1. An overview of Future Concretes
An overview of the alternative mineral binder systems and composites made with them including novel concrete technologies addressing practical supply chain and economic issues including energy
27/03/2017

2. Why Future Concretes?
What’s wrong with the concrete we use made with Portland Cement?
Embodied energy and emissions, shrinkage, durability, placement, tensile strength etc. etc. Not optimised for lifetime energy reduction.
We can make better more environmentally friendly materials but what about the cost?
Better concretes don’t necessarily produce more and those producing them will make more money.
Concrete made for purpose = Higher Margin?
Architectural façade, insulative properties, permeable pavement etc.

3. The Business Model
The industry model is like Woolworths or Coles. Head on competition. Low margins resulting in a reliance on turnover volume and cost control to produce profits.
This model is past its use by date.
"Firms need to embrace innovation to remain competitive. Future job creation will come as companies transform and adopt new practices. Putting it simply, firms that innovate will survive and be the market leaders of tomorrow." Source: Senator the Hon Kim Carr 24 Aug 2011
The need to innovate under a carbon price and trading system is significantly greater than without.
Given our problems the need to innovate goes beyond the immediate needs of the industry. There are other stakeholders
Innovation recognises new markets

4. Making Money Through Innovation
In Australia rules relating to the new R & D Tax Incentive have changed. The new scheme effective 1 July 2011 is more generous.
Make a $1 and pay 30c corporate tax
Spend a $1 to innovate thereby ensuring future profits and adding value to your balance sheet and the government will give you either 40 or 45c as a grant.
That’s a c difference!
Given the changes the industry business model needs to change.
TecEco are also changing their business model. We are going to register as a Research Service Provider (RSP) and become more aligned with the University of Tasmania to attract student power under my supervision.
The leverage provided by students will increase the value of investing in R & D to well over a dollar.

5. What we Sell in the Industry
Managers in the concrete industry seem to misunderstand what we sell.
They think we sell Portland cement and concrete made with it.
My analysis is that what we sell is the technical confidence in a liquid that sets as a solid material and it really would not matter what either was provided we could demonstrate technical merit and suitable properties.

6. Increases in Business Performance from the Previous Year, by Innovation Status 2008-9

7. Primary Production Process Build, & Manufacture Use Dispose
Some of the Issues?
The Techno Process
Primary Production Process Build, & Manufacture Use Dispose
Underlying Molecular Flows
Primary Production
Methane NOX & SOX Heavy Metals CO2 etc.
Embodied & Process Energy
Process, Build & Manufacture
NOX & SOX
Heavy Metals CO2 etc.
Embodied & Process Energy
Use
NOX & SOX
Heavy Metals CO2 etc.
Lifetime Energy
Dispose or Waste
Methane NOX & SOX
Heavy Metals CO2 etc.
Process Energy

8. Predicted Global Cement Demand and Emissions
Source: Quillin K. Low-CO2 Cements based on Calcium Sulfoaluminate [Internet]. Available from:

9. Energy Outlook to 2035
Source: U.S. Energy Information Administration. International Energy Outlook 2010 [Internet]. U.S. Energy Information Administration; 2010 [cited 2010 Sep 5]. Available from:

10. Global Waste – An Underestimate!
The challenge is to convert waste to resource.

11. There are Huge Change Opportunities
A wide variety of possible end uses with higher potential margins for which current solutions are sub-optimal.
E.g. Addessing properties affecting lifetime energy.
E.g. Mineral composites with higher “R” value
E.g. Particle boards made with mineral binders
E.g. Exterior structural panels with insulating properties
Huge opportunities for reducing the cost base and improving the properties of concretes by focusing on the process by which they are made and what they are made with.
A few tweaks to the formulations
Major changes to the process and some
Lateral thinking in relation to aggregates.
Every improvement counts but quantum improvements really matter – If implemented!
Implementation issue because of the low level of skills in the industry

12. Our Mantra Think outside the square.
Spend more time thinking (R & D) less time doing (earning low margins).
We cannot solve problems doing the same old thing in the same old way.
The technology paradigm defines what is or is not a resource.
Improvements through innovation = profit!
Think whole of material and whole of system
Refine definition of what’s important and what is not

