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DOE OSTI2020

Radiation Effects in Concrete for Nuclear Systems

Concrete is massively used in the construction of critical safety-related components in nuclear power plants. Among those, the concrete biological shield is exposed to high levels of neutron and gamma irradiation exiting the reactor pressure vessel. This article provides a comprehensive overview of the state-of-the-art knowledge on irradiated concrete. First, the fundamental irradiation-induced degradation mechanisms occurring at the level of the concrete constituents such as rock-forming minerals and hydrated cementitious phases are examined. The critical role of the mineralogical and chemical composition regarding concrete resistance against radiation effects such as amorphization, irradiation-induced expansion and radiolytic gas release are detailed. Second, the interactions between the varied irradiated phases are comprehensively analyzed and put in perspectives with the effects of prolonged irradiation on the structural properties of concrete aggregates, cement paste, and concretes. Finally, the significance of irradiation for the long-term operation of nuclear power plants is discussed in the light of the most recent knowledge and its limitations.

Le Pape, Yann↗

DOE OSTI2026

State of Innovation 2025: Progress in Accelerating Next-Generation Cement and Concrete Technologies

The cement and concrete sectors are entering a decisive period as next-generation technologies advance from laboratory research to demonstration, early deployment, and first-of-a-kind commercial plants. Building on the 2024 State of Innovation report, the 2025 outlook highlights both the rapid acceleration of innovation and the urgent need for coordinated action across the value chain. Venture capital activity into the cement and concrete space stabilized following the record surge of 2022-2023, yet landmark financings, such as Sublime Systems' $200 million round and Terra CO2's $124 million Series B, signal continued investor confidence in companies approaching commercialization. Corporate procurement has become a powerful new catalyst, with Microsoft, Amazon, and CRH (Cement Roadstone Holdings) Ventures providing long-term commitments that underpin the first wave of next-generation cementitious products. The sector is shifting from early-stage experimentation toward the scaling of well-capitalized leaders capable of bridging the critical "capitalization gap." Early innovators continue to expand the toolkit through novel binders, electrochemical cements, biogenic limestone, and carbonate mineralization pathways. Going into 2026, cost competitiveness, durability validation, and scalability enabled by resilient supply chains remain the decisive factors for market adoption. At the 2025 Next Generation Cement and Concrete Critical Technologies Meeting, attendees emphasized dual-track funding strategies that integrate federal grants with private capital as key to enabling market breakthrough. State programs and corporate demand are sustaining momentum, while successful companies increasingly demonstrate both economic value and reduced dependence on imported materials. The National Concrete Pavement Technology Center and others underscored that broad integration of next-generation materials will hinge on standards compatibility, verified field performance, and workforce readiness. Colorado continues to serve as a proving ground through pilot programs that combine supplier training, phased implementation, and real-world data to de-risk innovation and provide replicable models for other regions. The 2025 Cement and Concrete Critical Technologies Workshop reinforced that scaling next-generation materials will require alignment among technology innovation, performance validation, and market demand. Stakeholders must move beyond siloed efforts toward collaborative frameworks that coordinate standards, funding, and infrastructure deployment. As a neutral convener and technical validator, the National Laboratory of the Rockies (NLR) plays a pivotal role in bridging innovation and market adoption through collaborative research, technology validation, and entrepreneurship programs. By uniting innovators, incumbents, policymakers, contractors, and investors, NLR and its partners are helping chart a credible pathway toward widespread commercialization in the decade ahead.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

Sulfuric Acid Improves the Reactivity of Zeolites via Dealumination

The demand for supplementary cementitious materials (SCMs), like fly ash, slag, and silica fume, is projected to rise over the next few decades. However, global decarbonization efforts, such as decommissioning of coal-fired power plants, will limit the supply of SCMs. Therefore, alternative SCM sources are a critical need for the cement and concrete industry. However, the high crystallinity of zeolites limits their pozzolanic reactivity. The goal of this work was to improve the reactivity of two common zeolites, namely clinoptilolite and SSZ-13, by treating them with sulfuric acid. The treatment enhanced zeolite reactivity via dealumination and decreased particle sizes, which led to increased reactivity with calcium hydroxide, as indicated by a 42.0% increase in reaction heat measured by isothermal calorimetry. Here, we elucidate mechanistic understanding that smaller particle sizes induced by acid treatment accelerated peak heat evolution, while free aluminates from dealumination increased heat via direct reaction with aqueous Ca 2+ .

