US20210070656A1 - Process to make calcium oxide or ordinary portland cement from calcium bearing rocks and minerals - Google Patents

Process to make calcium oxide or ordinary portland cement from calcium bearing rocks and minerals Download PDF

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US20210070656A1
US20210070656A1 US16/992,318 US202016992318A US2021070656A1 US 20210070656 A1 US20210070656 A1 US 20210070656A1 US 202016992318 A US202016992318 A US 202016992318A US 2021070656 A1 US2021070656 A1 US 2021070656A1
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calcium
acid
optionally
aqueous
reacting
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Cody E. Finke
Hugo F. LEANDRI
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California Institute of Technology CalTech
Brimstone Energy Inc
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California Institute of Technology CalTech
Brimstone Energy Inc
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Priority to US16/992,318 priority Critical patent/US20210070656A1/en
Assigned to CALIFORNIA INSTITUTE OF TECHNOLOGY reassignment CALIFORNIA INSTITUTE OF TECHNOLOGY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: LEANDRI, Hugo F.
Assigned to BRIMSTONE ENERGY INC. reassignment BRIMSTONE ENERGY INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: FINKE, CODY E.
Publication of US20210070656A1 publication Critical patent/US20210070656A1/en
Priority to US17/894,621 priority patent/US11718558B2/en
Priority to US18/334,534 priority patent/US20230339807A1/en
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    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2/00—Lime, magnesia or dolomite
    • C04B2/10—Preheating, burning calcining or cooling
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B7/00—Hydraulic cements
    • C04B7/36—Manufacture of hydraulic cements in general
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B17/00—Sulfur; Compounds thereof
    • C01B17/69—Sulfur trioxide; Sulfuric acid
    • C01B17/74—Preparation
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01F—COMPOUNDS OF THE METALS BERYLLIUM, MAGNESIUM, ALUMINIUM, CALCIUM, STRONTIUM, BARIUM, RADIUM, THORIUM, OR OF THE RARE-EARTH METALS
    • C01F7/00—Compounds of aluminium
    • C01F7/48—Halides, with or without other cations besides aluminium
    • C01F7/56—Chlorides
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B11/00—Calcium sulfate cements
    • C04B11/005—Preparing or treating the raw materials
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B11/00—Calcium sulfate cements
    • C04B11/28—Mixtures thereof with other inorganic cementitious materials
    • C04B11/30—Mixtures thereof with other inorganic cementitious materials with hydraulic cements, e.g. Portland cements
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2/00—Lime, magnesia or dolomite
    • C04B2/005—Lime, magnesia or dolomite obtained from an industrial by-product
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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    • C04B22/00—Use of inorganic materials as active ingredients for mortars, concrete or artificial stone, e.g. accelerators, shrinkage compensating agents
    • C04B22/06—Oxides, Hydroxides
    • C04B22/062—Oxides, Hydroxides of the alkali or alkaline-earth metals
    • C04B22/064—Oxides, Hydroxides of the alkali or alkaline-earth metals of the alkaline-earth metals
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • C04B28/04—Portland cements
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/14—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B40/00—Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability
    • C04B40/0028—Aspects relating to the mixing step of the mortar preparation
    • C04B40/0039—Premixtures of ingredients
    • C04B40/0046—Premixtures of ingredients characterised by their processing, e.g. sequence of mixing the ingredients when preparing the premixtures
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B7/00—Hydraulic cements
    • C04B7/02—Portland cement
    • C04B7/04—Portland cement using raw materials containing gypsum, i.e. processes of the Mueller-Kuehne type
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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    • C04B7/00—Hydraulic cements
    • C04B7/14—Cements containing slag
    • C04B7/147—Metallurgical slag
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B7/00—Hydraulic cements
    • C04B7/24—Cements from oil shales, residues or waste other than slag
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B7/00—Hydraulic cements
    • C04B7/24—Cements from oil shales, residues or waste other than slag
    • C04B7/246—Cements from oil shales, residues or waste other than slag from waste building materials, e.g. waste asbestos-cement products, demolition waste
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B7/00—Hydraulic cements
    • C04B7/24—Cements from oil shales, residues or waste other than slag
    • C04B7/26—Cements from oil shales, residues or waste other than slag from raw materials containing flue dust, i.e. fly ash
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B7/00—Hydraulic cements
    • C04B7/36—Manufacture of hydraulic cements in general
    • C04B7/38—Preparing or treating the raw materials individually or as batches, e.g. mixing with fuel
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B7/00—Hydraulic cements
    • C04B7/36—Manufacture of hydraulic cements in general
    • C04B7/38—Preparing or treating the raw materials individually or as batches, e.g. mixing with fuel
    • C04B7/42—Active ingredients added before, or during, the burning process
    • C04B7/421—Inorganic materials
    • C04B7/422—Elements
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B7/00—Hydraulic cements
    • C04B7/36—Manufacture of hydraulic cements in general
    • C04B7/38—Preparing or treating the raw materials individually or as batches, e.g. mixing with fuel
    • C04B7/42—Active ingredients added before, or during, the burning process
    • C04B7/421—Inorganic materials
    • C04B7/424—Oxides, Hydroxides
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25B—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES FOR THE PRODUCTION OF COMPOUNDS OR NON-METALS; APPARATUS THEREFOR
    • C25B1/00—Electrolytic production of inorganic compounds or non-metals
    • C25B1/01—Products
    • C25B1/22—Inorganic acids
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25C—PROCESSES FOR THE ELECTROLYTIC PRODUCTION, RECOVERY OR REFINING OF METALS; APPARATUS THEREFOR
    • C25C1/00—Electrolytic production, recovery or refining of metals by electrolysis of solutions
    • C25C1/06—Electrolytic production, recovery or refining of metals by electrolysis of solutions or iron group metals, refractory metals or manganese
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01G—COMPOUNDS CONTAINING METALS NOT COVERED BY SUBCLASSES C01D OR C01F
    • C01G49/00—Compounds of iron
    • C01G49/14—Sulfates
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C1/00—Preparation of hydrocarbons from one or more compounds, none of them being a hydrocarbon
    • C07C1/32—Preparation of hydrocarbons from one or more compounds, none of them being a hydrocarbon starting from compounds containing hetero-atoms other than or in addition to oxygen or halogen
    • C07C1/325—Preparation of hydrocarbons from one or more compounds, none of them being a hydrocarbon starting from compounds containing hetero-atoms other than or in addition to oxygen or halogen the hetero-atom being a metal atom
    • C07C1/328—Preparation of hydrocarbons from one or more compounds, none of them being a hydrocarbon starting from compounds containing hetero-atoms other than or in addition to oxygen or halogen the hetero-atom being a metal atom the hetero-atom being an alkali metal atom
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P40/00—Technologies relating to the processing of minerals
    • Y02P40/10—Production of cement, e.g. improving or optimising the production methods; Cement grinding
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P40/00—Technologies relating to the processing of minerals
    • Y02P40/40—Production or processing of lime, e.g. limestone regeneration of lime in pulp and sugar mills

Definitions

  • cement materials that have any combination of the following advantages or features: less energy intensive than prior approaches, with some embodiments being net energy neutral or even net energy producing, regenerate certain reagents, characterized by a net reaction free of SO 2 and/or CO 2 , recycle certain byproducts, do not include producing CO 2 , can utilize a wider range of feedstock materials, including more complex materials, generate value-added side products, and/or generate composite cement materials.
