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All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Reinventing CEMENT: Carbonation-Enabled Mineralization to Engender Novel Technology

Cement is the most important building material used in civil infrastructure but it is extremely energy intensive to produce. We developed novel ways to make cements at low temperatures by mimicking the chemistry of the calcium silicate mineral pseudowollastonite. Pseudowollastonite is interesting because when it is exposed to hot (90-150oC), alkaline conditions with CO2 and water it reacts to form mineral phases that are much stronger than commercial cements. The resulting phases are also much more resistant to acid attack and have lower permeability, which will make them last longer. Many of the mineral phases in our cements are similar to those that exist in ancient Roman cements that have lasted thousands of years. Our objective was to understand how waste materials from industrial processes (such as power production, municipal solid waste treatment, or power plants) can be used to replicate the conditions that give pseudowollastonite cement its remarkable properties. We worked to optimize our formulations and incorporate the cements into concrete blends that the industry can test and consider using in different applications. Our cements could be used in pre-cast cement structural elements, which makes up nearly 20% of the total cement market and is growing rapidly. This work supports ARPA-E program objectives to significantly improve the industrial efficiency of materials production.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Predicting Cement-Sheath Integrity with Consideration of Initial State of Stress and Thermoporoelastic Effects

In conventional wellbore-integrity analysis, the cement sheath’s initial state of stress and transient thermoporoelastic effects are often neglected. However, the initial state of stress is prerequisite information for accurately predicting the safe operating conditions that prevent a cemented well from being damaged. In addition, transient thermoporoelastic effects can have a profound effect on when damage will occur. Here in this paper, we propose a model that includes these effects to predict the safe operating pressures and temperatures that will prevent cement-sheath failure. For the initial state of stress, we proposed an empirical model using measurements. Subsequent stress changes are evaluated by a fully coupled transient thermoporoelastic model to analyze the mechanical behavior of the cement sheath. We predict the safe operating envelope (SOE) for shear, tensile, and debonding cement-sheath failures caused by pressure and temperature perturbations after the cement sets. Our model predicts that pore pressure is a key factor for cement failure, especially for rapid temperature changes. If the formation is low permeability, the transient pore pressures are amplified, causing the risk of damage to increase. Compared with conventional thermoelastic models, the thermoporoelastic model predicts a smaller SOE when heating the internal casing fluid and a larger envelope when cooling the internal casing fluid. Finally, the heating rate was considered with respect to field applications. The heating rate was also considered, and slower heating/cooling rates can prevent damage to the cement sheath. Finally, the thermoporoelastic model was applied to explain several laboratory and field experiments and achieved good matches.

02 PETROLEUM↗
DOE OSTI2021

Chemical mechanisms and kinetic modeling of calcium aluminate cements hydration in diluted systems: Role of aluminium hydroxide formation

Calcium aluminate cements are niche cements used in the refractory industry and in non-structural applications for building chemistry with short return-to-service delay. The later applications use theses cements in combination with calcium sulfates for long-term stability. By being niche cements, the knowledge of calcium aluminate cements hydration is not as extensive as that of Portland cement. In the present paper, the calcium aluminate cements are studied in diluted suspensions as a function of different parameters such as the suspension concentration or the quantity of added calcium sulfates. The objective is to identify their baseline chemical mechanisms. This work demonstrates the essential role of hydroxide ions fluxes, i.e. quantity going in and out of the liquid phase per unit of time. The main quantitative flux is the formation of aluminium hydroxide but the activation of this reaction is difficult. This difficulty allows calcium aluminate to be used as cement by creating a dormant period (workability) for the overall reactivity. The identification of the key role of aluminium hydroxide formation explains the influence of the temperature, some mechanisms of setting admixtures and the early age of calcium aluminate cements.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Experimental and theoretical study of the restrained shrinkage cracking of early age well cement

