Description:FIELD OF THE INVENTION

[0001] The present invention relates to a direct air capture-enabled carbonation system for eco-friendly construction material production that is capable of capturing carbon dioxide from the ambient air for producing eco-friendly construction materials thereby contributing to environmental conservation and sustainable development.

BACKGROUND OF THE INVENTION

[0002] Building materials are essential for the construction of safe, durable, and sustainable structures that meet societal needs. They provide the fundamental foundation for residential, commercial, and infrastructural development, ensuring stability, safety, and comfort for occupants. The importance of building materials lies in their ability to influence the strength, longevity, thermal efficiency, and environmental impact of buildings. With the growing emphasis on sustainability, eco-friendly and innovative building materials play a crucial role in reducing the carbon footprint, conserving natural resources, and promoting environmentally responsible construction practices. Overall, suitable building materials are vital for creating resilient, cost-effective, and sustainable infrastructure that supports the well-being of communities and the environment.

[0003] Traditional methods of producing eco-friendly construction materials often involve natural or locally sourced resources, such as clay, lime, and timber, utilizing techniques like rammed earth, adobe, or bamboo construction. These methods typically require minimal energy, produce low emissions, and emphasize recycling and reuse of materials. They focus on sustainable practices that reduce environmental impact, promote energy efficiency, and enhance the durability of structures, aligning with eco-conscious building principles. Despite their eco-friendliness, traditional methods of producing construction materials have certain drawbacks. They often face limitations in strength, durability, and resistance to environmental factors like water and pests. Additionally, these methods require longer construction times and skilled labor, which increase costs. In some cases, they do not meet modern building codes or standards for safety and fire resistance, limiting their application in contemporary construction.

[0004] CN105731971A discloses an environment-friendly building material and a process for preparing the same. The environment-friendly building material mainly comprises, by weight, 70-85 parts of gypsum powder, 25-40 parts of talc powder, 3-6 parts of zinc borate, 10-16 parts of green tea, 15-22 parts of polyamide resin, 8-16 parts of calcium lignosulfonate, 6-14 parts of Arabic gum, 5-10 parts of trisodium phosphate, 12-18 parts of polyurethane and 3-8 parts of magnesium hydroxide. The environment-friendly building material and the process have the advantages that the environment-friendly building material is excellent in adhesive strength, bidirectional affinity, crack resistance, water resistance, leakage resistance and sag resistance and good in fireproof and flame-retardant properties, and is alkali-resistant to a certain extent, and coating is easy to color, uniform in color distribution, excellent in construction performance and storage stability and free of toxicity and peculiar smell, and is environmentally friendly and safe.

[0005] CN1245153A discloses a novel environment-friendly building material is prepared from daily discarded glass bottles and waste glass through crushing, grinding, sieving, using net layer as substrate, reinforcing colloid, and spreading broken glass. More important is to provide a building material which reduces environmental pollution, recycles effective resources and converts the waste glass bottle bodies into a material with high economic value and substantial effect.

[0006] Conventionally, many systems have been developed for the production of the eco-friendly building material but they lack in capturing carbon dioxide from the ambient air for producing eco-friendly construction materials for contributing to environmental conservation and sustainable development. They also lack in converting the carbon dioxide from gas into liquid form for efficient mixing with the constituent material for the production of the construction material.

[0007] In order to overcome the aforementioned drawbacks, there exists a need in the art to develop a system that requires to be capable of capturing carbon dioxide from the ambient air for producing eco-friendly construction materials for contributing to environmental conservation and sustainable development. Additionally, the system requires to be capable of converting the carbon dioxide from gas into liquid form for efficient mixing with the constituent material for the production of the construction material.

OBJECTS OF THE INVENTION

[0008] The principal object of the present invention is to overcome the disadvantages of the prior art.

[0009] An object of the present invention is to develop a system that is capable of capturing carbon dioxide from the ambient air for producing eco-friendly construction materials thereby contributing to environmental conservation and sustainable development.

[0010] Another object of the present invention is to develop a system that is capable of converting the carbon dioxide from gas into liquid form for efficient mixing with the constituent material for the production of the construction material.

[0011] Another object of the present invention is to develop a system that is capable of monitoring the flow interruptions in the passing of the constituent material for the preparation of the construction material and taking the necessary steps for enhancing the flow of the constituent material for resolving the material clumping and ensuring consistent feed.

[0012] Yet another object of the present invention is to develop a system that is capable of eliminating the trapped air pockets and improving density of the construction material thereby improving the strength, durability and overall quality of the final construction material.

[0013] The foregoing and other objects, features, and advantages of the present invention will become readily apparent upon further review of the following detailed description of the preferred embodiment as illustrated in the accompanying drawings.

