EP4367079A1

EP4367079A1 - Cementitious composition comprising biochar carbonate

Info

Publication number: EP4367079A1
Application number: EP22751134.2A
Authority: EP
Inventors: Laury Barnes-Davin; François HUE; Virginie NOWALSKI
Original assignee: Vicat SA
Current assignee: Vicat SA
Priority date: 2021-07-08
Filing date: 2022-07-07
Publication date: 2024-05-15
Also published as: FR3125034A1; WO2023281220A1

Abstract

The invention relates to a cementitious composition comprising at least 5% biochar carbonate, and to the use of a biochar carbonate as the main component of a cementitious composition.

Description

CEMENTITIOUS COMPOSITION COMPRISING CARBONATED BIOCHAR

The subject of the present invention is novel cementitious compositions with a low carbon balance containing carbonated biochar, as well as the use of carbonated biochar as the main constituent of a cementitious composition.

The manufacture of hydraulic binders, and in particular that of cements, essentially consists of calcining a mixture of judiciously chosen and dosed raw materials, also referred to by the term “raw”. Firing this cru gives an intermediate product, clinker, which, ground with any mineral additions, will give cement. The type of cement manufactured depends on the nature and proportions of the raw materials as well as the firing process. There are several types of cements: Portland cements (which represent the vast majority of cements produced in the world), aluminous cements (or calcium aluminate), natural quick cements, sulphoaluminous cements, sulpho- Belitic and other intermediate varieties.

The most common cements are Portland type cements. Portland cements are obtained from Portland clinker, obtained after clinkering at a temperature of around 1450°C of a raw material rich in calcium carbonate in a kiln. The production of one tonne of Portland clinker is accompanied by the emission of around 0.8 to 0.9 tonnes of C0 ₂ .

However, in 2014, the quantity of cement sold in the world was around 4.2 billion tonnes (source: Syndicat Français de l’Industrie Cimentière - SFIC). This figure, constantly increasing, has more than doubled in 15 years. The cement industry is therefore today looking for a valid alternative to Portland cement, that is to say cements with at least the same resistance and quality characteristics as Portland cements, but which, during their production, emit less CO2.

During the production of clinker, the main constituent of Portland cement, the release of CO2 is linked to:

- up to 40% for heating the cement kiln, for grinding and transport;

- up to 60% to so-called chemical CO2, or decarbonation. Decarbonation is a chemical reaction that takes place when limestone, the main raw material for the manufacture of Portland cement, is heated at high temperature. The limestone is then transformed into quicklime and CO2 according to the following chemical reaction:

The natural carbonation of cementitious materials, especially concretes, is a potential way to reduce the carbon footprint related to the manufacturing process and the use of cement. However, although the concretes prepared from these cements recarbonate naturally during the lifetime of the structures up to 15% to 20% of the CO2 emitted during manufacture, the carbon balance associated with the production of Portland cement remains positive. It therefore remains necessary to reduce CO2 emissions during the production of Portland cement and/or to improve the processes for recycling concrete at the end of its life.

To reduce CO2 emissions related to the production of Portland cement, several approaches have been considered so far:

- the adaptation or modernization of cement processes in order to maximize the efficiency of heat exchange;

- the development of new "low carbon" binders such as sulfoaluminous cements prepared from raw materials less rich in limestone and at a lower firing temperature, which reduces CO2 emissions by around 35%;

- or the (partial) substitution of clinker in cements with materials that limit CO2 emissions.

Carbon capture and storage technologies have also been developed to limit CO2 emissions from cement plants or coal-fired power plants. International patent application WO-A-2019/115722 describes a process allowing both the cleaning of exhaust gases containing CO2 and the manufacture of an additional cementitious material. The disclosed process involves using recycled concrete fines comprising supplying recycled concrete fines with dgo lb 1000 pm to stockpiles or a silo as a feedstock, rinsing the feedstock to provide a carbonaceous material, removal of the carbonaceous material and cleaned exhaust gas, and deagglomeration of the carbonaceous material to form the additional cementitious material, as well as the use of stockpiles or a silo containing a feedstock of recycled concrete fines with dgo £1000 pm for the cleaning of CO2-containing exhaust gases and the simultaneous manufacture of additional cementitious material. However, this method is complex to implement and requires the carbonated product to be dried before it can be used.

At the date of the present invention, it remains necessary to identify new substitute materials making it possible to significantly reduce CO2 emissions during the production of cement while maintaining the mechanical properties of building materials prepared from these cements. , in particular the medium and long-term compressive strengths, at levels allowing their use.

The term “biochar” is the abbreviation of “bio-charcoal” in which the prefix “bio” designates the biological origin and “charcoal” corresponds to the English term for charcoal. Thus, "biochar" designates a charcoal of plant origin obtained by the pyrolysis of organic matter of various origins such as plants, in particular wood, straw and agricultural or green space residues, or organic compounds such as wastewater treatment plant sludge known as “STEP sludge”.

