CO2 Utilization in Ready Mixed Concrete Productioncarboncure.com/wp-content/uploads/2016/03/2016_02-Carboncure-6th... · CO2 Utilization in Ready Mixed Concrete Production Sean Monkman,

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CO2 Utilization in Ready Mixed Concrete Production Sean Monkman, PhD PEng VP Technology Development CarbonCure Technologies Inc

2 www.carboncure.com Simply Better Concrete 6th Carbon Dioxide Utilization Summit, Newark, NJ

Feb 25, 2016

is the most abundant man-made material on the planet and makes up about 50% by mass of all materials produced globally.

Materials and the Environment, 2nd Ed, by M.F. Ashby, 2012

CONCRETE

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CO2 EMISSIONS

3 Damtoft et al, (2008). Cement and Concrete Research, 38(2), 115-127

are a byproduct of cement production and total about 5% of the total annual global. One tonne of cement

clinker results in about 865 kg of CO2 emitted.

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Carbon solution: upcycle CO2

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Limestone CaCO3

CO2 permanently mineralized within concrete

Concrete

Add aggregates & water

CaCO3 bound within

CO2

Cement CaO

Precipitation (CO2 Storage)

Ca+2(aq) + CO3

-2(aq) ↔ CaCO3 (s)

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Trial summary

o  Workability, temperature, isothermal calorimetry o  Compressive strength (1, 3, 7, 28, 56, 91 days), o  Resistivity

Truck 1 Control and three sequential doses of CO2

Truck 2 One dose of CO2 during batching

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Low dose trial

Strength - CO2 during batching

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114%

126%

121%

115%

118%

Con

trol

CO

2

0

1000

2000

3000

4000

5000

6000

1 day 3 day 7 day 28 day 56 day

Com

pres

sive

Str

engt

h (p

si)

Test Age

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Gas system meters CO2

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Gas delivery wand

Use wand to direct the injection

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Gas hooked onto the truck

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Pilot Program Research Goals

•  Investigate viable CO2 utilization approach in ready-mixed concrete

•  Establish impact on fresh properties •  Establish impact on hardened properties

•  Compressive strength •  Durability metrics

•  Develop optimized mix designs using CO2 as an admixture

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Pilot Program

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•  Technology trials at 14 locations through June 2015

•  Limited scale •  Optimal dosing

not necessarily achieved

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Trial – Miami Feb 2015 Design: 3000 psi @ 24 hrs and 6000 psi @ 28 days, 16% Class F fly ash

116%

113%

117%

107%

Con

trol

CO

2

0

2000

4000

6000

8000

10000

0

10

20

30

40

50

60

70

1 4 7 28

Com

pres

sive

Str

engt

h (p

si)

Com

pres

sive

Str

engt

h (M

Pa)

Test age (days) Control air = 0.7% CO2 air = 0.7%

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Trial – Virginia April 2015 Design: 5000 psi, 25% slag

Control air = 7.0% CO2 air = 7.5%

189%

153%

139%

120%

Con

trol

CO

2

0

2000

4000

6000

8000

10000

0

10

20

30

40

50

60

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1 day 4 day 7 day 28 day

Com

pres

sive

Str

engt

h (p

si)

Com

pres

sive

Str

engt

h (M

Pa)

Test age

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Trial – Chicago May 2015 Design: 4000 psi, 17.5% Class C fly ash

106%

113%

110%

116%

Con

trol

CO

2

0

1000

2000

3000

4000

5000

0

5

10

15

20

25

30

35

40

1 day 3 day 7 day 28 day

Com

pres

sive

Str

engt

h (p

si)

Com

pres

sive

Str

engt

h (M

Pa)

Test age Control air = 9.5% CO2 air = 9.7%

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Trial – Atlanta June 2015 Design: 5000 psi high early, 20.0% Class F fly ash

111%

115%

114%

108%

Con

trol

CO

2

0

1000

2000

3000

4000

5000

0

5

10

15

20

25

30

35

40

1 Day 3 Day 7 Day 28 Day

Com

pres

sive

Str

engt

h (p

si)

Com

pres

sive

Str

engt

h (M

Pa)

Test age Control air = 1.6% CO2 air = 1.8%

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Compressive Strength Results

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114% 116% 113% 110%

80%

100%

120%

140%

160%

180%

200%

1 day 3 days 7 days 28 days

Com

pres

sive

Str

engt

h R

elat

ive

to R

efer

ence

Test Age

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Influence on Slump

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0

2

4

6

8

10

12

Slum

p (in

ches

)

Mix

Control CO2 No effect on workability

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Influence on Air

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0%

2%

4%

6%

8%

10%

12%

Air

cont

ent

Mix

Control CO2 No effect on air content

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Durability testing

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TEST RESULT

Flexural Strength (C78)

Absorption (C642)

Abrasion (C944)

RCPT (C1202)

Resistivity

Bulk chloride diffusion (C1556)

Freeze/thaw (C666)

Drying Shrinkage (C426)

Service Carbonation (RILEM CPC-18)

Salt Scaling (BNQ NQ 2621-900)

Corrosion (G109, C876)

TEST RESULT

Flexural Strength (C78) Increased 6%

Absorption (C642) Equivalent

Abrasion (C944) Reduced 7%

RCPT (C1202) Equivalent (moderate)

Resistivity Equivalent (moderate)

Bulk chloride diffusion (C1556) Equivalent

Freeze/thaw (C666) Equivalent (mass loss <0.2%, pass)

Drying Shrinkage (C426) Equivalent

Service Carbonation (RILEM CPC-18) Reduced 29/54/25%

Salt Scaling (BNQ NQ 2621-900) Equivalent

Corrosion (G109, C876) Equivalent (none observed)

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Substrate

Mechanism

Carbonate Particle

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In-situ development of nano-CaCO3

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Current Status

•  Pilot effort is complete. •  Technology rollout

is underway.

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Future Work

Commissioning Program •  Five early adopter

installs identified •  DC, Charlotte, Atlanta

•  17 others at contracting stage

•  Long term operation will seek: •  Proven strength benefit •  Reproducibility •  End-user feedback •  Mix design optimization

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Environmental Impact •  Doses are small, but industry is huge •  A consistent strength benefit allows for

increased SCM usage thereby lowering the carbon footprint of the concrete mix design.

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CO2 Supply Today •  Market-based supplies •  CO2 sourced from large

industrial emitters

Tomorrow •  Integrated small supplies •  CO2 sourced from cement and

concrete plants •  Annual utilization of 30-50

tonnes/site

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Acknowledgements

•  NRC – Industrial Research Assistance Program (IRAP)

•  Sustainable Development Technology Canada (SDTC)

•  The industrial partners •  Doug Hooton (UofT) •  Mike Thomas (UNB) •  Greg Dipple (UBC)

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Concluding slide

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