SUMMARY OF THE INVENTION

[0014] The present invention relates to a direct air capture-enabled carbonation system for eco-friendly construction material production that is capable of converting the carbon dioxide from gas into liquid form for efficient mixing with the constituent material for the production of the construction material.

[0015] According to an embodiment of the present invention, a direct air capture-enabled carbonation system for eco-friendly construction material production is disclosed that comprises of a Direct Air Capture (DAC) unit including an air contactor with a fan and a honeycombed sorbent bed coated with amine filters configured to selectively absorb carbon dioxide gas from ambient air, a replaceable electrostatic HEPA (High Efficiency Particulate Air) filter is positioned between the fan and the sorbent bed for filtering dust and particulate matter, a heat exchanger arranged adjacent to the DAC unit for regenerating sorbent material by supplying or removing heat during carbon dioxide gas desorption, a compressor downstream of the heat exchanger is provided for pressurizing desorbed carbon dioxide gas to a supercritical pressure, a liquid carbon dioxide gas injection control valve connected to the condenser outlet for regulated injection of liquid carbon dioxide gas into a rotary mixer, a rotary mixer comprising twin motor-driven blades rotating in both clockwise and anti-clockwise directions for mixing cement, sand, aggregates, and water, the mixer is sealed/partially enclosed to retain carbon dioxide gas released from liquid carbon dioxide gas injection and facilitate absorption and carbonation reaction with cement components, producing calcium carbonate, with the carbonated mix discharged through a controlled iris opening for molding, a hopper integrated with the rotary mixer for automated raw material feed control that is monitored by load cell sensors connected via conduit to a multi-chamber container holding different raw materials with pre-fed dosing based on required brick quantities, pneumatic agitators are attached to the hopper via ball and socket joints are actuated upon flow interruption detection by level sensors to resolve material clumping and ensure consistent feed, an alkali dosage pump integrated with the rotary mixer actuated by the microcontroller to deliver alkaline solution in precise amounts based on raw material input data, a water metering pump is integrated into the system to precisely add water and alkali activators to twin-shaft high-shear mixer provided within the rotary mixer with temperature, viscosity and moisture sensors monitoring slurry consistency and hydration reactions including exothermic heat release.

[0016] According to another embodiment of the present invention, the system further comprises of a molding unit comprising a hydraulic press with adjustable pressure and interchangeable mold plates, an automated feeder unit provided with the molding unit ensuring consistent mold filling and a conveyor for transferring fresh mix from the mixer to the molds, a pneumatic compactor integrated within the molding unit equipped with mold vibrators and pneumatic pins to eliminate trapped air pockets and improve density and uniformity of molded blocks with pressure transducers providing real-time force measurement and control, a Dynamic Pressure Carbonation (DPC) unit comprising a sealed carbonation chamber, high-pressure carbon dioxide gas injector, pressure and temperature sensors, freshly molded blocks are conveyed into the chamber, high-pressure carbon dioxide gas is injected to promote carbonation and enhance mechanical properties, a user-interface is inbuilt in a computing unit that is accessed by a user to input initial commands regarding specification of brick that is to be manufactured along with receiving alert of maintenance requirements, sensor anomalies, power fluctuations, and safety events throughout the system, a thermal input is integrated with the heat exchanger dynamically adjusted by the microcontroller based on atmospheric carbon dioxide gas concentration to optimize desorption frequency and energy consumption, temperature and pressure sensors are integrated with the compressor to monitor compressor performance and the microcontroller activates heat recovery mode, auto-calibration, emergency shutdowns and operator alerts upon detection of overheating, insufficient compression, or unsafe pressure spikes, a backup portable carbon dioxide gas cylinder connected between the compressor and rotary mixer where the microcontroller activates the backup supply when ambient captured carbon dioxide gas concentration falls below a threshold and automatically shuts it off upon reaching target concentration as detected by a non-dispersive infrared (NDIR) carbon dioxide gas sensor and a battery is associated with the system for supplying power to electrical and electronically operated components.

[0017] While the invention has been described and shown with particular reference to the preferred embodiment, it will be apparent that variations might be possible that would fall within the scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
Figure 1 illustrates an isometric view of a direct air capture-enabled carbonation system for eco-friendly construction material production.

DETAILED DESCRIPTION OF THE INVENTION

[0019] The following description includes the preferred best mode of one embodiment of the present invention. It will be clear from this description of the invention that the invention is not limited to these illustrated embodiments but that the invention also includes a variety of modifications and embodiments thereto. Therefore, the present description should be seen as illustrative and not limiting. While the invention is susceptible to various modifications and alternative constructions, it should be understood, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention as defined in the claims.