36 MATERIALS SCIENCE↗

DOE OSTI2022

High Yield, Economical and Environmentally Benign Production of Rare Earth Elements from Coal Ash (Phase II Final Summary Report)

Fly ash stored in landfills and ponds across the United States is an attractive, abundant domestic resource for the cost-effective recovery of rare earth elements (REE) and other critical minerals (CM). Physical Sciences Inc. (PSI) and its team members, Winner Water Services (WWS) and University of Kentucky/Center for Applied Energy Research (UK/CAER) successfully executed a multiphase program that developed technologies and their implementation in a pilot plant. We demonstrated plant operations for cost-effective and environmentally-friendly production of rare earth element oxide (REO) concentrates, and the critical minerals scandium and aluminum (in the forms of salts or oxide products), from coal ash. We also constructed and demonstrated a research-scale (0.5 kg/day) micropilot facility to validate the key physical and chemical processing operations, predict yields, and troubleshoot process bottlenecks. The project team then designed, constructed and operated two decoupled pilot plants: (1) an operational pilot plant for physical separation processes with capacity of 0.4 metric tons per day (tpd), where we optimized processes to produce selected ash fractions as the feedstock for chemical processing and as valuable byproducts such as cenospheres, magnetic ash, and secondary fuel carbon, and (2) an operational pilot plant for chemical ash processing with a capacity of 0.5 tpd that developed optimized processes for the production of: (a) REO concentrates, (b) critical minerals (Sc, Al), and (c) beneficiated ash as a valuable byproduct suitable for cement applications. In Phase I, the project team (with Equinox Chemicals in place of WWS) developed and demonstrated the feasibility of the physical and chemical separation processes, developed the design of a pilot plant, and began the development of a preliminary techno-economic model. In the baseline (initial) Phase II program, the project team developed and demonstrated the above pilot scale plant, producing salable REE concentrates, including Y and Sc (REYSc), plus commercially viable byproducts, using environmentally safe and high-yield physical and chemical enrichment processes. The team successfully demonstrated chemical pilot design, construction, shakedown, and operations of the plant. We produced the Phase II deliverable REYSc concentrate ((50 g of >60 wt.% purity REYSc salts on elemental basis), generated the feed for the Phase II follow-on program, identified processing challenges for future optimizations, and refined the techno-economic model. In the Phase II follow-on program, the project team: (1) developed and demonstrated processes to increase the REE amount by 3X (content basis) and convert the Phase II REE salt mixture to an oxide mixture, (2) produced/delivered >38 g of REO mixture with >85 wt.% purity (elemental basis); (3) developed processes to recover critical minerals scandium and aluminum from intermediate streams; (4) produced/delivered > 1 g of scandium salt mixture with >85 wt. % purity (elemental basis); (5) produced/delivered > 100 g of aluminum oxide type material with >70% wt. purity (elemental basis); and (6) updated the techno-economic model from the baseline Phase II program to assess CAPEX and OPEX of a commercial operation. This program has developed extensive databases on process chemistry, unit operations, plant engineering, and techno-economics that will enable further scale-up toward commercial plant design. Specific future developments will be focused on achieving dramatic savings in energy, reagent usage, and operating costs. The combined results will contribute significantly for maturing the technologies of REE recovery from coal byproducts and promote the establishment of domestic REE and CM supply chains.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2025

LDR Inorganic Spiked Simulants in Pozzolan-Substituted Cast Stone for Hanford Pretreated Low-Activity Tank Waste

Pretreated Low Activity Waste (PTW/LAW) at the Hanford Site, is currently projected for disposition through a cementitious waste form. The current standard formulation, Cast Stone, uses Class F fly ash, blast furnace slag, and Portland cement. However, the future availability of Class F fly ash is uncertain, as many coal-fired power plants—the source of this byproduct—are being decommissioned or converted to natural gas. This issue has prompted research into identifying and evaluating suitable alternative materials to replace fly ash in the cementitious waste forms used by the Department of Energy (DOE). The Savannah River National Laboratory (SRNL) successfully identified four natural pozzolans for the replacement of Class F fly ash in the current Savannah River Site (SRS) low-level waste (LLW) form, Saltstone.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2025

