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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Comparative Life Cycle Analysis of Carbon Dioxide Utilization in Concrete Products

In this study, a comparative LCA of CO2U concrete processes is conducted, revealing promise in several research areas. The environmental impacts of replacing conventional binder and aggregates with carbonated steel slag and direct carbonation of concrete are investigated in ten different product systems, which include both ready-mix and pre-cast concretes. The results indicate that cement substitution, CO2 uptake, electricity consumption, and the electricity grid mix constitute critical levers for deep decarbonization of concrete building materials. This presentation applies LCA to inform the use of CO2U concrete technology pathways in the design of sustainable concrete while promoting transparency and rational assumptions in the presence of uncertainty. Broader themes in the work include LCA of emerging technologies and the sensitivity of LCA results to co-product management methods.

Clarke, James↗
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 OSTI2025

Quantifications of growth rate and particle size of magnesium silicate hydrate cement using small‐angle X‐ray scattering

The focus of recent research on cement binders has shifted to alternatives such as magnesium silicate hydrate (M-S-H) to mitigate the environmental impact of conventional concrete production. However, a detailed understanding of the morphology and growth rate of M-S-H, which informs its applicability as a cementing agent, is lacking. These properties are important as they influence cement hydration and consequently the development of macroscopic properties. Here, in this study, the particle size distribution and growth rate of M-S-H synthesized by mixing aqueous stock solutions were analyzed using synchrotron-based small-angle X-ray scattering. The reaction solutions contained dissolved magnesium and silicon with concentrations ranging from 2 to 500 mM, corresponding to saturation indices with respect to M-S-H endmembers, M 0.75 -S-H and M 1.50 -S-H, between 5.8 and 10.3. The precipitation rates of M-S-H align with affinity-based kinetic models and can be described by the following equations: For M 0.75 -S-H: 𝑟 M 0.75 −S−H =10 −9.54±0.70 ⁢(Ω$^{0.59±0.08}_{M_{0.75}⁢\textrm{SH}}$−1), and for M 1.50 -S-H: 𝑟 M 1.50 −S−H =10 −7.56±0.37 ⁢(Ω$^{0.34±0.04}_{M_{1.50}⁢\textrm{SH}}$−1), where 𝑟 is the rate in mol/L/s, and Ω represents the saturation ratio with respect to M-S-H. Moreover, we observed that changing the [Mg]/[Si] ratio affects particle size, a trend that cannot be fully explained by changes in the saturation index alone. These insights are critical for improving the predictability and control of cementation in concrete that utilizes M-S-H-based binders.

M-S-H↗
DOE OSTI2025

Extremely Durable Concrete using Methane Decarbonization Nanofiber Co-products with Hydrogen

This project successfully developed a scalable, low-cost co-production process for hydrogen (H₂) and carbon nanofibers (CNFs) using methane through catalytic chemical vapor deposition (CVD). CNFs are high-value materials with exceptional mechanical, electrical, and chemical properties, while hydrogen is a critical clean energy resource. By leveraging vapor deposition to create highly dispersed metal catalysts, this work addressed the dual challenge of producing low-cost hydrogen and enhancing the durability of concrete using co-produced CNFs. Unlike prior approaches, which required separating the carbon product from the catalyst, this innovative method integrated the carbon product, catalyst, and silica support as a crack-bridging additive for Portland cement. This novel application aimed to advance the performance of high-performance concrete (HPC) by improving its flexural toughness, durability, and resistance to environmental degradation.

08 HYDROGEN↗
DOE OSTI2024

A General Overview of Cathodic Protection in Reinforced Concrete

Corrosion of reinforcement steel in concrete is a prevalent issue in infrastructures worldwide, with the direct costs of repair estimated to be $1 trillion annually. Treatment options are complicated by the concrete’s role in the corrosion process. Ordinary, modern-day cement is so alkaline that it maintains a thick passive layer on the steel surface, reducing corrosion to inconsequential rates. However, environmental contaminants in the form of carbon dioxide or chlorides may cause a breakdown in the passive layer, exposing the steel surface to corrosion. Galvanic cells will be free to form due to potential differences along the rebar, and anode sites will create dissolved iron ions that cannot travel far through the still concrete. Thus, rust products will accumulate directly onto the steel/concrete interface. Iron oxides have a much higher volume relative to steel, and even a miniscule amount of rust can produce enough volumetric stress to cause cracking, spalling and delamination of the surrounding concrete, increasing the risk of structural failure. Safeguards and inhibiting technology exist to limit the chances of corrosion initiation by either species, but cracking of the concrete cover and gradual accumulation of contaminants means that corrosion is unavoidable in certain environments and will initiate, given enough time.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Characterization and effects of impurities on carbonate quantification in heterogenous matrices

