Commercialisation of geopolymer concrete as part of FP7 SUS-CON project
Commercialisation of Geopolymer Concrete as part of FP7 SUS-CON Project:Sustainable, Innovative and Energy-Efficient Concrete, based on the Integration of All-Waste Materials
Contents:• Geopolymer Team at Queen’s University Belfast.• Historical background – sustainable construction materials.• FP7 SUS-CON - Sustainable, Innovative and Energy- Efficient Concrete, based on the Integration of All-Waste Materials.• New binders from waste streams - WP3 work on pfa and ggbs based geopolymer concrete.• Possible sources of raw materials for “synthesizing” geopolymer concrete – a step towards commercialisation.• Conclusions.
Queen’s University Belfast Geopolymer Team (1 of 2)Prof. M Soutsos Prof. M Basheer Prof. D Cleland Prof. W ShaDr. S Nanukuttan Dr. A Boyle Dr. E Cunningham Dr. M Russell University of Liverpool
Queen’s University Belfast Geopolymer Team (2 of 2)S. Haji A. Hadjierakleous Q. Ma L. McCluskey University of Liverpool T. McGrath A. McIntosh A. Rafeet banah UK Ltd http://blogs.qub.ac.uk/geopolymer/
Historical Background: Sustainable Construction ProductsDeveloping Precast Concrete Products made with RecycledConstruction and Demolition Waste (C&DW): • Phase I : Concrete Building Blocks • Phase II: Concrete Paving Blocks and Flags Funded by: The Onyx (Veolia) Environmental Trust & Flintshire Community Trust (AD Waste Ltd) 5th March 2003
Historical Background: Sustainable Construction Products North West Construction Knowledge Hub Construction Sustainability Centre:(a) Recycled demolition aggregate in precast building and paving blocks and concrete flags,(b) Reactive glass powder concrete flags of superior strength,(c) Cementless “geopolymer” concrete products.
Historical Background: Ultra High Performance Fibre Reinforced Cementless Precast Concrete Products Applied Research Grant Support• The claims culture in the UK costs local authorities £500m each year from trip, slip and fall accidents arising from cracked pavements.• The superior performance of UHPFRC flags indicates that pavements are unlikely to crack even if they are overloaded by unplanned vehicle loading.
FP7 SUS-CON Project:Sustainable, Innovative and Energy-Efficient Concrete, based on the Integration of All-Waste Materials• The construction industry is one of the largest consumers raw materials and the built environment consumes a lot of energy and contributes significantly to greenhouse gas emissions.• Concrete producers need new, eco-friendly and cost- effective materials and binders for thermally efficient building components – energy efficient buildings.• Waste management is an increasingly complex and challenging task for both local authorities and waste recycling companies.
FP7 SUS-CON Project:Sustainable, Innovative and Energy-Efficient Concrete, based on the Integration of All-Waste Materials Develop novel technologies to integrate wastes for the production of lightweight concrete and thus achieve an all-waste and energy-efficient concrete.
FP7 SUS-CON Project:Sustainable, Innovative and Energy-Efficient Concrete, based on the Integration of All-Waste Materials• Main concrete components (binder and aggregates)• Combine them for an all-waste concrete on the basis of a new mix design model• Applications: structural and non structural cast-in-situ and pre-cast• Focus on waste materials that are cost-effective, readily available across EU and also a social problem (low- value, big quantities)
Work Packages in FP7 SUS-CON: INDUSTRIAL UPTAKE MATERIAL RESEARCH WP1. GEOCLUSTERING - Mapping availability of waste WP8. Certification, guidelines and decision support tool streams and normative framework across EU-27 WP9. Training, dissemination and exploitation WP7. LCA/LCC/HSE assessment WP2. WASTE MATERIALS - New lightweight aggregatesWP10. Project management and coordination from solid waste WP3. WASTE MATERIALS - New binding systems from waste alkaline solutions/streams and ashes WP4. WASTE MATERIALS - Mix design and testing of all waste concrete with benchmarking WP5. PRODUCTION UPSCALE - Process design and modelling WP6. PRODUCTION UPSCALE - Demonstration INDUSTRIAL IMPLEMENTATION
Complementarity of Partners: Waste recycling and processing Centro Riciclo Nano-additives andAggregates from waste Binders from waste surface treatments Cetma (polymers) QUB BASF TBTC (geo-polymers) S&B Centi Concrete design and process LCA/LCC/HSE/Certification TNO TRE FhG TUV Italia NTUA Industrial end-users Magnetti (pre-cast) Iston (ready-mixed) Iridex (builders) Acciona
FP7 SUS-CON – Project Information OTHER 4%Total cost: 7.200.000 € Manag. 5%EU funding: 4.500.000 €Cost per activity type: Demo. 23%Start date: 01/01/2012Duration: 4 years Research 68%
Work Package #3New Binders - What’s Wrong with Cement? Around 10 billion tonnes of concrete is used every year – more than any other industrial material! Ceramics (mostly concrete) Natural (mostly timber) Metals (mostly steel) Polymers UK production (2009) – 8 million tonnes of cement 5-8% of man-made CO2 – more than aviation Data from Ashby, Materials and the Environment (2009) and ONS
Work Package #3 New Binders from Waste Streams: Suitability of waste ash and alkali solutions for geopolymer concrete:1. Obtain samples from all available sources of reactive aluminosilicate wastes and activators.2. Assess their chemical and physical properties.3. Obtain samples of all available sources of waste alkali streams and assess their chemical and physical properties.4. Determine the reactivity potential of the above materials for form cementless concrete.
