Extremely Durable Concrete using Methane Decarbonization Nanofiber Co-products with Hydrogen (EERE - Pipeline H 2 ) Modular Processing of Flare Gas for Carbon Nanoproducts (NETL - Flare Gas) Alan W. Weimer, PI, University of Colorado – Boulder (CU) Mija H. Hubler, co-PI, University of Colorado – Boulder (CU) Team Members: Forge Nano (FN), National Ready Mixed Concrete Association (NRMCA) We are producing H 2 and a beneficial carbon nanofiber concrete additive from natural gas by chemical vapor deposition using a low-cost sacrificial and compatible catalyst support EERE: $1.25 M (36) NETL: $3.75 M (41) Project Vision Total Project Cost ( mo)
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Extremely Durable Concrete using Methane Decarbonization ......Ultra 6129 -5 Premix+Ultra 6815 +6 Fine sand only 6427 0 Fine Sand+CNFs+Ultra 6882 +7 Fine Sand+CNFs+Premix+Ultra 6936
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Extremely Durable Concrete using Methane Decarbonization Nanofiber
Co-products with Hydrogen (EERE - Pipeline H2)
Modular Processing of Flare Gas for Carbon Nanoproducts (NETL - Flare
Gas)
Alan W. Weimer, PI, University of Colorado – Boulder (CU)
Mija H. Hubler, co-PI, University of Colorado – Boulder (CU)
Team Members: Forge Nano (FN), National Ready Mixed Concrete Association (NRMCA)
We are producing H2 and a beneficial carbon nanofiber concrete additive
from natural gas by chemical vapor deposition using a low-cost sacrificial
1) premixing with HRWR to change surface properties
2) Ultrasound dispersion to break Van der Waals forces
Reproduce HPC Mix design (wt.%) with Expected Performance
w/c Cement Water Sand SF HRWRCoarse
aggregate
28-day comp.
strength (psi)
0.32 19.92 6.34 27.66 1.92 0.46 43.69 9732
Ensure Minor Change in Setting time of HPC when adding CNFs
70.0
75.0
80.0
85.0
90.0
95.0
0 200 400 600 800 1000 1200 1400 1600 1800
Te
mp
era
ture
, F
Time, min.
no CNFs
ultrasonic dispersed CNFs
HPC with commercial CNF toughness testing
NETL: Mix design and mechanical tests for UPHC
6
Develop Optimized UHPC mix design
Mix w/c Cement Water Sand SF HRWRGround
quartz
1 0.22 31.62 6.97 44.28 7.89 1.33 7.89
2 0.23 30.05 6.91 51.92 9.75 1.37 0.00
3 0.22 38.68 8.53 32.54 9.66 0.94 9.66
4 0.21 34.45 7.43 34.93 6.90 1.30 14.99
5 0.18 35.84 6.45 49.51 6.64 1.55 0.00
1 2 3 4 5
17103 15412 18795 15767 18007
Averaged compressive strength of samples after 28 days curing (psi)
1 2 3 4 5
4.25 3.25 3.5 3.875 4.75
Slump test results (in)
UHPC mix design (wt.%)
Optimized for
medium slump.
Achieved required UHPC
compressive strength.
Dispersion method Peak Load (N)Peak Load
Increment (%)
NoCNFs (general sand) 6440 0
Dumpin 6094 -5
Ultra 6129 -5
Premix+Ultra 6815 +6
Fine sand only 6427 0
Fine Sand+CNFs+Ultra 6882 +7
Fine Sand+CNFs+Premix+Ultra 6936 +8
Mix design 5 with 0.1 cwt% of commercial CNFs
Flexure Test
Optimize Dispersion for Improved Flexure Strength of UHPC with Commercial CNFs
Dispersion is critical for improved
mechanical performance.
EERE Results: Preliminary Technoeconomic Analysis
7
CVD
Reactor with
Integrated
Furnace
Heat
Exchanger
Sacrificial
CatalystCNF coated
Silica Fume
770k mt/yr
Pressure
Swing
Adsorbers
Furnace
Exhaust
Hydrogen
Product
43k mt/yr
Natural Gas
Feed
12 BSCF/yr
ParametersHydrogen price: $2/kg
NG cost: $3/KSCF
IRR: 10%
Lifetime: 15 years
Estimated TDC: $2B-4B
Cost of Capital: 8.5%
ResultsCNF coated silica, price range:
$2 - $4 per kg
Pure CNF, price range:
$10 - $20 per kg
Pure CNF, current technology:
$300 per kg (bulk)
Compressor
NETL Results: Preliminary Technoeconomic Analysis
8
CVD
Reactor with
Integrated
Furnace
Heat
Exchanger
Sacrificial
Catalyst
CNF coated
Silica Fume
580 mt/yr
Hydrogen
Pump
Natural Gas
Feed
9.7 MMSCF/yr
ParametersNG cost: Free
IRR: 10%
Lifetime: 15 years
Estimated TDC: $1M-2M
Cost of Capital: 8.5%
ResultsCNF coated silica, price range:
$2 - $4 per kg
Pure CNF, price range:
$10 - $20 per kg
Pure CNF, current technology:
$300 per kg (bulk)
Furnace
Exhaust
Challenges and Technical Partnerships
Challenges/Risks
‣ CNF/CNP Synthesis Risk - Particle ALD catalyst will be unable to grow substantial CNF/CNP quantity
‣ Cement Mixing Risks - The produced CNFs/CNPs are not easily homogenized with cement
‣ CVD Reactor Scale-up Risk
‣ Identify technology implementation of CNF/CNP additives
Reducing Risk/Mitigation Strategies
‣ CNF Synthesis Risk Reduction - Metal nanoparticles will be deposited as metals in-situ using ALD with a reduction step, followed by CVD (can be sequenced if desired)
‣ Cement Mixing Risk Reduction – Methods to ensure dispersion will be investigated using detergents and anti-foam agents
‣ Skid Design, Construction, and Operation at Forge Nano
‣ NRMCA will link the research team with potential contacts or organizations and the co-PI will be engaged in committees writing standards for implementation