The shrinkage cracking occurring in oil & gas well cement material is a major factor that reduces the cement sheath integrity and impairs the durability of an underground well. Shrinkage mainly takes place in the early hydration period of the cement, and the resulting restrained shrinkage cracking can form a leaking network for oil & gas or carbon dioxide stored in an underground reservoir. It is thus important to understand the early age behavior of well cement and the leaking pathway formation in the well. This study describes the application of the digital image correlation (DIC) method as a tool to measure the strain development and crack distributions of well cement in the lab during early phase changes. A theoretical model is presented to calculate the stress distribution built up in the cement sheath during early ages of well cement hydration, which helps to interpret the experimental observations and determine the major factors influencing the cracking sequences. This study presents the whole hydration – drying shrinkage – and cracking mechanism of early age well cement under restrained ring conditions experimentally and theoretically. Finally, the results offer useful insights on the key material and geometric parameters which control the fracture of a well cementing structure.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Thermal shock resistance of lightweight cements developed for geothermal conditions

Cements are a critical component in well construction, as they act to prevent well fluid and gas escape, prevent corrosion of the casing, and strengthen the wellbore to prevent deformation. Under the high temperature/pressure conditions common in geothermal systems, the injection of cold water for energy production is expected to induce cyclic damage to the borehole cement through the rapid temperature fluctuations. These “thermal shocks” are expected to cause casing shrinkage, annulus formation, and cement tensile stresses. To understand the effect of cold water injection on the wellbore environment, a set of rock-cement-steel samples were created to simulate the structure of a geothermal well. Lightweight thermally-insulating cement blends were tested under thermal shock conditions in this study. In each test, the samples were pressurized to an effective pressure of ~3.5 MPa and placed at high temperatures. Thermal shocks were performed by injecting cold water (~10-15 °C) through the samples at a constant rate while keeping the samples at high temperatures until the sample temperature stopped decreasing and deformation ceased. Eight thermal shock tests were conducted with each sample – two at 100 °C and six at 200 °C. Post-tests analysis was then conducted by cutting open each sample to examine the damage in each component of the simulated wellbore. Experimental results suggest that all samples experienced similar degrees of axial and lateral contraction during cold water injection, but for the most part this contraction is recoverable when injection halts. Post-test analysis revealed that fly ash cenosphere pre-treatment had the best effect on improving thermal shock resistance in the cement blends. Thermomechanical modeling of likely stress paths experienced by the cements during heating/cooling cycles shows that elasto-plastic cement constitutive behavior results in most plastic strain occurring during the initial heating steps, with mostly elastic strain occurring during the thermal shock cycles. In conclusion, this agrees with experimental evidence, suggesting that cement damage from shocking occurs via other mechanisms such as chemical alteration, corrosion, and fatigue.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Sulfate Promotes Compact CaCO 3 Formation and Protects Portland Cement from Supercritical CO 2 Attack

Supercritical (sc) CO 2 in geologic carbon sequestration (GCS) can chemically and mechanically deteriorate wellbore cement, raising concerns for long-term operations. In contrast to the conventional view of “sulfate attack” on cement, we found that adding 0.15 M sulfate to the acidic brine can significantly reduce the impact of scCO 2 attack on Portland cement, resulting in stronger cement than that found in a sulfate-free system. Scanning electron microscopy revealed a decreased total attack depth in reacted cement in the presence of sulfate. With a newly defined minimum porosity term in reactive transport modeling, our model suggests that sulfate caused CaCO 3 to fill more nanopore spaces in the cement. Small angle X-ray scattering experiments also showed that sulfate can decrease the pore sizes of the carbonate layer. The results suggest that the interactions between sulfate and cement can generate a less porous CaCO 3 layer, which better resists acidic brine. Using this mechanism as a proof-of-concept, we tested the incorporation of sodium sulfate into Portland cement and synthesized new cement composites that show stronger resistance against scCO 2 attacks. Finally, these newly discovered interfacial interactions between CaCO 3 and sulfate provide new insights into engineering mechanically strong and green materials for safer GCS.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2020