Mineral carbonation simulates a natural weathering phenomena by breaking down silicates and oxides to form Ca & Mg carbonates. Various mineralization methods have been demonstrated as a potential technique to improve the quality of slags and tailings through neutralization and stabilization of problematic species to yield a product better suited for use in concrete. This study aims to characterize, quantify and analyze carbonates in various carbonated products such as mineralized CaCO 3 , CO 2 mineralized Steel Slags and Mine Tailings. More than 10 samples were analyzed for carbonate measurement and verification from industrial and academic partners that pioneer commercial CO 2 mineralization technologies. The samples were characterized primarily by using X-ray diffraction (XRD), Thermogravimetric Analyses (TGA), and Scanning Electron Microscopy (SEM) to gain insights into CaCO 3 content. A baseline characterization of lab-grade CaCO 3 and MgCO 3 also revealed important considerations for CaCO 3 measurement using TGA alone. The experiments using synthetic lab-grade samples also revealed that the presence of MgCO 3 /MgO can accelerate the decomposition of CaCO 3 and thus can affect measurement parameters. Lab-grade CaCO 3 samples dosed into steel slag and mine tailing also showed significant deviation in their decomposition behavior. These insights are used to inform the development of a standardized protocol for the measurement and verification of carbonate-bearing products.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2026

A rapid embodied carbon assessment tool for priority materials

Embodied carbon limits within building materials are a driving factor in global trade, generating new research and analysis tools in industry. These product assessments, which require utilizing life-cycle assessment (LCA) across broad supply chains, can be expensive, time and data-intensive, and subject to significant variations. Existing methods and tools, such as specific environmental product declarations, typically do not capture these variations and dynamics in supply and manufacturing. Moreover, models and tools must enable stakeholders to assess customized supply chains and future scenarios. In this study, we present the Rapid Embodied Carbon Assessment and Target-setting for Emissions-intensive Materials (REDuCE) tool for building materials. We developed a tool that allows users to select production technologies, transportation mode and distances, concrete carbonation, fuel sources, and regional electricity mixes to supply customization for cement and concrete produced and consumed in California. We generated and integrated a material demand model using residential building stock projections. We provide the user with a wide range of mitigation alternatives through low-carbon production pathways, material use efficiency, transportation modes, and projected electricity grid mixes. In a case study application through four mitigation scenarios, we find emission savings up to 80% by maximizing user mitigation alternatives, primarily driven by reductions in material use intensities. This work represents a foundation for expanding LCA and embodied carbon tools to better enable stakeholders to rapidly and accurately assess customized supply chains while meeting trade requirements.

building materials↗
DOE OSTI2026

Hybrid-Energy-Powered Electrochemical Ocean Alkalinity Enhancement Model: Plant Operation, Cost, and Profitability

Electrochemical ocean alkalinity enhancement is a form of marine carbon dioxide removal, a rapidly growing industry that is powered by efficient onshore or offshore energy sources. As more and larger deployments are being planned, it is important to consider how variable energy sources like tidal energy can impact plant performance and costs. An open-source Python-based generalizable model for electrodialysis-based ocean alkalinity enhancement has been developed that can capture key system-level insights of the electrochemistry, ocean chemistry, acid disposal, and co-product creation of these plants under various conditions. The model additionally accounts for hybrid energy system performance profiles and costs via the National Laboratory of the Rockies’ H2Integrate tool. The model was used to analyze an example theoretical plant deployment in North Admiralty Inlet, including how the plant is impacted by the available energy sources in the region and the scale at which plant costs are covered by the co-products it generates, such as recycled concrete aggregates, without requiring carbon credits. The results show that the example plant could be profitable without carbon credits at commercial scales of 100,000 to 1 million tons of carbon dioxide removal per year, so long as it uses low-cost electricity sources and either sells acid or recovers recycled concrete aggregates with about 1 molar acid concentrations, though more research is needed to confirm these results.

hybrid energy↗
DOE OSTI2024

Use of a Lignin-Based Admixture for Tailoring the Rheological Properties of Mortars for 3D Printing: Preprint

