Valorization of CO2 for low carbon cement

Orient cement at daylightOrient cement at daylight

CO2Valorize pioneers research on abundant, carbon-modified, supplementary cementitious materials (SCM) as a part-replacement of limestone in the cement process to drastically reduce carbon emissions from the cement industry in the short- to medium-term. This will address a major knowledge gap and impact the cement market.

Overview
Enabling carbon emissions reduction in the cement industry

CO2Valorize focuses on the carbonation process of recycled concrete and mine tailings from scientific understandings of the carbonation mechanisms to the quality of the carbonated SCMs, such as their impact on the workability and compressive strength of cement products.


CO2Valorize will impact the scientific state-of-the-art, encourage cement producers to develop a new frame of add-on process lines, enhance opportunities to develop market innovations, create business opportunities, and disseminate knowledge to innovators, policymakers and society.

CO2Valorize addresses an urgent need for new experts who are able to develop efficient solutions to decarbonise the cement industry (and hence the process industry) as well as translate research results into technical innovations and processes in Europe. Eight (7+1) doctoral candidates (DCs) will be trained through excellent research and knowledge of industrial applications on a global scale. Scientific excellence is ensured through the direct contribution of project leaders who pioneer their fields with ground-breaking innovations protected by patent portfolios and regular contributions to major journals. The programme is complemented by expertise on industrial implementation of carbonation mechanisms; process innovation practice; clinical application; valorisation of research results, and career development, encouraging entrepreneurship and business opportunities.

The public-private network - CO2Valorize - enables regional integration of research on decarbonation and training and tackles one of the major issues of Europe’s (and the world’s) progress in carbon emission reduction, the regional fragmentation, and the limited number of multidisciplinary and transnational collaborations.

OVERVIEW AND OBJECTIVES
A new approach to drastically remove carbon emissions from cement production

CO2Valorize aims to develop new supplementary cementitious materials to replace partly CO2 emitting limestone for the decarbonation of the sector.

Project timeline

START

01.Sep.2022

END

01.Aug.2026

The Horizon Programme

This project has received funding from the European Union’s Horizon Europe research and innovation programme under the Marie Skłodowska-Curie grant agreement No 101073547.

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PhD Projects

8 complementary PhD projects

DC-1

Characterisation of raw materials, carbonated components, and cementitious products

The specific objectives are: 1) To develop protocols to support the optimisation of enhanced carbonation of a variety of raw materials towards their performance in cementitious systems, such as mortar and concrete; 2) To improve our understanding of the reactions of enhanced carbonated materials when used in cementitious systems. Employment periods: 1) 15 months at FLSMIDTH AS, Denmark, 2) 21 months at NTNU, Norway. Secondment at CEMMAC AS, Slovakia or a different organisation during the second employment period.

Selection Process

Doctoral Candidate

DC-2

Supplementary Cementitious Materials (SCMs) from Waste Concrete: Carbonation Kinetics in a Semi-Dry Stirred Reactor

The objectives of the project are: 1) Experimental carbonation of standardised waste concrete fines in a semi-wet stirred autoclave with continuous sampling and temperature, pressure, pCO2, pH2O monitored. Sample analysis with XRD, TG-FTIR. 2) Design of a plant configuration consisting of energy and material balanced individual components based on literature and data from the partners. 3) Scenario calculations based on the plant model, estimated scale-up factors and costs. Employment periods: 1) 15 months at FLSMIDTH AS, Denmark, 2) 21 months at KIT, Germany. Secondment at CEMMAC AS, Slovakia or a different organisation during the second employment period.

Claudia Rodriguez

Doctoral Candidate

Bachelor Degree

Chemical Engineer / 08 October 2010 / National University of Colombia. Project Title: Electrochemical Impedance Spectroscopy applied on coating.

