beneficial use of co in precast concrete production library/events/2012/carbon storage rd...in...
TRANSCRIPT
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Beneficial Use of CO2 in
Precast Concrete Production
DE-FE0004285
Yixin Shao, Yaodong Jia Liang Hu
McGill University 3H Company
U.S. Department of Energy
National Energy Technology Laboratory
Carbon Storage R&D Project Review Meeting
Developing the Technologies and Building the
Infrastructure for CO2 Storage
August 21-23, 2012
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Presentation outline
• Goals and objectives
• Benefits to the program
• Project overview
• Technical status
• Accomplishment to date
• Summary
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Objective
Masonry blocks Fiber-cement panels Prefabricated
buildings
Concrete pipes
To develop a carbonation process to replace steam curing in precast
concrete production for energy reduction, and carbon storage and
utilization.
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Goals
• CO2 sequestration capacity by cement:
%CO2 = 0.78 CaO + 1.1 MgO + 1.4 Na2O + 0.9
K2O
• CO2 uptake target:
– Each 8” concrete block shall take 0.75 lb CO2
(25% based on dry cement )
– Each 4’x8’ fiber-cement panel shall take 10.5
lb CO2 (30% based on dry cement)
• Utilization process cost shall be less than
$10/tCO2
• CO2 capture cost shall be less than
$50/tCO2
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Benefit to the Program
• Develop technologies that will support industries’
ability to capture and utilize CO2 at the vicinity of
the sources.
• Concrete blocks are produced at 4.3 billion
units/year in US and fiber-cement panels are
produced at 9.8 billion ft2/year in US.
• If the uptake targets can be met, concrete block
industry and fiber-cement industry alone can utilize
2.9 Mt CO2 every year in the United States.
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Project overview
• Produce commercial blocks and panels in lab
• Maximize carbonation by optimizing process
parameters
• Develop CO2 recovery process by self-
concentration absorption method
• Evaluate performance of carbonated products
• Recover CO2 from residual gas
• Perform experiment production
• Conduct cost analysis
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Carbonation Mechanism
• Carbonation curing of fresh concrete (C3S, C2S):
• Carbonation curing after initial hydration (CH, CSH,
C3S, C2S):
• CO2 diffusion in precast products:
7
OHCaCOaqCOCa 2322 )(OH
322222 332333 CaCOOHSiOCaOOHCOSiOCaO
322222 232322 CaCOOHSiOCaOOHCOSiOCaO
OHSiOCaCOCOOHSiOCaO 223222 3233323
322222 332333 CaCOOHSiOCaOOHCOSiOCaO
322222 232322 CaCOOHSiOCaOOHCOSiOCaO
2
2
2
2
x
COD
t
COconcrete
2.28.16 11064.1 DSD pconcrerte
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Static carbonation setup
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Dynamic carbonation setup
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CO2 uptake calculation
• Mass gain method (average)
• Mass curve method (average)
• Furnace thermal analysis (30-70g mass)
cement
waterlostCObefCOaft
cement
CO
m
MassMassMass
m
muptakeCO
)()()(2%
2,2,2
cement
masscurveCO
m
muptakeCO
)(2% 2
CementM
MMContentCO 1000550
2 (%)
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Fresh concrete carbonation
11
6.46
6.07
3.74
0.90
0
2
4
6
8
10
12
14
16
0
1
2
3
4
5
6
7
8
W/C=0.3, 0%SP W/C=0.3, 5%SP W/C=0.6, 0%SP W/C=0.6, 1%SP
Str
ength
, M
Pa
Up
tak
e, %
Uptake Strength/4H 2H+2C in static system
P=0.1MPa,
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Carbonation after 18 hr hydration
12
7.84 8.09
11.49
7.37
7.46
11.95
15.12
15.64
0
2
4
6
8
10
12
14
16
18
20
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
W/C=0.3, 0%SP W/C=0.3, 5%SP W/C=0.6, 0%SP W/C=0.6, 1%SP
Str
ength
, M
Pa
Up
tak
e, %
Uptake Strength/20H 18H+2C in static system
Air curing in RH=60%
Water loss=35%
P=0.1MPa
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Water loss in initial open air hydration