  • the disclosed two-acid approach provides for the ability to digest complex calcium-bearing materials, including those with Ca as well as other metal (including metalloid) elements such Si, Al, and other species, and even forming value-added side products from those non-Ca metals, while also regenerating reagent acids.
  • these methods can also be free of CO 2 generation and can include converting SO 2 into a reagent acid, thereby eliminating or dramatically reducing SO 2 emissions for CaSO 4 based approaches to cement manufacturing.
  • aspects of the invention include a method of producing a cement material comprising steps of: first reacting a calcium-bearing starting material with a first acid to produce an aqueous first calcium salt; second reacting the aqueous first calcium salt with a second acid to produce a solid second calcium salt; wherein the second acid is different from the first acid and the second calcium salt is different from the first calcium salt; and thermally treating one or more calcium salts to produce a first cement material.
  • the one or more calcium salts is the second calcium salt.
  • reaction between the first calcium salt and the second acid regenerates the first acid.
  • the methods are characterized by a net reaction free of an acid-forming gas product.
  • the method comprises forming the solid second calcium salt characterized by a purity of greater than or equal to 90 dry wt. % purity.
  • any of the methods disclosed herein include a first separating step after the first reacting step and before the second reacting step; the first separating step comprising separating a first aqueous fraction from a first solid fraction; wherein the first aqueous fraction comprises the aqueous first calcium salt and the first solid fraction comprises one or more solid byproducts formed during the first reacting step.
  • any of the methods disclosed herein include a second separating step after the second reacting step and before the thermally treating step; the second separating step comprising separating a second solid fraction from a second aqueous fraction; wherein the second solid fraction comprises the solid second calcium salt and the second aqueous fraction comprises one or more aqueous byproducts formed during the second reacting step.
  • the solid fraction is characterized by a dry mass at least 90 wt. % of which is the second calcium salt.
  • any of the methods disclosed herein include a second acid regeneration step; wherein the second acid regeneration step comprises converting one or more gas products of the thermally treating step to the second acid.
  • the second acid regeneration step is a non-electrochemical process performed according to formula FX1A: SO 2 +1 ⁇ 2O 2 +H 2 O ⁇ H 2 SO 4 (FX1A) wherein: the SO 2 in FX1A is a gas product of the thermally treating step; the H 2 SO 4 generated in FX1A is used as at least a fraction of the second acid during the second reacting step.
  • the second acid regeneration step is a non-electrochemical process performed according to formula FX1B: SO 2 +H 2 O ⁇ H 2 SO 3 (FX1B) wherein: the SO 2 in FX1B is a gas product of the thermally treating step; the H 2 SO 3 generated in FX1B is used as at least a fraction of the second acid during the second reacting step.
  • the second acid regeneration step comprises (i) electrochemically oxidizing sulfur dioxide to sulfuric acid and (ii) forming hydrogen gas via a reduction reaction; and wherein the second acid regeneration step is performed according to formula FX2: SO 2 +2H 2 O H 2 SO 4 +H 2 (FX2); wherein: the SO 2 in FX2 is a gas product of the thermally treating step; the H 2 SO 4 generated in FX2 is used as at least a fraction of the second acid during the second reacting step.
  • the thermally treating step comprises using energy generated from oxidizing the hydrogen gas formed as a result of the second acid regeneration.
  • the hydrogen gas produced via the method can be used to power the electrochemical step, such as via a fuel cell or turbine.
  • the electrochemically oxidizing sulfur dioxide comprises using energy generated as a result of the second acid regeneration step. It is noted that when H 2 SO 4 is added to a solution that contains both MgCl 2 and CaCl 2 ), only CaSO 4 will precipitate. If H 2 SO 3 is added to a solution of MgCl 2 and CaCl 2 ), both MgSO 3 and CaSO 3 will precipitate. Of consideration is that there are currently regulations against having Mg in cement, such that the calcium-bearing starting material preferably has a low-Mg content so minimize amount of Mg material precipitated.
  • reaction between the first calcium salt and the second acid regenerates the first acid according to formula FX3: CaCl 2(aq) +H 2 SO 4 ->CaSO 4 (s) 2HCl (FX3); wherein: the first calcium salt is CaCl 2 ); the first acid is HCl; the second acid is H 2 SO 4 ; and the second calcium salt is CaSO 4 .
  • the calcium-bearing starting material comprises Ca.
  • the calcium-bearing starting material has a chemical composition comprising the element Ca.
  • the calcium-bearing starting material has a chemical composition comprising the element Ca wherein the weight percent and/or the molar percent of Ca in said calcium-bearing starting material is at least 0.001%, preferably at least 0.01%, preferably at least 0.1%, more preferably at least 1%, further more preferably at least 5%, still more preferably at least 10%, and yet more preferably at least 20%.
  • the calcium-bearing starting material has a chemical composition comprising the element Ca wherein the weight percent and/or the molar percent of Ca in said calcium-bearing starting material is selected from the range of 1% to 80%, optionally 1% to 60%, optionally 1% to 55%, optionally 1% to 50%.
  • the calcium-bearing starting material comprises at least one multinary metal oxide material having a composition comprising Ca and at least one other metal element selected from the group consisting of Al, Si, Fe, Mn, and Mg.
  • the composition of the at least one multinary metal oxide comprises less than or equal to 55 wt. % of Ca.
  • the composition of the at least one multinary metal oxide comprises less than or equal to 60 wt. % of Ca.
  • the at least one multinary metal oxide material is at least one natural rock or mineral.
  • the at least one natural rock or mineral comprises basalt, igneous appetites, wollastonite, anorthosite, montmorillonite, bentonite, calcium-containing feldspar, anorthite, diopside, pyroxene, pyroxenite, mafurite, kamafurite, clinopyroxene, colemonite, grossular, augite, pigeonite, margarite, calcium serpentine, garnet, scheilite, skarn, limestone, natural gypsum, appetite, fluorapatite, or any combination of these.
  • calcium-bearing starting material comprises cement, concrete, Portland cement, fly ash, slag, or any combination of these. If the calcium-bearing starting material comprises CaCO 3 , then CO 2 may be generated during the method. However, wherein CO 2 is generated, the CO 2 is at a high concentration and can be stored and/or utilized.
  • the first acid comprises hydrochloric acid (HCl).
  • the first acid is hydrochloric acid.
  • the second acid comprises sulfuric acid (H 2 SO 4 ) and/or sulfurous acid (H 2 SO 3 ).
  • the second acid is sulfuric acid and/or sulfurous acid.
  • the second acid is sulfuric acid.
  • the second acid is sulfurous acid.