Master Degree

Material and Processes / 08 June 2020/ National University of Colombia.
Project Title: Calcined clays as SCM in cements

PhD

Topic: Supplementary Cementitious Materials (SCMs) from Waste Concrete.
Goal: Kinetic-Thermodynamic model of the carbonation of concrete waste fines; Supervisors: John Soosaialphonse, Wilson Ricardo Leal, Peter Stemmermann and Dieter Stapf.

Mobility

Cement Industrial experience in US and Colombia.

Knowledge

Holistic view of the construction industry, proficiency in the characterization of cementitious materials.

DC-3

Aqueous carbonation of mineral tailings: reaction mechanisms and in-situ compositional analysis using Raman spectrocopy

The objectives of the project are: 1) Quantitative characterization of the reaction by interferometric measurements of temperature and concentration; 2) Characterization of the composition of the product phase by Raman spectroscopy and MLA of feed and product streams; 3) Outline of a process sensor based on Raman spectroscopy for the purpose of process digitalization and advanced process control. Employment: 36 months at HZDR Innovation GmbH, Germany. Secondment at NTNU, Norway or a different organisation during the employment period.

Sahra Homaee

Doctoral Candidate

Bachelor Degree

B.Sc.Engineering Physics / 2018 / Alzahra university of Tehran, Iran.
Project Title: Synthesis of Gold Nanoparticles.

Master Degree

M.Sc.Materials Science and Engineering (Extractive Metallurgy) / 2020 / University Sharif University of Technology, Iran. [Project Title: Investigation of The effect of process variables on boric acid production] Knowledge:
Theoretical knowledge in topics related to Physics and Chemistry, Characterization Methods(ICP, XRD, XRF, Raman Spectroscopy,..),Titration, Design of Experiment, Minitab

Mobility

Writing International conference papers, working in Research & Innovation Co.

PhD

Topic: Aqueous carbonation of mineral tailings: reaction mechanisms and in- Situ compositional analysis using Raman spectroscopy.
Goal: Create new knowledge on the mechanisms of carbonation of minerals from tailings. Supervisors: Dr. Martin Rudolph, Dr. Carola Franzen, Prof. Kerstin Eckert

DC-4

Investigation of the carbonation performance of cement-based materials at high temperatures

The objectives of the project are: 1) To optimise the feedstock conditions, i.e. bulk chemical composition, particle size, porosity etc.; 2) Optimisation of TGA conditions, temperature, residence time, CO2, H2O concentration; 3) TGA studies of interaction between different feedstock bulk ash chemistries and CO2 (synthetic mixtures composed of Al2O3, Fe2O3, SiO2 and CaO). Employment periods: 1) 15 months at FLSMIDTH AS, Denmark, 2) 21 months at DTU, Denmark. Secondment at CEMMAC AS, Slovakia or a different organisation during the second employment period.

Arailym Umirova

Doctoral Candidate

Bachelor Degree

Bachelor of Engineering / 2019 / Kazakh National Research Technical University, Kazakhstan; Project Title: Plant to produce cellular concrete products with natural low-quartz raw materials and waste from its processing with an annual capacity of 50,000 m3 in Aktobe city.

Master Degree

Advanced Materials Science and Engineering (Erasmus Mundus Joint Master Degree) / 2022 / Master of Science / Saarland University, Germany and Luleå University of Technology, Sweden; Project Title: Experimental Design for Ceramic Panel Production

Knowledge

Extensive experience in sample preparation and material characterization, optimization of parameters, analytical skills, working in multinational team.

Mobility

Heidelberg Cement Kazakhstan, Internship at a concrete plant - Freiberg University of Mining and Technology, Exchange semester - Zagreb University of Applied Sciences, Internship in the laboratory for materials.