Biochar differs from charcoal in its use as a fertilizer rather than as fuel and in its environmental impact, since it acts as a carbon sink (or CO2 sink) rather than releasing CO2 into the atmosphere during combustion.

Biochar is therefore interesting for two reasons: it concentrates a large quantity of biogenic carbon (between 40 and more than 80%); and its structure develops a large specific surface capable of adsorbing CO2 in large quantities.

Biochar is thus traditionally used in agriculture to increase the quality of soils, and therefore their productivity. However, although carbon sequestration in the soil by burying biochar has been practiced for many years to combat its acidification and increase its fertility, carbon losses and emissions in the form of CO2 have been identified when the chemical balances of the soil (pH, leaching, depth of burial etc...) vary. International patent application WO-A-2018/203829 describes the use of biochar as a substitute sand for the preparation of construction materials of the concrete or mortar type. However, this patent application does not describe the use of biochar as a cementitious additive.

In the publication “The use of Biochar to reduce the carbon footprint of cement-based materials”, Procedia Structural Integrity, 26 (2020), 199-210, the authors Suarez-Riera et al. describe the use of biochar as a cement additive (or filler) to reduce the carbon footprint of both cement production and the building material prepared from it. According to the authors, the rate of substitution of cement by the optimum biochar is 2%, which remains relatively low.

In the publication “Use of biochar as carbon sequestering additive in cement mortar”, Cernent and Concrète Composition, 87 (2018), 110-129, the authors Gupta et al. describe the use of biochar or carbonated biochar as an admixture (i.e. “admixture”) for mortar. Biochar, carbonated or not, is added to mortar compositions in addition to other ingredients, including cement, but does not replace the cement used to prepare the mortar. In addition, biochar, carbonated or not, is only added up to 2% by weight of the cement content. Finally, the authors conclude that the addition of non-carbonated biochar should be preferred to the addition of carbonated biochar, the resulting construction materials having significantly improved mechanical strength and permeability compared to construction material obtained following the addition of a previously carbonated biochar.

In another publication entitled "Carbon sequestration in cementitious matrix containing pyrogenic carbon from waste biomass: A comparison of external and internal carbonation approach", Journal of Building Engineering, 43 (2021 ), 1-20, the author Gupta studies the use of biochar, carbonated or not, as an additive in cementitious compositions. In this publication, the author compares the mechanical properties of cementitious compositions containing 2.5% by weight of biochar, carbonated or not, with the mechanical properties of a composition consisting of 100% cement and a composition containing 8% silica fume. The author concludes that carbonated biochar could be used as an admixture, which implies the use of small amounts of carbonated biochar in the cementitious composition. However, it has now been found quite surprisingly that carbonated biochar could be used as the main constituent of a cementitious composition, which makes it possible to significantly increase the rate of substitution of cement compared to what was recommended until now, and therefore to significantly lower the carbon footprint of the building material finally prepared while maintaining mechanical properties, and in particular medium and long-term compressive strengths compatible with the intended uses.

Thus, the present invention relates to a cementitious composition comprising at least 5% of carbonated biochar.

The addition of carbonated biochar in the compositions of the invention makes it possible to significantly increase the rate of substitution of cement in comparison with biochar, and therefore to significantly lower the carbon footprint of the construction material finally prepared from said composition. , while maintaining mechanical properties, and in particular medium and long-term compressive strengths compatible with the intended uses.

In the context of the present invention:

- the term "adjuvant" (or "admixture") is understood to mean any adjuvant for concrete, mortar or grout within the meaning of standard NF EN 934-2, i.e. any product incorporated at the time of mixing the concrete of the mortar or grout at a dose less than or equal to 5% by weight of the cement content of the concrete in order to modify the properties of the mixture in the fresh and/or hardened state;

- "biochar" means any material obtained by pyrolysis of biomass of organic materials of various origins such as plants, in particular wood, straw and agricultural or green space residues, or organic compounds such as sludge sewage treatment plant known as “STEP sludge”;

- the term "carbonated biochar" means any biochar which, after having been brought into contact with a gas stream enriched in CO2, retains part of it in its porous structure, and therefore contains adsorbed CO2;

- “aluminous cement” means any cement, amorphous or not, obtained by firing a mixture of limestone and bauxite and containing at least 5% CA monocalcium aluminate;

- "prompt natural cement" means any hydraulic binder with rapid setting and hardening in accordance with standard NF P 15-314: 1993 in force on the date of this document. invention. Preferably, "prompt natural cement" designates a cement prepared from a clinker comprising:

> from 0% to 20% of C ₃ S;