  • the aqueous first calcium salt is calcium chloride (CaCl 2 )).
  • the solid second calcium salt is calcium sulfate (CaSO 4 ) and/or calcium sulfite (CaSO 3 ).
  • the solid second calcium salt is calcium sulfate.
  • the solid second calcium salt is calcium sulfite (CaSO 3 ).
  • the first cement material comprises CaO.
  • the first cement material is calcium oxide (CaO).
  • the first cement material is calcium oxide (CaO) or Portland cement clinker.
  • the first cement material is Portland cement clinker.
  • the acid-forming gas product is SO 2 and/or CO 2 .
  • the acid-forming gas product is SO 2 .
  • the acid-forming gas product is CO 2 .
  • the first reacting step comprises reacting the calcium-bearing starting material with hydrochloric acid to form at least aqueous calcium chloride, aqueous aluminum chloride, and solid silica.
  • the first separating step comprises separating a first aqueous fraction comprising the aqueous calcium chloride and the aqueous aluminum chloride from a first solid fraction comprising the solid silica.
  • the second reacting step comprises reacting at least the aqueous calcium chloride, the aqueous aluminum chloride, and sulfuric acid to form at least solid calcium sulfate, aqueous aluminum sulfate, and hydrochloric acid.
  • the thermally treating step comprises heating the calcium sulfate to form calcium oxide.
  • the first reacting step comprises reacting the calcium-bearing starting material with hydrochloric acid to form at least aqueous calcium chloride, aqueous aluminum chloride, aqueous iron chloride, aqueous magnesium chloride, and solid silica.
  • the first separating step comprises separating a first aqueous fraction comprising the aqueous calcium chloride and the aqueous aluminum chloride from a first solid fraction comprising the solid silica.
  • the second reacting step comprises reacting at least the aqueous calcium chloride, and sulfuric acid to form at least solid calcium sulfate, solid calcium sulfate, and hydrochloric acid.
  • the thermally treating step comprises heating the calcium sulfate to form calcium oxide.
  • any of the methods disclosed herein comprises an ion exchange step; wherein the ion exchange step comprises exchanging one or more anions of the first calcium salt and/or the second calcium salt for one or more hydroxyl anions to form a third calcium salt.
  • the ion exchange step comprises reacting the first calcium salt and/or the second calcium salt with a chelating agent to form a calcium-chelator compound and reacting the calcium-chelator compound with a base to form the third calcium salt.
  • the ion exchange step comprises reacting the first calcium salt and/or the second calcium salt with a base to form the third calcium salt.
  • the ion exchange step comprises using an ion exchange membrane to perform the exchanging one or more anions of the first calcium salt and/or the second calcium salt for one or more hydroxyl anions to form the third calcium salt.
  • the one or more calcium salts of the thermally treating step is the third calcium salt.
  • the third calcium salt is Ca(OH) 2 .
  • any of the methods disclosed herein comprises a step of regenerating the chelating agent, wherein the step of regenerating the chelating agent comprises producing the third calcium salt.
  • any of the methods disclosed herein comprises a step of forming the first cement material from the third calcium salt.
  • the step of forming the first cement material from the third calcium salt comprises dehydrating the third calcium salt or directly releasing the first cement material from the calcium-chelator compound, optionally via a base.
  • CaO can be formed by using a chelating agent or base to react the CaCl 2 ), CaSO 3 , or CaSO 4 .
  • the chelating agent or base can be regenerated in a manner that releases Ca(OH) 2 which can be dehydrated to CaO or CaO could be directly released from the chelator.
  • a chelating agent such as EDTA can be reacted with CaSO 4 to make Ca-EDTA.
  • a base such as NaOH can then be used to directly produce Ca(OH) 2 and regenerate the EDTA.
  • any method disclosed herein comprises a step of forming a composite cement material; wherein: (i) the thermally treating step comprises the step of forming the composite cement material and the first cement material is the composite cement material or (ii) the step of forming the composite material is performed using the first cement material formed during the thermally treating step.
  • the step of forming the composite material is performed using the first cement material formed during the thermally treating step
  • the formation of the composite material can occur simultaneously with formation of the first cement material (e.g., CaO) or subsequently after formation of the first cement material (e.g., CaO).
  • any method disclosed herein comprises a step of forming a composite cement material; wherein the thermally treating step comprises the step of forming the composite cement material and the first cement material is the composite cement material.
  • any method disclosed herein comprises a step of forming a composite cement material; wherein the step of forming the composite material is performed using the first cement material formed during the thermally treating step.
  • the step of forming the composite cement material comprises heating the second calcium salt and/or the first cement material together with one or more additives.
  • the step of forming the composite cement material comprises heating the second calcium salt together with one or more additives.
  • the step of forming the composite cement material comprises heating the first cement material together with one or more additives.
  • the step of forming the composite cement material is performed simultaneously with the thermally treating step.
  • the composite cement material is Portland cement clinker.
  • the composite cement material is ordinary Portland cement and/or the first cement material is calcium oxide.
  • the first cement material is calcium oxide.
  • the composite cement material is ordinary Portland cement.
  • any method disclosed herein comprises forming the one or more additives from the calcium-bearing starting material.
  • the one or more additives are one or more byproducts of the first reacting step and/or are formed from one or more byproducts of the first reacting step and/or are one or more byproducts of the second reacting step and/or are formed from one or more byproducts of the second reacting step.
  • the one or more additives are one or more byproducts of the first reacting step and/or are formed from one or more byproducts of the first reacting step.
  • the one or more additives are one or more byproducts of the second reacting step and/or are formed from one or more byproducts of the second reacting step.
  • the one or more additives are one or more byproducts of the first reacting step.
  • the one or more additives are one or more byproducts of the second reacting step.
  • the one or more additives are one or more byproducts of the first reacting step and/or are one or more byproducts of the second reacting step.
  • a combined chemical composition of the one or more additives comprises Al and Si.
  • the one or more additives are at least Al 2 O 3 and SiO 2 .
  • An advantage of the methods disclosed herein is that value-added side products can be formed.
  • simple calcium sources such as limestone or gypsum as starting materials
  • complex minerals that include Ca and Si, and optionally other metals such as Al, Mg, and/or Fe.
  • the methods disclosed herein can include steps to form and isolate valuable products having these extra elements, such as oxides of Al, oxides of Mg, and/or oxides of Fe. These steps do not contribution significant additional operational costs.
  • any method disclosed herein comprises forming and isolating silica-fume grade silica, nano-silica, and/or micro-silica from the calcium-bearing starting material.
  • any method disclosed herein comprises forming and isolating alumina from the calcium-bearing starting material.
  • the first reacting step comprises reacting the calcium-bearing starting material with hydrochloric acid to form at least aqueous aluminum chloride; wherein the method further comprises: precipitating the aluminum chloride in the presence of hydrochloric acid; and optionally reacting the precipitated aluminum chloride with sulfuric acid to form solid aluminum sulfate; heating the aluminum sulfate and/or aluminum chloride to form alumina.