Water loss due to initial hydration at different RH condition (W/C=0.6) 13
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Effect of water removal on carbon uptake
14
14.9
16.3
17.3
14.6
14.2
12.1 11.4
14.7
0
2
4
6
8
10
12
14
16
18
20
14
15
15
16
16
17
17
18
18
34.0 50.9 54.5 71.5
Str
en
gth
, M
Pa
Up
tak
e, %
Uptake Strength/20H
water loss, %
W/C=0.6
18H+2C in static system
P=0.2MPa
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Effect of gas pressure
15
15.2
17.3
18.5 10.5
11.4 11.4
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
0
2
4
6
8
10
12
14
16
18
20
22
24
0.1 Mpa 0.2 Mpa 0.5Mpa
Str
ength
, M
pa
Up
tak
e, %
Gas Pressure
Uptake Strength/20H W/C=0.6
18H+2C in static system
Air curing in RH= 20%
Water loss around 60%
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Effect of carbonation duration
16
13.3
21.5
24.8
10.2(20H)
34.9(42H)
35.3(66H)
0
5
10
15
20
25
30
35
40
45
50
0
5
10
15
20
25
30
2H 24H 48H
Str
engh
t, M
pa
Up
tak
e, %
Carbonation time
uptake Strength W/C=0.6
Carbonated in static system
Water loss 50%
Air curing in RH= 30%
P=0.1Mpa
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Dynamic for fresh carbonation
17
5.93
9.48
1.80 1.37
5.17
7.29
0.67
0
1
2
3
4
5
6
7
8
9
10
0
1
2
3
4
5
6
7
8
9
10
11
12
Static Dynamic Steam Reference
Str
ength
, M
Pa
Up
tak
e, %
Uptake Strength/4H Fresh concrete
W/C=0.6
2H+2C in dynamic system
P=0.1Mpa
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Dynamic for hardened carbonation
18
10.07
13.31
0.60
15.12 15.16 15.61
10.67
0
2
4
6
8
10
12
14
16
18
20
22
24
0
2
4
6
8
10
12
14
16
18
20
Static Dynamic Steam Reference
Str
ength
, M
Pa
Up
tak
e, %
Uptake Strength/20H W/C=0.6
18H+2C in dynamic system
Water loss 35%
Air curing in RH= 60%
P=0.1Mpa
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Full size concrete blocks
19
12.12
15.82 16.4 13.23
13.75
9.78
11.83
0
2
4
6
8
10
12
14
16
0
2
4
6
8
10
12
14
16
18
20
18H+2C
(Dyn,WL 35%)
18H+24C
(Dyn,WL 35%)
4H+4C
(Sta, WL 60%, Fan
dry)
Reference
Str
ength
, M
Pa
Up
tak
e, %
Uptake
Strength/28d
W/C=0.6,
P=0.1Mpa
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Carbonation of fiber-cement panels
10.86
13.63
18.61
20.14
7.16
3.09
4.52 5.01
8.33
3.80 3.09
4.97 6.14
11.22
4.25
0
2
4
6
8
10
12
14
16
0
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
0.08 0.16 0.20 0.24 0.28
Str
en
gth
, M
pa
Up
tak
e,%
initial water/cement ratio before carbonation
Carbonation
flexural strength /18.5H
compressive strength /18.5H
18H+0.5C in static system
Curing in air
P=0.5 MPa
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Effect of pressure and duration
NO. Process
parameters
Molding
pressure
Air curing
time
Carbonation
time
Carbonatio
n pressure
A Reference 0.7 Mpa 18H 0.5 H 5 bar
B Gas pressure 0.7 Mpa 18H 0.5 H 2 bar
C Time 0.7 Mpa 18H 4 H 5 bar
D Molding pressure 7 Mpa 18H 4H 5 bar
E Air curing(Hydration only reference)
F Sealed in bag(Hydration only reference)
21
20.14
17.54
23.16
18.32
8.33
7.59 7.35
11.00
2.11
2.97
11.22
8.94
7.40
14.71
2.81 3.21
0
2
4
6
8
10
12
14
16
18
20
0
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
A B C D E F
Str
en
gth
, M
pa
Up
take,%
Carbonation
flexural strength/24H
Compressive Strength/24H
Carbonation in static system
Initial water/cement ratio 0.20-0.24
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Near surface dynamic carbonation
No. Molding
pressure
Air curing
time
Oven
curing
time
Carbonation
time
Carbonati
on
pressure
Carbonation method
G 0.7 Mpa 18H / 0.5 H 5 bar static
H 0.7 Mpa / 0.5H 0.5 H 5 bar static
J 0.7 Mpa 18H / 0.5 H 2bar Near surface with gas flow
K 0.7Mpa 18H / 0.5 H 2 bar Near surface with vacuum
at bottom
Table 2 influencing factor of carbonation
Air tight Mold
Sample
Pressurized CO2 in
CO2 flow freely or by vacuum
20.14
12.23 14.14
33.49
0
5
10
15
20
25
30
35
40
G H J K
Up
take,%
G:Static+air dry
H:Static+oven dry
J: Near surface with gas flow
K:Near surface with vacuum at
Observation:
1) In static system, air dry method
is superior to oven dry.
