b&i2013 donderdag 15.45_zaal_b_low-carbon concretes using novel mineral binders as cemetn...
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Low Carbon Concretes – Delft, 31.10.2013Low Carbon Concretes – Delft, 31.10.2013 11
Zero Carbon Cement Substitutes for Concrete
Low Carbon Concretes (LCC)Low Carbon Concretes (LCC)
using novel mineral binders as cement substitutesusing novel mineral binders as cement substitutes
Low Carbon Concretes – Delft, 31.10.2013Low Carbon Concretes – Delft, 31.10.2013 22
Zero Carbon Cement Substitutes for Concrete
LCC - what does it mean?LCC - what does it mean?
Advanced normal concrete, specifically engineered with reduction of greenhouse
gas emissions – mainly CO2 - in mind with respect to
• Choice of concrete materials
• Design and manufacturing of concrete
• Materials and concrete transport
Build up concrete constructions with higher functionality, longer lifetime and
reduced effort for maintenance and repairs
Low Carbon Concretes – Delft, 31.10.2013Low Carbon Concretes – Delft, 31.10.2013 33
Zero Carbon Cement Substitutes for Concrete
Why LCC?Why LCC?
Concrete is the world‘s most
consumed man-made material.
Portland cement is the essential
constituent of nearly all concretes.
The demand and consumption of
concretes and cements are constantly
increasing.
CO2-emissions derived from concrete Cement manufacturing leads to release
of 2,9 billion tons of greenhouse gases
per year (2011), mainly CO2.
In 2050 cement production will
cause >10% of total CO2-release.
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Zero Carbon Cement Substitutes for Concrete
Evaluation of concrete products: An integrated approachEvaluation of concrete products: An integrated approach
Applicability
Efficiency
ProductProduct
Feasibility
Standards & Directives, Market
Costs, Prices, Revenues Engineering, Materials,Know-how, Staff skills Lowest carbon footprint product
(Concept of LCC)
New materials and advanced technologiesin concrete productions
Sustainability
New additional assessing criterias for products
durable
reusablenon-polluting
resource-efficient
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Zero Carbon Cement Substitutes for Concrete
Partial substitution of Partial substitution of conventional materialsconventional materials
• Unchanged productUnchanged product• Unchanged technologyUnchanged technology• Innovative potential within Innovative potential within
material onlymaterial only
Complete substitution of Complete substitution of conventional materialsconventional materials
• Competitive productCompetitive product• Unchanged or modified technologyUnchanged or modified technology• Innovative potential within material Innovative potential within material
and technologyand technology
New products with new New products with new materialsmaterials
• Novel productNovel product• Modified or new technologyModified or new technology• Innovative potential within Innovative potential within
material, technology and material, technology and final product propertiesfinal product properties
Development efforts (time, cost, staff)Development efforts (time, cost, staff) Degree of innovationDegree of innovation Sustainability (low carbon footprint)Sustainability (low carbon footprint) Potential of profitPotential of profit
Development strategy for Low Carbon ConcretesDevelopment strategy for Low Carbon Concretes
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Zero Carbon Cement Substitutes for Concrete
Low Carbon Concrete for sustainable buildingLow Carbon Concrete for sustainable building
Traditional approachTraditional approach
Advanced cement technology (blended cements)
Consume less clinker
Concrete mix design and modified technical requirements
Consume less cement
Innovative architecture and structural design (HPC)
Consume less concrete
New approachNew approach
Use novel binders toreplace cement
bifamentbifament
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Zero Carbon Cement Substitutes for Concrete
Pure OPC (CEM I)Pure OPC (CEM I)
Blended OPC with single SCMsBlended OPC with single SCMsup to 35% (CEM II)up to 35% (CEM II)
Blended OPC with several SCMsBlended OPC with several SCMsup to 35% (CEM II) orup to 35% (CEM II) orwith single SCM up to 95% (CEM III)with single SCM up to 95% (CEM III)
Blended Cements to reduce carbon footprintBlended Cements to reduce carbon footprint
Development Development
-43%-43%
+62% +62%
+112%+112%
Overall market share Overall market share
56% 29% 56% 29%
German cement market (2002-2012) German cement market (2002-2012)
30% 48% 30% 48%
11% 22% 11% 22%
Low Carbon Concretes – Delft, 31.10.2013Low Carbon Concretes – Delft, 31.10.2013 88
Zero Carbon Cement Substitutes for Concrete
bifament bifament - a novel binder with zero carbon footprint- a novel binder with zero carbon footprint
stand alone mineral binder for concretes in competition to conventional cementsstand alone mineral binder for concretes in competition to conventional cements
specially developed and processed mineral binder, which
• consists of industrial by-products only (100% cement-free!),
• contains up to 100% of pretreated, hydraulic lignite fly ash,
• has binding properties like cement
is added to concrete as reactive mineral powder replacing
• conventional fillers to 100%,
• conventional cements from 30 up to 100%
with no restrictions on properties of concrete products
NEW
NEW
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Zero Carbon Cement Substitutes for Concrete
Emission of COEmission of CO22 during production process during production process
bifamentwill be manufactured with
no release of CO2
in contrast to cements!