Advanced Self-Healing Polymer-Cement Composites for Geothermal Wellbore Application at 300 °C

Polymer-cement composites were formulated using two base cements and three polymers and evaluated as potential alternatives to conventional geothermal wellbore cementitious material. To mimic geothermal conditions these cement composites were cured at 300 °C and their mechanical properties, including compressive strength, Young modulus, shear bond strength to steel casing, and self-healing and re-adhering (to steel) capability were tested. To test thermal stability the samples were cured at 300 °C for up to 30 days followed by analysis of their mineralogy and chemical composition by X-ray diffraction spectroscopy (XRD), 13C NMR, and total organic carbon (TOC). These tests showed that all polymer composites formulated were thermally stable as supported by almost 100% TOC of the 300 ?C cured samples and presence of all the polymer signals in 13C NMR permeability tests performed before and after healing a longitudinal fracture base cements and polymer-cement composites gave lower (2nd/1st) permeability ratios with respect to base cements which suggests that introduction polymers result in self-healing composite materials. Curing two of the best performing polymer-cement composites for a period of 30 days at 300 °C maintained the self-healing capability. These advanced polymer-cement composites with higher mechanical stability, ductility and self-healing capability are promising alternatives to wellbore cement materials for geothermal and fossil energy applications.

polymer-cement, composite, wellbore, self-healing,↗
DOE OSTI2021

DPC Cement Filler Development (Progress Report)

The fillers research and development (R&D) program, mostly experimental, is part of a broader R&D program that includes new process modeling and performance assessment of criticality effects and the overall importance of criticality to repository performance (consequence screening). A literature research and consultation effort with experts by Hardin and Brady (2018) identified several potentially effective and workable filler materials including cements (primarily phosphate based), moltenmetal alloys, and low-temperature glasses. Filler attributes were defined, and the preliminary lists were compared qualitatively. Further comparative analysis will be done (e.g., cost estimates) after experimental screening has narrowed the list of alternatives. The following cement filler compositions were selected for experimental development work and accelerated testing in FY20: Aluminum phosphate cements (APCs); more specifically aluminum oxide / aluminum phosphate (Al 2 O 3 / AlPO 4 ) cements in which Al 2 O 3 serves as the filler material bound by an AlPO 4 binder formed by the reaction of Al 2 O 3 with H 3 PO 4 ; Calcium phosphate cements (CPCs); more specifically composed of pure or nearly pure hydroxyapatite or HAP (Ca 5 (PO 4 ) 3 (OH)); Wollastonite phosphate cements (WPC), specifically wollastonite and aluminum or calcium aluminum phosphates in which CaSiO 3 serves as the filler material and the phosphate serves as the binder. The FY20 effort focused on the optimization of compositions and subsequent processing of these three materials to achieve dense and well-consolidated monolithic samples with 30 to 40% porosity and permeabilities of 1 millidarcy. At the close of this progress report the aluminum phosphate cements (APCs) and the wollastonite phosphate cements (WPCs) appear to show the most promise for continued development. Less progress has been made with the calcium phosphate cements (CPCs); their slurry viscosities are high (and difficult to measure) and they exhibit relatively short cure times of 2 to 3 hours with concomitant and excessive volatile (e.g. CO 2 ) generation.