Evaluation of Pozzolan-substituted Cast Stone for Pretreated Hanford Tank Waste

Portland cement. The future availability of quality Class F fly ash has come into question as coal-fired power plants are being converted to gas or taken offline. Consequently, alternative pozzolanic reagents are being evaluated for fly ash replacement in cementitious matrices for treating radioactive waste and debris. In 2023 and 2024, Savannah River National Laboratory (SRNL) was funded to evaluate natural pozzolans for the replacement of Class F fly in the Savannah River Site (SRS) Saltstone formulation. Based on the promising results and uncertain availability of Class F fly ash in the northwestern US, Hanford Tank Waste Operations & Closure, LLC (H2C) requested SRNL to evaluate the potential for substituting natural pozzolans in the Hanford West Area Pretreated Low Activity Tank Waste (PTW/LAW) Cast Stone formulation1 . Task 1 in this request was to determine the change in Cast Stone volume resulting from stabilization/solidification of 1 L of PTW/LAW tank waste. The densities of three (Hess Pumice, tephra pumice, and clinoptilolite zeolite) pozzolan-substituted Baseline Cast Stone mixes were determined, and volume changes relative to the fly ash-Baseline Mix with a water-to-dry mix = 0.40 were calculated.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

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 OSTI2021

Lawrence Livermore National Laboratory (LLNL) Hybrid-Energy Technology for Power and Industrial Heat with Near-Zero or Negative CO 2 Emissions

Major contributors to global CO 2 emissions include electricity (27%) and industry (23%), such as cement manufacturing (8%). Using post-combustion technology to reduce CO 2 emissions by 85-90% could increase the cost of generating electricity with fossil fuel by 40-70%, while increasing cement-manufacturing cost by 75-140%. Both sectors are under pressure to reduce CO 2 emissions and are seeking cost-effective, energy-efficient solutions to decarbonizing energy.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

Replacement of Fly Ash with Natural Pozzolans in Cementitious Waste Forms

OBJECTIVE Address long-term and emerging issues for Cementitious Waste forms • Future availability of fly ash from coal fired power plants is uncertain • Improve waste form properties • Regionally available ingredients • Reduce cost and embodied Energy • Increase Salt Solution Waste Loading (water : cementitious reagents) in cement waste forms

Hill, Katie A. [Savannah River National Laboratory↗

DOE OSTI2024

Assessments of advanced reactor heat supply to high temperature industrial unit operations: Heat Engines and Heat Pumps

In this report, the feasibility of employing Advanced Nuclear Reactors to supply the necessary high-quality heat to Industrial Processes is investigated. As a first step, the most relevant industrial applications that could benefit from this coupling were identified. Four industries including petroleum refining (distillation, catalyst regeneration, hydro-steam cracking), chemical polymers, steel manufacturing (metals annealing/soaking) and cement manufacturing (calcination of limestone and dolomite industries) were considered. An overview of the heat duties, i.e., the temperatures and thermal powers required by representative plants of the different processes, was provided. Secondly, the thermodynamic conditions of the steam produced by representative designs of Advanced Reactor concepts (Liquid Metal Fast Breeder Reactors, Molten Salt Reactors, and High Temperature Gas-cooled Reactors) were summarized. The comparison between the requirements of the industrial processes and the capabilities of the candidate nuclear power plants showed that only a few processes could benefit from the coupling. Although Advanced Reactors operate at higher temperatures than Light Water Reactors, the thermodynamic conditions of the generated steam flow rates are generally not suitable for the selected applications. At the same time, data indicate that most of the processes can be suitably supplied if the temperature of steam is elevated to 900 °C. One possible solution to boost the quality of the steam from the nuclear island involves the use of a heat pump. Based on a technology similar to that found in refrigerators and air conditioners, heat pumps extract heat from a source, elevate its temperature and transfer it to where it is needed. A simple numerical example illustrating the viability of this method is described. Specifically, the energy conversion cycle of a conventional Pressurized Water Reactor was extended to incorporate a compressor to raise the heating value of the steam produced by the reactor. Two reference configurations, i.e., one where the industrial process coupled to the nuclear power plant exhausts saturated liquid and the other where it exhausts saturated steam, were considered. The thermal efficiencies achievable by increasing the heating value of the reactor steam in this way are significantly greater than by direct electric heating.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2021