Pulverised Fuel Ash based GeopolymerVariables: M+ dosage (%) & Alkali Modulus (AM)• Alkali dosage (M+ dosage) is the mass ratio of alkali metal oxides (Na₂O + K2O) in the activating solution to PFA.• Alkali modulus (AM) is the mass ratio of alkali metal oxides to silica plus aluminate in the activating solution.• Fixed parameters in the mix designs were: – Water/solids ratio 0.37. Total water includes added water and that already present in the pre-mixed alkaline solutions (e.g Na-silicate). Total solids include PFA and mass of alkali solids, including those dissolved in pre- mixed solutions. Mass of sand is not included in mass of the solids here. – Sand/Binder ratio: 2.75:1
“Advanced” Microstructural Techniques for the Identification of Reaction Products Scanning Electron Microscopy (SEM)
“Advanced” Microstructural Techniques for the Identification of Reaction ProductsChemical mapping of PFA-sodium silicate geopolymer
“Advanced” Microstructural Techniques for the Identification of Reaction Products Secondary electron imaging & EDS
“Advanced” Microstructural Techniques for the Identification of Reaction Products Secondary electron images of PFA-based mortars
“Advanced” Microstructural Techniques for the Identification of Reaction ProductsSodium silicate crystals in mortar with low alkali modulus
Effect of PFA/GGBS ratio on the strength Alkali dosage of 7.5%
100% GGBS cured at 200CSi (green), Ca (blue), and Al (red)
Class C PFA from GreeceSi (green), Ca (blue), and Al (red)
Commercialisation of Geopolymer Concrete?Cost of Alkali Activated Binders:Assuming commercial alkalis are used, concrete based onalkali-activated binders is estimated to cost around 20-25%more than cement-based concrete.Possible Solutions:1. Produce products that will meet higher specifications or last longer than existing ones.2. Low carbon footprint - Green taxes or carbon credits.3. Find cheaper sources of alkalis - sodium silicate is the most expensive component!
Cheaper Sources of Raw Materials for Geopolymer Concrete?Possible sources:1. Incinerated paper pulp sludge.2. Air pollution control residues (APC).3. Basic oxygen slag (BOS).4. TRAAS5. MIKROVER6. Incinerated sewage sludge ash7. Bauxite residues (Red mud)8. Alumina
Hungarys toxic aftermath -An aerial photo shows the ruptured wall of the alumina plant reservoir.
The sludge, which contains a mix of metal oxides, is now making its way towards the Danube, Europes second-longest river.
Develop an Understanding of the Reaction Mechanism
CONCLUSIONS• An optimum alkali composition was identified for alkali activation of PFA giving 70 N/mm2 compressive strength.• Addition of GGBS enables the production of cement-free concrete at ambient temperatures.• There is some evidence that that there is interaction between the two reactions occurring in alkali-activated binders containing PFA and GGBS.• We need to develop a better understanding of the reaction mechanism so we can use materials from waste streams to synthesize geopolymer - commercialisation is likely if a reduction in the cost of producing it is achieved.
And finally......Thank you for your attention.Are there any questions?