Feasibility analysis for implementing CO<sub>2</sub> curing in a concrete block industry in the São Paulo Region

Fortunato, Lívia Regueira; Parsekian, Guilherme Aris; Neves Junior, Alex

doi:10.1590/S1983-41952022000600007

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Revista IBRACON de Estruturas e Materiais

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ORIGINAL ARTICLE • Rev. IBRACON Estrut. Mater. 15 (6) • 2022 • https://doi.org/10.1590/S1983-41952022000600007 copy

Feasibility analysis for implementing CO₂ curing in a concrete block industry in the São Paulo Region

Análise de viabilidade para implantação de cura com CO₂ em uma indústria de blocos de concreto na região de São Paulo

Authorship SCIMAGO INSTITUTIONS RANKINGS

abstract:

The project feasibility analysis determines whether the project should be carried out from different spheres: strategic, technical, operational, legal, economic-financial, environmental, marketing, political, fiscal, location, among others. These are not excluding analyzes, all aspects must be assessed before implementing a new project or new process. This work will focus on the analysis of the technical feasibility of the innovative project to implement carbonation curing in a concrete block factory in the region of São Paulo. An overview of the CO₂ curing process and changing needs is presented, including identifying local CO₂ sources and delivering cost, gas consumption for chamber saturation, estimation of CO₂ uptake by masonry units during curing, estimation of consumption and monthly cost of CO₂, curing chamber changes needs, new equipment acquisition, estimation of cost for retrofit and new installations, potential best definitions on optimal temperature, humidity, and CO₂ concentration. International succeeded cases are presented. The study concludes that the technology can be easily implemented in the region, with few changes on a plant production process and on the curing chamber. There would be an increase of 4% to 14% on the block cost depending on the distance to the CO₂ supplier. Considering the Brazilian production of concrete blocks, up to 168,780 tons of CO₂ per year can be sequestered, this value is equivalent to the CO₂ sequestered by 21,100 trees.

