Geopolymer Concrete Geopolymer Concrete for for Green Construction Green Construction

Materials Materials Dr. Erez Allouche Dr. Erez Allouche

Trenchless Technology CenterTrenchless Technology Center

Louisiana Tech University Louisiana Tech University November 5, 2009November 5, 2009

Summary StatementSummary Statement

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

Research Context and Research Context and Prior WorkPrior Work 49.6% of the US electrical energy production is fueled by 49.6% of the US electrical energy production is fueled by

coal coal (western USA has 250-year supply of recoverable coal)(western USA has 250-year supply of recoverable coal) 72 M tones of fly ash are produced; only 38.1% is recycled 72 M tones of fly ash are produced; only 38.1% is recycled The US produce 110 million metric tones of cement, The US produce 110 million metric tones of cement,

resulting in 90 million metric tones of carbon dioxide. resulting in 90 million metric tones of carbon dioxide. Cement production contributes 7% of human COCement production contributes 7% of human CO22 emissions emissions Cement production - energy intensive processCement production - energy intensive process (heat raw (heat raw

materials to 2550 F)materials to 2550 F)

Re-Arranging the Re-Arranging the Equation Equation

Power Generation Refinery/Chemical industryCement Production

Re-Arranging the Re-Arranging the Equation Equation

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Accomplishments to DateAccomplishments to Date Evaluate the geopolymerization potential Evaluate the geopolymerization potential

of 28 samples of fly ash collected from 18 of 28 samples of fly ash collected from 18 power plants power plants

Develop chemical additives that enable Develop chemical additives that enable the pouring of large volumes of the pouring of large volumes of geopolymer concretegeopolymer concrete

Development of additives that enable Development of additives that enable pumping and spraying of geopolymer pumping and spraying of geopolymer grout grout

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[Matco_B040405.dif] 90081-9 GP 3/16/09 w/ 4.94% Si(1) 97-008-9278> Quartz - SiO2

(2) 97-002-3726> Mull i te - Al2.35Si.64O4.82(3) 97-005-2266> Sil icon - Si

(5) 97-003-0860> Magneti te - Fe3O4

Accomplishments to DateAccomplishments to Date We are on the verge of lunching our first We are on the verge of lunching our first

commercially viable product – sprayable commercially viable product – sprayable geopolymer grout for the rehabilitation of geopolymer grout for the rehabilitation of manhole structures & sewer pipesmanhole structures & sewer pipes

Develop formulation for stabilizing fly ash Develop formulation for stabilizing fly ash generated by waste-to-energy programs generated by waste-to-energy programs (incineration of municipal waste; Vancouver, (incineration of municipal waste; Vancouver, Canada)Canada)

Plans for 2009-10 – New Plans for 2009-10 – New ApplicationsApplications

High-energy efficient, low-carbon footprint High-energy efficient, low-carbon footprint homes using geopolymer filled insulated homes using geopolymer filled insulated concrete forms (ICF). concrete forms (ICF).

High temp grout material for oil/gas wells casing High temp grout material for oil/gas wells casing (2,500 F; 16,000 psi in 24 hrs)(2,500 F; 16,000 psi in 24 hrs)

Development of ‘Eco-Reef’, ultra low cost Development of ‘Eco-Reef’, ultra low cost artificial rock for aiding costal restoration; artificial rock for aiding costal restoration; production potential up to 30 million ton per production potential up to 30 million ton per year along AL-MS-LA-TX coastline) year along AL-MS-LA-TX coastline)

Value PropositionValue Proposition