  • the hydrochloric acid is regenerated in these steps.
  • the reaction of the precipitated aluminum chloride forms hydrochloric acid.
  • the hydrochloric acid is regenerated in these steps.
  • the second reacting step comprises the step of reacting the precipitated aluminum chloride.
  • the thermally treating step comprises the heating the aluminum sulfate step.
  • the thermally treating step comprises the heating the aluminum chloride step.
  • any method disclosed herein comprises forming and isolating iron oxide from the calcium-bearing starting material.
  • the forming and isolating the iron oxide comprises: forming an aqueous solution having aqueous iron sulfate and/or iron chloride and optionally at least one other metal magnesium sulfate salt and/or chloride salt formed as byproducts during the second reacting step; wherein the aqueous solution is free of a calcium salt and free of an aluminum salt; drying the aqueous solution to form solid iron sulfate and/or solid iron chloride and optionally the at least one other metal sulfate salt; heating the solid iron sulfate and optionally the at least one other metal sulfate salt to form a water-insoluble iron oxide; and optionally, dissolving the at least one other metal sulfate salt to isolate the water-insoluble iron oxide.
  • any method disclosed herein comprises forming and isolating iron oxide from the calcium-bearing starting material.
  • the forming and isolating the iron oxide comprises: forming an aqueous solution having aqueous iron sulfate or iron chloride and optionally at least one other metal magnesium sulfate or chloride salt formed as byproducts during the second reacting step; wherein the aqueous solution is free of a calcium salt and free of an aluminum salt; using SO 2 to precipitate MgSO 3 ; separating the aqueous iron salt from the solid magnesium salt; drying the aqueous solution to form solid iron sulfate or chloride and optionally the at least one other metal sulfate salt; heating the solid iron sulfate and optionally the at least one other metal sulfate salt to form a water-insoluble iron oxide; and optionally, dissolving the at least one other metal sulfate salt to isolate the water-insoluble iron oxide.
  • iron chloride, iron sulfate, aluminum chloride, and/or aluminum sulfate, and/or any other iron and/or aluminum salt is produced and sold and/or combined with electrochemical strategies to make iron and aluminum metals from the aluminum chloride, sulfate, and/or other salts.
  • aluminum chloride can be isolated and aluminum can be electrowon from aluminum chloride while co-producing chlorine gas. This chlorine gas can then be reacted with hydrogen, possibly hydrogen from the cogeneration of sulfuric acid and hydrogen to regenerate HCl.
  • iron can be electrowon from iron sulfate to regenerate sulfuric acid.
  • Methods disclosed herein can comprise one or more acid-forming reactions.
  • An acid-forming reaction can be a reaction to regenerate an acid that is consumed in a different reaction of the method.
  • the acid-forming reaction can be a reaction that supplies the acid to the (first and/or second) reacting step wherein the acid is consumed.
  • reagents that form said acid are supplied to the reacting step such that said reacting step comprises both forming the acid and the respective acid consumption (or, salt forming) reaction.
  • any method disclosed herein comprises a step of forming the first acid; wherein: (i) the first reacting step comprises the step of forming the first acid and the step of forming the first acid occurs simultaneously with the first reacting step, or (ii) the step of forming the first acid is performed separately from the first reacting step.
  • any method disclosed herein comprises a step of forming the first acid; wherein the first reacting step comprises the step of forming the first acid and the step of forming the first acid is occurs simultaneously with the first reacting step.
  • any method disclosed herein comprises a step of forming the first acid; wherein the step of forming the first acid is performed separately from the first reacting step.
  • any method disclosed herein comprises a step of forming the second acid; wherein: (i) the second reacting step comprises the step of forming the second acid and the step of forming the second acid occurs simultaneously with the second reacting step, or (ii) the step of forming the second acid is performed separately from the second reacting step.
  • any method disclosed herein comprises a step of forming the second acid; wherein the second reacting step comprises the step of forming the second acid and the step of forming the second acid occurs simultaneously with the second reacting step.
  • any method disclosed herein comprises a step of forming the second acid; wherein the step of forming the second acid is performed separately from the second reacting step.
  • the step of forming the second acid comprises reacting SO 2 with water to form H 2 SO 3 and/or H 2 SO 4 ; wherein the second acid is H 2 SO 3 and/or H 2 SO 4 .
  • the second acid is H 2 SO 3 and/or H 2 SO 4 and wherein the second calcium salt is CaSO 3 and/or CaSO 4 , respectively.
  • the first acid and/or the second acid is a bulk acid.
  • the first acid is a bulk acid.
  • the second acid is a bulk acid.
  • the step of forming the first acid comprises forming a pH gradient via water electrolysis; wherein the first acid is formed via the water electrolysis.
  • the step of forming the second acid comprises forming a pH gradient via water electrolysis; wherein the second acid is formed via the water electrolysis.
  • the second acid regeneration step according to formula FX1A is performed at a temperature selected from the range of 400° C. to 1800° C.
  • the second acid regeneration step according to formula FX1A is performed at a temperature selected from the range of 400° C. to 600° C.
  • the second acid regeneration step according to formula FX1A is performed at a temperature selected from the range of 400° C. to 600° C.
  • the catalyst comprises vanadium oxide.
  • the method is characterized by a net energy selected from the range of ⁇ 2 to +2 GJ per metric ton of produced cement material (e.g., produced first cement material or produced composite cement material, such as OPC).
  • produced cement material e.g., produced first cement material or produced composite cement material, such as OPC.
  • the method is characterized by a net energy selected from the range of ⁇ 10 to +10 GJ/t, optionally ⁇ 5 to +5 GJ/t, optionally ⁇ 5 to +4 GJ/t, optionally ⁇ 5 to +3 GJ/t, optionally ⁇ 5 to +2 GJ/t, optionally ⁇ 5 to +1 GJ/t, optionally ⁇ 5 to +0.5 GJ/t, optionally ⁇ 5 to +0.2 GJ/t, optionally ⁇ 5 to +0.1 GJ/t, optionally ⁇ 5 to 0 GJ/t, optionally ⁇ 2 to 1 GJ/t, optionally ⁇ 2 to ⁇ 1.5 GJ/t, optionally ⁇ 2 to +1.0 GJ/t, optionally ⁇ 2 to +0.5 GJ/t, optionally ⁇ 2 to +0.3 GJ/t, optionally ⁇ 2 to +0.2 GJ/t, optionally ⁇ 2 to +0.1 GJ/t, optionally ⁇ 2 to +0 G
  • the first reacting step is exothermic.
  • the second acid regeneration step is exothermic.
  • the first reacting step is performed at a temperature of at least 50° C.
  • the first reacting step is performed at a temperature selected from the range of 80° C. to 100° C., preferably 90 ⁇ 5° C.
  • the thermally treating step is performed at a temperature selected from the range of 1100° C. to 1800° C.
  • the thermally treating step comprises thermally treating the second calcium salt in the presence of a chemical reductant and is performed at a temperature selected from the range of 800° C. to 1200° C.