[0020] In any embodiment described herein, the open-ended terms "comprising," "comprises,” and the like (which are synonymous with "including," "having” and "characterized by") may be replaced by the respective partially closed phrases "consisting essentially of," consists essentially of," and the like or the respective closed phrases "consisting of," "consists of, the like.

[0021] As used herein, the singular forms “a,” “an,” and “the” designate both the singular and the plural, unless expressly stated to designate the singular only.

[0022] The present invention relates to a direct air capture-enabled carbonation system for eco-friendly construction material production that is capable of eliminating the trapped air pockets and improving density of the construction material thereby improving the strength, durability and overall quality of the final construction material.

[0023] Referring to Figure 1, an isometric view of a direct air capture-enabled carbonation system for eco-friendly construction material production is illustrated comprising a Direct Air Capture (DAC) unit 101, a fan 102 and a honeycombed sorbent bed 103, a replaceable electrostatic HEPA (High Efficiency Particulate Air) filter 104 is positioned between the fan 102 and the sorbent bed 103, a heat exchanger 105 arranged adjacent to the DAC unit 101, a compressor 106 downstream of the heat exchanger 105, a condenser 107 positioned next to the compressor 106, a liquid carbon dioxide gas injection control valve 108, a rotary mixer 109 comprising twin motor-driven blades, a hopper 110 integrated with the rotary mixer 109, a multi-chamber container 111 holding different raw materials, pneumatic agitators 112 are attached to the hopper 110, an alkali dosage pump 113 integrated with the rotary mixer 109, a water metering pump 114 is integrated into the system, twin-shaft high-shear mixer 115 provided within the rotary mixer 109, a molding unit 116 adjacent to the rotary mixer 109 comprising a hydraulic press 117 with adjustable pressure and interchangeable mold plates 118, an automated feeder unit 119, a conveyor 120 for transferring fresh mix from the mixer 109 to the molds, a pneumatic compactor 121 integrated within the molding unit 116, a Dynamic Pressure Carbonation (DPC) unit 122, a backup portable carbon dioxide gas cylinder 123 connected between the compressor 106 and rotary mixer 109.

[0024] The system disclosed herein employs a Direct Air Capture (DAC) unit 101. The Direct Air Capture (DAC) unit 101 includes an air contactor with a fan 102 and a honeycombed sorbent bed 103 coated with amine filters configured to selectively absorb carbon dioxide gas from ambient air. The honeycombed sorbent bed 103 coated with amine filters features a structured, porous design that maximizes surface area for efficient carbon dioxide adsorption. The amine coatings chemically react with carbon dioxide, selectively capturing the Carbon dioxide from ambient air as the fan 102 pulls air through the honeycomb structure.

[0025] For activating the system, the user needs to press a push button which is arranged on the Direct Air Capture (DAC) unit 101 which in turn activates all the related components for performing the desired task. After pressing the button, a closed electrical circuit is formed and current starts to flow that powers an inbuilt microcontroller to allow all the linked components to perform their respective task upon actuation.

[0026] For filtering dust and particulate matter in the incoming air, a replaceable electrostatic HEPA (High Efficiency Particulate Air) filter 104 is positioned in between the fan 102 and the sorbent bed 103. The electrostatic HEPA (High Efficiency Particulate Air) filter 104 functions by utilizing both mechanical interception and electrostatic attraction to efficiently capture dust and particulate matter from incoming air. As air is drawn through the filter 104, the HEPA (High Efficiency Particulate Air) filter 104, composed of densely packed fibers with an embedded electrostatic charge, creates multiple filtration arrangements. The mechanical filtration occurs when particles are physically trapped within the fiber matrix, especially larger particles that cannot pass through the pore spaces. Concurrently, the electrostatic charge on the fibers attracts and captures smaller, charged, or neutral particles through electrostatic attraction, significantly enhancing filtration efficiency. This combination ensures that a high percentage of airborne contaminants are removed before the air reaches the sorbent bed 103, preventing particulate buildup and prolonging the bed’s functional lifespan.

[0027] A heat exchanger 105 is arranged adjacent to the DAC unit 101 for regenerating sorbent material by supplying or removing heat during carbon dioxide gas desorption. The heat exchanger 105 regenerates the sorbent material by facilitating efficient heat transfer. The heat exchanger 105 operates on the principle of heat exchange between two fluids at different temperatures, with one fluid being the sorbent material in the spent state and the other fluid serving as the heat transfer medium. The sorbent material, typically in a calcium based form, has absorbed carbon dioxide from the air and is now in a desorption phase, requiring heat to release the captured carbon dioxide. The heat exchanger's core consists of a network of tubes through which the sorbent material flows, while the heat transfer medium, such as hot air, flows through a separate circuit. As the sorbent material passes through the heat exchanger 105, the material comes into contact with the heat transfer medium, allowing for efficient heat transfer to occur. The heat transferred to the sorbent material enables to release the captured carbon dioxide.

