Forschungszentrum Karlsruhein der Helmholtz - Gemeinschaft

Folie: 1Dr.-Ing. Marcel Weil ITC-ZTS

Sustainable Design of Geopolymers - Integration of Economic and

Environmental Aspects in the Early Stages of Material Development

Marcel Weil,Katja Dombrowski, Anja Buchwald

Forschungszentrum Karlsruhein der Helmholtz - Gemeinschaft

Folie: 2Dr.-Ing. Marcel Weil ITC-ZTS

Development of Geopolymers supported by System Analysis

A. Buchwald BauhausUni. Weimar

K. Dombrowski TU Freiberg

M.Weil Forschungs-zentrum Karlsruhe

materials

Forschungszentrum Karlsruhein der Helmholtz - Gemeinschaft

Folie: 3Dr.-Ing. Marcel Weil ITC-ZTS

What Are Geopolymers?

AAlumosilicatic polymeric binderslumosilicatic polymeric binders

BBinderinder

Ability to build non-Ability to build non-crystalline networks crystalline networks (molecules)(molecules)

Silicate: Si-O-SiSilicate: Si-O-SiAluminate: Al-O-AlAluminate: Al-O-Al

Forschungszentrum Karlsruhein der Helmholtz - Gemeinschaft

Folie: 4Dr.-Ing. Marcel Weil ITC-ZTS

Geopolymer

Binder

Geopolymer

Setting

Mixing

Binding material:•Metakaolin•Slag•Fly ash•Activated clay•...

Solid

Alkaline activator:•NaOH/KOH•Sodium water glass•Potassium water glass•...+ Water

Fluid

Forschungszentrum Karlsruhein der Helmholtz - Gemeinschaft

Folie: 6Dr.-Ing. Marcel Weil ITC-ZTS

Geopolymer

- high strength- resistance against acids- temperature resistance - cold setting- quick setting

technical performance

environmental impact

costs (LCC)

- use of secondary raw materials - extended lifetime

Forschungszentrum Karlsruhein der Helmholtz - Gemeinschaft

Folie: 7Dr.-Ing. Marcel Weil ITC-ZTS

Material Development

Early stage

Material development

Degree of freedom

TP

Information

Product development

TM [t]

Late stage

Product

Forschungszentrum Karlsruhein der Helmholtz - Gemeinschaft

Folie: 8Dr.-Ing. Marcel Weil ITC-ZTS

Goal

Selection and optimisation of the most promising geopolymer compositions for specific fields of

application

by the use of system analytical tools

Forschungszentrum Karlsruhein der Helmholtz - Gemeinschaft

Folie: 9Dr.-Ing. Marcel Weil ITC-ZTS

Approach

3rd Step:Detailed LCA, LCC, and optimisation of most promising geopolymers

1st Step: Screening of mineral raw materials

1st Step: Screening of mineral raw materials

2nd Step: Streamlined LCA, LCC, and key properties of geopolymers

1

22

33

Forschungszentrum Karlsruhein der Helmholtz - Gemeinschaft

Folie: 10Dr.-Ing. Marcel Weil ITC-ZTS

• Situation: 58 raw materials (35)

Forschungszentrum Karlsruhein der Helmholtz - Gemeinschaft

Folie: 11Dr.-Ing. Marcel Weil ITC-ZTS

Raw materials

Secondary resources

Ceramic waste materials• tiles• sanitary porcelain• kiln lining material

Ashes• hard coal ash• soft coal ash• sewage sludge ash

Slags• blast furnace slag• steel slag• copper slag• municipal waste slag

Others• broken down masonry • brick scrap• glass industry waste

Primary resourcesClays• kaolinitic clays• ilitic clay• dolomitic clay

Volcanic deposits• trass• tuff• basalt

Forschungszentrum Karlsruhein der Helmholtz - Gemeinschaft

Folie: 12Dr.-Ing. Marcel Weil ITC-ZTS

• Task: Screening of raw materials• What should not happen: Loosing valuable

candidates• Strategies:

1. Select a group of promising candidates

2. Use different methods for the screening process

• Situation: 58 raw materials (35)

Forschungszentrum Karlsruhein der Helmholtz - Gemeinschaft

Folie: 13Dr.-Ing. Marcel Weil ITC-ZTS

Non-compensatory method

Without weighting of the indicators and objectives

Compensatory method

With weighting of the technical indicators and the objectives technology, economy, ecology/health