  • the chemical reductant is water, carbon (or any allotrope or combination of allotropes of carbon, hydrogen gas, methane, gas, or any combination of these.
  • the chemical reductant is water, carbon (or any allotrope or combination of allotropes of carbon, methane, gas, or any combination of these.
  • the thermally treating step can be performed according to any one or a combination of formulas FX4A, FX4B, FX4C, and FX4D: CaSO 4 +H 2 O ⁇ CaO+H 2 SO 4 (FX4A); CaSO 4 +2C CaS+2CO 2 (FX4B); CaSO 4 +CH 4 ⁇ CaS+CO 2 +2H 2 O (FX4C); CaS+3CaSO 4 ⁇ 4CaO (FX4D).
  • Any of the methods disclosed herein can be performed as a batch process, a plug flow process, a semi-continuous process, a staged process, a continuous process, or any combination of these. Any of step of any method disclosed herein can be performed as a batch process, a plug flow process, a semi-continuous process, a staged process, a continuous process, or any combination of these.
  • Additional aspects of the invention disclosed herein include a method for producing a cement material via reductive thermal decomposition, the method comprising steps of: reacting a calcium-bearing material with a chemically reducing gas to produce methane and a cement material.
  • the calcium-bearing material comprises CaCO 3 , CaSO 4 , CaS, a calcium salt, or any combination thereof.
  • the calcium-bearing material is CaCO 3 , CaSO 4 , CaS, or any combination thereof.
  • the calcium-bearing material is CaCO 3 .
  • the calcium-bearing material comprises CaCO 3 .
  • the chemically reducing gas is hydrogen gas or a gas that comprises hydrogen gas, such as forming gas.
  • the cement material comprises CaO.
  • the cement material is CaO.
  • a molar ratio of calcium-bearing material reacting with the chemically reducing gas is 1:4 or 1:2.
  • the reacting is performed in the presence of water.
  • the reacting is performed in the absence of water.
  • the molar ratio of CaCO 3 reacts with hydrogen gas at a molar ratio of 1:4 during the step of reacting.
  • the molar ratio of CaCO 3 reacts with hydrogen gas at a molar ratio of 1:2 during the step of reacting.
  • the reaction according to a 1:4 molar ratio is lower energy but high OpEx because more H 2 needs to be made, but a lower temp can be used.
  • the reaction according to a 1:2 molar ratio has a higher energy but lower OpEx.
  • any method for producing a cement material via reductive thermal decomposition comprises a step of decomposing the methane to produce hydrogen gas and one or more carbon materials.
  • the method does not comprise forming CO 2 .
  • the step of reacting is characterized by a lower heating value (LHV) of 720 kJ/mol or less and a high heating value (HHV) of 800 kJ/mol or less.
  • the step of reacting is performed at a temperature of at least 700° C.
  • a method of producing a cement material comprises steps of: first reacting a calcium-bearing starting material with a first acid to produce a first aqueous fraction comprising an aqueous first calcium salt and a first solid fraction comprising one or more solid byproducts; wherein: the calcium-bearing starting material has a chemical composition comprising a plurality of metal elements including at least Ca and Si; the one or more solid byproducts comprises a silicon salt; first separating the first aqueous fraction from the first solid fraction; and treating the first calcium salt to produce a first cement material.
  • the treating step comprises thermally treating (or, thermally decomposing) the first calcium salt in the presence of water to produce the first cement material.
  • thermally treating (or, thermally decomposing) the first calcium salt regenerates the first acid.
  • the treating step comprises an ion exchange step; wherein the ion exchange step comprises exchanging the one or more anions of the first calcium salt for one or more hydroxyl anions to form a third calcium salt.
  • the ion exchange step comprises reacting the first calcium salt with a chelating agent to form a calcium-chelator compound and reacting the calcium-chelator compound with a base to form the third calcium salt.
  • the ion exchange step comprises reacting the first calcium salt with a base to form the third calcium salt.
  • the ion exchange step comprises using an ion exchange membrane to perform the exchanging one or more anions of the first calcium salt for hydroxyl anions to form the third calcium salt.
  • the third calcium salt is Ca(OH) 2 .
  • the treating step comprises thermally treating (or, thermally decomposing) the third calcium salt to produce the first cement material.
  • the base is a hydroxide compound.
  • the first calcium salt is CaCl 2 ).
  • the treating step comprises thermally decomposing CaCl 2 ) in presence of air according to formula: CaCl 2 )+02->CaO+Cl 2 +1 ⁇ 2O 2 .
  • the treating step comprises thermally treating CaCl 2 in the presence of water according to formula: CaCl 2 +H 2 O->CaO+2HCl.
  • the treating step comprises ion exchange using an ion exchange membrane to exchange Cl ions for OH ions thereby forming Ca(OH) 2 .
  • the treating step further comprises dehydrating the Ca(OH) 2 to make the first cement material.
  • the treating step comprises reacting the first calcium salt with a chelating agent to form a calcium-chelator compound.
  • the treating step comprises reacting a base such as NaOH, Mg(OH) 2 , or MgCl(OH), with the first calcium salt, such as CaCl 2 to form Ca(OH) 2 .
  • the treating step further comprises thermally decomposing Ca(OH) 2 to make the first cement material.
  • the first cement material optionally is or optionally comprises CaO.
  • the first acid is hydrogen chloride.
  • the one or more solid byproducts comprise SiO 2 .
  • the at least one multinary metal oxide material is at least one natural rock or mineral.
  • the first calcium salt and/or the second calcium salt is other than Ca(OH) 2 or comprises a salt other than Ca(OH) 2 .
  • the first reacting step is not an electrochemical step.
  • the second reacting step is not an electrochemical step.
  • the calcium-bearing starting material is other than CaCO 3 or comprises a material other than CaCO 3 .
  • FIG. 1 A plot showing methane production in a tube furnace in partial pressure of methane versus temperature. 0.3 lpm of forming gas (5% H 2 , 95% N 2 ) flow rate.
  • FIG. 2 A plot showing methane production in a tube furnace in mole methane versus time. 0.3 lpm of forming gas (5% H 2 , 95% N 2 ) flow rate.
  • FIG. 3 An XPS pattern of a product obtained from reacting CaCO 3 in a reducing environment illustrating the pure CaO appears to be produced.
  • thermal conversion and “thermally converting” refer to the conversion of a first chemical species to a second chemical species via a thermally-activated or thermally-driven process, which may also be referred to as a thermochemical process.
  • An exemplary process for thermal conversion of a chemical species is burning, though thermal conversion processes are not necessarily limited thereto.
  • thermal conversion of sulfur to sulfur dioxide may include burning of the sulfur, such as via a sulfur burner system.
  • Thermal oxidation of a species is a form of thermal conversion of the species.
  • thermal conversion of sulfur to sulfur dioxide may be referred to as thermal oxidation of the sulfur to sulfur dioxide.
  • thermal conversion may be aided by a catalyst.
  • thermal conversion does not require a catalyst or is performed without a catalyst.