[0028] For pressurizing desorbed carbon dioxide gas to a supercritical pressure, a compressor 106 downstream of the heat exchanger 105 is provided. The compressor 106 functions to pressurize the desorbed carbon dioxide gas to reach supercritical conditions. Inside the compressor 106, the carbon dioxide gas from the heat exchanger 105 enters the compression chamber, where pistons increase the gas pressure by reducing the volume. As the gas is compressed, the temperature also rises due to adiabatic compression. The high-pressure, heated carbon dioxide then exits the compressor 106 and flows into downstream, such as a conditioning arrangement to reduce the temperature to the desired supercritical state.

[0029] For monitoring the compressor 106 performance, temperature and pressure sensors are configured with the compressor 106. The pressure sensor employs a piezoresistive sensing element, such as a silicon-based pressure transducer. When the internal pressure of the compressor 106 changes, it exerts a force on a diaphragm within the sensor. This diaphragm deflects proportionally to the pressure variation, causing a change in the electrical resistance of the piezoresistive element attached to the diaphragm. An internal Wheatstone bridge circuit detects resistance changes, converting mechanical deformation into an electrical signal. This voltage signal provides real-time pressure readings with high accuracy.

[0030] The temperature sensor, configured with the compressor 106 is a RTD (Resistance Temperature Detector). The platinum RTD works by having a thin platinum wire whose electrical resistance varies predictably with temperature. As the temperature increases, the resistance of the platinum wire increases proportionally. The sensor's internal circuitry measures this resistance change and converts it into an electrical voltage. This signal is then processed by the microcontroller to determine the precise temperature of the compressor 106. The microcontroller activates heat recovery mode, auto-calibration, emergency shutdowns, and operator alerts upon detection of overheating, insufficient compression, or unsafe pressure spikes.

[0031] The pressurized carbon dioxide gas is then liquefied. A condenser 107 is positioned next to the compressor 106 to liquefy carbon dioxide gas by lowering the temperature below the condensation point at working pressure. The condenser 107 functions by transferring heat from the high-pressure, superheated carbon dioxide gas exiting the compressor 106 to a cooling medium, such as water. As the gas flows through the condenser 107 coils, the external cooling medium absorbs heat, causing the temperature of the carbon dioxide to decrease. Once the temperature drops below the condensation point at the operating pressure, the carbon dioxide transitions from a gaseous to a liquid state.

[0032] A liquid carbon dioxide gas injection control valve 108 is connected to the condenser 107 outlet for regulated injection of liquid carbon dioxide gas into a rotary mixer 109. The valve 108 consists of a piezoelectric actuator that regulates the opening and closing of the nozzle based on input signals. This allows for highly accurate and consistent injection of liquid carbon dioxide gas into the rotary mixer 109.

[0033] A rotary mixer 109 comprising twin motor-driven blades rotating in both clockwise and anti-clockwise directions for mixing cement, sand, aggregates, and water. The rotary mixer 109 operates with twin motor-driven blades mounted on a central shaft, with each set of blades rotating in opposite directions, one clockwise and the other anti-clockwise, creating a thorough and uniform mixing action. Inside the mixer 109, the cement, sand, aggregates, and water are loaded into a sealed chamber, where the dual blades continuously rotate, generating a shearing and tumbling motion that effectively combines all ingredients. The opposing rotation directions help to break up clumps, ensure even distribution of materials, and promote thorough mixing without dead zones. The mixer 109 is sealed/partially enclosed to retain carbon dioxide gas released from liquid carbon dioxide gas injection and facilitate absorption and carbonation reaction with cement components, producing calcium carbonate, with the carbonated mix discharged through a controlled iris opening for molding.

[0034] A hopper 110 is integrated with the rotary mixer 109 for automated raw material feed control, monitored by load cell sensors, connected via conduit to a multi-chamber container 111 holding different raw materials, with pre-fed dosing based on required brick quantities. The load cell sensors function by measuring the precise weight of the raw materials contained within the hopper 110. Inside the load cell, a strain gauge is bonded to a flexible metallic structure, when the hopper 110 is filled, the resulting force causes deformation of the strain gauges. This deformation alters the electrical resistance proportional to the applied load. The sensor's signal is transmitted to the microcontroller, which continuously monitors the weight, allowing for real-time assessment of raw material level.