Methodes

selection of dominant alternatives

X

°A3 °A1

°A4

°A8

°A2

°A6

°A7

°A9

°A5 °A12

°A10 X

X X X

°A11

°A14

°A15 °A13

ranking order

P1A26A53A25A16A5A1A17A3A15

P1A3

A53A17A16A5A1

A25A26A15

Pre-selection

Forschungszentrum Karlsruhein der Helmholtz - Gemeinschaft

Folie: 15Dr.-Ing. Marcel Weil ITC-ZTS

Indicators

Technical

-        reactivity (quantitative)

-        mechanical strength (quantitative)

-        resistance against acids (qualitative)

-        temperature resistance (quantitative)

-        setting time (quantitative)

-        workability (qualitative)

-        handling (qualitative)

Forschungszentrum Karlsruhein der Helmholtz - Gemeinschaft

Folie: 16Dr.-Ing. Marcel Weil ITC-ZTS

IndicatorsEconomy-      raw material costs (quantitative)-      costs of the thermal activation of raw materials (qualitative)-      costs of grinding raw materials (qualitative)-      follow-up costs caused by slow setting (qualitative)-      follow-up costs caused by high water absorption (qualitative)Ecology/Health-      availability/consumption of mineral resources (quantitative)-      consumption of energy resources (qualitative)-      toxic load (qualitative)-      health and safety at the workplace (qualitative)

Forschungszentrum Karlsruhein der Helmholtz - Gemeinschaft

Folie: 17Dr.-Ing. Marcel Weil ITC-ZTS

Compensatory method - Application fields 

cost sensitive 

require high  performance  

acid resistant coating  

mass construction material  

temperature resistant plate 

Forschungszentrum Karlsruhein der Helmholtz - Gemeinschaft

Folie: 19Dr.-Ing. Marcel Weil ITC-ZTS

Compensatory method

Specifications of the application P1P2...Pn

AHP(Analytical Hierarchy Process)

weighting stage 2Objectives

Atributes/Indicator a1 a2 .... an b1 b2 ... bn c1 c2 ... cnweighting stage 1

raw materialsA1A2A3A4A5A6A7A8A9A10A11A12.....An

Ecology/HealthTechnology Economy

Forschungszentrum Karlsruhein der Helmholtz - Gemeinschaft

Folie: 20Dr.-Ing. Marcel Weil ITC-ZTS

Ranking order of the alternatives for different application fields

Problem:

Determination of the cut-off level

P1 P2 ... PnA3 A53 ...

A53 A1A17 ...A16A5A1

A25A26A15A33A24

..

Compensatory method

Forschungszentrum Karlsruhein der Helmholtz - Gemeinschaft

Folie: 21Dr.-Ing. Marcel Weil ITC-ZTS

Results (compensatory method)

acid resistant coating

temperature resistant plate

construction material

SM SM SP3

SP3 SP3 S2

T2 M1b O3

P1 K1 T2

Forschungszentrum Karlsruhein der Helmholtz - Gemeinschaft

Folie: 22Dr.-Ing. Marcel Weil ITC-ZTS

Non-compensatory method

„dominance concept“

• No weighting of objectives• No consideration of application field

Forschungszentrum Karlsruhein der Helmholtz - Gemeinschaft

Folie: 23Dr.-Ing. Marcel Weil ITC-ZTS

XX

XX

„dominance concept“

°A3 °A1

°A4

°A8

°A2

°A6

°A7

°A9

°A5°A12°A10

°A11

°A14

°A15°A13

technology

economy

Ecology/Health

Stage 1 (preselection)

Forschungszentrum Karlsruhein der Helmholtz - Gemeinschaft

Folie: 24Dr.-Ing. Marcel Weil ITC-ZTS

„dominant concept“

Forschungszentrum Karlsruhein der Helmholtz - Gemeinschaft

Folie: 25Dr.-Ing. Marcel Weil ITC-ZTS

Conclusions

• Introduction of Life Cycle Thinking in the early phase of material development is possible

• Preselection is important step

• too strong -> exclusion of valuable alternatives

• too weak -> additional work, costs, …

• Compensatory methods allows a good decision support in screening phase

• Dominance concept is a powerful tool for a rough screening

Forschungszentrum Karlsruhein der Helmholtz - Gemeinschaft

Folie: 26Dr.-Ing. Marcel Weil ITC-ZTS

Technical perspective

Economic perspective

Application

Raw materials

Development of materials

Ecological perspective

Thank

You