> from 40% to 60% of C ₂ S;

> from 7% to 12% of C ₄ AF;

> from 2% to 10% of C ₃ A;

> from 10% to 15% of CaC0 ₃ (calcite);

> from 10% to 15% of Cas(Si04)2C0 ₃ (spurrite);

> from 3% to 10% sulfate phases: yeelimite C4A $ ₃ , langbeinite (K2Mg2(SC>4) ₃ , anhydrite (CaSCU); and

> 10% to 20% lime, periclase, quartz and/or one or more amorphous phases;

- “Portland cement” means any Portland clinker-based cement classified as CEM (I, II, III, IV or V) according to standard NF EN 197-1;

- "sulfoaluminous cement" means any cement prepared from a sulfoaluminous clinker containing from 5% to 90% of 'yeelimite' phase 0 ₄ ^$, from a source of sulphate, and, optionally, from an addition limestone;

- “cementitious composition” means any composition based on cement or an alkali-activated binder that can be used for the preparation of a construction material;

- "main constituent of a cementitious composition" means any main constituent within the meaning of standard NF EN 197-1, i.e. any mineral material present in the cementitious composition in a proportion greater than 5% by weight of the cementitious composition; and

- “construction material” means cement, concrete, mortar.

In the context of the present invention, the “rate of adsorbed CO2” corresponds to the quantity (% w/w) of adsorbed CO2 contained in the carbonated biochar relative to the total weight of the carbonated biochar.

To determine the rate of adsorbed CO2, different methods can be used such as for example a combination of calcination at different temperatures and an analysis of elemental carbon making it possible to distinguish organic carbon, inorganic carbon and with certain devices to determine carbon under d other forms.

Using a BET analyzer can also help determine the amount of CO2 adsorbed in the porosity of the biochar. Finally, Raman and infrared spectroscopy are complementary techniques to the previous ones for detecting adsorbed CO2. Thus, to determine the rate of CO2 adsorbed, the following procedure can in particular be implemented: place an alumina crucible on a balance and carry out the tare; fill the crucible with the powder (biochar or cementitious material) to be analyzed by spreading it out and weigh the test sample; introducing the filled crucible into the CHS elemental analyzer; enter the value of the sample mass; note the total carbon content (TC) measured by the device; then, to determine the inorganic carbon (TIC), start by calcining the powder (biochar or cementitious material) at 500°C, then repeat the previous steps.

In the context of the present invention, the "total organic carbon" or "TOC" corresponds to the quantity (% w/w) of carbon which is not in inorganic form contained in an entity relative to the total weight of carbon contained in that entity. TOC includes in particular the carbon which is contained in organic compounds and the adsorbed C02.

The TOC value of an entity is determined according to the following formula:

TOC=CT-TIC in which

"CT" means the amount (% w/w) of total carbon of the entity obtained through elemental analysis with a carbon/sulfur (CS) analyzer on a raw sample; and

“TIC” designates the quantity (% w/w) of total inorganic carbon of the entity obtained by calcining the sample to be analyzed at 500°C before carrying out a new determination of elemental carbon by a CS analyzer.

In the context of the present invention, the median diameter or dso corresponds to the diameter below which there is 50% of the total mass of the particles of the sample considered. This can be determined by any method known to those skilled in the art, in particular by dry or wet laser granulometry.

Finally, in the context of the present invention, the proportions expressed in % correspond to mass percentages relative to the total weight of the entity (e.g. clinker or cement) considered.

The present invention therefore relates to a cementitious composition comprising at least 5% carbonated biochar. Preferably, the subject of the present invention is a cementitious composition as defined previously having the following characteristics, chosen alone or in combination: the composition comprises more than 5% of carbonated biochar; preferably the composition comprises at least 6% carbonated biochar; more preferably the composition comprises at least 8% of carbonated biochar; most preferably, the composition comprises at least 10% of carbonated biochar; the composition includes up to 30% carbonated biochar; preferably the composition comprises up to 25% carbonated biochar; most preferably, the composition comprises up to 20% of carbonated biochar; the carbonated biochar contains at least 1% adsorbed carbon; preferably the carbonated biochar contains at least 3% adsorbed carbon; more preferably the carbonated biochar contains at least 5% adsorbed carbon; most preferably, the carbonated biochar contains at least 7% adsorbed carbon; the composition contains from 70% to 99% cement or alkali-activated binder; preferably the composition contains from 75% to 98% cement or alkali-activated binder; more preferably the composition still contains from 80% to 97% of cement or alkali-activated binder; most preferably, the composition contains from 80% to 95% cement or alkali-activated binder; the composition contains an aluminous cement, a prompt natural cement, a Portland cement or a sulfoaluminous cement; and/or the composition additionally contains a filler or a cement additive according to standard EN 197-1.

