FuCCI focuses on decarbonizing traditional (portland) cement and developing new-concept, carbon-efficient, and transformative alternative cements; as well as leveraging the cement theories to develop carbon-negative materials and processes for thermal energy storage, geological carbon storage/ mineralization, and recovery of energy-relevant critical minerals (e.g., nickel). FuCCI researchers also develop multi-scale numerical models, chemical and biological technologies, and sensing and inspection techniques for understanding the deterioration of concrete structures and prolong their service lives. As an emerging methodology, FuCCI also develops and shares databases in the field of cement and concrete research, to facilitate training and validation of AI tools for high-fidelity performance prediction and/or performance-based materials design.
Carbon-Negative SCMs
We are innovating carbon-negative supplementary cementitious materials (SCMs) funded by National Science Foundation and industry. This technology can upcycle negative-value solid wastes (e.g., off-spec coal ashes, municipal solid waste incineration ashes, slags, recycled concrete fines, etc.) using carbon mineralization reactions into >$50/t commodity blended SCMs which can replace >50% of cement for making concrete without compromising performance of the concrete. The carbon mineralization reactions can use CO2 captured from air or point sources, CO2-rich flue gas, or CO2-derived chemicals as carbon-negative precursors, and, thus can be highly adaptable and scalable. FuCCI is looking for partners to scale up this technology.
Carbon-Negative Alternative Cements
We are exploring carbonation and alternative mineralization pathways as carbon-negative alternative cementation mechanisms. These mechanisms will enable development of alternative cements that have comparable workability and mechanical performance, as well as superior volumetric stability and durability (e.g., frost resistance and steel rebar protectiveness) to the conventional portland cement. These cements use abundant and widely available solid wastes or natural minerals as base precursor and CO2/CO2-derived chemicals as activator. This technology is currently at TRL2-4.
Carbon-Negative Mining of Critical Minerals
Funded by ARPA-E, we are innovating carbon-negative pre-processing technologies for ores or mine wastes (e.g., tailings) which can reduce comminution energy and enhance the yield of critical minerals recovery using hydro-metallurgic approaches. Currently we are focusing on energy-relevant critical minerals, such as nickel, cobalt, lithium, and copper, of which the US supply chain rely on import. We are also optimizing the processes to avoid re-emission of CO2 during and after recovery of the critical minerals, and beneficially use the by-products in construction.
Mineralization-Based Self-Healing Concrete
Funded by DARPA, we are working with Lawrence Livermore and Lawrence Berkeley National Laboratories and several other universities to arm aged concrete structures with a self-healing capacity. The self-healing mechanism is mainly a carbon-negative mineralization reaction. We will also develop novel sensors and non-destructive testing (NDT) technologies to validate the effectiveness of self-filling, self-sealing, and self-healing both in labs and in fields.
Carbon-Efficient and Alternative SCMs
Funded by NSF (2017-2022), we elucidated the effects of many factors on the reactivity of calcined clay, and developed strategies of maximizing the substitution of portland cement with mixtures of calcined clay and fillers. We are also evaluating reactivities of various solid wastes and their feasibility of being used as alternative supplementary cementitious materials (SCMs). These solid wastes include coal combustion bottom ash and off-spec fly ash (supported by EPRI), municipal solid waste incineration (MSWI) fly ash and bottom ash (supported by Covanta and York County), steel slag (supported by AIST), and hybrid alternative SCMs for ultra-high-volume cement replacement (supported by Ecocem).
Advanced Alternative Cements and Functional Composites
We have been studying a series of acid-base cements (ABCs), including phosphate cements, oxalate cements, and other emerging cements. These ABCs are normally characterized by high early-age strength, extremely low shrinkage, high bonding capacity, and superior durability. Notably, they can passivate the surface of streel rebar via unique mechanisms, and, thus, can protect steel rebar from corrosion even better than portland cement (see the associated figure; both immersed in seawater for 1 month). Funded by National Science Foundation, we are also advancing existing alternative cements like calcium sulfoaluminate cement.
Carbon Removal Measurement, Reporting & Verification (MRV)
While more and more technologies are available on the market, how to better verify the effectiveness of these technologies will be crucial. Funded by DOE/OTT, FuCCI is working with NREL, LLNL and the Lightwave Technology Lab at Missouri S&T to develop a characterization and data science based framework to measure, report and verify the carbon removal capacities of commercial products and novel/emerging technologies.
Anti-Washout (Self-Consolidating) Concrete and Underwater 3D Printing
We have developed anti-washout concrete and self-consolidating concrete (SCC) for underwater construction and/or repair. The design of such materials balances the functions of superplasticizers and viscosity modifying agents which must have good chemical compatibility with the cementitious binders and with each other. Leveraging our experience in 3D concrete printing, we have also developed underwater 3D printing materials and technologies. The anti-washout SCC can be used to construct a “hard floor” on any soft underwater sediments before 3D printing operations for underwater construction projects. See more details here.
More Coming……
Thermochemical materials for thermal energy storage;
Accelerated/Enhanced geologic carbon mineralization;
AI-guided 3DP concrete designed with indigenous materials;
Sensing, monitoring and NDT technologies;
Carbon-negative mixing protocols for concrete plants;
Alternative fuel and heating technologies for the productions of cement and SCMs;
…