13. Example of a Decision Matrix to Help us Improve the Future

14. Future Cement Contenders Portland Cement
Cements Based on
Process
Process CO2 (tonnes CO2 / tonne Compound )
Decarbonat ion CO2 (tonnes CO2 / tonne Compound)
Emissions (if no kiln capture– tonnes CO2 / tonne Compoun d)
Emission s (kiln capture– tonnes CO2 / tonne Compoun d)
Absorpti on (tonnes CO2 / tonne Compoun d, Assuming 100% carbonati on 1 year)
Net Emissions (Sequestrat ion – No kiln Capture)
(tonnes CO2 / tonne Compound, Assuming 100% carbonatio n 1 year)
Example of Cement Type
Apply to
Comment
Notes PC
Current Methods
.369
 0.498
.868
None
.001
.867
Split process lime with recapture then clinker
Most dense concretes
No supplementary cementitious or pozzolanic materials 1
Permeable Block formulation
0.498
.144
.724
Ordinary Portland Cement
Split Process – Lime then clinker
.368

15. The Potential of CO2 Release and Capture - Portland Cements
Split Process with Capture during Manufacture
No Capture during Manufacture
Capture during Manufacture
CO2 capture (e.g. N-Mg process etc.)
CO2 capture (e.g. N-Mg process etc.)
CO2 in atmosphere
Net Emissions (Sequestration) Kg CO2/Kg product
Net Emissions (Sequestration) kg CO2/kg product
Net Emissions (Sequestration) kg CO2/kg product
CaCO3 + Clays
CaCO3 + Clays
CaCO3
H2O
CaO + Clays
H2O
Net Energy 3962 kJ/kg product
H2O
Net Energy 3962 kJ/kg product
Net Energy 3962 kJ/kg product
Clinker
Clinker
Clinker
Hydrated Cement Paste
Hydrated Cement Paste
Hydrated Cement Paste
Carbon positive. Chemical and process emissions
Carbon positive. Chemical and process emissions
Net sequestration less carbon from process emissions
Use of non fossil fuels => Low or no process emissions
Source Data:

16. Future Cement Contenders Mg Group
Cements Based on
Process
Process CO2 (tonnes CO2 / tonne Compound)
Decarbona tion CO2 (tonnes CO2 / tonne Compoun d)
Emission s (if no kiln capture– tonnes CO2 / tonne Compou nd)
Emission s (kiln capture– tonnes CO2 / tonne Compou nd)
Absorpti on (tonnes CO2 / tonne Compou nd, Assumin g 100% carbonati on 1 year)
Net Emission s (Sequestr ation) (tonnes CO2 / tonne Compou nd, Assumin g 100% carbonati on 1 year)
Example of Cement Type
Apply to
Comment
Notes
<750 oC
MgCO3
.403
 1.092
1.495
-1.092
.-.688
Eco-cement concrete, pure MgO concretes. Novacem concretes
TecEco, Cambridge & Novacem
TecEco Eco-Cement Force carbonated pure MgO 3
<450 oC
MgCO3.3H2O
.693
1.784
-.399
Eco-cement concrete, pure MgO concretes. Novacem concretes?
N-Mg route University of Rome
MgCO3.3H2O Including capture during production of nesquehonite
-2.184
-1.491
Silicate route  ?
Novacem
After Klaus Lackner?
Modified Ternary Blends (50% PC)
Split Process – Lime (with capture) then clinker
.185
.002
.183
Ternary mix with MgO additive.
Most dense concretes
Faster setting and higher early strength 2

17. The Potential of CO2 Release and Capture Magnesium Carbonating System MgCO3 Route using TecEco Tec-Kiln
No Capture during Manufacture
With Capture during Manufacture
<7250C
CO2 capture (e.g. N-Mg process etc.)
CO2
Net Emissions (Sequestration) kg CO2/kg product
CO2 from atmosphere
Net Emissions (Sequestration) Kg CO2/Kg product
MgCO3
MgCO3
H2O
H2O
H2O
H2O
Net Energy 4084 kJ/kg product
Net Energy 4084 kJ/kg product
MgO
MgO
Mg(OH)2
Mg(OH)2
H2O
H2O
Carbon neutral except for carbon from process emissions
Net sequestration less carbon from process emissions
Use of non fossil fuels => Low or no process emissions
Source Data:

