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C-Crete Technologies, LLC has teamed with Rice University and NRG Energy, Inc. to further develop a mineral carbonation technology to generate high-value concrete products that economically store carbon dioxide (CO2) captured from coal-fired power plant flue gas. The two-step process begins with the in-situ preparation of porous low-density materials from industrial waste (such as asphalt), which serve as support for CO2 mineralization in the pores. The resulting enriched porous carbons are then used as an additive in concrete production to impart unique properties, such as high mechanical strength, electrical and thermal conductivity, magnetic properties, and hydrophobicity. The team will optimize the conditions for synthesis of the activated carbon sorbent and characterize the material properties to maximize mineralization efficiency. Aqueous-phase and gas-phase mineralization of CO2 in activated asphalt and coal waste will be evaluated to determine the best method for scale up. The team will design, construct, and test a small-scale pilot system to produce multifunctional concrete, in ton quantities, using CO2 from the carbon capture facility at NRG’s Petra Nova coal-fired power plant. Test results will be analyzed to evaluate the commercial feasibility of the technology, and will include a Technology Gap Analysis to identify the required research to fully develop the technology to commercialization.

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Porous carbon concrete production process block flow diagram.
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Principal Investigator
Rouzbeh Shahsavari
rouzbeh@rice.edu
Project Benefits

This two-step CO2 mineralization technology provides a viable path for making value-added concrete products that efficiently and permanently store CO2 from coal-fired power plants at industrial scale without generating additional CO2 emissions. The technology advances the Carbon Use and Reuse Program goals by mitigating CO2 emissions and offsetting the cost of carbon capture.

Project ID
FE0030716