36 MATERIALS SCIENCE↗
DOE OSTI2024

State of Innovation 2024: Paving the Way for Low-Carbon Cement and Concrete

Concrete production in the U.S. accounted for nearly 393 million cubic yards in 2023, with $38.8 billion in revenue. While cement, the key ingredient in concrete, is only 10%-15% of concrete's mixture by mass, 8% of total global emissions come from the production of cement. A significant challenge lies in the fact that roughly 51% of concrete emissions stem from the material calcination process of cement production. Stakeholders ranging from cement producers to government agencies are beginning to take measures to significantly reduce concrete emissions by 2050 and are seeking novel technologies from the startup community. Strategies to lower carbon emissions include reducing quantities of cement in concrete formulas; optimizing digital and automated production; lower temperature processing; carbon capture, utilization, and durable storage; and other cost-saving approaches to energy and material efficiencies. New materials based on carbon mineralization and novel cement chemistries hold the potential to reach net-zero or even carbon-negative concrete production; however, there is presently no readily available substitute that can replicate concrete's unique properties and versatility at the volume demanded by construction worldwide. The nature of concrete's raw materials, diverse applications, and scale of demand means that complete decarbonization will rely on a combination of innovative production methods and novel cement chemistries. Low-carbon solutions will need to compete economically with traditional concrete to become viable in a high-volume commodity market, although consumer demand and regulation will play important roles. Despite these challenges, this analysis reveals that venture capital (VC) investments in low-carbon concrete reflect a growing awareness of the decarbonized cement market opportunity. Between 2022 and 2023 emerging low-carbon technologies garnered more than $700 million in VC investments, representing a growing share of investment in the built environment. An investment gap appears after Series A for technology solutions, demonstrating the sector's potential, as well as the need for additional performance assurance and technology incubation.

cement↗
DOE OSTI2026

Discovery of nanopore filling by gypsum in wellbore cement exposed to 17 MPa CO 2 under geologic carbon storage conditions

Here, this study investigates the pore structure evolution of the reaction zones in wellbore cement samples exposed to a CO 2 -rich solution in equilibrium with 17 MPa supercritical CO 2 over 14 days. Through advanced characterization methods of field emission SEM, Quantitative Evaluation of Minerals by Scanning Electron Microscopy (QEMSCAN), and micro-CT, a new mechanism of CO 2 -cement reaction involving filling of nanopores in the interior of cement by gypsum was revealed. Gypsum was formed by the liberation of SO 4 2− from ettringite (AFt) and monosulfate (AFm) caused by a decrease in pH. Based on these experimental observations, a new CO 2 -cement reaction model that incorporates four distinct reaction zones is developed. This model provides a comprehensive framework for understanding the spatial and temporal distribution of minerals in cement due to high pressure CO 2 —cement reactions. This study demonstrates that the major damage induced by high pressure CO 2 alteration occurs in the most exterior region of the cement. The interior region of the cement maintains its integrity due to nanopore filling by gypsum.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

Testing Various Cement Formulations under Temperature Cycles and Drying Shrinkage for Low-Temperature Geothermal Wells

Low-enthalpy geothermal wells are considered a sustainable energy source, particularly for district heating in the Netherlands. The cement sheath in these wells experiences thermal cycles. The stability of cement recipes under such conditions is not well understood. In this work, thermal cycling experiments for intermediate- and low-temperature geothermal well cements have been conducted. The samples were cured either under ambient conditions or under realistic pressure and temperature for 7 days. The samples did not show any signs of failure after performing 10 cycles of thermal treatment between 100 °C and 18 °C. We also tested cement formulations under drying conditions. Drying shrinkage is caused by a reduction in the water content of cement, which leads to capillary forces that can damage cement. Such circumstances lead to tensile stresses causing radial cracks. Most samples exhibited cracks under low humidity conditions (drying). Fiber reinforcement, especially using short PP fibers, improved the cement’s resilience to temperature and humidity changes. Such additives can improve the longevity of cement sheaths in geothermal wells.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Thermally Insulating, Thermal Shock Resistant Calcium Aluminate Phosphate Cement Composites for Reservoir Thermal Energy Storage

