Scaling CO2 Utilization in Ready Mixed Concrete...

1 www.carboncure.com Simply Better Concrete NASEM CDU Meeting II • January 31st, 2018 1

Scaling CO2 Utilization in Ready Mixed Concrete Production Sean Monkman PhD PEng CarbonCure Technologies Inc

2 www.carboncure.com Simply Better Concrete NASEM CDU Meeting II • January 31st, 2018

The Importance of Concrete

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4500

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1950 1960 1970 1980 1990 2000 2010 2020

Cem

ent P

rodu

ctio

n (M

t)

Wor

ld P

opul

atio

n (b

illio

ns)

Year

Population (billions)

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


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.


Sectorial CO2 mitigation approach

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CO2 Emissions CCUS

Clinker Substitution

Alternative Fuel

Energy Efficiency

1.50

1.75

2.00

2.25

2.50

2010 2020 2030 2040 2050

Dire

ct E

mis

sion

s (G

t CO

2)

WBCSD CSI

800 Mt reduction needed by 2050. 56% of required carbon reduction in the cement and concrete industry is associated with CCUS


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


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


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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4,000

6,000

8,000

7 day 28 day

Aver

age

Com

pres

sive

Str

engt

h (p

si)

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

loading 10


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%

10%

15%

20%

25%

-100% -50% 0% 50% 100% 150%

Spec

ific P

roce

ss E

mis

sion

(k

g CO

2e/k

g CO

2 dos

ed)

Change in parameter

Grid

Gas

Transport

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


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


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


Increasing the carbon impact Aspect Drivers

Greater market penetration • Diffusion of innovation • Codes and standards • Improved scientific understanding

Aspect Drivers


Improve economic motivation • Develop cheaper CO2 • Implement carbon pricing • Increasing cement price

Aspect Drivers



Reduce process emissions • More efficient CO2 capture • Lower carbon intensity power • Reduced CO2 transport distances

Aspect Drivers



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


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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2017 Ready Mix Rollout


Concluding slide

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