Efforts toward decarbonizing construction materials and industrial processes related to cement and concrete can be aided via multifaceted approaches that target alternative admixtures as well as precision control of fabrication. Chemical admixtures for water reduction have played a crucial role in the development of advanced concrete mixtures. Newer biomass processing techniques developed for aviation fuel production from corn stover biomass produce a more reactive lignin byproduct that is suitable for chemical modifications to mimic the properties of polycarboxylate ether admixtures with a smaller carbon footprint. The present study examines the use of lignin-based water-reducing admixture in cement pastes and mortar mixtures for 3D printing. The experimental program explores the use of different dosages of lignin-based admixture to produce 3D-printed samples with appropriate extrudability and buildability. The rheological characterization was performed to determine the flow curve of various mixtures. Finally, the heat of hydration of cement pastes was monitored via isothermal calorimetry to assess the impact of lignin-based admixtures on the hydration process of cement. The results of this study indicate that the use of biomass by-products, such as lignin-based admixtures have great potential to effectively control the fresh-state properties of cement-based materials.

bio-based admixtures↗
DOE OSTI2024

Direct Air Capture and Utilization System (DACUS): FEED Study of CarbonCapture Inc. DAC and CarbonCure Utilization Technologies Using United States Steel’s Gary Works Plant Waste Heat

The effects of climate change are drastically perceived through the alarming rates of severe events such as flooding, hurricanes, wildfires, global temperature rise, sea-level rise, and ocean acidification etc., which has prompted the nations across the globe to control & reduce greenhouse gas (GHG) emissions, by massive adoption of electric vehicles, switching to renewal energy sources and promoting sustainable green products. However, recent climate studies have shown that such efforts will not be enough to keep the global temperature rising under 1.5° Celsius by the year 2050, which lead to the development of multiple Direct Air Capture (DAC) technologies. A DAC system extracts CO2 directly from the atmosphere, which is either stored underground for long term or utilized in other processes. The DACUS proposed at U.S. Steel Corporation’s Gary Works Plant in Gary, Indiana, will include an innovative DAC technology from CarbonCapture Inc. (CCI), which will be collocated and powered by waste heat from the steel plant to capture CO2 from ambient air, and CarbonCure CO2 utilization technology- which is a commercial technology that is already installed and in use by early adopters in more than 150 concrete mixing plants across North America and Asia. The University of Illinois at Urbana Champaign spearheaded this Front-End Engineering Design (FEED) study project, which was funded by US Department of Energy (DOE), aimed at designing a state-of-the art DACU system that can remove minimum of 5,000 tonne/year net CO2 from air (based on cradle-to-gate LCA) and converting the captured CO2 into low carbon intensity products. The off takers of the low Carbon product produced by the DACUS have also been identified near the steel plant in the Indiana, Illinois & Wisconsin Region. This creates a full CO2 value chain and provides a means to assess the impact of this holistic approach on job creation, regional economic impact, and environmental justice. DACUS is a promising new technology for reducing greenhouse gas in the atmosphere. Operation costs are minimized by locating CCI’s innovative DAC collector at United States Steel's Gary Works site where waste heat is utilized. Carbon emissions are minimized in CO2 transportation. The captured CO2 will be permanently sequestered in concrete used as construction material. This DOE funded FEED study demonstrates a full CO2 value chain for a DACU system, supported by an industrial facility. If this project were constructed, it would have a very positive and lasting impact on both the environment and the community.

42 ENGINEERING↗
DOE OSTI2025

Color glass condensate meets high twist expansion

We establish the correspondence between two well-known frameworks for quantum chromodynamics (QCD) multiple scattering in nuclear media: the color glass condensate (CGC) and the high-twist (HT) expansion formalism. We argue that a consistent matching between both frameworks, in their common domain of validity, is achieved by incorporating the subeikonal longitudinal momentum phase in the CGC formalism, which mediates the transition between coherent and incoherent scattering. We perform a detailed calculation and analysis of direct photon production in proton-nucleus scattering as a concrete example to establish the matching between HT and CGC up to twist-4, including initial- and final-state interactions, as well as their interferences. The techniques developed in this work can be adapted to other processes in electron-nucleus and proton-nucleus collisions, and they provide a potential avenue for a unified picture of dilute-dense dynamics in nuclear media.

quantum chromodynamics↗
DOE OSTI2025

Feasibility of Algal Biochar, a Byproduct of Biofuel Production, as a Supplemental Cementitious Material

