Formed building materials

Abstract

Formed building materials comprising a sequestered CO 2 are provided. The building materials of the invention include a composition comprising a carbonate/bicarbonate component. Additional aspects of the invention include methods of making and using the formed building materials.

1 - 24 . (canceled) 
     
     
         25 . A lightweight masonry unit, comprising: at least 50% w/w sequestered-CO 2  component, wherein the sequestered-CO 2  component comprises metastable carbonate selected from the group consisting of vaterite, aragonite, and combination thereof, wherein the sequestered-CO 2  component has a δ 13 C less than −15%, and wherein the lightweight masonry unit has a porosity of at least 30%. 
     
     
         26 . The lightweight masonry unit of  claim 25 , wherein the masonry unit has a porosity of between 30-90%. 
     
     
         27 . The lightweight masonry unit of  claim 25 , wherein the masonry unit comprises between 50-99% w/w carbonate or combination of carbonate and bicarbonate. 
     
     
         28 . The lightweight masonry unit of  claim 25 , wherein the masonry unit is a tile. 
     
     
         29 . The lightweight masonry unit of  claim 28 , wherein the tile is a ceiling tile. 
     
     
         30 . The lightweight masonry unit of  claim 28 , wherein the tile has a flexural strength of between 0.5 to 7.5 MPa, compressive strength of between 5 to 75 MPa, or both. 
     
     
         31 . The lightweight masonry unit of  claim 25 , wherein the masonry unit is a block. 
     
     
         32 . The lightweight masonry unit of  claim 31 , wherein the block has a flexural strength of between 0.5 to 15 MPa, compressive strength of between 5-100 MPa, or both. 
     
     
         33 . The lightweight masonry unit of  claim 25 , wherein the masonry unit further comprises one or more additives selected from anti-desiccant, plasticizer, fibrous material, accelerator, set retarder, foaming agent, mildew resistance agent, fire resistance agent, and polyvinyl alcohol. 
     
     
         34 . The lightweight masonry unit of  claim 25 , wherein the masonry unit further comprises recycled material selected from fly ash, slag, cement kiln dust, and combinations thereof. 
     
     
         35 . The lightweight masonry unit of  claim 25 , wherein the masonry unit further comprises at least one additional component selected from clay, shale, soft slate, calcium silicate, quarried stone, Portland cement, metakaolin, cement, aggregate, silica fume, and pozzolan. 
     
     
         36 . A method for producing a masonry unit, comprising:
 a) processing a waste gas stream comprising carbon dioxide with a process water to produce a composition wherein the composition comprises a metastable carbonate comprising vaterite, wherein the vaterite has a δ 13 C less than −15%;   b) producing a slurry mixture from the composition; and   c) processing the slurry mixture to form a lightweight masonry unit wherein the masonry unit comprises at least 50% w/w aragonite and has a porosity of between 30-90%.   
     
     
         37 . The method of  claim 36 , comprising transforming the vaterite to aragonite when the lightweight masonry unit is formed. 
     
     
         38 . The method of  claim 36 , further comprising concentrating the composition to dryness to produce a dry composition. 
     
     
         39 . The method of  claim 36 , wherein the method further comprises adding one or more additives to the slurry mixture, wherein the one or more additives are selected from the group consisting of anti-desiccant, fibrous material, accelerator, set retarder, plasticizer, foaming agent, polyvinyl alcohol, fire resistance agent, and mildew resistance agent. 
     
     
         40 . The method of  claim 36 , wherein the method further comprises adding recycled material to the slurry mixture wherein the recycled material is selected from the group consisting of fly ash, slag, cement kiln dust, and combinations thereof. 
     
     
         41 . The method of  claim 36 , further comprising depositing the slurry mixture in a mold without backing material, or between two sheets of backing material, wherein the backing material comprises sheets of paper or fiberglass. 
     
     
         42 . The method of  claim 36 , wherein the method further comprises adding at least one additional component to the slurry mixture selected from clay, shale, soft slate, calcium silicate, quarried stone, Portland cement, metakaolin, cement, aggregate, silica fume, and pozzolan. 
     
     
         43 . The method of  claim 36  wherein the lightweight masonry unit is tile. 
     
     
         44 . The method of  claim 36  wherein the lightweight masonry unit is block.