[0035] Upon flow interruption detected by level sensors, pneumatic agitators 112 that are attached to the hopper 110 via ball and socket joints are actuated by the microcontroller to resolve material clumping and ensure consistent feed. The level sensors in the hopper 110 are typically ultrasonic sensors that emit high-frequency sound waves toward the surface of the raw material. When the sound waves hit the material surface, they reflect back to the sensor. The sensor calculates the distance based on the time taken for the echo to return. If the measured distance exceeds a set threshold, it indicates the material level is low, if the distance is below the threshold, the hopper 110 is considered full. The sensor continuously sends this data to the microcontroller, enabling the detection of flow interruptions.

[0036] The pneumatic agitators 112 operate by utilizing compressed air to generate controlled rotational movements that break up material clumping and promote uniform flow. When the level sensor detects a flow interruption, the microcontroller sends the signal to activate the pneumatic unit, which directs compressed air into the agitator 112. The pneumatic unit for extension and retraction operates using compressed air to drive a piston inside a cylinder. When air is supplied to one side of the piston, it creates pressure that pushes the piston rod outward, causing extension. To retract, air is supplied to the opposite side while the initial chamber is vented, pulling the piston rod back.

[0037] The pneumatic unit extends and rotates the agitators 112 through the ball and socket joints, producing mechanical agitation within the hopper 110. The ball and socket joint enables precise rotational movement in multiple directions by integrating an electric motor. The ball, typically attached to a shaft, fits into the socket, allowing it to rotate freely around several axes. The motor is responsible for rotating the ball within the socket, providing controlled movement along different planes, ensuring thorough mixing and preventing material buildup or blockages.

[0038] The microcontroller actuates an alkali dosage pump 113 that is integrated with the rotary mixer 109 to deliver the alkaline solution in precise amounts based on raw material input data. The alkali dosage pump 113 operates as a precisely controlled diaphragm pump that is activated by the microcontroller based on input data regarding raw material flow and requirements. When the microcontroller determines that additional alkaline solution is needed, an electrical signal is sent to the pump's control circuitry. The pump 113 then dispenses alkaline solution by actuating a diaphragm to draw in and push out the solution.

[0039] A water metering pump is integrated into the system to precisely add water and alkali activators to twin-shaft high-shear mixer 115 that is provided within the rotary mixer 109, with temperature, viscosity, and moisture sensors monitoring slurry consistency and hydration reactions, including exothermic heat release. The temperature sensor uses a thermocouple, which works by generating a voltage proportional to the temperature difference between the junctions. When immersed in the slurry, the thermocouple produces a millivolt signal directly related to the mixture’s temperature. This voltage is transmitted to the microcontroller, which converts it into a temperature reading. The sensor specifically detects the heat released from exothermic hydration reactions, providing real-time data to regulate mixing conditions and prevent overheating.

[0040] The viscosity sensor employs a rotational method, where a rotating spindle is immersed in the slurry. As the spindle turns, the motor’s torque required to maintain a set rotational speed is measured. The torque correlates directly with the slurry’s viscosity, higher torque indicates higher viscosity. The sensor sends this torque data to the microcontroller, enabling precise monitoring of the mixture’s flow resistance during hydration and ensuring proper consistency. The moisture sensor utilizes capacitance measurement, where two electrodes form a capacitor immersed in the slurry. The dielectric constant of the mixture affects the capacitance value. As water content increases, the dielectric constant rises, leading to an increase in measured capacitance. The sensor detects these changes and sends capacitance data to the microcontroller, providing an accurate, real-time measurement of moisture content within the slurry.

[0041] Adjacent to the rotary mixer 109, a molding unit 116 is positioned that comprises of a hydraulic press 117 with adjustable pressure and interchangeable mold plates 118. An automated feeder unit 119 is provided with the molding unit 116, ensuring consistent mold filling and a conveyor 120 for transferring fresh mix from the mixer 109 to the molds. The working of the automated feeder unit 119 begins with the motor-driven conveyor 120. The conveyor 120 operates by continuously moving materials from one point to another using a motor-driven belt looped around rollers. The belt is made of a durable material that provides traction and support for the fresh mix being transported. The conveyor 120 is synchronized with the molding unit 116 to deliver a precise amount of mix at regular intervals, facilitating consistent mold filling. The tensioners and rollers are included to maintain proper belt tension and alignment, preventing slippage or misalignment during operation.