18. The Potential of CO2 Release and Capture Magnesium Carbonating System MgCO3.3H20 Route using TecEco Tec Kiln
No Capture during Manufacture
With Capture during Manufacture
<4200C
CO2 capture (e.g. N-Mg process etc.)
Net Emissions (Sequestration) kg CO2/kg product
CO2
CO2 from atmosphere
Net Emissions (Sequestration) Kg CO2/Kg product
MgCO3.3H2O
MgCO3.3H2O
H2O
H2O
H2O
H2O
Net Energy 7140 kJ/kg product
Net Energy 7140 kJ/kg product
MgO
MgO
Mg(OH)2
Mg(OH)2
H2O
H2O
Carbon neutral except for carbon from process emissions
Net sequestration less carbon from process emissions
Use of non fossil fuels => Low or no process emissions
Source Data:

19. Gaia Engineering kg CO2-e/kg product -1.092 -.399
>2 kg CO2-e/kg Mg product 2 3 1
Or similar. The annual world production of HCl is about 20 million tons, most of which is captive (about 5 million tons on the merchant market). 

20. The N-Mg Process A Modified Solvay Process for Nesquehonite Tec-Kiln
HCl
NH3 and a small amount of CO2
MgCO3.3H2O
Mg rich water
CO2
Tec-Kiln
MgO
Ammoniacal Mg rich water
H2O
Mg(OH)2
MgO
Steam
MgCO3.3H2O
Filter
NH4Cl and a small amount of NH4HCO3
Filter
A Modified Solvay Process for Nesquehonite

21. The Tec-Reactor Hydroxide Carbonate Capture Cycle
The solubility of carbon dioxide gas in seawater
Increases as the temperature approached zero and
Is at a maxima around 4oC
This phenomenon is related to the chemical nature of CO2 and water and
Can be utilised in a carbonate – hydroxide slurry process to capture CO2 out of the air and release it for storage or use in a controlled manner

22. Gaia Engineering NH4Cl or HCl Portland Cement Manufacture
CaO
TecEco Tec-Kiln
Industrial CO2
MgO
Clays
Brine, Sea water, Oil Process water, De Sal Waste Water etc .
TecEco Cement Manufacture
GBFS
N-Mg Process
MgCO3.3H2O
Fly ash
Eco-Cements
Tec-Cements
NH4Cl or HCl
Fresh Water
Building components & aggregates
Other wastes

23. Man Made Carbonate Aggregate?
Source USGS: Cement Pages
Assumptions % non PC N-Mg mix and Substitution by Mg Carbonate Aggregate
Percentage by Weight of Cement in Concrete
15.00%
Percentage by weight of MgO in cement 6%
Percentage by weight CaO in cement
29%
Proportion Cement Flyash and/or GBFS
50%
1 tonne Portland Cement
0.867
Tonnes CO2
Proportion Concrete that is Aggregate
85%
CO2 captured in 1 tonne aggregate
1.092

24. Magnesium Carbonate Cements
Magnesite (MgCO3) and the di, tri, and pentahydrates known as barringtonite (MgCO3·2H2O), nesquehonite (MgCO3·3H2O), and lansfordite (MgCO3·5H2O), respectively.
Some basic forms such as artinite (MgCO3·Mg(OH)2·3H2O), hydromagnestite (4MgCO3·Mg(OH)2·4H2O) and dypingite (4MgCO3· Mg(OH)2·5H2O) also occur as minerals.
We pointed out as early as 2001 that magnesium carbonates are ideal for sequestration as building materials mainly because a higher proportion of CO2 than with calcium can be bound and significant strength can be achieved.
The significant strength is a result of increased density through carbonation (high molar volume increases) and the microstructure developed by some forms.

25. TecEco Eco-Cements
Eco-Cements are blends of one or more hydraulic cements and relatively high proportions of reactive magnesia with or without pozzolans and supplementary cementitious additions. They will only carbonate in gas permeable substrates forming strong fibrous minerals. Water vapour and CO2 must be available for carbonation to ensue.
Eco-Cements can be used in a wide range of products from foamed concretes to bricks, blocks and pavers, mortars renders, grouts and pervious concretes such as our own permeacocrete. Somewhere in the vicinity of the Pareto proportion (80%) of conventional concretes could be replaced by Eco-Cement.
Left: Recent Eco-Cement blocks made, transported and erected in a week. Laying and Eco-Cement floor. Eco-Cement mortar & Eco-cement mud bricks. Right: Eco-Cement permeacocretes and foamed concretes

