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Description
UP Catalyst and SafeRock are jointly implementing a Second Small Grant Scheme project to start producing CO2 negative concrete with enhanced mechanical properties by adding UP Catalyst carbon nanotubes (CNT) to Saferock geopolymer concrete alternative. Initial results from the project showed an excellent effect of the CNTs on the geopolymer mixes rheological properties as well as the mechanical properties of the final concrete product such as a 190% increase in compressive strength. The best results were achieved using oxidised CNTs (ox-CNTs) with a small content of oxidised substituents such as alcohols and carboxylic acids.
Additional call project focuses on the further development of UP Catalyst and Saferock joint products, with them main focus on developing ox-CNTs with a higher oxygen content. Using ox-CNTs with higher oxygen content in concrete allows for the development of two next generation geopolymer products that will allowsus to target new market sectors and achieve market growth. Project is expected to have a high impact on lowering the greenhouse gas emissions of the cement industry, which currently account for a whopping 8% of all global CO2 emissions, as using the materials developed in this project 50% less concrete can be used in construction due to its improved strength properties. Furthermore, as 3.7kg of CO2 will be sequestered in the process of producing 1kg of carbon nanomaterials used in our product, further CO2 emission reduction goals will be fulfilled. By developing a more economical geopolymer product in this project, we will make these reductions attractive and available to more industries and by offering concrete that suits underwater applications in offshore windfarms we are further empowering the green energy transition in Europe and beyond.
Summary of project results
In May 2022, Estonian technology start-up UP Catalyst and Norwegian start-up SafeRock joined forces in the Norway Grants „Green ICT“ programme carried out by Enterprise Estonia to start producing CO2 negative concrete with enhanced mechanical properties by adding UP Catalyst carbon nanotubes (CNT) to Saferock geopolymer concrete alternative. Initial results from the project showed an excellent effect of the CNTs on the geopolymer mixes rheological properties as well as the mechanical properties of the final concrete product such as a 190% increase in compressive strength. The best results were achieved using oxidised CNTs (ox-CNTs) with a small content of oxidised substituents such as alcohols and carboxylic acids. This project focuses on the further development of UP Catalyst and Saferock joint products, with them main focus on making the created material cheaper and more waterproof, opening the market to use in offshore wind farms. For this, partners further develop ox-CNTs with a higher oxygen content. Using ox-CNTs with higher oxygen content in concrete allows for the development of two next generation geopolymer products.
Project aimed to produce a geopolymer product where ox-CNT additives can be used at a lower percentage, while still delivering significant improvements in mechanical properties. This will cater to clients seeking cost-effective solutions. For this, a geopolymer product was produced with higher ox-CNT content, resulting in stronger and less water-permeable concrete, a characteristic highly sought after by the burgeoning offshore wind park construction industry, which is projected to reach a market size of EUR 800 billion by 2050. These objectives align with companies'' commitment to innovation and addressing diverse market needs. All project activities were successfully implemented.
Project results have huge impact on lowering the greenhouse gas emissions of the cement industry, which currently account for a whopping 8% of all global CO2 emissions, as using the materials developed in this project 50% less concrete can be used in construction due to its improved strength properties. Furthermore, as 3.7kg of CO2 will be sequestered in the process of producing 1kg of carbon nanomaterials used in our product, further CO2 emission reduction goals will be fulfilled. By developing a more economical geopolymer product in this project, we will make these reductions attractive and available to more industries and by offering concrete that suits underwater applications in offshore windfarms we are further empowering the green energy transition in Europe and beyond.
Summary of bilateral results
The second project was great in expanding the impact of the first project, as much more new information was uncovered about the benefits of using UP Catalyst CNTs in Saferock geopolymer concrete. The first project focused on using CNTs as a strengthening additive in geopolymer and showed promising results. However, as Saferock continued developing their geopolymer recipe, extremely high strength results outperforming the current industry standard OPC were achieved, thus making the strength gains showed by addition of CNTs less consequential. The second project allowed to explore additional benefits of CNT addition beyond increases in compressive and flexural strength, including durability in cold climates, investigated through freeze/thaw tests. The addition of CNTs greatly improved the durability of geopolymer concrete in extreme cold conditions and extreme temperature variation, making this product especially attractive to the main target market of Scandinavia. Furthermore, the water permeability of CNT enhanced concrete was investigated by using Cl- ion migration tests. Here again the addition of CNTs gave statistically significant results, showing that the addition of CNTs can make the material less permeable to water, a very attractive attribute for using the material in underwater applications such as ports or offshore wind parks and allowing us to access this new market segment. Both products still need some degree of optimisation, especially in terms of the wt% of CNTs added, as despite much improving the characteristics of the geopolymer material, the results are slightly below the benchmarks set by industry. Possible avenues to continue this work are in discussion between the companies.