[0042] The microcontroller then actuates a pneumatic compactor 121 that is configured within the molding unit 116 equipped with mold vibrators and pneumatic pins to eliminate trapped air pockets and improve density and uniformity of molded blocks, with pressure transducers providing real-time force measurement and control. The mold vibrators within the molding unit 116 operate by receiving signals from the microcontroller, which activates an electromagnetic vibration medium. When energized, the vibrators generate high-frequency oscillations that are transmitted directly to the mold walls. These vibrations cause the fresh mix inside the mold to settle more densely by reducing internal air pockets and allowing the material to flow into all corners uniformly.

[0043] The pneumatic pins extend and retract by using nested sections that slide within each other, driven by a pneumatic unit. The pneumatic unit for extension and retraction operates using compressed air to drive a piston inside a cylinder. When air is supplied to one side of the piston, it creates pressure that pushes the piston rod outward, causing extension. To retract, air is supplied to the opposite side while the initial chamber is vented, pulling the piston rod back. Hence, eliminating the trapped air pockets and improve density and uniformity of molded blocks.

[0044] The pressure transducers operate using the strain gauge method, where they consist of a set of strain gauges bonded to a flexible, elastic diaphragm within the transducer housing. During the compaction process, as the mold vibrators and pneumatic pins exert force on the mold, the resulting mechanical stress causes slight deformation of the diaphragm. This deformation changes the electrical resistance of the strain gauges arranged in a Wheatstone bridge configuration. The microcontroller continuously monitors the voltage output from this bridge, which is directly proportional to the applied force. By converting these electrical signals into force values in real-time, the system precisely controls the compaction process to eliminate trapped air and achieve desired density and uniformity of the molded blocks.

[0045] A Dynamic Pressure Carbonation (DPC) unit 122, is comprising a sealed carbonation chamber, high-pressure carbon dioxide gas injector, pressure and temperature sensors. The freshly molded blocks are conveyed into the chamber, high-pressure carbon dioxide gas is injected to promote carbonation and enhance mechanical properties. The high-pressure carbon dioxide gas injector functions by precisely delivering carbon dioxide into the sealed carbonation chamber to facilitate effective carbonation of the freshly molded blocks. The injector typically consists of a high-pressure gas reservoir connected to a controlled valve that regulates gas flow. When activated, the injector opens to release carbon dioxide from the reservoir into the chamber at a predetermined pressure and flow rate, as monitored by the pressure and temperature sensors.

[0046] A user-interface is inbuilt in a computing unit that accessed by a user to input initial commands regarding specification of brick that is to be manufactured, along with receiving alert of maintenance requirements, sensor anomalies, power fluctuations, and safety events throughout the system. The user input commands through the keyboard or touch interactive display panel of the computing unit that is transmitted to the microcontroller through a communication module. The communication module includes, but not limited to Wi-Fi (Wireless Fidelity) module, Bluetooth module, GSM (Global System for Mobile Communication) module. The Wi-Fi module contains transmitters and receivers that use radio frequency signals to transmit data wirelessly to the microcontroller. The wireless module typically includes components such as antennas, amplifiers, and processors to facilitate communication and further connected to networks such as Wi-Fi, Bluetooth, or cellular networks, allowing systems to exchange information over short or long distances.

[0047] With the heat exchanger 105, a thermal input is integrated that is dynamically adjusted by the microcontroller based on atmospheric carbon dioxide gas concentration to optimize desorption frequency and energy consumption. The thermal input is provided by the heat exchanger 105 connected to the microcontroller-controlled heating element, which dynamically adjusts the thermal output based on real-time measurements of atmospheric carbon dioxide concentration. The microcontroller continuously receives data from the carbon dioxide sensor monitoring the ambient gas levels around the system. When the sensor detects higher carbon dioxide concentrations, indicating increased need for desorption, the microcontroller increases the thermal input by modulating the heat exchanger’s energy supply, raising the temperature to accelerate the desorption process.

[0048] In between the compressor 106 and rotary mixer 109, a backup portable carbon dioxide gas cylinder 123 is connected. The microcontroller activates the backup supply when ambient captured carbon dioxide gas concentration falls below a threshold and automatically shuts it off upon reaching target concentration as detected by a non-dispersive infrared (NDIR) carbon dioxide gas sensor. The non-dispersive infrared carbon dioxide gas sensor operates based on the principle that carbon dioxide molecules absorb infrared light at specific wavelengths. When ambient air passes through the sensor’s measurement chamber, an infrared light source emits a beam that traverses the chamber. Carbon dioxide molecules in the air absorb some of this infrared radiation at characteristic wavelengths, reducing the intensity of the transmitted light reaching the sensor’s photodetector. The sensor’s internal electronics convert this reduction in light intensity into an electrical signal, which is directly proportional to the concentration of carbon dioxide in the air. The sensor provides continuous real-time data to the microcontroller, enabling precise monitoring of the ambient carbon dioxide levels.