Algal biochar, as the solid residue of biofuel production from algal biomass, is reported to explore disposition options, aiming to lessen the liability or obstacles to biofuel production processes. However, landfills and open combustion lead to adverse environmental impacts. One way to add value to such wastes is to use them as admixtures in cementitious construction materials. This study aims to investigate the feasibility of algae-derived biochar as supplementary cementitious materials (SCM) at different water contents and mixture ratios. Algal biochar-cement composites were prepared with different algal biochar content as well as different water-to-cement (w/c) ratios, and the surface area, morphology, elemental, and mineralogical composition were characterized. To compensate for the high-water absorption of algal biochar, a small concentration of a superplasticizer was used since higher w/c ratios negatively impact strength. The mechanical performance of algal biochar-cement composites is compared with control composites using commercial silica fume as a typical commercial SCM. The findings suggest that algal biochar is a promising candidate to replace commercial SCM, like silica fume, since algal biochar-cement composites can reach comparable compressive strength and Young’s modulus to commercial pozzolan-cement materials with the same w/c ratio, though at later curing times, 33 days. Although the tensile strength of algal biochar-cement composites is statistically similar at 7 days, it is significantly lower at later curing times, and further investigation is required to improve this property. Algal biochar-based cement binders showed comparable embodied carbon to silica fume-based cement binders based on a cradle-to-gate lifecycle analysis. However, the ability of algal biochar to absorb large volumes of CO 2 over short periods of time, as measured in this study, makes this novel SCM an excellent alternative to reduce the embodied carbon of concrete structures cradle-to-grave at 1/10 of the cost. In conclusion, valorization of algae-derived solid waste provides great potential to reduce embodied carbon and brings credit to biofuel production and concrete-based construction.

algae-derived↗
DOE OSTI2024

Use of Lignin-Based Admixture as Water Reducer (WRA) for Tailoring the Rheological Properties of Mortars for 3D-Printing

Efforts towards decarbonizing construction materials and industrial processes related to cement and concrete can be aided via multifaceted approaches that target alternative admixtures as well as precision control of fabrication. Chemical admixtures for water reduction have played a crucial role in the development of advanced mortar and concrete mixtures. Newer biomass processing techniques developed for aviation fuel production from corn stover biomass produce a highly reactive lignin byproduct that is suitable for chemical modifications to mimic the properties of commonly used polycarboxylate ethers (PCEs) with a smaller carbon footprint. These lignin-based plasticizers developed at NREL can be used in place of petrochemical-derived superplasticizers to tailor the rheological properties of cement-based systems for applications such as additive manufacturing while reducing the carbon intensity of the concrete mix. Lignosulfonates derived from paper pulping were historically used as water reducers only to be displaced with the rise of PCEs. The present study examines the use of a NREL produced lignin-based water reducing admixture (WRA), in cement pastes and mortar mixtures for 3D-printing at small- (mm) scale. The experimental program consisted of different formulations of oxidized lignin-based WRAs added in variable dosages to cement pastes with a fixed water-to-cement ratio. The objective is to achieve an appropriate workability, extrudability and buildability of mortar mixtures to produce 3D-printed specimens. The rheological characterization was performed to compare the initial yield stress and viscosity of the different mixtures with lignin-based admixture with respect to conventional PCE superplasticizers. The rheological characterization shows that the proposed material act as an effective water-reducer in cement systems, affecting the yield stress, plastic viscosity, and structuration rate of the mixtures evaluated. On the other hand, the effect on early hydration process of the cement pastes containing lignin-based admixtures is comparable to conventional superplasticizers.

3D-printing↗
DOE OSTI2026

Cementless Concrete: Advancing Alkali-Activated Slag Composites with Black Liquor

This project explores the use of black liquor, a byproduct of sustainable aviation fuel production, as an alkaline activator for industrial byproducts such as steel slags to produce alkali-activated composites (AACs). The resulting cementless concrete cures at ambient temperature, demonstrates comparable performance to conventional cement, and offers a safer, lower-energy alternative for durable construction materials.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Greenhouse gas emissions of global construction material production

Abstract Global production of building materials is a primary contributor to greenhouse gas (GHG) emissions, but the production of these materials is necessary for modern infrastructure and society. Understanding the GHG emissions from building materials production in the context of their function is critical to decarbonizing this important sector. In this work, we present estimates of global production, approximate ranges of GHG emissions, and ranges of material properties of 12 critical building material classes to provide a unified dataset across material types. This dataset drew from industry analyses of production and emissions, ranges of emission factors within a material type, and broad reporting of thermal and mechanical properties to compare both within and between material types. Globally, in 2019, we estimate 42.8 Gt of these 12 materials were produced, with 38.6 Gt used in the building and construction industry. As a result of this production, 9.3 Gt of CO 2 was emitted, or 25% of global fossil GHG emissions, with 5.8 Gt CO 2 (16% of global GHG emissions) due to materials used in construction applications. Both construction material production and emissions are primarily driven by structural materials, such as concrete and steel. Material selection can play a key role in reducing emissions in the context of the function, with variation in emissions of structural materials per unit strength between 0.001–0.1 kg CO 2 /kg/MPa and in insulation materials per R -value/thickness of 0.018–0.14 kg CO 2 /kg/(K⋅m 2 W −1 ))). The developed dataset can play a key role in supporting decision-making in materials by providing a unified source for examining emissions, material properties, and quantity of material produced.

