19th November 2008

Introduction to Accelerated Carbonation Carbonation

Robert WilliamsRobert Williams

Carbon8 SystemsCarbon8 Systems Ltd Ltd

www.c8s.co.ukwww.c8s.co.uk

Objectives:Objectives:

- to use CO- to use CO22 gas as a resource gas as a resource

- to utilise the latent reactivity of industrial - to utilise the latent reactivity of industrial wastes (and soil) to COwastes (and soil) to CO22 for the: for the:

1) pre-treatment of landfill waste1) pre-treatment of landfill waste

2) diversion of landfill waste via the2) diversion of landfill waste via the production of engineering materials production of engineering materials

3) manufacture of specialist products3) manufacture of specialist products

Drivers:Drivers:

- Landfill directive- Landfill directive

- Sustainable waste management - Sustainable waste management

- Reduction in CO - Reduction in CO22 emissions emissions

- Diminishing aggregate resources - Diminishing aggregate resources

- Recycling of contaminated land - Recycling of contaminated land

History:History:

7000 B.C7000 B.C First lime mortars usedFirst lime mortars used

27 B.C.27 B.C. [[VitruviusVitruvius] writes at length about the conditioning of lime ] writes at length about the conditioning of lime mortars (The 10 books of architecture)mortars (The 10 books of architecture)

79 79 [[PlinyPliny] further explores conditioning of lime mortars] further explores conditioning of lime mortars

1870 1870 Setting accelerated by raised COSetting accelerated by raised CO22 level in curing level in curing environmentenvironment

1925 1925 [[FullerFuller] conditioned fresh cement with CO] conditioned fresh cement with CO22

1970’s1970’s [[Berger et alBerger et al.] carbonated calcium silicate materials.] carbonated calcium silicate materials

1980’s1980’s [[RedlandRedland] accelerated curing of roof tiles] accelerated curing of roof tiles

DCR treatment for contaminated soil (organics)DCR treatment for contaminated soil (organics)

1990’s1990’s [[JonesJones] used of super critical CO] used of super critical CO22 (SCCO (SCCO22) with composites) with composites

[[HillsHills] Treatment of hazardous waste] Treatment of hazardous waste

2006 2006 [[Carbon8Carbon8] Production of aggregates by carbonation] Production of aggregates by carbonation

20082008 [[Carbon8Carbon8] Carbonated building materials] Carbonated building materials

‘Quirks’ of the carbonation reaction:

C or CH-basedC or CH-based CS -basedCS -based

CO2CO2

Intra-grain reaction Intra-grain reaction productsproducts

Extra-grain reaction Extra-grain reaction productsproducts

Ca

CaCa

CaCa

CO2

CO2

CO2

CO2

Early observations:Early observations:

50 um50 um

Carbonate-ability of thermal wastesCarbonate-ability of thermal wastes

Influence of ACT on pHInfluence of ACT on pH

Carbonation of contaminated soilCarbonation of contaminated soil

Trials in E. London, April 2008Trials in E. London, April 2008

Treatment of hazardous wasteTreatment of hazardous waste

Sludges untreated

Carbonated sludge with PFA and bentonite Carbonated sludge with PFA and bentonite

Production of artificial aggregatesProduction of artificial aggregates

•Key considerations include:Key considerations include:

- choice/availability of active/suitable wastes- choice/availability of active/suitable wastes

- waste blends- waste blends

- process condition, e.g. CO- process condition, e.g. CO22 partial pressure partial pressure

- throughput- throughput

- market need?- market need?

Production of aggregatesProduction of aggregates

Steel Wastewater Sludge Quarry Fines

Bauxite

Wood Ash

Paper Ash

Metal Dust

Aggregate structureAggregate structure

Aggregate propertiesAggregate properties

Full-scale scale plant ca 70,000kg/hr (soil/waste)Full-scale scale plant ca 70,000kg/hr (soil/waste)

Manufacture of light-weight or dense-weight Manufacture of light-weight or dense-weight aggregates (10,000 -50,000kg/hr)aggregates (10,000 -50,000kg/hr)

Manufacture of carbonated building materials, Manufacture of carbonated building materials, through:through:

Optimisation of processes for specific applicationsOptimisation of processes for specific applications

Performance testing/certification of productsPerformance testing/certification of products

Key industrial partnerships with Carbon8 SystemsKey industrial partnerships with Carbon8 Systems

Next Stage of development for ACTNext Stage of development for ACT

ACT is a developing technologyACT is a developing technology

Potential to recycle waste in carbonated products Potential to recycle waste in carbonated products utilising greenhouse gas emissionsutilising greenhouse gas emissions

Intermediate-scale manufacture of carbonated Intermediate-scale manufacture of carbonated aggregates available shortlyaggregates available shortly

Optimisation of carbonation process for specific Optimisation of carbonation process for specific applications underwayapplications underway

Wider opportunities for the application of Wider opportunities for the application of carbonation technologytechnology

Acceptance of technology by IChemE, Shell Acceptance of technology by IChemE, Shell Springboard Challenge and Times HE outstanding Springboard Challenge and Times HE outstanding innovation award successesinnovation award successes

SummarySummary

Acknowledgements

Shell/BPShell/BP

NISPNISP

RE-KTN/EPSRCRE-KTN/EPSRC

Gallagher AggregatesGallagher Aggregates

Viridor Waste ManagementViridor Waste Management

Waste Recycling GroupWaste Recycling Group

E-onE-on

Carbon-Free Group

Southern and Scottish