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BIA-Brukerstyrt innovasjonsarena

Geopolymer Concrete Based on Mining Residues

Alternativ tittel: Geopolymer sement basert på gruveavfall

Tildelt: kr 6,8 mill.

Betong er verdens mest brukte byggemateriale. Betong består av sement og tilslag (stein og grus), hvor sementen er bindemiddelet som limer sammen tilslaget slik at betongen har høy styrke. En utfordring derimot, er at Portland sement, som er den sementen som i hovedsak brukes som bindemiddel i betong, har betydelige CO2 utslipp under produksjon. Faktisk utgjør Portland sement produksjon 6-8 % av alle menneskeskapte CO2 utslipp på verdensbasis. Det er derfor et behov for å finne alternative bindemidler til betong som har betydelige lavere CO2 utslipp enn Portland sement. Saferock utvikler en ny type betong helt uten Portland sement. Bindemiddelet i Saferocks betong er en alkali-aktivert sement, også kalt «geopolymer», hvor gruveavfall og andre, industrielle avfallsmaterialer brukes som råstoff til å lage bindemiddelet. Dette gir en redusert CO2 fotavtrykk på 80 % sammenlignet med Portland sement. I dette prosjektet har Saferock samarbeidet med gruveselskapet Titania om å bruke avgangsmasser fra deres gruve til å lage sement-fri betong. Nøkkelpersoner fra Titania har bidratt med nyttig informasjon om for eksempel mineralogi på avgangsmassen, og samarbeidet har fungert svært godt gjennom hele prosjektperioden. Bruk av Titanias gruveavfall til å lage betong vil kunne betydelig redusere Titanias framtidige behov for deponi. Dessuten, dette baner vei for mulige framtidige samarbeid med andre gruveselskaper andre steder i Norge også, slik at andre gruveavfall også kan brukes til å lage bindemiddel til betong i stedet for å deponeres. Saferock har også hatt et samarbeid med Universitetet i Stavanger i dette prosjektet, for eksempel gjennom en felles Post.Doc, og i tillegg skrev to masterstudenter i betongteknologi sin diplomoppgave om Saferocks betong basert på eksperimenter de gjennomførte i Saferocks laboratorier. Dette IPN-prosjektet har vært avgjørende for Saferocks pågående produktutvikling, som hittil fokuserer på «enkle» betongprodukter slik som belegningsstein, heller og avrettingsmasse. Utfallet av dette prosjektet er at Saferock nå er svært nær å introdusere sitt første betongprodukt i markedet.

In this project, Saferock is developing a new type of sustainable concrete without Portland cement. As concrete is the most widely used construction material in the world, and production of Portland cement is one of the main causes of anthropogenic CO2 emissions, there is a need to develop new concrete products without Portland cement. Therefore, future use of a new concrete completely without Portland, such as Saferock’s new concrete, will have a conservable positive impact on the environment. Moreover, the binder material in Saferock’s concrete is based upon mine tailings, i.e., residue from mining activities, where this surplus residue is normally disposed of in landfills, causing various environmental challenges. Due to the current and future high activity level in the mining industry, the amounts of such surplus tailings to be deposited is expected to increase considerable. Consequently, Saferock’s new concrete may contribute to reducing the need for landfills and thus have another major positive impact on the environment. In addition to these future environmental impacts, this IPN-project has been crucial for Saferock as a small start-up company. The project has resulted in product developments of concrete without Portland cement, and the outcome of the project is that Saferock is now very close to introduce its first product into the marked. For Saferock, this project has been a success.

Concrete is the main construction material used on earth. Ordinary Portland Cement (OPC), representing as € 620 bn/year business, works as the glue that binds the aggregates in concrete together. However, the industry is facing challenges as OPC production is responsible for 6-8% of all human-made global carbon emissions, more than 3 billion tons CO2/year. The production also consumes a large amount of natural limestone and releases SO2, SO3 and NOx that can cause acid rain. Adding to the challenge, the price of fly ash, a key ingredient in mixed cements, is also increasing due to coal power plants being shut down in Europe. SafeRock is developing unique rock-based geopolymer binders, providing more than 80% reduction of the CO2 footprint compared to OPC due to no calcination, and offering favorable mechanical properties. The project will optimize SafeRock’s mix design by broadening the choice of binders, hardeners and additives, cater to handling and upscaling challenges in relation to production, storage, and loading/offloading, and initiate an effort to create value from a circular economy involving mining residues. The core team of SafeRock has very high competencies in geopolymeric materials, regulations and practical building experience. Industry players along the value chain have joined the team on the road to market. UiS is a natural R&D partner providing expertise, infrastructure and validation of results. The ultimate ambition is for the technology to be suitable for widespread international use in the building and construction industry. Market entry is planned based on using the material as screed (“avrettningsmasse”) and in other non-structural applications. Taking advantage also of developments in the areas of materials science, processing engineering, structural engineering, infrastructure systems, and market perspectives, the innovation has the potential to be a breakthrough in sustainable building materials.

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BIA-Brukerstyrt innovasjonsarena