Scaling CO2 Utilization in Ready Mixed Concrete...
Transcript of Scaling CO2 Utilization in Ready Mixed Concrete...
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Scaling CO2 Utilization in Ready Mixed Concrete Production Sean Monkman PhD PEng CarbonCure Technologies Inc
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The Importance of Concrete
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Cement Production (Mt)
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Approximately 0.4 tonnes concrete/person
Approximately 4.3 tonnes concrete/person
Estimated output of plastic is less than 0.1% of the output of concrete
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Cement and CO2 emissions
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5.6% of annual global carbon dioxide emissions attributable to fossil fuels and industry are associated with cement production.
C. Le Quéré et al., Global Carbon Budget 2016, Earth Syst. Sci. Data. 8 (2016) 605–649. doi:10.5194/essd-8-605-2016.
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Sectorial CO2 mitigation approach
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CO2 Emissions CCUS
Clinker Substitution
Alternative Fuel
Energy Efficiency
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Dire
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WBCSD CSI
800 Mt reduction needed by 2050. 56% of required carbon reduction in the cement and concrete industry is associated with CCUS
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US Concrete Market Segmentation
Ready mix 61%
Precast 25%
Masonry 14%
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• Total US market for concrete about $49B per year
• Ready mix = cast in place • Precast = factory produced • Masonry = pipe and block • Estimated 5,550 ready mix
plants in US
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CarbonCure technology development
• CO2 utilization for concrete production
• Graduate research 2004-08 • Masonry technology
o Development started 2008 o Commercialization 2013
• Ready mix technology o Development started 2013 o Commercialization 2016
Beneficial CO2 Utilization
Ca2+ Water
Cement SiO4
4-
OH-
CO2
CO32-
CaCO3
C-S-H Carbonate reaction product
Nucleus for hydration
Cement grain
Carbonate Reaction Product
The carbonation reaction results in the in-situ development of
carbonate particles that act within the hydration process
Carbonation Reaction Product
200 nm
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Compressive strength benefit
4,772
6,459
4,206
5,717 5,348
7,036
100%
100%
88%
89% 112%
109%
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Control Mix
Control Mix with 5%cement reduction
Mix with 5% cementreduction + CO2
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Environmental impact
• Even if a CO2 utilization technology is not sold on an environmental basis it should offer a net environmental benefit
• Analysis considers • mix design changes • capture and compression of the CO2 • transportation of the CO2 • production of the gas injection equipment • transportation of the gas equipment • Direct CO2 mineralization • Avoided CO2 emissions via reduced cement
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LCA - Overall Emissions Balance
Generic inputs • CO2 dose 0.15% by weight of cement • Cement reduction 5% • Gas processing at 200 kWh/tonne CO2
• Gas transport 100 miles • Electrical grid emissions per EPA US Avg • Carbon intensity of cement from PCA EPD
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LCA – Process emissions • Specific emissions
• 49 g CO2/m3 concrete for CO2 • 167 g CO2/m3 concrete for admixtures (EFCA
and NRMCA data) • There are four main aspects affecting
the carbon emissions of the approach • Grid – carbon intensity of the electrical
grid (re: capture and operations) • Gas – energy required to capture and
liquefy the CO2 • Transport – how far the CO2 is
transported • Hardware – energy demand of the
injection hardware 0%
5%
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-100% -50% 0% 50% 100% 150%
Spec
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Change in parameter
Grid
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Hardware
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Process Emissions breakdown
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CO2 Capture, 76% Hardware operation, 14% CO2 Transport, 9%
Hardware production, 0%
Hardware transport, 0%
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
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25 masonry installations 41 ready mix installations
+20 in progress
Technology Rollout
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Feasibility • Material resources
• Equipment made of steel, brass, plastic • About 80 kg CO2e per system
• Land Use, Siting of Plants • Retrofit to existing concrete plants • 5,550 ready mix concrete plants exist in US • No greenfield or brownfield building required
• Water • No water requirement
• Energy • CO2 mineralization requires no energy • Avoided energy re: cement reduction • Ongoing equipment operation
• CO2 Impact • Indirect 30 to 80 times greater than direct
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Scale of Deployment
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Segment Market Scale
($billion) Penetration
Ready Mix US $30 1.2%
ROW $462 0%
Precast US $12 0%
ROW $35 0%
Masonry US $7 <1%
ROW $21 0%
New concrete technology in a conservative industry - only 50% of production is immediately addressable
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Potential Annual CO2 Impact
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• Complete RM market penetration uses 9 Mt of CO2 and realizes a benefit of 248 Mt CO2/yr
• Rises to 230 Mt used / 696 Mt benefit with next generation technology
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Increasing the carbon impact Aspect Drivers
Greater market penetration • Diffusion of innovation • Codes and standards • Improved scientific understanding
Aspect Drivers
Greater market penetration • Diffusion of innovation • Codes and standards • Improved scientific understanding
Improve economic motivation • Develop cheaper CO2 • Implement carbon pricing • Increasing cement price
Aspect Drivers
Greater market penetration • Diffusion of innovation • Codes and standards • Improved scientific understanding
Improve economic motivation • Develop cheaper CO2 • Implement carbon pricing • Increasing cement price
Reduce process emissions • More efficient CO2 capture • Lower carbon intensity power • Reduced CO2 transport distances
Aspect Drivers
Greater market penetration • Diffusion of innovation • Codes and standards • Improved scientific understanding
Improve economic motivation • Develop cheaper CO2 • Implement carbon pricing • Increasing cement price
Reduce process emissions • More efficient CO2 capture • Lower carbon intensity power • Reduced CO2 transport distances
Next generation technology • Fundamental R&D • Industry CO2 and water reduction goals • Economic motivations
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Cement plant CO2 sourcing
• CO2 from merchant sources • Typically from ethanol, ammonia or
hydrogen production • Can be $300 - $400 per ton • No relationship with concrete production
• CO2 from cement plants • Not an established commercial source • Logistic synergies with concrete
production, reduce transport distances • Smaller scale, lower cost?
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North American Cement Plants
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Integrated CO2 Capture and Use
• CO2 captured from cement kiln flue gas
• Use of retrofit cryogenic CO2 capture technology
• Downstream utilization in concrete production Feb 2018
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Future Milestones
• Ready mix market penetration o 100 plants in 2018 o Expand beyond easiest 50% of mixes o New technology market development 2019?
• Precast o Similar to ready mix, research needed
• Cement plant CO2 sourcing o Proof of concept trial complete o Full integrated supply chain within 5 years?
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Concluding slide
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