is the market ready for the adoption of alkali …...jannie van deventer – ceo zeobond group is...
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Jannie van Deventer – CEO Zeobond Group
Is the market ready for the adoption of alkali-activated
cements?
Jannie S.J. Van Deventer
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Portland Cement ProductionQuarried Limestone
Storage
Rotary Cement Kiln
Grinding
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No Change
OPC ‘Best Practice’
60% reduction from 2008 levels
Some facts about Cement• Cement manufacture makes up 5-8% of all CO2 (3rd highest)
• Second most used material next to WATER
• 1 ton of CO2 per 1 ton of cement
• Market to double to 2050
• Alternatives to OPC are required to meet market demand for low CO2 building materials.
Jannie van Deventer– CEO Zeobond
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Cement value chain • Ownership of limestone assets and permits • Limestone is available everywhere • High sunken capital in clinker kilns • Operating margins relatively high in clinker
production and grinding • Control over supply chain and logistics • Ownership of sand and aggregate quarries • Margins relatively low in pre-mixed concrete • Margins slightly better in precast and
concrete placement.
Jannie van Deventer– CEO, Zeobond
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Alkali-Activated Cement: A Simplified View
Fly Ash
Metallurgical Slags
Natural Pozzolans
Alkaline Activator
Cementitious Components
Binder for Concrete
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Alkali-Activated Cement Production
StorageGrinding
Metallurgical Slags Fly Ash Alkali Activator
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Business As Usual
Stretch/Aspirational
Best Practice 2010
Since 2008
Jannie van Deventer– CEO, Zeobond
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History of Alkali-Activation• Romans used alkali-activated concrete (AAC). • 1940s - Idea of AAC re-emerged (Purdon). • Late 1950s - Glukhovsky in Kiev developed alkali-
activated binders, followed by Krivenko, who constructed slag AAC structures and a high rise building in Russia in the 1960s.
• Davidovits coined term geopolymer in the 1970s. • Van Deventer made first geopolymer early 1993. • Today many universities do some geopolymer
research, but still little commercial activity.
Jannie van Deventer – CEO Zeobond Group
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Drivers for /Obstacles to AAC adoption• Relative cost of ash/slag Driver/Obstacle • Waste utilisation Driver • Cost of activators Obstacle • Technical properties Partial driver • Customer focus on low CO2 Main driver • Control over the supply chain Driver/Obstacle • Standards based on OPC Obstacle • Questions on durability Obstacle • Engineering design methods Obstacle • Long track record of OPC Obstacle • Desire to innovate Driver
Jannie van Deventer – CEO Zeobond Pty Ltd
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Role of Research in Market Adoption
Engineering Properties
Durability
Enhancing confidence in in AAC
Microstructure Phase assemblage
Workability
10
Jannie van Deventer – CEO Zeobond Group
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Market Acceptance and Regulatory Approval
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AA100S
AA50S/50FA
100OPC 28 90
28
9028
90
Baroghel-Bouny V.. ‘Conception des bétons pour une durée de vie donnée des ouvrages, Maîtrise de la durabilité vis-à-vis de la corrosion des armatures et de l’alcali réaction, Etat de l’art et Guide pour la mise en œuvre d’une approche performantielle et prédictive sur la base d’indicateurs de durabilité’, 2004.