PhD

Topic: Investigation of the carbonation performance of cement-based materials at high temperatures. Goal: Optimization of feedstock conditions (particle size, porosity, etc.) and laboratory reactor conditions (temperature, residence time, CO2, H2O concentration, etc.) for conduction of carbonation on cementitious materials at high temperatures. Supervisors: Peter Arendt Jensen, Flemming Jappe Frandsen, Lars Skaarup Jensen, Mohammadhadi Nakhaei

DC-5

Process optimisation of aqueous mineral carbonation using novel three-phase reactors

The objectives of the project are: 1) Develop a novel and fully instrumented 3-phase carbonation reaction employing principles known from flotation; 2) Measure fluid dynamics, mass transfer rates and temperature evolution in the reactor and composition feed/product streams; 3) Dynamic modelling of the process based on the large data sets of process and material data obtained. Employment: 36 months at HZDR Innovation GmbH, Germany. Secondment at University of Padova, Italy or a different organisation during the employment period.

Elena Maria Salute

Doctoral Candidate

Bachelor Degree

B.Sc. Chemical Engineering / University of Pisa, Italy; Project Title: "Critical Raw Materials: recovery and recycling processes of lithium from exhausted batteries".

Master Degree

M.Sc. Chemical Engineering / University of Pisa (Italy) and Helmholtz-Zentrum Dresden-Rossendorf (Germany); Project Title: "Experimental investigation of two-phase flow on fixed valve trays for distillation columns".

Knowledge

Theoretical knowledge in the design of industrial plants, with a particular focus on equipment such as reactors, heat exchangers, and distillation columns, and on liquid-gas mass transfer.

Mobility

Traineeship at Helmholtz-Zentrum Dresden-Rossendorf (Germany).

PhD

Topic: Process optimization of aqueous mineral carbonation using novel three-phase reactors. Goal: Develop a novel and fully instrumented 3-phase carbonation reactor employing flotation principles; measure fluid dynamics, mass transfer rates, and temperature evolution in the reactor, as well as composition of feed/product streams; and dynamically model the process based on the extensive datasets of process and material data obtained. Supervisors: Prof. Kerstin Eckert, Dr. Carola Franzen and Dr. Till Zurner.Show less

DC-6

Process optimisation of aqueous mineral carbonation using novel three-phase reactors

The objectives of the project are: 1) Develop a model-based design of experiments procedure for kinetic model discrimination and calibration in carbonation processes; 2) Integrate the kinetic model with mass and heat transfer information; 3) Validate model with real data. Employment periods: 1) 6 months at FLSMIDTH AS, Denmark, 2) 30 months at University of Padova, Italy. Secondment at Siemens Process Systems Enterprise, United Kingdom or a different organisation during the second employment period.

Seyed Zuhair Bolourchian Tabrizi

Doctoral Candidate

Bachelor Degree

Bachelor of Science, Chemical Engineering / 2016 / University of Tabriz, Iran
Project Title: Numerical investigation of windbreaker arrangement on natural draft dry cooling towers efficiency.

Master Degree

Master of Science, Process Design Engineering / 2019 / Iran University of Science and Technology, Iran; Project Title: The empirical investigation of aqueous base Nanofluids stability and their effect on CO2 absorption enhancement

Knowledge

Reaction Kinetic modelling, Design of Experiments, Characterization Tests Analysis (FTIR, XRD, XRF, TGA, SEM, EDX)

Mobility

Process engineer and Quicklime production supervisor (National Iranian Copper industries Co., Iran, 3.5 years), Internship (Espandar Cement Investment Co., and Tabriz Petrochemical Complex, Iran, 0.5 year), Researcher (Process design and simulation laboratory, Iran University of Science and Technology, Iran, 1.5 year)

PhD

Topic: Streamlining experimental information for carbonation process modelling. Goal: Developing a model-based design of the experiment's procedure for kinetic model discrimination and calibration in the carbonation process, Integrate the kinetic model with mass and heat transfer information and developing a multiscale model of a carbonation Reactor.
Supervisors: Fabrizio Bezzo, Wilson Ricardo Leal Da Silva

DC-7

Integrating state-of-the-art technologies for sustainable cement production

The objectives of the project are: 1) Develop a flowsheet-based model of cement production including different capture technologies; 2) Develop a super- structure modelling framework for process integration and optimization; 3) Integrate electrified facilities with power grid. Employment periods: 1) 6 months at FLSMIDTH AS, Denmark, 2) 30 months at the University of Padova, Italy. Secondment at Siemens Process Systems Enterprise, United Kingdom or a different organisation during the second employment period.

