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Recycling end-of-life concrete: The C2CA project

2014

Recycling EoL concrete: The C2CA project Francesco Di Maio1, Peter Rem1 Somayeh Lotfi1, Maarten Bakker1, Mingming Hu2, 2014 International Concrete Sustainability Conference, Conference Boston, May 12-15, 2014 1 2 Challenge the future Outline:  Motivation  Objectives and challenges  The C2CA project  Main results Challenge the future Motivations  Decreasing demand for road foundation materials Challenge the future Objectives and challenges Economy I n-situ processing C2CA Quality Assurance Stakeholders “Turn EOL concrete into recycled cement and aggregate” Challenge the future Challenges Economy y Natural aggregate prices fluctuate, but recycling costs do not Price e of grave el Recession, river dredging projects, .. max. recycling process costs ~ 0€ Time Essential to minimize process cost (in absence of regulation/ taxes) Challenge the future Challenges IIn-situ i processing i Mobile recycling technology (low noise, off-gas, ..) Dry mechanical processing technologies: • Dismantling (non (non-concrete concrete materials materials, brick brick, gypsum gypsum,..)) • Demolition • Mobile crushing g • Mobile sensor sorting (for coarse contaminants) • Mobile milling/grinding • Mobile ADR → Recycle aggregate, Raw material for cement production Challenge the future Challenges Quality Q li Assurance Inline quality control & certification Applying off-spec aggregate is non-acceptable risk. Recycled R l d aggregate t tto b be transported t t d to t reuse location directly after processing. Inline quality assurance technology (per truck-load) truck load) • Hyperspectral Imaging • Laser-induced Laser induced Breakdown Spectroscopy Challenge the future Challenges Stakeholders, Transition & Forces Stakeholders Recycling of building materials Acting stakeholder Transition Negative / Positive force y Recycler Granulate for road > Aggregate for mortar Unstable p prices / Shrinking g market for road materials Mortar producer Natural aggregate > Recycle aggregate Consistent quality / Automated quality control, control lower material prices Cement producer Limestone > EOL Cement paste Quality, Control over input, Ownership of quarry / CO2 reduction, “Green market” Construction firm > Secondary mortar I mage Challenge the future The C2CA Project TU Delft - Strukton - Heidelberg Cement - Holcim - DV - Laser 2000 – Inashco -Theo Pouw – La Sapienza Roma - AGH University - FORTH - BSC – Leiden University - TU Denmark Challenge the future C2CA in brief Aggregates CO2-emission Kiln Old solution 2 New Solution Silica & Clay Milling Limestone 3 Construction Coa rse SiO Fi n C aS e iO Concrete ADR Demolition Breaker Road Construction Challenge the future Challenge the future First case study of C2CA: Materials and Method Demolishing obsolete governmental buildings Challenge the future Careful demolition approach: layer layer-by-layer by layer Challenge the future Different types of concrete Challenge the future  ADR classification Removal of fines and light pollutants from aggregate Challenge the future  ADR geometry has been optimized for in situ (mobile) application  Despite the more compact size, separation performance improved! Challenge the future ADR products Rotor fraction Airknife fraction Coarse fraction Qualified 4-16 mm aggregates Challenge the future Rotor fraction Products from crushed concrete by ADR: coarse (left) and fine (right) Challenge the future Problems associated with lacking quality of recycled y aggregate gg g ((RA))  Recycled y aggregate gg g concrete must match primary p y materials in: Workability Compressive strength Durability  It is crucial to reduce the contents of: Floating pollutants (light) fines < 2mm Challenge the future Current routes of concrete recycling and RA usage  Diluting Natural aggregate with Recycled aggregate  Removing fines by either fully drying & screening, or directly wet screening Disadvantages:  Drying consumes a lot of energy  Wet methods leave a sludge with high disposal costs  Both methods are less suitable for in situ recycling y g Challenge the future C2CA production of crushed EOL concrete 1) Collecting clean end of life concrete into two 10000 ton batches 2) Crushing EOL applying an industrial jaw crusher ((Kleemann:SSTR1400)) to <40 mm. 3) Floating test of crushed EOL according to EN 12620 Size of crushed aggregates(mm) 4-8 8-11.2 11.2-16 16-22.4 22.4-31.5 Total floating materials [cm3/ per kg of crushed concrete] 0.38 0.09 0.05 0.08 0.14 0.74 Floating materials in crushed EOL is less than 1 cm3/ per kg Challenge the future Compressive strength of RAC and NAC Recycled l d Natural Comparison of compressive strength development of Recycled aggregate t concrete(brown) t (b ) and d Natural N t l aggregate t concrete t (blue) (bl ) Challenge the future LIBS Quality Assessment Challenge the future Costs breakdown of Wet vs ADR processes € 3.5 3.23 WET: €8.93 € 3.0 mobile ADR: €5.52 2.5 € 2.5 25 2.22 € 2.0 € 1.5 1.29 1 1 0.92 € 1.0 0.76 0.65 € 0.5 0.32 0.03 0.03 0.26 0.16 0.06 0.02 € 0.0 Challenge the future Summary and Conclusion  A new concrete recycling process is under development in the context of the C2CA project  Autogenous g milling g and ADR p produces clean 2-16 mm RA  ADR also efficiently separates moist material into fines and a clean coarse fraction  RAC show 30% higher compressive strength after 7 days  Th The ffreeze-thaw h resistance i for f RAC is i not equall to NAC, NAC but b it i still fulfils the requirements for class F100  The processing costs are lower than for conventional solutions  LIBS shows great potential for inline assessment for RA quality Challenge the future Thank you Francesco Di Maio Email address: [email protected] Acknowledgements The project is realized with the financial support of the European Commission in the framework of the FP7 Collaborative project. Grant Agreement No. 265189. Challenge the future