Resistance classesLow Medium High
LowMedium
High
Very high
Durability classes
Durability Classes- Chloride Permeability C
hlor
ide
mig
ratio
n co
effic
ient
(x10
-12 m
2 /s)
Jannie van Deventer – CEO Zeobond Group
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Australian, European, US Standards
Prescriptive approach Performance based approach
Performance is as good as a prescriptive concrete
Results are good enough according to approved values
Alkali-activated concrete
Reference concrete
=Highly corrosive conditions
Porosity (%) (xy standard)
Gas Permeation (10-18 m2) (xy standard)
<30 years <16 -30-50 years <1450-100 years <12 <100100-120 years <9 <10
Durability study of E-Crete
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Jannie van Deventer – CEO Zeobond Group
E-Crete™ ‘from the Ground Up’
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Footpaths
Jannie van Deventer – CEO Zeobond Group
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Footpath, Westgate Freeway, Melbourne
Jannie van Deventer – CEO Zeobond Group
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E-Crete™ Precast Panels
Jannie van Deventer – CEO Zeobond Group
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Thomastown Recreational & Aquatic Centre,Melbourne, Australia
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Jannie van Deventer – CEO Zeobond Group
E-Crete™ Precast Products• Manholes, Lids, Bases • Box Culverts • Septic Tanks • Pits • Floor toppings • Pavers • Anti-graffiti panels and Sound-barriers
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Salmon Street, Port Melbourne, Bridge Decks
Jannie van Deventer – CEO Zeobond Group
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Jannie van Deventer – CEO Zeobond Group
Swan Street Bridge formwork pour – 17 Sept 09
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Scope: 40MPa Retaining Wall Location: Swan St Bridge, Richmond, Melbourne, Australia Date:2009
Jannie van Deventer – CEO Zeobond Group
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AAC Structural BeamsScope: 40MPa – 33 Structural Beams (10.8m by 2.4m by 9.6m) Suspended Floor in 5 storey building at University of Queensland, Australia
Jannie van Deventer – CEO Zeobond Group
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AAC Precast PanelsScope: 40MPa Precast Panels – Exposed Aggregate Finish Location: Melton, Melbourne, Australia Date: 2012
Jannie van Deventer – CEO Zeobond Group
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AAC Precast PanelsScope: 40MPa Precast Panels – Exposed Aggregate Finish Location: Melton, Melbourne, Australia Date: 2012
Jannie van Deventer – CEO Zeobond Group
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Regional Rail Link project, Melbourne
Jannie van Deventer CEO Zeobond Group
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Zeobond’s Licensee for geopolymer pre-mix concrete
Jannie van Deventer – CEO Zeobond Group
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Scope: Reinforced Drainage and Sewerage Pipe, Melbourne, Kilmore, Australia Started in 2012
28Jannie van Deventer – CEO Zeobond Group
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Sewerage Pipe Project at Werribee, February 2015
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Portland Cement versus Geopolymer
• Hydrated Portland cement – Silica chains (“dreierketten”) – Break two Si-O-Si bonds
to remove a silicon atom – Bound water of hydration
• Geopolymer – Highly crosslinked gel structure
(pseudo-zeolitic) – Break four Si-O-(Si,Al) bonds to
remove Si or Al – Little chemically bound water
C-S-H image from: I.G. Richardson, Cement and Concrete Research, 2004, 34(9): 1733-1777.
Jannie van Deventer – CEO Zeobond Group
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Cross-Linked Substituted Tobermorite Model (CSTM) (Provis & Myers, Sheffield)
Jannie van Deventer – CEO Zeobond Group
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I. García-Lodeiro, A. Palomo, A. Fernández-Jiménez, D.E. Macphee, Cement & Concrete Research, 2011, 41(9):923-931
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Jannie van Deventer – CEO Zeobond Group
Structural performance testing
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Good ductile behaviour of the geopolymer concrete in bending
Beam test: Strength at 800KN
Geopolymer concrete cracked in the middle but not further
No explosion as in usual cement based concrete
Middle of the Bolted steel-AAC
beam 50cm from the middle of the Bolted
steel-AAC beam
Jannie van Deventer – CEO Zeobond Group
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Department of Chemical & Biomolecular Engineering
Tel: +61-3-90353263 Email: [email protected]
Website: www.chemeng.unimelb.edu.au/
geopolymer
PO Box 23450, Docklands, Victoria 8012, AUSTRALIA.
Mobile: +61 430 777 111 Email: [email protected] [email protected]
Website: www.zeobond.com