The cementitious composition according to the present invention can be prepared according to any method known to those skilled in the art. By way of example, the composition according to the present invention can in particular be prepared by simple mixing in a grinder or a mixer of a cement or an alkali-activated binder with the carbonated biochar or else by mixing in a grinder or a mixer of a clinker, gypsum (and optionally limestone filler or any known additive) and carbonated biochar.

The cementitious composition according to the present invention is therefore obtained from a clinker, an alkali-activated binder or a cement and a carbonated biochar. The carbonated biochar can be obtained according to any method known to those skilled in the art. By way of example, mention may in particular be made of a process for the preparation of carbonated biochar comprising the following steps: introduction of the biochar into a reactor of the rotating drum, mixer, container or fluidized bed type; bringing the biochar into contact with a source of CO2 such as exhaust gases from a cement factory or a thermal power station; and stopping the gas injection and recovering the carbonated biochar obtained.

The cementitious composition according to the present invention can be used to prepare a building material.

Finally, the carbonated biochar described above can therefore be used as the main constituent of a cementitious composition. Thus, the present invention also relates to the use of a carbonated biochar as the main constituent of a cementitious composition.

The present invention can be illustrated without limitation by the following examples.

Example 1 - Carbonated Biochar

A carbonated biochar is obtained by placing approximately 500g of biochar obtained by pyrolysis of wood in a tank which is itself placed in a hermetically sealed glass reactor.

The reactor is equipped with a cup containing water to regulate the relative humidity in the reactor.

This cup is placed at the bottom of the reactor under the tank containing the biochar.

The lid of the reactor is equipped with a glass stopper pierced with 2 holes which allow the injection of a gas and its evacuation.

The gas injected for 65 hours consists of 100% CO2.

The thus carbonated biochar has the following characteristics (Table 1).

Table 1 - Biochar/carbonated biochar

Example 2 - Cementitious Compositions According to the Invention A reference Portland cement of class CEM I 52.5 R is mixed with different quantities of powder of the carbonated biochar obtained in Example 1 or with the powder of the non-carbonated biochar used in the example 1.

Biochar powder is obtained by grinding a biochar whose all particles are less than 2mm and the dso is 43pm. When ground in a ring mill, the biochar has a dso of 11 µm.

The composition of cementitious compositions 2 and 4 (compositions according to the invention) and 3 and 5 (cementitious compositions prepared from a non-carbonated biochar) thus obtained is reported in Table 2 below.

Table 2 - Cementitious compositions 1 to 5 The gain in CO2 emissions for cementitious compositions 2 to 5 compared to the reference cementitious composition 1 is reported in Table 3 below.

Table 3 - CO2 gain for cement compositions 2 to 5

Example 3 - Mechanical performance

The compressive strength of the cementitious compositions 1, 2, 4 and 5 obtained in Example 2 were measured on prismatic specimens of standardized mortar (4x4x16cm ³ ), at different times (1, 2, 7 and 28 days) according to standard EN 196-1.

The results obtained are reported in Table 4 below.

Table 4 - Compressive strengths of cementitious compositions 1, 2, 4 and 5

The cementitious compositions according to the invention (ie 2 and 4) exhibit acceptable performances with regard to those observed for the reference CEM I at all deadlines. On the other hand, a reduction in the mechanical performance of composition 5 containing 10% of non-carbonated biochar is noted, whereas for composition 4 containing carbonated biochar in the same proportions, there is a maintenance of mechanical performance in the short, medium and long term. at an acceptable level. The addition of 10% of carbonated biochar therefore makes it possible to maintain a level of resistance higher than that observed for the composition containing the same quantity of non-carbonated biochar.

Claims

1. Cementitious composition comprising at least 5% carbonated biochar.

2. Cementitious composition according to claim 1, characterized in that it comprises more than 5% carbonated biochar.

3. Cementitious composition according to claim 2, characterized in that it comprises at least 8% carbonated biochar.

4. Cementitious composition according to claim 3, characterized in that it comprises at least 10% carbonated biochar.

5. Cementitious composition according to any one of claims 1 to 4, characterized in that it comprises up to 30% carbonated biochar.

6. Cementitious composition according to claim 5, characterized in that it comprises up to 25% of carbonated biochar.

7. Cementitious composition according to any one of claims 1 to 6, characterized in that the carbonated biochar contains at least 1% adsorbed carbon

8. Cementitious composition according to any one of claims 1 and 5 to 7, characterized in that it contains from 70% to 99% cement or alkali-activated binder.

9. Cementitious composition according to any one of claims 1 to 8, characterized in that it contains an aluminous cement, a prompt natural cement, a Portland cement or a sulfoaluminous cement.

10. Use of a carbonated biochar as the main constituent of a cementitious composition.