that the predetermined amount of carbon dioxide has been injected into the mixing chamber of the mixer comprises as least one of measuring a weight of the storage container and measuring a mass of carbon dioxide that has flowed from the storage container. 
     
     
         20 . A method of applying carbon dioxide to concrete materials used in the production of the concrete, the method comprising:
 providing a supply of carbon dioxide in a storage container;   placing concrete materials in a chamber of a material container, wherein the material container has a plurality of injectors, wherein the injectors have an inlet on an exterior surface of the chamber, and wherein the injectors have an outlet directed into the chamber;   interconnecting the storage container to the inlets of the plurality of injectors of the material container;   moving a control valve in fluid communication with the storage container and the plurality of injectors to an open configuration to allow carbon dioxide to leave the storage container and pass through the plurality of injectors into the chamber of the material container; and   moving the control valve to a closed configuration after determining that a sufficient amount of carbon dioxide has been added to the concrete materials in the material container.