Brine Availability Test in Salt (BATS) FY21 Update

This report summarizes the 2021 fiscal year (FY21) status of ongoing borehole heater tests in salt funded by the disposal research and development (R&D) program of the Office of Spent Fuel & Waste Science and Technology (SFWST) of the US Department of Energy’s Office of Nuclear Energy’s (DOE-NE) Office of Spent Fuel and Waste Disposition (SFWD). This report satisfies SFWST milestone M2SF- 21SN010303052 by summarizing test activities and data collected during FY21. The Brine Availability Test in Salt (BATS) is fielded in a pair of similar arrays of horizontal boreholes in an experimental area at the Waste Isolation Pilot Plant (WIPP). One array is heated, the other unheated. Each array consists of 14 boreholes, including a central borehole with gas circulation to measure water production, a cement seal exposure test, thermocouples to measure temperature, electrodes to infer resistivity, a packer-isolated borehole to add tracers, fiber optics to measure temperature and strain, and piezoelectric transducers to measure acoustic emissions. The key new data collected during FY21 include a series of gas tracer tests (BATS phase 1b), a pair of liquid tracer tests (BATS phase 1c), and data collected under ambient conditions (including a period with limited access due to the ongoing pandemic) since BATS phase 1a in 2020. A comparison of heated and unheated gas tracer test results clearly shows a decrease in permeability of the salt upon heating (i.e., thermal expansion closes fractures, which reduces permeability).

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

Printable Fiber Reinforced Cement Composites – Feasibility Study

Additive manufacturing is enabling the manufacturability of structures with previously unattainable complexity or functionality, and there is growing interest in additive manufacturing of “printed” concrete structures. The focus of this Phase 1 Technical Collaboration (TC) project was to evaluate feasibility of printing hybrid cement composite structures reinforced with textile carbon fibers (tCF). This project leverages other (non-IACMI) projects on cement formulation and printing process development, as well as on the production process for tCF. This project’s primary focus was to explore cement composite mix design with textile carbon fibers to be manufactured by MonteFibre (TC partner) and evaluate suitable fiber-matrix interface or sizing for cement composites working with Michelman (TC Partner). This project supports IACMI’s goal of reducing the cost and embodied energy of carbon fiber composites. Cost is one of the fundamental challenges to carbon fiber reinforced cement composites. Cement is an extremely inexpensive material (approximately $\$$0.05/lb). Adding 1 wt% of conventional carbon fiber to cement quadruples its cost. Therefore, the need to use low-cost carbon fiber and ensure that the additional cost of the carbon fiber has a greater cost benefit to the final product. This was the first preliminary evaluation to integrate tCF reinforcement in cement composites, and such potential tCF utilization should significantly reduce materials cost. Cement composite production is energy and emissions intensive, thus by strengthening it less material will be required. Hence, the embodied energy and production time of the resulting structures will be reduced. Additionally, integrating these new materials into additive processes can enable selective use of the material in high load or stress areas. It is noteworthy that past work in this field of fiber reinforced cement composites did not consider the optimization of fiber-matrix interface using suitable sizing. Carbon fiber reinforcement offers potential added benefits of thermal conductivity (which affects cure rate) and flow behavior that could provide opportunities for site specific utilization of carbon fiber on hybrid cement structures (e.g. use the fiber reinforcement on outer surfaces to enhance strength and modulus and then infiltrating the internal structures with conventional concrete). MonteFibre was the industry lead and planned on supplying the tCF for this project. However, during the short Phase-1 duration of this project, MonteFibre was unable to produce tCF for this project due to manufacturing plant being off-line throughout the course of the project. The project team decided to pursue an alternate option which involved demonstrating printable concrete with steel fibers by the ORNL lead, Dr. Brian Post. The University of Tennessee collaboration team focused on evaluating the suitable chemical sizing for carbon fibers working with Michelman and also developed methods for material characterization of cement-based composites to evaluate the material response for compression, shear, flexure, and tension. The two milestones for University of Tennessee, Knoxville were realized related to identification of one sizing suitable for carbon fiber reinforced cement composite and developing data associated with mechanical behavior of unreinforced (neat) and carbon fiber reinforced cement composites. ORNL could not complete the task of carbon fiber reinforced printed cement composites due to the reasons mentioned earlier, but was able to replace tCF with steel fibers to demonstrate the feasibility of printing with fiber reinforced cement composites. The Project team reviewed possible sizing chemistry available in collaboration with Michelman for use on carbon fiber reinforcement in cement composites and concrete applications. Our initial goal was to identify a sizing most promising for formulation with textile carbon fibers (tCF) to deliver excellent mechanical properties in composite material state. Since tCF was not available for this project as originally envisioned, the team continued this task to identify a suitable sizing for carbon fiber applications by applying such sizing to lower cost carbon fibers currently available commercially from Zoltek called Panex fibers. At a future time this can be optimized for textile carbon fibers from Montefibre. The bulk of previous work on carbon fiber reinforced cement has neglected the importance of fiber-matrix adhesion on mechanical properties of the cement composite and identifying this missing link was an important accomplishment for future research. Tensile behavior of fiber reinforced concrete is important to evaluate in order to realize the dream of concrete products that do not need reinforcing steel. Important sample preparation and testing procedures were addressed in this study and it was concluded that substantial improvements in tensile behavior, without compromising compressive strength, and improved ductility can result from the use of carbon fiber reinforcement.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Development of a Reconstruction Methodology Based on X-Ray Computed Tomography to Generate Realistic 3D Concrete Microstructures in MOSAIC

