Innovation

Solidia Cement™ is composed primarily of low-lime containing calcium silicate phases. The curing of concrete products made using Solidia Cement is derived from a reaction between low-lime calcium silicate phases and gaseous CO2 in the presence of moisture. During the carbonation curing process, calcite (CaCO3) and silica gel (SiO2) are formed and are responsible for the development of strength within the concrete. This is in contrast to the hydration process occurring in Portland cement-based concrete, which involves the hydration reaction between high-lime calcium silicate phases and water to form calcium-silicate-hydrate gel and calcium hydroxide.

Solidia Concrete contains the same raw materials as those used in concrete products made with ordinary Portland cement (OPC), namely, fine and coarse aggregate, supplementary cementitious materials, and chemical admixtures. In addition, the manufacturing of Solidia Concrete products is performed using identical mixing and forming processes as those adopted in OPC-based concrete production.

The curing process of concrete made using Solidia Cement sequesters up to 300 kg of CO2 per tonne[1] of cement used. Solidia Concrete can be produced by manufacturers of traditional concretes and can be designed to address virtually any precast concrete application. Additionally, the Solidia Concrete curing process can be complete. As water is not consumed during the Solidia Concrete curing process, it can be collected and reused, with recycle rates in excess of 60%, and potentially as high as 100%.

[1] All calculations are based on the tonne, also known as the metric ton, equaling 1,000 kilograms.

Inspiration

Concrete is the world’s second most utilized substance, exceeded only by the consumption of water, and third biggest polluter of greenhouse gases, behind only the petrochemical, iron and steel industries. According to a 2005 study by the World Resources Institute (WRI) on greenhouse gas emissions by major industries, cement and concrete makers are responsible for five to seven percent of carbon dioxide (CO2) emissions.

The idea to create a less polluting concrete has been pursued for more than 50 years. According to Solidia Technologies’ CEO Tom Schuler, the biggest challenge was making a complex technology simple and commercially viable.

Overall impact

Solidia's technology offers the building materials and construction industry a more environmentally friendly and cost effective way to manufacture cement and concrete that uses existing plants, with minimal requirements for new supply chains and capital investment.

According to the company's website, Solidia’s systems reduce production costs and save time and energy.

The patented processes for producing sustainable cement and concrete reduces carbon emissions up to 70 percent and recycles 60 to 80 percent of water used. Energy consumption is reduced by up to 30 percent.

Business benefit

Solidia’s technology saves concrete and cement manufacturers time, money, water and energy. CEO Thomas Schuler says the company has worked hard to make the technology adaptable to a wide variety of concrete formulations, production methods and specifications.

According to the company's website, Solidia's cement and concrete making processes:

• Reduces energy costs in cement production.
• Reduces concrete manufacturing costs because of more efficient curing times, inventory reduction and faster clean-up.
• Reduces emissions by 70 percent, helping to mitigate the impact of new carbon taxes.
• Produces a better concrete in less time.
• Uses the same equipment, raw materials, and manufacturing process.
• Reduces water consumption.
• Offers cost-competitive solutions, enhanced product quality, flexibility and performance, and ease of adoption.

While Solidia's initial focus was on unreinforced precast applications, including pavers and blocks, the company is also developing commercial processes for reinforced applications, including aerated concrete, railroad ties, architectural panels and hollow core extrusions. The company's IP portfolio includes over 200 patent applications worldwide, with 31 issued patents and 15 scheduled to be issued in the near future.

Social and environmental benefit

According to a 2005 study by the World Resources Institute (WRI) on greenhouse gas emissions by major industries, the cement industry was responsible for 3.8 percent of total global emissions, equivalent to five to seven percent of industrial carbon dioxide. Combined, Solidia's patented processes reduce emissions by up to 70 percent.

It also promotes the responsible consumption of water, energy and alternate fuels. In 2011, the concrete industry produced over 30 billion tons of concrete, using an estimated 2.6 billion tons of water. According to Solidia's website, the company's technology reduces energy consumption by nearly 30 percent and water use 60 to 80. If Solidia Cement were used instead of OPC, the amount of water consumed during the production of concrete could be reduced around 0.26 to 0.45 billion tons. This corresponds to an annual global water savings approaching two billion tons, or two trillion liters.

Both accomplishments address multiple United Nations’ Sustainable Development Goals and the goal of The Cement Sustainability Initiative of the World Business Council for Sustainable Development (WBCSD) "a CEO led organization of over 200 leading businesses and partners working together to accelerate the transition to a sustainable world," to halve carbon emissions worldwide by 2050.

Another benefit of Solidia Cement is that it uses less limestone than traditional methods, offering the potential of extending the lifetime of limestone quarries. It also allows for more efficient heat management throughout the cement-making process. A reduced kiln temperature may allow the burning of low-caloric value, alternative fuels.

Rising global concerns around water scarcity, particularly in select regions of the world, heighten the demand for non-hydraulic building materials, adding to the potential value of Solidia Cement as a material of the future.

Interview

Ellen Yui, Founding Principal of YUI+Company, Inc., and Media Relations contact for Solidia Technologies