Keywords:
analysis; feasibility; technical; curing; CO₂

Authors	Samples	Time and type of initial cure (h)	Carbonation curing time (h)	Carbonation Chamber				CO₂ absorption (%)	Compressive strength
Authors	Samples	Time and type of initial cure (h)	Carbonation curing time (h)	CO₂ concentration (%)	Pressure (MPa)	T (°C)	RH (%)	CO₂ absorption (%)	Compressive strength
[³3 G. Ye, "Carbon dioxide uptake by concrete through early-age curing", MSc dissertation, Dept. Civil Eng. Applied Mech., McGill Univ., Montreal, Canada, 2003.]	Cubes (100×100mm) dry concrete	no initial cure	2	100	0.5	environment	-------	7.0 - 8.0	˃ 40 MPa after 2hs of carbonation
[¹⁶16 Y. Shao, S. Monkman, and E. S. Yuan, "Market analysis of CO2 sequestration in concrete building products", in Proc. 2nd Int. Conf. Sustain. Constr. Mater. Tech., Italy, Ancona, 28-30 June, 2010.]	Concrete masonry units and concrete units for pavement (w/c=0,25)	no initial cure	2	100	0.5	45-95	-------	9.8	10.3 MPa after 2 hours of carbonation ~ 50% increase compared to the reference at 28 days)
[¹⁶16 Y. Shao, S. Monkman, and E. S. Yuan, "Market analysis of CO2 sequestration in concrete building products", in Proc. 2nd Int. Conf. Sustain. Constr. Mater. Tech., Italy, Ancona, 28-30 June, 2010.]	Cement bead board comprised cement paste and expanded polyethylene beads (w/c=0,36)	no initial cure	2	100	0.5	45-95	-------	12.2	7.8 MPa after 2 hours of carbonation, same value was obtained for reference boards at 28 days
[⁴4 Shao, Y., Zhou, X. and Monkman, S., A new CO2 sequestration process via concrete products production’, in IEEE EIC Climate Change Technology, Ottawa, ON, Canada, 10-12 May, 2006.]	Concrete masonry units	no initial cure	2	100	0.15	environment	-------	8.2 - 10.6	Increase of compressive strength of 78% in relation to the reference
[⁵5 Y. Shao, and X. Lin, "Early-age carbonation curing of concrete using recovered CO2", Concr. Int., v. 33, pp. 50-56, 2011.]	Concrete units for pavement (10x20x64mm) (w/c=0,4)	2 - 19 wet curing	4 - 5	99,5	0.15	56	65	3.4 -7.4	Tests done after 24 hours of production: 31MPa (after 4hs of carbonation) and 46 MPa (after 5hs of carbonation)
[⁵5 Y. Shao, and X. Lin, "Early-age carbonation curing of concrete using recovered CO2", Concr. Int., v. 33, pp. 50-56, 2011.]	Zero slump concrete samples (127×76×20 mm)	no initial cure	2	99,5	0.15	40 - 56	65	11.7	9.6 MPa (after 2hs of carbonation) ~ 60% increase compared to the reference at 28 days)
[¹⁷17 V. Rostami, Y. Shao, and A.J. Boyd, "Microstructure of cement paste subject to early carbonation curing," Cem. Concr. Res., vol. 42, no. 1, pp. 186-193, 2012.]	Cement paste, (14×14×6mm) (w/c = 0.36)	18 wet curing	2	99,5	0.15	environment	-------	8.9	76.8 MPa without water spray and 123,7 MPa with water spray after carbonation
[¹⁸18 Boyd, A. J., Rostami, V. and Shao, Y., "Carbonation curing versus steam curing for precast concrete production", J. Mater. Civ. Eng., vol. 24, no. 9, pp. 1221-1229, 2012.]	Zero slump concrete samples w/c = 0,36	18 air curing	2	100	0.15	25	-------	6.9 - 7.3	28.8 MPa without water spray and 38.9 MPa with water spray after carbonation
[¹⁹19 H. El-Hassan, Y. Shao, and Z. Ghouleh, "Effect of initial curing on carbonation of lightweight concrete masonry units", ACI Mater. J., vol. 110, no. 4, pp. 441-450, 2013.]	Concrete masonry unit w/c=0,40	0, 4, 6, 8, 18 air curing	2, 4, 96	100	0.01	25	50	9.0 - 35.0	Compressive strength with water spray after carbonation comparable to non-carbonated ones with thermal curing
[²⁰20 B. Zhan, C. Poon, and C. Shi, "CO2 curing for improving the properties of concrete blocks containing recycled aggregates," Cement Concr. Compos., vol. 42, pp. 1-8, 2013.]	Concrete masonry units with recycled aggregates	no initial cure	6, 12, 24	100	0.01	--------	-------	22.49- 43.96	Compressive strength gains ranging from 108% to 151% within 24 hours of carbonation
[²¹21 El-Hassan, H. and Shao, Y., "Early carbonation curing of concrete masonry units with Portland limestone cement", Cem & Concr. Compos., vol. 62, pp. 168-177, 2015. https://doi.org/10.1016/j.cemconcomp.2015.07.004. https://doi.org/10.1016/j.cemconcomp.201... ]	Concrete masonry unit with blast furnace slag produced in manual factory (127×76×38 mm)	0, 4, 6, 8, 18 thermal curing	2, 4, 96	100	0.1	25	50	8.3 - 35.1	Compressive strength with water spray after carbonation comparable to non-carbonated ones with thermal curing
[²²22 D. MacMaster, and O. Tavares, "Carbon sequestration of concrete masonry units," ACI Mater. J., vol. 112, no. 6, pp. 775-780, 2015.]	Concrete Masonry Units	not executed	2	100	1.39	30	50	8.62	After 2 hours, net compressive strength of 35.72MPa carbonated Concrete masonry units and 10.14MPa steam cured concrete Masonry Units
[¹⁵15 L. R. Fortunato, G. A. Parsekian, and A. Neves Jr., "CO2 capture of concrete units for pavement through accelerated carbonation cure", Int. J. Mason. Res. Innov., vol. 7, no. 3, pp. 233-265, 2022.]	Concrete unit for pavement (100×200×60 mm)	12 hours outdoor cure and 12 hours initial steam cure	4 and 16	20	0,1	23	65	1.5% - 5.1%	At 02 days, the compressive strength of the carbonated pieces was superior to the reference and at 28 days too

Mix	Cement (kg)	Fine gravel (l)	Crushed sand (l)	Dust of stone (l)	Water (l)	Admixture (l)	Water/cement factor
Concrete masonry units	40	160	160	240	50	0,1	1,25

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E-mail: arlene@ibracon.org.br

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[1] Corresponding author: Lívia Regueira Fortunato. E-mail: liviarfortunato@hotmail.com

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Feasibility analysis for implementing CO2 curing in a concrete block industry in the São Paulo Region

Análise de viabilidade para implantação de cura com CO2 em uma indústria de blocos de concreto na região de São Paulo

abstract:

Feasibility analysis for implementing CO₂ curing in a concrete block industry in the São Paulo Region

Análise de viabilidade para implantação de cura com CO₂ em uma indústria de blocos de concreto na região de São Paulo