26. TecEco Tec-Kiln, N-Mg route
The calcination of nesquehonite has a relatively high enthalpy but there is significant scope for reducing energy using waste heat
Initial weight loss below C consists almost entirely of water (1.3 molecules per molecule of nesquehonite). Between 100 and 1500C volatilization of further water is associated with a small loss of carbon dioxide (~3-5 %).
From 1500C to 2500C, the residual water content varies between 0-6 and 0-2 molecules per molecule of MgC Above 3000C, loss of carbon dioxide becomes appreciable and is virtually complete by 4200C, leaving MgO with a small residual water content.
Energy could be saved using a two stage calcination process using waste energy for the first stage.
Dell, R. M. and S. W. Weller (1959). "The Thermal Decomposition of Nesquehonite MgCO3 3H20 And Magnesium Ammonium Carbonate MgCO3 (NH4)2CO3 4H2O." Trans Faraday Soc 55(10):

27. Modified PC 50% Ternary Mix with N-Mg Route Mg Carbonate Aggregate
25-30% improvement in strength
Fast first set
Better Rheology
Less shrinkage – less cracking
Less bleeding
Long term durability
Solve autogenous shrinkage?
Criteria
Good
Bad
Energy Requirements and Chemical Releases, Reabsorption (Sequestration?)
Use >50% replacements and still set like “normal” concrete!
Speed and Ease of Implementation
Rapid adoption possible
Barriers to Deployment
Permissions and rewards systems see
Cost/Benefit
Excellent until fly ash runs out!
Use of Wastes? or Allow Use of Wastes?
Uses GBFS and fly ash and manufactured nesquehonite based aggregate
Performance
Engineering
Excellent all round
Thermal
High thermal capacity
Architectural
Excellent
Safety
No issues
Audience 1
Audience 2

28. Magnesium Phosphate Cements
Chemical cements that rely on the precipitation of insoluble magnesium phosphate from a mix of magnesium oxide and a soluble phosphate.
Some of the oldest binders known (dung +MgO)
Potentially very green
if the magnesium oxide used is made with no releases or via the nesquehonite (N-Mg route) and
a way can be found to utilise waste phosphate from intensive agriculture and fisheries e.g. feedlots. (Thereby solving another environmental problem)
Criteria
Good
Bad
Energy Requirements and Chemical Releases, Reabsorption (Sequestration?)
The MgO used could be made without releases
There is not much phosphate on the planet
Speed and Ease of Implementation
Rapid adoption possible
If barrier overcome (see below)
Barriers to Deployment
Permissions and rewards systems see Must find a way to extract phosphate from organic pollution.
Cost/Benefit
Economies of scale issue for MgO to overcome
Use of Wastes? or Allow Use of Wastes?
With technology could use waste phosphate reducing water pollution
Performance
Engineering
Excellent all round
Thermal
High thermal capacity
Architectural
Safety
No issues
Audience 1
Audience 2

29. Sorel Type Cements and Derivatives
Sorel Type Cements and Derivatives are all nano or mechano composites relying on a mix of ionic, co-valent and polar bonding.
There are a very large number of permutations and combinations and thus a large number of patents
Criteria
Good
Bad
Energy Requirements and Chemical Releases, Reabsorption (Sequestration?)
The MgO used could be made without releases
Speed and Ease of Implementation
More could be used
If barrier overcome (see below)
Barriers to Deployment
Not waterproof even with modification.
Cost/Benefit
Economies of scale issue for MgO to overcome
Use of Wastes? or Allow Use of Wastes?
Not waterproof
Performance
Engineering
Excellent except
Not waterpoof, salt affect metals
Thermal
High thermal capacity
Architectural
Safety
No issues
Audience 1
Audience 2

30. Future Cement Contenders
Cements Based on
Process
Process CO2 (tonnes CO2 / tonne Compound)
Decarbon ation CO2 (tonnes CO2 / tonne Compoun d)
Emission s (if no kiln capture– tonnes CO2 / tonne Compou nd)
Emission s (kiln capture– tonnes CO2 / tonne Compou nd)
Absorpt ion (tonnes CO2 / tonne Compou nd, Assumi ng 100% carbona tion 1 year)
Net Emissions (Sequestr ation)
(tonnes CO2 / tonne Compoun d, Assuming 100% carbonati on 1 year)
Example of Cement Type
Apply to
Comment
Notes
CaO
Conventional
.453
0.785
1.237
-0.332
Carbonating lime mortar
Calera, British Lime Assn. & many others
Small net sequestration with TecEco kiln 1
C3S ?
0.578
>0.578 3
C2S
0.511
>0.511
Belite cement
Chinese & others
C3A
0.594
>0.594
Tri calcium aluminate cement
Increased proportion
C4A3S
0.216
>0.216
Calcium sulfoaluminate cement
Quillin, K. and P. Nixon (2006). Environmentally Friendly MgO-based cements to support sustainable construction - Final report, British Research Establishment.

