Hybrid Salgenx Saltwater Battery Electrolyzer for Zero-Emission Cement and Concrete Production by Salgenx

TEL: 1-608-238-6001 Email: greg@salgenx.com

Now developing cement production simultaneously while charging Using limestone one of the applications is producing a green version of cement... More Info

Once you have the output product of lime (Ca(OH)₂) from the electrochemical process, it must be processed and combined with other materials to form cement or concrete. Here's a clear step-by-step explanation of how to go from lime to the final construction product.

From Lime to Cement or Concrete: Step-by-Step

Step 1: Start with Calcium Hydroxide (Hydrated Lime)

This is the product from your electrolyzer:

Chemical formula: Ca(OH)₂

Fine white powder or slurry

Acts as a reactive binder when mixed with pozzolanic or siliceous materials

Step 2: Choose Cement Type

There are two main paths depending on your target material:

Option A: Make Pozzolanic or Non-Portland Cement

If you're not using a rotary kiln or traditional clinker:

1. Mix Ca(OH)₂ with pozzolanic material, such as:

Fly ash

Volcanic ash

Silica fume

Rice husk ash

2. Optional: Add ground slag or natural cement rock

3. Result:

Pozzolanic cement, sets through a chemical reaction with Ca(OH)₂

Low-heat, low-carbon, and durable in marine/acidic conditions

Option B: Reconstruct Portland Cement (Clinker Route)

If aiming for conventional Portland cement, you need to:

1. Dry and dehydrate the Ca(OH)₂ to form CaO (quicklime):

\text{Ca(OH)₂} \xrightarrow{\Delta} \text{CaO} + \text{H₂O}

2. Mix with silica (SiO₂), alumina (Al₂O₃), and iron oxide (Fe₂O₃):

These are typically derived from clay, shale, or industrial byproducts

3. Heat to \~1450°C to form clinker (you would still need a kiln)

4. Grind clinker + gypsum → Portland cement powder

This path reintroduces high heat but can use electrified kilns or concentrated solar heat for carbon-neutral production.

Step 3: Make Concrete from Cement

Regardless of cement type (Pozzolanic or Portland), make concrete by mixing:

| Ingredient | Typical Proportion (by volume) |

| -------------------• | -----------------------------------• |

| Cement | 10–15% |

| Water | 15–20% |

| Sand | 25–30% |

| Gravel/Aggregate | 40–50% |

| Optional Additives | Plasticizers, retarders, silica fume |

The chemical reaction between cement and water (hydration) binds the sand and gravel into a hard, stone-like material.

Alternative Cement Systems You Can Use With Electrochemical Lime

| -----------------------• | -------------• | ---------------• | ---------------------------------------------• |

| Geopolymer cement | No | Low | Uses alkali activators and fly ash |

Conclusion

After producing lime from limestone electrochemically, you can:

Directly mix it with pozzolans for low-carbon cement

Reconvert it to CaO and combine with other oxides for Portland cement if needed

Combine the resulting cement with aggregates and water to produce concrete

This method unlocks a new, electrified, and potentially zero-emission path to cement and concrete manufacturing without reliance on fossil-fueled kilns.

Hybrid Salgenx Saltwater Battery Electrolyzer for Zero-Emission Cement and Concrete Production

The construction industry is facing growing pressure to reduce its carbon footprint, particularly in cement and concrete manufacturing, which accounts for roughly 8 percent of global CO₂ emissions. A novel approach integrates the Salgenx saltwater battery system as both a grid-scale energy storage platform and an electrolytic reactor. This hybrid process not only stores electricity but simultaneously drives the decomposition of limestone slurry into valuable industrial gases and calcium hydroxide, a key component of cement and concrete.

The Electrolyzer Battery Platform

The Salgenx saltwater battery operates using a non-toxic, non-flammable saline solution as its electrolyte. Traditionally used to store and release electricity on demand, the Salgenx system also supports electrochemical reactions when operated in a specific mode. By introducing a limestone slurry into the electrolyte, the system can serve a dual role as both an energy storage medium and a material production reactor.

The electrolyzer cell stack consists of titanium-ruthenium coated electrodes and selective ion exchange membranes, enabling the following reactions:

At the anode:

Oxidation of chloride ions to produce chlorine gas

Liberation of carbon dioxide from limestone as it converts to calcium ions

At the cathode:

Reduction of water to produce hydrogen gas

Formation of hydroxide ions, which bind with calcium to form calcium hydroxide

Feedstock: Limestone Slurry and Saltwater

Instead of relying on mined limestone chunks and fossil fuel kilns, the process uses finely ground limestone mixed with water to form a slurry. This slurry is introduced into the saltwater electrolyte within the battery cell.

The presence of salt allows for simultaneous chlorine generation, while the limestone undergoes electrochemical conversion into:

Calcium hydroxide (Ca(OH)₂): Precursor to cement and concrete

Carbon dioxide (CO₂): Captured in pure form for reuse or storage

Hydrogen gas (H₂): Can be stored or used for heat or fuel cells

Chlorine gas (Cl₂): Useful for industrial applications such as disinfectants and plastics

Electricity Storage and Discharge

When electricity from solar, wind, or other renewable sources is abundant, it charges the Salgenx system and drives the electrolytic reactions. During periods of low generation or high demand, the system can switch to discharge mode, functioning like a conventional battery by supplying electricity back to the grid or facility.

This configuration allows for continuous integration with renewable energy, making it suitable for off-grid construction, remote manufacturing, or distributed energy production.

Benefits of the Hybrid System

| Feature | Benefit |

| --------------------------• | ---------------------------------------------------------------• |

| Dual-purpose operation | Simultaneous energy storage and material processing |

| CO₂-free heat replacement | No fossil fuels used for lime or cement production |

| Elemental gas capture | Pure streams of H₂ and Cl₂ for secondary markets |

| Cement precursor production | On-site Ca(OH)₂ for concrete mixing and casting |

| Modular and scalable | Adaptable for mobile, industrial, or decentralized installations |

Application in Green Construction

The calcium hydroxide produced can be blended with pozzolanic materials or supplementary cementitious additives to create carbon-reduced or carbon-negative concrete formulations. By using CO₂ captured from the process itself for curing or carbonation, the cycle closes with near-zero or negative net emissions.

This approach enables localized, energy-resilient cement production without reliance on high-temperature kilns or fossil fuels, transforming the traditional cement plant into a clean electrochemical factory.

Conclusion

By merging the capabilities of the Salgenx saltwater battery with the electrochemical decomposition of limestone, a new pathway emerges for sustainable cement and concrete production. This innovation reduces emissions, harnesses renewable energy, and creates value from all byproducts. As infrastructure demands continue to grow, this hybrid system offers a path toward a cleaner, decentralized, and circular construction economy.

CONTACT TEL: +1 608-238-6001 (Chicago Time Zone) Email: greg@salgenx.com | AMP | PDF