This paper presents the use of hydrophobic silica aerogel (HSA) and hydrophilic fly ash cenosphere (FCS) aggregates for improvements in the thermal insulating and mechanical properties of 100- and 250 °C-autoclaved calcium aluminate phosphate (CaP) cement composites reinforced with micro-glass (MGF) and micro-carbon (MCF) fibers for deployment in medium- (100 °C) and high-temperature (250 °C) reservoir thermal energy storage systems. The following six factors were assessed: (1) Hydrothermal stability of HSA; (2) Pozzolanic activity of the two aggregates and MGF in an alkali cement environment; (3) CaP cement slurry heat release during hydration and chemical reactions; (4) Composite phase compositions and phase transitions; (5) Mechanical behavior; (6) Thermal shock (TS) resistance at temperature gradients of 150 and 225 °C. The results showed that hydrophobic trimethylsilyl groups in trimethylsiloxy-linked silica aerogel structure were susceptible to hydrothermal degradation at 250 °C. This degradation was followed by pozzolanic reactions (PR) of HSA, its dissolution, and the formation of a porous microstructure that caused a major loss in the compressive strength of the composites at 250 °C. The pozzolanic activities of FCS and MGF were moderate, and they offered improved interfacial bonding at cement-FCS and cement-MGF joints through a bridging effect by PR products. Despite the PR of MGF, both MGF and MCF played an essential role in minimizing the considerable losses in compressive strength, particularly in toughness, engendered by incorporating weak HSA. As a result, a FCS/HSA ratio of 90/10 in the CaP composite system was identified as the most effective hybrid insulating aggregate composition, with a persistent compressive strength of more than 7 MPa after three TS tests at a 150 °C temperature gradient. This composite displayed thermal conductivity of 0.28 and 0.35 W/mK after TS with 225 and 150 °C thermal gradients, respectively. These values, below the TC of water (TC water = 0.6 W/mK), were measured under water-saturated conditions for applications in underground reservoirs. However, considering the hydrothermal disintegration of HSA at 250 °C, these CaP composites have potential applications for use in thermally insulating, thermal shock-resistant well cement in a mid-temperature range (100 to 175 °C) reservoir thermal energy storage system.

58 GEOSCIENCES↗
DOE OSTI2021

Effectiveness of PCE superplasticizers in calcined clay blended cements

Highlights: • Cements containing 0–40 wt% of a calcined clay rich in meta kaolin were studied. • The calcined clay decreases fluidity of the blended cements considerably. • In cement, the calcined clay adsorbs a large amount of Ca{sup 2+} ions. • A common HPEG polycarboxylate superplasticizer fluidizes OPC/CC blends best. • A zwitterionic PCE also fluidizes well and adsorbs in similar amounts as HPEG. The impact of a calcined clay (CC) rich in meta kaolin (~50 wt%) present in composite cements at 0–40% substitution rate for the clinker was studied relative to the dispersing force of different PCE superplasticizers. It was found that CC increases the water demand of the blended cements considerably (+85% for the 60:40 blend vs. neat OPC). Furthermore, PCEs which fluidize OPC best also provide optimal performance in CC blended cements, but require much higher dosages (in OPC/CC 60:40, 4–6 times as compared to neat OPC). In all systems, HPEG-PCE produced superior dispersing performance over anionic MPEG-PCEs. A mechanistic study involving zeta potential measurements revealed that the initially negatively charged calcined clay surface adsorbs huge amounts of Ca{sup 2+} ions from the pore solution, thus facilitating adsorption of anionic PCE superplasticizers. The results signify that commercially available PCE products can effectively fluidize OPC/CC blended cements.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Influence of cementation on the yield surface of rocks numerically determined from digital microstructures