  • thermal oxidation and electrochemical oxidation are different processes, where thermal oxidation is driven or activated thermally (via heat or burning) and electrochemical oxidation is driven electrochemically (e.g., via applying or withdrawing electrical energy, optionally with the aid of an electrochemical catalyst).
  • thermalally treating refers thermal treatment or exposure to heat, preferably in excess of room temperature heat, of one or more materials (such as a calcium salt, such as CaSO 4 ) such that the one or more material may thermally convert, thermally decompose, or otherwise experience a heat-induced chemical change into another material (such as a cement material, such as CaO).
  • calcium sulfate may thermally convert/decompose into calcium oxide (CaO), along with formation of byproducts such as SO 2 and oxygen.
  • a thermal treatment may also cause a plurality of materials, such as a plurality of materials comprising calcium, aluminum, and silicon, to convert into or otherwise form a composite cement material, such as Ordinary Portland Cement (OPC).
  • OPC Ordinary Portland Cement
  • calcium-bearing starting material refers to one or more materials the chemical composition of which comprises Ca.
  • a calcium-bearing starting material can be a single material, such as a mineral whose chemical composition includes the element Ca, such as in the form of Ca cations as part of an ionic material, such as a multinary metal oxide material.
  • a calcium-bearing starting material can be a plurality of materials, such as one or more rocks, minerals, and/or industrially-processed material, wherein the chemical composition of the combination of said plurality of materials includes the element Ca, such as in the form of Ca cations of an ionic material, such as a multinary metal oxide material.
  • a calcium-bearing starting material is a plurality of materials
  • any one or any combination of said plurality of materials can have a chemical composition comprising the element Ca in order for the chemical composition of the combination of said plurality of materials (which together are the calcium-bearing starting material) to include the element Ca.
  • a calcium-bearing starting material having a chemical composition comprising the element Ca refers to the weight percent and/or the molar percent of Ca in said calcium-bearing starting material being at least 0.001%, preferably at least 0.01%, preferably at least 0.1%, more preferably at least 1%, further more preferably at least 5%, still more preferably at least 10%, and yet more preferably at least 20%.
  • the methods disclosed herein are compatible with a calcium-bearing starting material whose chemical composition has a low weight percent and/or molar percent, such as less than 60%, less than 55%, less than 50%, less than 45%, less than 40%, and less than 20%, at least because Ca, along with respective counterions, can be isolated.
  • material or species having a chemical composition characterized as comprising an element X refers to the weight percent and/or the molar percent of X in said material or species being at least 0.001%, preferably at least 0.01%, more preferably at least 0.1%, and still more preferably at least 1%.
  • calcium salt refers to a salt whose chemical composition comprises the element Ca, for example in the form of Ca cations.
  • a salt is a chemical compound comprising ionic species associated with each other at least in part via ionic bonding.
  • CaSO 4 and CaCl 2 are calcium salts wherein Ca is a cation and SO 4 and CI, respectively, are anions.
  • a regeneration step refers to a step of a process for producing a species or material using a product of a different step that consumes (e.g., converted via chemical change into another species or material) in said species or material.
  • a reaction characterized by (A+B->C+D) consumes species A and B to form species C and D.
  • a reaction characterized by (C+E->A+F) can be referred to as a regeneration reaction for regenerating species A using a product (species C) of the reaction that consumed species A.
  • solid fraction refers to solid species present in a mixture of solid(s) and liquid(s).
  • liquid fraction refers to liquid species and species dissolved in the liquid species in a mixture of solid(s) and liquid(s).
  • a solid fraction can have the solid products of a chemical reaction and liquid fraction can have the liquid and dissolved products of the chemical reaction.
  • Each of the solid fraction and the liquid fraction can optionally include unreacted reagents.
  • the liquid fraction can include solvent(s) and ions dissolved in said solvent(s).
  • a “dry mass” of one or more materials refers to the mass of the one or more materials being free of water, and optionally free of any liquid species.
  • metal oxide generally refers to a material whose chemical composition comprises one or more metal elements and the element O.
  • a metal oxide material is an ionic material or at least partially an ionic material wherein at least a fraction of the chemical bonding is characterized as ionic bonding.
  • a metal element is any metal element or metalloid element of the periodic table of elements. Generally, a metalloid element is selected from the group consisting of B, Si, Ge, As, Se, Sb, Te, Po, and At.
  • Natural rock or mineral refers to one or more materials that is naturally found in and has been extracted from the Earth's crust. Natural rocks and minerals include, but are not limited to, basalt, igneous appetites, wollastonite, anorthosite, montmorillonite, bentonite, calcium-containing feldspar, anorthite, diopside, pyroxene, pyroxenite, mafurite, kamafurite, clinopyroxene, colemonite, grossular, augite, pigeonite, margarite, calcium serpentine, garnet, scheilite, skarn, limestone, natural gypsum, appetite, fluorapatite, and any combination of these. In contrast, cement, concrete, Portland cements, fly ash, and slag are not natural rocks or mineral but may be referred to as industrially-derived materials.
  • bulk acid refers to an acid or acid solution that does not require continuous input of energy (such as electrical energy) and/or exchange of electrons with an electrode surface to exist and function as required by a given process or step thereof.
  • energy such as electrical energy
  • a heterogeneous or local acidic solution such as of hydronium ions or protons, near an electrode and formed as a result of and substantially only during exchange of electrons between the electrode and the solution is not a bulk acid.
  • a bulk acid is not a heterogeneous or local or acidic solution corresponding to a pH gradient formed at an electrode during water electrolysis.
  • the term “bulk acid” refers to an acid or acid solution that exhibits thermodynamic, chemical, and/or kinetic stability on a time scale of at least 10 seconds, preferably at least 1 minute, in the absence of electrical energy input. In certain embodiments, the term “bulk acid” refers to an acid or acid solution that does exhibit or is capable of exhibiting thermodynamic, chemical, and/or kinetic stability on a time scale of at least 1 seconds and a length scale of at least 10 cm, preferably at least 10 cm from a surface of a bulk material, in the absence of electrical energy input.
  • Electrochemical cell refers to devices and/or device components that perform electrochemistry. Electrochemistry refers to conversion of chemical energy into electrical energy or electrical energy into chemical energy. Chemical energy can correspond to a chemical change or chemical reaction. Electrochemistry can thus refer to a chemical change (e.g., a chemical reaction of one or more chemical species into one or more other species) generating electrical energy and/or electrical energy being converted into or used to induce a chemical change. Electrical energy refers to electric potential energy, corresponding to a combination of electric current and electric potential in an electrical circuit. Electrochemical cells have two or more electrodes (e.g., positive and negative electrodes; e.g., cathode and anode) and one or more electrolytes.
  • electrodes e.g., positive and negative electrodes; e.g., cathode and anode
  • An electrolyte may include species that are oxidized and species that are reduced during charging or discharging of the electrochemical cell. Reactions occurring at the electrode, such as sorption and desorption of a chemical species or such as an oxidation or reduction reaction, contribute to charge transfer processes in the electrochemical cell. Electrochemical cells include, but are not limited to, electrolytic cells such as electrolysers and fuel cells. Electrochemical oxidation may occur at the positive electrode, for example, and electrochemical reduction may occur at the negative electrode, for example. Electrochemical oxidation refers to a chemical oxidation reaction accompanied by a transfer of electrical energy (e.g., electrical energy input driving the oxidation reaction) occurring in the context an electrochemical cell.