Kane, Seth (ORCID:0000000269401369)↗
DOE OSTI2025

Greenhouse Gas Emissions and Decarbonization Potential of Global Fired Clay Brick Production

Fired clay bricks (FCBs) are a dominant building material globally due to their low cost and simplicity of production, especially in low- and middle-income countries. With a projected rising housing demand, commensurate growth in brick demand is anticipated, the production of which could result in significant greenhouse gas (GHG) emissions. Robust models are needed to estimate brick demand and emissions to systematically address decarbonization pathways. Few sources report production values; hence, we present two novel proxy models: (i) a consumption prediction model, relying on country-specific clay extraction data, dynamic building stock modeling, and average material intensity use allowing for projections to 2050; and (ii) a GHG emissions model, using literature-based data and production technology-specific inputs. Based on these models, the current global FCB consumption is estimated as 2.18 Gt annually, resulting in approximately 500 million tCO2e (1% of current global GHG emissions). If unaddressed, this fraction could increase to 3.5-5% in 2050 considering a moderate SSP 2-4.5 climate change mitigation scenario. Consequently, we explored three potential decarbonization pathways: (i) improving energy efficiency; (ii) shifting production to best practices; and (iii) replacing half of FCB demand with hollow concrete blocks, resulting in 27%, 49%, and 51% reduction in GHG emissions, respectively.

Olsson, Josefine A↗
DOE OSTI2024

Relevant biochar characteristics influencing compressive strength of biochar-cement mortars

To counteract the contribution of CO 2 emissions by cement production and utilization, biochar is being harnessed as a carbon-negative additive in concrete. Increasing the cement replacement and biochar dosage will increase the carbon offset, but there is large variability in methods being used and many researchers report strength decreases at cement replacements beyond 5%. This work presents a reliable method to replace 10% of the cement mass with a vast selection of biochars without decreasing ultimate compressive strength, and in many cases significantly improving it. By carefully quantifying the physical and chemical properties of each biochar used, machine learning algorithms were used to elucidate the three most influential biochar characteristics that control mortar strength: initial saturation percentage, oxygen-to-carbon ratio, and soluble silicon. These results provide additional research avenues for utilizing several potential biomass waste streams to increase the biochar dosage in cement mixes without decreasing mechanical properties.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

Pretest Modeling A Spent Nuclear Fuel Seismic Shake Test

The U.S. Department of Energy Spent Fuel and Waste Science and Technology (SFWST) program is planning to conduct a series of full-scale shake table tests to simulate hypothetical earthquake conditions and record the response of surrogate spent nuclear fuel (SNF) assemblies in a dry canister storage system mockup. The shake table motions will represent a range of hypothetical earthquake conditions at hypothetical locations in the continental U.S. to generally define the range of mechanical loads that SNF can be expected to experience during extended dry storage periods. This paper describes the pretest predictions made with LS-DYNA models of the mockup storage systems. The test will use two dry storage system configurations, a mockup vertical concrete cask (VCC) and a mockup horizontal storage module (HSM). The test will use a production-quality canister and basket. Within the canister will be four instrumented fuel assemblies with fuel rods containing surrogate mass and 28 instrumented dummy assemblies that are intended to match the mass and outer dimension of a fuel assembly. The finite element models include models of the VCC and HSM on the shake table to calculate the system level dynamic responses and separate single fuel assembly models to calculate stress and strain in fuel assembly components. Both types of models include nonlinear behavior like rod-to-rod contact and the ability for VCC’s to rock and slide. This paper presents the expected response of the VCC, HSM, and fuel assemblies to the shake table testing that is planned to start in April of 2024. The earthquake conditions represent seismic hazards in the 2,000-to-20,000-year return period range. The test data is expected to confirm the expectation that fuel rod cladding will remain intact, fuel assembly structural components like guide tubes will remain intact, and no significant VCC sliding or tipping will occur in the range of conditions to be tested with the shake table.

Klymyshyn, Nicholas A.↗