Digital Rock Physics has reached a level of maturity on the characterisation of primary properties that depend on the microstructure – such as porosity, permeability or elastic moduli – by numerically solving field equations on μCT scan images of rock. After small deformations or at depth though, most rocks eventually reach their limit of elasticity and the complementary plastic properties are needed to describe the full mechanical behaviour. Currently, determination of a rock’s yield surface from its microstructure is often restricted to semi-analytical criteria derived by limit analysis or numerical simulations performed on idealised geometries. Such simplification lacks representativeness, particularly for processes that affect directly the pore-grain interface such as the cementation phenomenon, happening during diagenesis. Eventually, only direct numerical simulation of elasto-plasticity performed on digitalised microstructures can be used to assess the strength of different cemented materials and its evolution with the alteration of the microstructure. In this study, we provide a comprehensive parametric study on the impact of cementation on rock strength for real microstructures of cemented granular materials. Compared to most previous studies, the whole yield surface is determined numerically (using Finite Element Method) in order to assess the influence of cementation for different stress-paths. The previously known tendency of rock to strengthen with increasing cementation volume is verified. New results on the influence of cement property namely Young’s modulus, friction and cohesion on the rock’s yield surface are explored. The envelopes obtained are compared to the ones obtained by experimental data and existing models. Finally, the framework presented in this study showcases the wider possibility of determining any rock’s or porous material’s yield surface from its microstructure.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Vertical effective stress and temperature as controls of quartz cementation in sandstones: Evidence from North Sea Fulmar and Gulf of Mexico Wilcox sandstones

Here we present quantitative petrographic data, high spatial resolution oxygen isotope analyses of quartz cement, basin modelling and a kinetic model for quartz precipitation for two Paleocene-Eocene Wilcox Group sandstones from Texas and two Jurassic Fulmar Formation sandstones from the Central North Sea. At each location, one sandstone has been buried to ca. 145 °C and one to ca. 185 °C. A key difference between the Wilcox and Fulmar burial histories is that the Wilcox sandstones are currently at higher vertical effective stresses and, from basin modelling studies, have been subjected to generally higher vertical effective stresses through their burial history. The amounts of quartz cement in the Wilcox sandstones are between 12 and 18%, and between 2 and 6% in the Fulmar sandstones. High-spatial-resolution oxygen isotope data obtained from the quartz cements suggest temperature ranges for quartz precipitation from 60 to 80 °C to values approaching maximum burial temperature. Factors such as grain coatings or the timing of petroleum emplacement cannot explain the differences in the amounts of quartz cement. Petrographic data show that most of the silica for quartz cement can be derived from intergranular pressure dissolution. Although the sample set is small, we interpret the results to suggest that the differences in quartz cementation in Fulmar and Wilcox sandstones can be explained better by differences in their vertical effective stress history than their temperature history; in this case, the supply of silica rather than the precipitation of quartz becomes an important control on the rate and extent of cementation.

58 GEOSCIENCES↗
DOE OSTI2021

Alteration in micro-mechanical characteristics of wellbore cement fracture surfaces due to fluid exposure

The stiffness of wellbore cement fracture surfaces was measured after exposing to the advective flow of nitrogen, silicone oil, and medium sweet dead crude oil for different exposure periods. The test specimens were extracted from fractured cement cylinders, where the cement fracture surfaces were exposed to the different fluids up to 15 weeks. A nanoindenter with a Berkovich indenter tip was used to measure load-indentation depth data, which was used to extract the elastic modulus (E) and nano-hardness (H) of the cement fracture surfaces. A reduction in the elastic modulus compared with an unexposed specimen were observed in all the specimens. Both elastic modulus and nano-hardness for the specimens exposed to silicone oil were lower than specimens exposed to nitrogen gas and varied with the period of exposure. The elastic modulus and nano-hardness of the specimens exposed to crude oil were the lowest with a significant decrement with the exposure period. The frequency distribution of the nanoindentation measurements shows that the volume-fraction ratio of the two types of cement hydrated nanocomposites for both the unexposed and test specimens is about 70:30%. Phase transformation beneath the indenter is observed for all of the specimens, with more obvious plastic deformation in specimens exposed to crude oil. Analytical measurements (SEM, EDS, FT-IR, and XRD) on exposed cement fracture surfaces reveal different levels of physical and chemical alteration that are consistent with the reduction in stiffness measured by nanoindentation. Furthermore, the study suggests that cement stiffness will decrease due to crude oil exposure, and the fracture will be sensitive to stress and pore pressure with time.