Quelle (Zementdaten): Staatl. Forschungsstelle für Energiewirtschaft München – Ganzheitliche Bilanzierung von Grundstoffen und Halbzeugen (1999)
bifament
0 kg/t CO2 !
CO
2-re
leas
e (k
g/t
)
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Zero Carbon Cement Substitutes for Concrete
bifamentbifament lowers the carbon footprint of concrete products lowers the carbon footprint of concrete products
Quelle (Zementdaten): Staatl. Forschungsstelle für Energiewirtschaft München – Ganzheitliche Bilanzierung von Grundstoffen und Halbzeugen (1999)
bifament bifament bifament
Example: Concrete paving blocks
up to 94% less CO2-release if substituting cements by bifament
CO
2-re
leas
e (k
g/t
)
Cement
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Zero Carbon Cement Substitutes for Concrete
Specific characteristics of Specific characteristics of bifamentbifament
Self-hardening
need no activators (alkalis, cement, lime ...)
Contains typical components of cements, slags and fly ashes initially by origin
composition and materials behavior are similar to a supersulfated cement
Free of shrinkage
no particular precautions for preventing cracks (joints, fibres)
Material behavior in concrete production is similar to cements
requires no technical changes within production process
Properties can be customized by selected composition and degree of processing
different qualities designed to individual application or product
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Zero Carbon Cement Substitutes for Concrete
The The bifamentbifament-project-project
Basic scientific researchand developmentsince 1998
Application testsand optimizationsince 2005
Long term experiences infly ash processing andmaterial behavior in practicesince 1994
• Product implementation on customers site
• Quality assurance in production
Applied researchand suitability testssince 2000
• Foundation of production and sales company in 2011• Installation of production facility in 2013/14
• Continual product development
• Product approvals
From 2014:
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Zero Carbon Cement Substitutes for Concrete
Industrial application example 1: Manufacturing of paving blocksIndustrial application example 1: Manufacturing of paving blocks- High-volume cement substitution by - High-volume cement substitution by bifament bifament --
Increase in product qualityIncrease in product quality
at lower production costsat lower production costs
up toup to 36 % 36 %
oror
Maximum potential reductionMaximum potential reduction
in cement consumption andin cement consumption and
mixture costsmixture costs
at equal product qualityat equal product quality
more thanmore than 50 % 50 %
Strength development
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Zero Carbon Cement Substitutes for Concrete
Industrial application example 1: Manufacturing of paving blocksIndustrial application example 1: Manufacturing of paving blocks
- Improvement of frost resistance -- Improvement of frost resistance -
Traditional mix without bifamentbifament Advanced mix with partial substitutionof cement by bifamentbifament
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Zero Carbon Cement Substitutes for Concrete
Industrial application example 2: Manufacturing of masonry blocksIndustrial application example 2: Manufacturing of masonry blocks- Complete cement replacement by - Complete cement replacement by bifamentbifament --
Strength development
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Zero Carbon Cement Substitutes for Concrete
OutlookOutlook
Commissioning of production plant in 2014
Availability of bifamentbifament up to 150.000 tons per year
Several pilot projects for German market are being prepared
Concrete repair, flood protection, immobilization
Few custom projects have already been started in Germany
Concrete goods, civil engineering products, ground and road construction
Looking for additional projects abroad
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Zero Carbon Cement Substitutes for Concrete
Thank you for your attention!
The University of Queensland‘s Global Change Institute (GCI) Australia
World‘s first building made from cement-free concrete for structural construction
Photography by Angus Martin