Geopolymer Concrete for Green Construction Materials

Dr. Erez Allouche Trenchless Technology Center Louisiana Tech University

November 5, 2009

Summary Statement
Inorganic polymer concrete (geopolymer) is an emerging class of cementitious materials that aimed at utilizing one of the most abundant industrial by-products on earth, fly ash (800,000,000 tons per year), as a substitute for the most widely produced man-made material on earth, Portland cement (2,600,000,000 tons/yr).

Research Context and Prior Work

49.6% of the US electrical energy production is fueled by coal

(western USA has 250-year supply of recoverable coal)

72 M tones of fly ash are produced; only 38.1% is recycled The US produce 110 million metric tones of cement, resulting in 90 million metric tones of carbon dioxide. Cement production contributes 7% of human CO2 emissions Cement production - energy intensive process (heat raw
materials to 2550 F)

Re-Arranging the Equation

Power Generation

Cement Production

Refinery/Chemical industry

Re-Arranging the Equation

+

Accomplishments to Date

Evaluate the geopolymerization potential of 28 samples of fly ash collected from 18 power plants Develop chemical additives that enable the pouring of large volumes of geopolymer concrete Development of additives that enable pumping and spraying of geopolymer grout
8000
BY ML MO OH DH DH2
(1) 97-008-9278> Quartz - SiO2 (2) 97-002-3726> M ullite - Al2.35Si.64O4.82 (3) 97-005-2266> Silicon - Si (5) 97-003-0860> M agnetite - Fe3O4 1

[Matco_B040405.dif] 90081-9 GP 3/16/09 w/ 4.94% Si

100 90 80
3

7000 6000 5000

70

Intensity(%)

60 50 40
3 3

4000
3000 2000
3 1 1 3 2 1 5 2 5 1 1 21 12 2 3 25 1 2 2 2 2 2 21 2 225 5 5 2 1 2 25 2 5 22 2 2 1 1

30 20 10 0
2 5

2 2

52

5 1 2 2 5

1 2 12

1 25

1 2 2 5 2 22 1 2

1000 0 0 0.001 0.002 0.003

2 5

20

30

40 50 Two-Theta (deg)

60

70

Accomplishments to Date

We are on the verge of lunching our first commercially viable product sprayable geopolymer grout for the rehabilitation of manhole structures & sewer pipes Develop formulation for stabilizing fly ash generated by waste-to-energy programs (incineration of municipal
waste; Vancouver, Canada)

Plans for 2009-10 New Applications

High-energy efficient, low-carbon footprint homes using geopolymer filled insulated concrete forms (ICF). High temp grout material for oil/gas wells casing (2,500 F; 16,000 psi in 24 hrs) Development of Eco-Reef, ultra low cost artificial rock for aiding costal restoration; production potential up to 30 million ton per year along AL-MS-LA-TX coastline)

Value Proposition