[0049] The backup portable carbon dioxide gas cylinder 123 is equipped with an electronically controlled valve, such as a solenoid valve, which is operated by the microcontroller. When the ambient carbon dioxide gas concentration, as measured by the non-dispersive infrared sensor, drops below a predetermined threshold value, the microcontroller sends a signal to open the valve, allowing carbon dioxide gas stored in the cylinder 123 to flow into the system. This ensures the system maintains the required gas concentration for optimal operation.

[0050] For supplying power to electrical and electronically operated components, a battery is associated with the system. The battery powers electrical and electronic components by converting stored chemical energy into electrical energy. The battery’s terminals provide a voltage difference, allowing current to flow through circuits that supplies consistent energy to actuate and operate components like motors, sensors and microcontroller, ensuring seamless functionality.

[0051] The present invention works best in the following manner, where the Direct Air Capture (DAC) unit 101 is including the air contactor with the fan 102 and the honeycombed sorbent bed 103 coated with the amine filters is configured to selectively absorb carbon dioxide gas from ambient air. The replaceable electrostatic HEPA (High Efficiency Particulate Air) filter 104 filters dust and particulate matter. The heat exchanger 105 regenerates sorbent material by supplying or removing heat during carbon dioxide gas desorption. The compressor 106 downstream of the heat exchanger 105 for pressurizing desorbed carbon dioxide gas to the supercritical pressure. The temperature and pressure sensors monitor compressor 106 performance and the microcontroller activates heat recovery mode, auto-calibration, emergency shutdowns, and operator alerts upon detection of overheating, insufficient compression, or unsafe pressure spikes. The condenser 107 is to liquefy carbon dioxide gas by lowering the temperature below condensation point at working pressure. The liquid carbon dioxide gas injection control valve 108 is for regulated injection of liquid carbon dioxide gas into the rotary mixer 109. The rotary mixer 109 comprising twin motor-driven blades rotating in both clockwise and anti-clockwise directions for mixing cement, sand, aggregates, and water. The mixer 109 is sealed/partially enclosed to retain carbon dioxide gas released from liquid carbon dioxide gas injection and facilitate absorption and carbonation reaction with cement components, producing calcium carbonate with the carbonated mix discharged through the controlled iris opening for molding. The hopper 110 is for automated raw material feed control monitored by load cell sensors connected via conduit to the multi-chamber container 111 holding different raw materials with pre-fed dosing based on required brick quantities. The pneumatic agitators 112 are attached to the hopper 110 via the ball and socket joints that upon flow interruption detection by level sensors to resolve material clumping and ensure consistent feed. The alkali dosage pump 113 to deliver alkaline solution in precise amounts based on raw material input data.

[0052] In continuation, the water metering pump 114 is to add water and alkali activators to twin-shaft high-shear mixer 115 provided within the rotary mixer 109 with temperature, viscosity, and moisture sensors monitoring slurry consistency and hydration reactions, including exothermic heat release. The molding unit 116 comprising the hydraulic press 117 with adjustable pressure and interchangeable mold plates 118, the automated feeder unit 119 provided with the molding unit 116 ensuring consistent mold filling, and the conveyor 120 for transferring fresh mix from the mixer 109 to the molds. The pneumatic compactor 121 is equipped with mold vibrators and pneumatic pins to eliminate trapped air pockets and improve the density and uniformity of molded blocks with pressure transducers providing real-time force measurement and control. The Dynamic Pressure Carbonation (DPC) unit 122 is comprising the sealed carbonation chamber, high-pressure carbon dioxide gas injector, pressure and temperature sensors where freshly molded blocks are conveyed into the chamber, high-pressure carbon dioxide gas is injected to promote carbonation and enhance mechanical properties. The user-interface is inbuilt in the computing unit that is accessed by the user to input initial commands regarding specification of brick that is to be manufactured, along with receiving alert of maintenance requirements, sensor anomalies, power fluctuations, and safety events throughout the system. The thermal input is integrated with the heat exchanger 105, dynamically adjusted by the microcontroller based on atmospheric carbon dioxide gas concentration to optimize desorption frequency and energy consumption. The backup portable carbon dioxide gas cylinder 123 that is connected between the compressor 106 and rotary mixer 109. The microcontroller activates the backup supply when ambient captured carbon dioxide gas concentration falls below the threshold and automatically shuts it off upon reaching target concentration as detected by the non-dispersive infrared (NDIR) carbon dioxide gas sensor.