Despite being passive components, concrete structures represent a major capital investment in nuclear power plants. However, some concrete components are critical for the safety and long-term operation of the reactors: the concrete containment building protects the reactors from external aggression. The concrete biological shield (CBS) contains the radiation exiting the reactor to protect equipment and personnel. Depending on the design, the CBS also has a function for supporting the reactor’s systems. This function needs to be ensured in-service and during accident scenarios. After several decades of use, the CBS is exposed to high-energy irradiation over an extended operation time, exceeding the fluence level currently considered detrimental for the concrete’s structural properties. Such conditions occur at different times depending on the reactor’s operation and design. Nevertheless, from the perspective of subsequent license application, it is mandatory to assess the potential effects of prolonged irradiation on concrete. Unlike steel components, concrete structures are built with local constituents (cement, sand, and coarse aggregates) to avoid prohibitive transportation costs. Thus, concrete performance is determined by the tolerance or the susceptibility of its constituents against any aging mechanism. The tolerance against irradiation of the CBSs may vary greatly among the 56 nuclear power plants and 93 nuclear power reactors that form the current US light-water reactor fleet. Irradiation-induced degradation is mainly a result of amorphization-induced expansions of the silicated minerals present in the aggregates. The neutron irradiation–induced expansion varies from one rock-forming mineral to another: well framework–structured silicates (e.g., quartz and feldspars) exhibit higher swelling than chained (e.g., pyroxene) or isolated silicates (e.g., garnet). Silicates make up nearly 90% of the Earth’s crust. Other common minerals present in construction aggregates are carbonates found, for example, in limestone. Irradiated carbonates exhibit only very minor expansions.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Development of Magnesium Oxysulfate Formulation for SRPPF Aqueous Recovery Liquid Solidification

The liquid effluent from the Savannah River Plutonium Processing Facility (SRPPF) Aqueous Recovery Processes will be solidified into a stable form that is acceptable by Waste Isolation Pilot Plant (WIPP) for disposal. The current Aqueous Recovery flow sheet proposes to solidify the liquid effluent using a grout formula that was developed and tested for the former Waste Solidification Building process. This Portland cement based mixture results in a high pH (~13) leachate from the solidified waste form which is not acceptable to WIPP in the large quantities expected from production at SRPPF. Various cementitious materials were previously evaluated as alternative grout formulations to Portland cement and a MgO-based mix was identified as a promising alternative. A magnesium oxysulfate (MOS) cement formulation comprised of reactive magnesium oxide (MgO), anhydrous magnesium sulfate (MgSO 4 ), and sand, as a non-reactive heat sink provided good mixability, similar density to the original Portland-cement based mix, and a leachate pH of 9.4, within the assumed WIPP brine pH range. However, the MOS formulation exhibited an appreciable amount of heat generation, which resulted in premature setting of a large-scale test.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

NASA NTRS1978

A technical analysis for cogeneration systems with potential applications in twelve California industrial plants

In a study sponsored by the State of California Energy Resources Conservation and Development Commission, 12 industrial plants in five utility districts were surveyed to assess the potential applications of the cogeneration of heat and electricity in California industry. Thermodynamic calculations were made for each plant in determining the energy required to meet the existing electrical and steam demands. The present systems were then compared to conceptual cogeneration systems specified for each plant. Overall energy savings were determined for the cogeneration applications. Steam and gas turbine topping cycle systems were considered as well as bottoming cycle systems. Types of industries studied were: pulp and paper, timber, cement, petroleum refining, enhanced oil recovery, foods processing, steel and glass