42 ENGINEERING↗
DOE OSTI2024

Economic and Jobs Impacts of Point-Source Carbon Capture in Cement Industry – Case Study

The cement industry accounts for an estimated 8% of global CO2 emissions, which surpasses that of the entire aviation sector. In contrast with other industries, where CO2 emissions can be drastically reduced via electrification or fuels substitution, cement production releases CO2 as part of its process, during the calcination of carbonates to yield oxides. Thus, point-source carbon capture has become a key technology in the cement industry’s decarbonization. Apart from the expected environmental benefits, point-source carbon capture in the cement industry can yield important economic benefits and create jobs. The objective of this study was to perform a preliminary assessment of the economic and workforce impacts associated with the construction and operation of a point-source carbon capture retrofit of an existing cement production facility, using as a basis the data from a front-end engineering design (FEED) study to install a 3.9 million metric tons per year (Mtpy) CO2 capture facility at Holcim Ste Genevieve cement plant in Missouri, United States of America. The advanced carbon capture technology used in this FEED study was Air Liquide’s Cryocap™ FG carbon capture technology. The study evaluated the direct, indirect, and induced economic impacts of the construction, operation, and maintenance activities of the project over its lifespan. It also covered how the project will generate new jobs, their nature, and quantity, along with strategies to prepare the workforce. To perform this study, construction, operation, and maintenance cost estimates, as well as construction and operation staffing plans from the FEED study were input into IMPLAN version 7.5 software, licensed by IMPLAN Group LLC (Huntersville, VC), to predict the direct, indirect and induced economic impacts of the project using industry multipliers from the software. Additionally, recruitment strategies were developed for hiring individuals who belong to groups that are historically underserved or underrepresented, as well as anticipated recruitment of workers from the local community (whether training will be required or if the skills are associated with an existing labor force). The analysis estimated that the construction and operation of the carbon capture at Holcim Ste. Genevive will result in over 24 thousand work-years of job opportunities, close to USD 10 billion of economic impacts, including over USD 460 million of tax revenue. These results encompass the direct, indirect, and induced effects. A strategy to maximize hiring from the project and neighboring counties was developed, leveraging training agreements with local trade groups and universities. The result of this study can be used for a strategic preliminary assessment of the potential regional economic and job impacts of retrofitting existing cement plants with point source carbon systems, and its methodology can be replicated to individual projects to aid in planning and workforce development.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2023

Hydrophobic, Thermal Shock-and-Corrosion-Resistant XSBR Latex-Modified Lightweight Class G Cement Composites in Geothermal Well Energy Storage Systems

Energy losses can be significantly reduced if thermally insulating cement is used for energy storage and recovery. The thermal conductivity (TC) of the currently used cement is between 1 and 1.2 W/mK. In this study we assessed the ability of polystyrene (PS)–polybutadiene (PB)–polyacrylic acid (PAA) terpolymer (cross-linked styrene–butadiene rubber, XSBR) latex to improve thermal insulating properties and thermal shock (TS) resistance of class G ordinary Portland cement (OPC) and fly ash cenosphere (FCSs) composites in the temperature range of 100–175 °C. The composites autoclaved at 100 °C were subjected to three cycles, one cycle: 175 °C heat → 25 °C water quenching). In hydrothermal and thermal (TS) environments at elevated temperatures in cement slurries the XSBR latex formed acrylic calcium complexes through acid–base reactions, and the number of such complexes increased at higher temperatures due to the XSBR degradation with formation of additional acrylic groups. As a result, these complexes offered the following five advanced properties to the OPC-based composites: (1) enhanced hydrophobicity; (2) decreased water-fillable porosity; (3) reduced TC for water-saturated composites; (4) minimized loss of compressive strength, Young’s modulus, and compressive fracture toughness after TS; and (5) abated pozzolanic activity of FCSs, which allowed FCSs to persist as thermal insulators under strongly alkaline conditions of cement slurries. Additionally, XSBR-modified slurries possessed improved workability and decreased slurry density due to the air-entraining effect of latex, which resulted in further improvement of thermal insulation performance of the modified composites.

15 GEOTHERMAL ENERGY↗