Leonardo Varnier

Doctoral Candidate

Bachelor Degree

Chemical and Material Engineering / 2020 / University of Padova, Italy; Project Title: Application of anion exchange resins for the removal of PFAS from drinking water.

Master Degree

Chemical and Process Engineering / 2022 / University of Padova, Italy [Project Title: Design and optimization of membrane processes for carbon capture purposes] Knowledge: Carbon capture: main techniques and features Process design, modelling and optimization (especially with Aspen)

Mobility

Erasmus exchange at Technical University of Eindhoven (Master Thesis)

PhD

Topic: Integrating state-of-the-art technologies for sustainable cement production; Goal: Provide a modelling tool to design and optimize the new generation cement production processes, where new production technologies, particularly carbonation processes, are simultaneously considered. Supervisors: Fabrizio Bezzo, Kim Clausen, Federico D’Amore
Show less

DC-8

Techno-economic analysis of CO2-neutral cement plants

The objectives of the project are: 1) Create a new prototype tool to assess the performance of these technologies in the context of a large-scale cement production facility; 2) Provide a means to predict the impact on overall plant carbon dioxide emissions and process economics; 3) Develop a prototype tool-kit for techno-economic assessment of future innovations in cement production. Employment: 36 months at Siemens Process Systems Enterprise, United Kingdom. Secondment at University of Padova, Italy or a different organisation during the employment period.

George Melitos

Doctoral Candidate

Bachelor

Chemical Engineering | 2021 | Aristotle University of Thessaloniki
Project: Waste to sustainable biohydrogen production via photo-fermentation and biophotolysis

Master

Chemical Engineering | 2023 | Aristotle University of Thessaloniki
Thesis: Process synthesis, modelling and techno-economic assessment of bio-succinic acid production facilities.

Knowledge

Developing process models in batch (dynamic) and continuous (steady state) processes. Extensive work with flow sheeting in both continuous and hybrid (batch-continuous) mode. Relevant experience with process simulation software. Mathematical modelling and optimization in a flowsheet level (experience in GAMS and Matlab).

Mobility

Intelligen INC, Master Thesis Student and Research Engineer (Developed a novel flowsheet for the production of succinic acid (adopted by the company in the libraries of the software) and completed techno-economical evaluations and assessments on utilization of different waste feedstocks) – Centre for Research & Technology Hellas, 3 month collaboration for the construction of a hydrogen fuel cell as part of a university project.

PhD

Techno-economic assessment of CO2 neutral cement plants. Goal: Development of a digital tool for process modelling, environmental and techno-economic evaluations of cement plants, able to predict the financial and environmental feasibility of novel green investments in the cement sector (including carbonation). Supervisors: Bart de Groot, Fabrizio Bezzo

*DC8: SPSE, United Kingdom, originally participated as Beneficiary and host of DC8. Currently UK is not associated to Horizon Europe and therefore SPSE is not eligible for funding and cannot be Beneficiary. For this case, the following contingency measure applies. The consortium decided that SPSE changes the status to Associated Partner and participates with own funding. The UK government gives a Horizon Europe guarantee and funds the participation of SPSE through UK Research and Innovation (UKRI). DC8 will implement all research tasks, obtains co-supervision, participates in all network-wide trainings, conduct the local trainings, and contributes to dissemination, exploitation and communication activities - as described in the DoA.

CONTACT

Get in touch with us

You can get in touch with our project coordinator and project manager by using one of the contact methods.

Pinto Christy

Project Manager

FLSmidth Cement A/S

Vigerslev Allé 77, 2500, Valby, Copenhagen Denmark