Moretti, V. C.↗

DOE OSTI2024

Industrial Carbon Capture from a Cement Facility Using the Cryocap™ FG Process

The objective of the project was to execute and complete front-end engineering and design (FEED) studies for commercial-scale, carbon capture projects that separate 95% of the total CO 2 emissions at an industrial facility, producing at least 100,000 metric tonnes/year of CO 2 for sequestration. The industrial facility selected is the Holcim (US) Ste. Genevieve cement manufacturing facility (the largest single kiln line in the world), while the carbon capture system selected is Pressure Swing Adsorption system (PSA) assisted Cryocap™ technology developed by Air Liquide. The industrial host site emits approximately 3 million tonnes CO 2 /year based on plant data from 2020-2022. The captured CO 2 will meet the requirements of transport (Pipeline Grade) and geological storage, and the geological storage facilities within 80 miles of the CO 2 source. The impact of the project on Environmental Justice and the regional economy was also analyzed.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2024

FEED Study of Carbon Capture Inc. DAC and CarbonCure Utilization Using United States Steel's Gary Works Waste Plant

The University of Illinois Urbana-Champaign (UIUC) is spearheading a front-end engineering design (FEED) study of a Direct Air Capture and Utilization System (DACUS) that can remove 5,000 tonnes/yr net CO2 from ambient air, utilizing it in the production of concrete. The designed system, if built, would be larger than any currently existing DAC collector. Such carbon negative technologies are critical to meeting the goals of the DOE’s program to accelerate climate-critical technology. DAC is a promising new technology for reducing the greenhouse gas in the atmosphere but is expensive, partly due to the energy required to capture and then release CO2 during the process. By integrating CarbonCapture Technologies Inc. DAC collector at United States Steel's Gary Works and utilizing steel plant's waste heat, energy, and location so energy & transportation costs can be minimized. CarbonCapture has developed an innovative DAC system using novel adsorbents to cost- effectively capture CO2. The captured, liquified CO2 will be trucked to ready-mix concrete plants across Illinois, Indiana, & Wisconsin, where CarbonCure will inject it into concrete during the mixing process. The carbon dioxide reacts with concrete, mineralizing into calcium carbonate (CaCO3), sequestering the CO2 into the concrete, and reducing the amount of cement, the manufacturing of which is among the major sources of CO2 emissions. This FEED study demonstrates a full CO2 value chain for DACUS from industrial facilities. It also provided an opportunity to assess the impact of this holistic approach on job creation, regional economic impact, and environmental justice.

Carbon management, ccus, carbon capture, utilizati↗

DOE OSTI2022

Remining and Restoring Abandoned US Mining Sites: The Case for Materials Needed for Zero-Carbon Transition

The electricity generation sector is responsible for 25% of the world’s greenhouse gas (GHG) emissions and thus has been the focus of efforts to transition to clean energy and sustainable development in many nations. In the past 20 years, renewable energy sources have been the fastest-growing energy source in the world, comprising almost 29% of the world’s electricity generation in 2020. Renewable energy sources are expected to comprise nearly 95% of the world’s power capacity growth through 2026, with a share of planned capacity expansion of up to 46% in 2026. The rapid development of renewable energy sources and technologies will require an enormous amount of raw materials to replace coal and gas plants and increase in the capacity to handle growing electricity demand because renewable energy sources have a low-power density and intermittent behavior. Accounting for the expected scale of rapidly deploying renewable energy sources that require rare earth elements (REEs), cement, and steel, the mining industry may face a supply problem for the materials critical for clean energy. And, as the exploration and development of new mining sites can be expensive and risky, the mining industry may require economic stimuli to grow supply. The increasing demand for renewable energy resources makes mining a threat to the environment unless proper regulations are established and calls for remining, cleanup, and circular economic development are made. Mining also contributes to environmental injustices related to the exploitation and pollution of lands near communities that are dependent on biodiversity in the area, while not always benefiting from technological advancements provided by the use of renewable energy and technologies. This study explored the opportunity of remining abandoned mining waste to extract metals and minerals essential for the production of renewable energy sources. The authors analyzed materials used in the production of these technologies, materials readily available in the United States, and which materials can be extracted locally in the United States from abandoned mine waste. The authors also studied environmental injustices that populations near mining sites experience and ways to mitigate these injustices, such as providing more control over extraction and cleanup activities, providing more job opportunities in those areas, and offsetting costs associated with cleanup and land restoration projects.

42 ENGINEERING↗