[0053] Although the field of the invention has been described herein with limited reference to specific embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternate embodiments of the invention, will become apparent to persons skilled in the art upon reference to the description of the invention. , Claims:1) A direct air capture-enabled carbonation system for eco-friendly construction material production, comprising:

i) a Direct Air Capture (DAC) unit 101 including an air contactor with a fan 102 and a honeycombed sorbent bed 103 coated with amine filters configured to selectively absorb carbon dioxide gas from ambient air, wherein a replaceable electrostatic HEPA (High Efficiency Particulate Air) filter 104 is positioned between the fan 102 and the sorbent bed 103 for filtering dust and particulate matter;
ii) a heat exchanger 105 arranged adjacent to the DAC unit 101 for regenerating sorbent material by supplying or removing heat during carbon dioxide gas desorption, wherein a compressor 106 downstream of the heat exchanger 105 is provided for pressurizing desorbed carbon dioxide gas to a supercritical pressure;
iii) a condenser 107 positioned next to the compressor 106 to liquefy carbon dioxide gas by lowering its temperature below condensation point at working pressure, wherein a liquid carbon dioxide gas injection control valve 108 is connected to the condenser 107 outlet for regulated injection of liquid carbon dioxide gas into a rotary mixer 109;
iv) a rotary mixer 109 comprising twin motor-driven blades rotating in both clockwise and anti-clockwise directions for mixing cement, sand, aggregates, and water, wherein the mixer 109 is sealed/partially enclosed to retain carbon dioxide gas released from liquid carbon dioxide gas injection and facilitate absorption and carbonation reaction with cement components, producing calcium carbonate, with the carbonated mix discharged through a controlled iris opening for molding;
v) a hopper 110 integrated with the rotary mixer 109 for automated raw material feed control, monitored by load cell sensors, connected via conduit to a multi-chamber container 111 holding different raw materials, with pre-fed dosing based on required brick quantities, wherein pneumatic agitators 112 are attached to the hopper 110 via ball and socket joints, actuated by the microcontroller upon flow interruption detection by level sensors to resolve material clumping and ensure consistent feed;
vi) an alkali dosage pump 113 integrated with the rotary mixer 109 actuated by the microcontroller to deliver alkaline solution in precise amounts based on raw material input data, wherein a water metering pump 114 is integrated into the system to precisely add water and alkali activators to twin-shaft high-shear mixer 115 provided within the rotary mixer 109, with temperature, viscosity, and moisture sensors monitoring slurry consistency and hydration reactions, including exothermic heat release;
vii) a molding unit 116 adjacent to the rotary mixer 109 comprising a hydraulic press 117 with adjustable pressure and interchangeable mold plates 118, an automated feeder unit 119 is provided with the molding unit 116 ensuring consistent mold filling, and a conveyor 120 for transferring fresh mix from the mixer 109 to the molds;
viii) a pneumatic compactor 121 integrated within the molding unit 116 equipped with mold vibrators and pneumatic pins actuated by the microcontroller to eliminate trapped air pockets and improve density and uniformity of molded blocks, with pressure transducers providing real-time force measurement and control; and
ix) a Dynamic Pressure Carbonation (DPC) unit 122 comprising a sealed carbonation chamber, high-pressure carbon dioxide gas injector, pressure and temperature sensors, wherein freshly molded blocks are conveyed into the chamber, high-pressure carbon dioxide gas is injected to promote carbonation and enhance mechanical properties.

2) The system as claimed in claim 1, wherein a user-interface is inbuilt in a computing unit, accessed by a user to input initial commands regarding specification of brick that is to be manufactured, along with receiving alert of maintenance requirements, sensor anomalies, power fluctuations, and safety events throughout the system.

3) The system as claimed in claim 1, wherein a thermal input is integrated with the heat exchanger 105, dynamically adjusted by the microcontroller based on atmospheric carbon dioxide gas concentration to optimize desorption frequency and energy consumption.

4) The system as claimed in claim 1, wherein temperature and pressure sensors are integrated with the compressor 106 to monitor compressor 106 performance, and the microcontroller activates heat recovery mode, auto-calibration, emergency shutdowns, and operator alerts upon detection of overheating, insufficient compression, or unsafe pressure spikes.

5) The system as claimed in claim 1, wherein a backup portable carbon dioxide gas cylinder 123 is connected between the compressor 106 and rotary mixer 109, the microcontroller activates the backup supply when ambient captured carbon dioxide gas concentration falls below a threshold and automatically shuts it off upon reaching target concentration as detected by a non-dispersive infrared (NDIR) carbon dioxide gas sensor.

6) The system as claimed in claim 1, wherein a battery is associated with said system for supplying power to electrical and electronically operated components associated with said system.