31. Future Cement Contenders
Cements Based on
Process
Process CO2 (tonnes CO2 / tonne Compound)
Decarbon ation CO2 (tonnes CO2 / tonne Compoun d)
Emission s (if no kiln capture– tonnes CO2 / tonne Compou nd)
Emission s (kiln capture– tonnes CO2 / tonne Compou nd)
Absorpt ion (tonnes CO2 / tonne Compou nd, Assumi ng 100% carbona tion 1 year)
Net Emissions (Sequestr ation)
(tonnes CO2 / tonne Compoun d, Assuming 100% carbonati on 1 year)
Example of Cement Type
Apply to
Comment
Notes
Alakali Activated Ground Granulate d Blast Furnace Slag (GBFS)
GBFS (“slag”) is a waste product from the manuf acture of iron and steel
Nil to cement industry
GBFS with MgO activator
Many other activators
Patented by TecEco
Not patented 1
Geo polymers
Fly ash + NaOH
0.16
Geopolymer Alliance,
Geopolymer Institute, University Melbourne 6

32. CaO-Lime Criteria Good Bad
Energy Requirements and Chemical Releases, Reabsorption (Sequestration?)
The CaO used could be made without
Speed and Ease of Implementation
Easily implemented as no carbonation rooms etc reqd.
Permissions and rewards systems see
Barriers to Deployment
We need carbon trading!
Cost/Benefit
Use of Wastes? or Allow Use of Wastes?
Performance
Engineering
Thermal
Engineered thermal capacity and conductivity.
Architectural
Safety
An irritating dust
Audience 1
Audience 2

33. Geopolymers
Criteria
Good
Bad
Energy Requirements and Chemical Releases, Reabsorption (Sequestration?)
Low provided we do not run out of fly ash
Speed and Ease of Implementation
Process issues to be overcome
Permissions and rewards systems see
Barriers to Deployment
We need carbon trading!
Cost/Benefit
Use of Wastes? or Allow Use of Wastes?
Performance
Engineering
Good but inconsistent
Thermal
Engineered thermal capacity and conductivity.
Architectural
Safety
Caustic liquors
Audience 1
Audience 2
Geopolymers as a future concrete suffer from two basic flaws on one very high risk
Flaw. 1. The nanoporisity flaw which leads to durability problems and Flaw. 2. The fact that water is not consumed in the geopolymerisation process resulting in the almost impossible task of making them fluid enough for placement. Too much water reduces alkalinity and hence the high risk.

34. Other Contenders
Slag cements a variant of Portland cement as CSH is the main product.
Supersulfated cements have potential as they are made mostly from GBFS and gypsum which are wastes and only a small amount of PC or lime. The main hydration product is ettringite and they show good resistance to aggressive agents including sulphate but are slow to set. (A derivative)
Calcium aluminate cements are hydraulic cements made from limestone and bauxite. The main components are monocalcium aluminate CaAl2O4 (CA) and mayenite Ca12Al14O33 (C12A7) which hydrate to give strength. Calcium aluminate cements are chemically resistant and stable to quite high temperatures.
Calcium sulfoaluminate cements & belite calcium sulfoaluminate cements are low energy cements that have the potential to be made from industrial by products such as low calcium fly ash and sulphur rich wastes. The main hydration product producing strength is ettringite. Their use has been pioneered in China (A derivative)

35. Other Contenders
Belite cements can be made at a lower temperature and contains less lime than Portland cement and therefore has much lower embodied energy and emissions. Cements containing predominantly belite are slower to set but otherwise have satisfactory properties. Many early Portland type cements such as Rosendale cement were rich in belite like phases. (a variant, See
PC - MgO – GBFS – fly ash blends. MgO is the most powerful new tool in hydraulic cement blends since the revelation that reactive magnesia can be blended with other hydraulic cements such as Portland cement % improvements in compressive strength and greater improvements in tensile strength, faster first set, better rheology and less shrinkage and cracking less bleeding and long term durability have been demonstrated. It is also possible autogenous shrinkage has been solved.
MgO blended with other hydraulic cements, pozzolans and supplementary cementitious materials (SCM’s). Amazingly very little real research has been done on optimised blends particularly with cements other than Portland cement.