  • electrical energy e.g., electrical energy input driving the oxidation reaction
  • electrochemical reduction refers to a chemical reduction reaction accompanied by a transfer of electrical energy occurring in the context an electrochemical cell.
  • a chemical species electrochemically oxidized during charging may be electrochemically reduced during discharging, and vice versa.
  • electrochemically or “electrochemical” may describe a reaction, process, or a step thereof, as part of which chemical energy is converted into electrical energy or electrical energy is converted into chemical energy.
  • a product may be electrochemically formed when electrical energy is provided to help the chemical conversion of a reactant(s) to the product proceed.
  • non-electrochemical refers to a reaction or process that does not include electrochemistry and/or does not require electrochemistry in order to be performed.
  • a reacting step refers to a process step wherein a chemical reaction occurs, characterized by one or more chemical species experiencing a chemical change (such as via chemically reacting with each other) into another one or more chemical species.
  • mental sulfur refers to any one or combination of the allotropes of sulfur, such as, but not limited to, S7, S8, S6, S12, and S18, and including crystalline, polycrystalline, and/or amorphous sulfur.
  • RHE refers to the reference electrode commonly referred to as the reversible hydrogen electrode.
  • SCE refers to the reference electrode commonly referred to as the saturated calomel electrode.
  • initial hours of operation refers to the time during which the cell is operational starting from the very first/initial operation, or “turning on,” of the cell. Time during which the cell or system is not being operated (i.e., no electrochemical reduction or oxidation occurring therein, or no electrical energy input or output is occurring) is not included in the initial hours of operation determination.
  • aqueous refers to a solution where the solvent is water such that other species of the solution, or solutes, are substantially solvated by water.
  • aqueous may generally refer to a solution comprising water.
  • an aqueous solution or an aqueous solvent includes 5 vol. % or less of non-aqueous solvent and/or solute species.
  • sending agricultural water refers to changing or adding something, such as a solute, to agricultural water.
  • acidification of agricultural water by the addition of sulfuric acid, such as a solution including sulfuric acid to agricultural water.
  • Agricultural water refers to water used for an agricultural purpose, such as irrigation.
  • amending soil refers to changing or adding something to soil.
  • cement refers to hydraulic, non-hydraulic, or both hydraulic and non-hydraulic cement material.
  • An exemplary cement is, but is not limited to, Portland cement.
  • a cement is a binder material, which, for example, may be mixed with fine aggregate particles (such as to produce mortar for masonry) or with sand and gravel (to produce concrete).
  • cement comprises calcium oxide.
  • cement may optionally further comprise one or more other materials including, but not limited to, certain silicate(s), SiO 2 , certain oxide(s), Fe 2 O 3 , certain aluminate(s), Al 2 O 3 , belite, alite, tricalcium aluminate, brownmillerite,
  • a “cement material” refers to a material that is or can be a constituent of cement.
  • a cement material has a chemical composition comprising Ca or CaO.
  • CaO is a cement material.
  • a cementitious material is a cement material.
  • a composite cement material may include a plurality of materials, including at least one cement materials and optionally one or more additives.
  • Exemplary composite cement materials are, but are not limited to, Portland cement clinker and Portland cement, such as Ordinary Portland Cement (OPC).
  • substantially refers to a property or condition that is within 20%, optionally within 10%, optionally within 5%, optionally within 1%, or optionally is equivalent to a reference property or condition.
  • a voltage that is substantially 500 mV (or, substantially equivalent to 500 mV) is within 20%, optionally within 10%, optionally within 5%, optionally within 1%, or optionally equal to 500 mV.
  • a voltage is substantially greater than 500 mV if the voltage is at least 20% greater than, optionally at least 10% greater than, optionally at least 5% greater than, or optionally at least 1 greater than 500 mV.
  • substantially less when used in conjunction with a reference value or condition describing a property or condition, refers to a value or condition that is at least 2%, optionally at least 5%, optionally at least 10%, or optionally at least 20% less than the provided reference value.
  • a voltage is substantially less than 500 mV if the voltage is at least 20% less than, optionally at least 10% less than, optionally at least 5% less than, or optionally at least 1% less than 500 mV.
  • a composition or compound of the invention such as an alloy or precursor to an alloy, is isolated or substantially purified.
  • an isolated or purified compound is at least partially isolated or substantially purified as would be understood in the art.
  • a substantially purified composition, compound or formulation of the invention has a chemical purity of 95%, optionally for some applications 99%, optionally for some applications 99.9%, optionally for some applications 99.99%, and optionally for some applications 99.999% pure.
  • Example 1 A Process to Make Calcium Oxide or Ordinary Portland Cement from Calcium Bearing Rocks and Minerals
  • Methods disclosed herein can use an acid (e.g. H 2 SO 4 , HF, HCl, H 2 CO 3 ) or a combination of acids plus a calcium bearing rock or mineral (e.g. anorthosite, montmorillonite, wollastonite) to produce a calcium salt (e.g. CaSO 4 , CaF 2 , CaCl 2 ), CaCO 3 ). It is then possible to hydrate or thermally decompose this salt to produce CaO. It may also be possible to achieve the correct ratios of starting materials to thermally decompose the calcium salt and byproducts into a cementitious material including Ordinary Portland Cement or calcium sulfoaluminate cement.
  • an acid e.g. H 2 SO 4 , HF, HCl, H 2 CO 3
  • a calcium bearing rock or mineral e.g. anorthosite, montmorillonite, wollastonite
  • the strength, concentration, or quality of the acid and the particle size of the mined calcium-bearing rock can change the kinetics of the removal of calcium salts from the calcium-bearing starting material and different acid concentrations and crushed rock sizes may be optimal for different versions of this process.
  • This process could also be used to make clean hydrogen if electrochemical cogeneration of H 2 and H 2 SO 4 are used:
  • Lime is used directly as a commodity chemical as well as the primary constituent of cement which is the most consumed human made material on the planet. Lime is currently produced via the thermal decomposition of limestone in an air atmosphere (FX16).
  • Included in this invention is a process to produce cement from limestone via reductive thermal decomposition with hydrogen.
  • the first step in the process may follow the following reactions:
  • Water content of the reacting gas influences whether the reaction proceeds according to FX17A, FX17B, or both.
  • CaCO 3 can react with H 2 to either make CaO+CH 4 +O 2 or CaO+CH 4 +2H 2 O. If H 2 O is formed, 4H 2 s are consumed. If O 2 is formed, only 2H 2 s are consumed. This reaction can be driven to only consume 2H 2 s if there is a water atmosphere, for example.