2) Near surface carbonation
method with vacuum at bottom
has the potential to improve the
carbonation reaction.
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Large fiber cement panel (1’x2’) tests
1’×2’ panel sample and test chamber
Table 3: Results of 1’×2’ panels (static carbonation)
NO. Pressure Carb.
Time
Air curing
time*
Oven dry
time**
CO2
uptake
28d Strength, Mpa***
Flexural Compressive
Slab 1
2 bar
1 H 18 H
2H
16.06% 6.03±1.07 10.05±2.97
Slab 2 1 H 18 H 16.52% 5.91±1.17 7.86±2.21
Slab 3 12 H 18 H 20.46% 6.57±0.52 8.97±3.00
Observation:
1) The process is possible to be
scaled up.
2) Carbon uptake reaches to 16-
20%.
3) Flexural and compressive
strengths are comparable to
commercial products.
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Flue gas capture and CO2 recovery
• Flue gas was collected from cement plant
• The flue gas contains 13% CO2 at 2000 psi.
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CO2 recovery by
Self-Concentration Absorption Method
• Developed and patented by 3H Company.
• Increased height of absorber enables capture
efficiency to 90% and recovered CO2 purity
to 99%.
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Accomplishments to Date
– Static and dynamic carbonation systems are developed
for concrete block and fiber-cement panel production.
– Carbonation chambers are designed and fabricated for
laboratory investigation and can be scaled up for
commercial production.
– Carbon uptake of 16-25% for concrete blocks and 16-
30% for fiber-cement panels are reached at laboratory
optimized conditions.
– CO2 recovery system using self-concentrating
absorption method is modified to reach a capture
efficiency of 90%.
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Project Summary
• Carbonation of hydration products is more efficient
than carbonation of calcium silicates.
• Longer reaction time and higher gas pressure lead
to higher reactivity.
• Water content in precast products plays critical role
in promoting the degree of carbonation.
• The cost limit by $10/tCO2 is challenging.
• Carbon uptake and cost limit are conflicting.
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Future work
• The system will be further optimized to reduce
energy use in every step.
• Cost analysis will be performed together with
technology development.
• Self-concentration absorption method will be used
to recover CO2 from residual gas after process.
• Experiment production will be carried out to link
CO2 capture to CO2 utilization.
• Large scale network operation will be established
to implement CO2 capture, compression, transport
and utilization.
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Appendix
– These slides will not be discussed during the
presentation, but are mandatory
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Organization Chart
• Describe project team, organization, and
participants. – McGill University (Materials development, carbonation
systems, performance assessment, cost analysis.)
– 3H Company (Self-concentrating absorption system,
cost analysis, carbonation systems.)
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Gantt Chart
The following tasks are accomplished in Budget Period 1: Task 1.0 – Project Management and
Planning; Task 2.1 Fabricate Block CO2clave; Task 2.2 Fabricate Panel CO2clave; Task 3.1 Prepare
Cement Mixes; Task 3.2 Prepare Blocks; Task 3.3 Prepare Panels; Task 3.4 Use Seeding
Technology; Task 4.1 Conduct Single Block Tests; Task 4.3 Conduct Panel Tests; Task 6.1 Capture
of Flue Gas from Power Plant or Cement Plant for CO2 Recovery; Task 6.2 Production of CO2
Using Self-Concentrating Absorption Technology. Task 7.1 Determine Utilization Cost.
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Bibliography
Not available yet.
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