  • the reaction may stop there or the second step may be methane pyrolysis to regenerate the hydrogen, or any methane involving chemical reaction:
  • reaction FX17A is a lower energy requirement than traditional thermal decomposition of limestone (13.1 kJ/mol).
  • a benefit of reaction FX17B is that 100% of the necessary hydrogen can be regenerated from methane pyrolysis.
  • reaction FX17A occurs under reducing conditions above 700C for example in an H 2 , an H 2 /N 2 atmosphere or any other combination.
  • Reaction FX17B may occur above 700C with H 2 under a water atmosphere.
  • lpm liters per minute
  • we attached a gas analyzer to the back of the furnace to measure the methane concentration. Data is found in FIGS. 1 and 2 .
  • XPS is to determine that the resulting thermal decomposition yielded >99% lime ( FIG. 3 ).
  • Exemplary aspect 1 The production of ordinary portland cement (OPC) from any calcium containing starting material without the net production of acid-forming gases (e.g. SO 2 and CO 2 ).
  • Examples of calcium containing starting materials include: basalt, igneous appetites, wollastonite, slag, fly ash, anorthosite, montmorillonite, bentonite, calcium-containing feldspar, anorthite, diopside, pyroxene, pyroxenite, mafurite, kamafurite, clinopyroxene, colemonite, grossular, augite, pigeonite, margarite, calcium serpentine, garnet, scheilite, OPC, concrete, any rock that has any Ca or CaO by mass especially rocks with >5%, >10%, or >15% CaO, any skarns, limestone, gypsum, appetite, or fluorapatite.
  • we do this by first producing >90% pure synthetic gypsum from the above calcium containing rocks (details in claim 2 ) and then thermally decomposing this gypsum to make CaO and then mixing it with the proper ratios of other materials to form OPC.
  • the produced SO 2 is then reformed into sulfuric acid (via the contact process or via a sulfur depolarization electrolyzer) which can then be recycled to make synthetic gypsum.
  • the general chemistry is below:
  • Ordinary Portland Cement is made in industry today exclusively from limestone (primarily CaCO 3 ).
  • the production of OPC involves first producing CaO by thermally decomposing CaCO 3 (e.g. CaCO 3 +heat->CaO+CO 2 ) and then heating the CaO with silica and alumina to form OPC which is ⁇ 60% CaO by mass.
  • the production of CO 2 from cement manufacturing is responsible for >5% of global CO 2 emissions.
  • OPC may also be made from gypsum (CaSO 4 ).
  • Mined gypsum (CaSO 4 ) can be used by some methods for producing OPC.
  • CaSO 4 is thermally decomposed to produce CaO (e.g. CaSO 4 +heat ⁇ CaO+1 ⁇ 2O 2 +SO 2 ).
  • This process can also be accomplished with carbo or hydro thermic reduction in which case CaS is produced by reacting CaSO 4 with a reductant (e.g. coal) and then CaS is co-thermally-decomposed with CaSO 4 to make CaO.
  • This process is known as the Mueller-Kuehne Process. Neither of these processes are practiced commercially today because SO 2 cannot be released into the atmosphere and the global demand for SO 2 is far lower than the demand for OPC.
  • OPC can be produced from “phosphogypsum” (CaSO 4 produced by reacting phosphate rock with H 2 SO 4 to make phosphoric acid and gypsum).
  • the fertilizer industry produces waste CaSO 4 by reacting sulfuric acid with phosphate rock (primarily Ca 5 (PO 4 ) 3 OH) to make phosphoric acid.
  • This synthetic gypsum can be thermally decomposed to make CaO and then OPC as in the process above.
  • Exemplary Aspect 2 The production of >90% purity CaSO 4 from any calcium containing rock.
  • HCl is first reacted with the rock to dissolve the calcium chloride, precipitates out >90 dry wt % purity SiO2, and other byproducts.
  • sulfuric acid which selectively precipitates out CaSO 4 as this is the only sulfate salt among the common sulfate salts (MgSO 4 , Al 2 (SO 4 ) 3 , Fe 2 (SO 4 ) 3 ) that does not dissolve in water. This also regenerates the HCl.
  • Sample chemistry is below:
  • Methods disclosed herein include production of >90 dry wt. % purity CaSO 4 , which is make the process less expensive, less complicated, more controllable of necessary materials ratios for accurate production of OPC.
  • 90 dry wt. % calcium sulfate can also be produced as a byproduct of reacting sulfuric acid with either limestone (CaCO 3 ) and phosphate rock (Ca 5 (PO 4 ) 30 H or Ca 5 (PO 4 ) 3 F).
  • the products of these reactions are either water soluble (HF, H 2 PO 4 ), liquid (H 2 O) or gaseous (CO 2 ).
  • methods disclosed herein can yield highly pure synthetic gypsum from any rock even if the byproducts are not soluble in sulfuric acid.
  • Exemplary aspect 3 The production of alumina from any calcium containing rock. This can be done by first leaching with HCl and then saturating the leach solution with HCl, the high HCl concentration causes AlCl 3 to precipitate. AlCl 3 can then be mixed with H 2 SO 4 to make Al 2 (SO 4 ) 3 and regenerate the HCl. Al 2 (SO 4 ) 3 can be thermally decomposed to make Al 2 O 3 and make SO 2 in order to regenerate the sulfuric acid. Exemplary chemistry below:
  • Exemplary aspect 4 The production of iron oxide from any calcium containing rock. Once Al, Ca, and Si are removed via the process described above, only aqueous iron sulfate and magnesium sulfate are left in solution. If the water is evaporated and the salts are raised to 500-700C iron sulfate will decompose into insoluble iron oxide and the remaining magnesium sulfate can be dissolved away in water leaving only iron oxide.
  • Exemplary aspect 5 The production of supplementary cementitious materials including silica fume from calcium-containing rocks.
  • a side benefit of our process is that because it dissolves everything except the silica, the particle size of everything is very small and therefore we can make synthetic silica fume.
  • Methods disclosed herein include benefits of expanding the starting materials that are capable of making these products, and, in many cases, achieving better processes efficiencies, product purities, and qualities than conventional processes.
  • isotopic variants of compounds disclosed herein are intended to be encompassed by the disclosure.
  • any one or more hydrogens in a molecule disclosed can be replaced with deuterium or tritium.
  • Isotopic variants of a molecule are generally useful as standards in assays for the molecule and in chemical and biological research related to the molecule or its use. Methods for making such isotopic variants are known in the art. Specific names of compounds are intended to be exemplary, as it is known that one of ordinary skill in the art can name the same compounds differently.
  • Certain molecules disclosed herein may contain one or more ionizable groups [groups from which a proton can be removed (e.g., —COOH) or added (e.g., amines) or which can be quaternized (e.g., amines)]. All possible ionic forms of such molecules and salts thereof are intended to be included individually in the disclosure herein. With regard to salts of the compounds herein, one of ordinary skill in the art can select from among a wide variety of available counterions those that are appropriate for preparation of salts of this invention for a given application. In specific applications, the selection of a given anion or cation for preparation of a salt may result in increased or decreased solubility of that salt.
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