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Taleen Sameh
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 So 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.
A anlise de viabilidade de projetos determina se o projeto deve ou no ser colocado em prtica e pode ser realizada a partir de diferentes esferas: estratgica, tcnica, operacional, legal, econmico-financeira, ambiental, mercadolgica, poltica, fiscal, localizao, entre outras. As referidas anlises no so excludentes, por conseguinte, possvel que para um nico projeto sejam realizadas todas elas. No entanto, este trabalho ter enfoque na anlise da viabilidade tcnica do projeto inovador de implementao da cura qumica com CO2 em fbrica de blocos de concreto na regio de So Paulo. Para tanto, ser apresentada uma viso geral do processo de cura com CO2 e possveis modificaes para realiz-la na indstria, alm da identificao de fontes locais de CO2 e custo de entrega, necessidades de mudanas na cmara de cura, aquisio de novos equipamentos, possveis melhores definies sobre temperatura ideal, umidade e concentrao de CO2. Casos de sucesso internacionais so apresentados. O estudo conclui que a tecnologia pode ser facilmente implantada na regio, com poucas mudanas no processo produtivo da planta e na cmara de cura. Dependendo da distncia da fbrica ao fornecedor de CO2, poder haver um aumento de 4% a 14% no custo do bloco. Considerando a produo brasileira de blocos de concreto, at 168.780 toneladas de CO2 por ano podem ser sequestradas, este valor equivale ao sequestro de CO2 realizado por 21.100 rvores.
Accelerated carbonation curing or CO2 chemical curing of concrete blocks is an innovation. According to the Oslo Manual [1]1 Organisation for Economic Co-operation and Development, The Oslo Manual: The Measurement of Scientific and Technical Activities, Paris: OECD; Eurostat, 1997., innovating means implementing a new or significantly improved product (good or service). However, chemical curing with CO2 should not be considered just an innovation, but a sustainable innovation. According to Barbieri et al. [2]2 J. C. Barbieri, I. F. G. Vasconcelos, T. Andreassi, and F.C. Vasconcelos, "Inovao e sustentabilidade: novos modelos e proposies", RAE, v. 50, n. 2, pp. 146-154, 2010. innovation and the sustainable development of organizations are one most important social movement today, since there is a global need to replace old means and practices with others that translate the principles, objectives, and guidelines new movement. When committing to sustainable development, the company must, at the very least, change the way it operates, to create strategies to reduce social and environmental impacts.
By implementing the sustainable innovation of accelerated carbonation curing, the Brazilian concrete block industries will contribute on a world scale to the reduction of global warming, reduction of water and electric energy consumption. Furthermore, they will have the benefit of reduced curing time and blocks will acquire final strength much more quickly, reducing waiting time in the industrial yard and providing faster production.
To carry out the chemical curing with CO2, the newly manufactured unreinforced cementitious products are introduced into a carbonation chamber with adequate concentrations of CO2, humidity, temperature, and pressure, and at the end, in a few hours, the advantages of said curing are verified that are the permanent absorption of CO2 from the medium and premature gain in mechanical strength [3]3 G. Ye, "Carbon dioxide uptake by concrete through early-age curing", MSc dissertation, Dept. Civil Eng. Applied Mech., McGill Univ., Montreal, Canada, 2003.-[66 L. R. Fortunato, "Captura de CO2 em peas de concreto para pavimentao atravs da cura por carbonatao acelerada", M.S. thesis, Univ. Fed. So Carlos, So Carlos, SP, Brasil, 2019.]. During curing, the CO2 reacts with the main cement hydration product (Ca(OH)2), C-S-H, and others) and is transformed into calcium carbonate (CaCO3) and water. The formation of calcium carbonate promotes the permanent sequestration of CO2 and the gain on mechanical strength, since calcium carbonate precipitates in the concrete pores, in the mineralogical form of calcite, vaterite and aragonite [7]7 H. G. Smoczyk, "Physical and chemical phenomena of carbonation,", in Proc. RILEM Colloquium on Carbonation of Concr., Paper 1.1, 1976, 10 p..
The idea is to capture the CO2 emitted from the industries chimneys, use it during carbonation curing and store it permanently in unreinforced cement prefabrications. This cure type is already successfully done in countries such as the United States, Canada, and the United Kingdom, in industries like Carboclave, Solidia Technologies, CarbonBuilt and CarbiCrete [8]8 J. G. Jang, G. M. Kim, H. J. Kim, and H. K. Lee, "Review on recent advances in CO2 utilization and sequestration technologies in cement-based materials," Constr. Build. Mater., vol. 127, pp. 762-773, 2016,
. Through this study we intend to analyze the technical and locational feasibility of introducing it in Brazil, more precisely in industries close to the Greater So Paulo area.
In a technical feasibility study, also called engineering or technology study, it is necessary to understand the production processes to manufacture the product, as well as whether it is possible to produce the product or service to be commercialized in scale. As differentiated as the innovations may be, it is necessary to have coherence between the invention and its usability [9]9 J. Schneider, "A viabilidade da inovao." Notisul, 2019. -de-inovacao-e-empreendedorismo-da-unisul-agetec/a-viabilidade-da-inovacao/ (accessed: June 1, 2021).
. This technical feasibility and innovation study will comprise a) Characteristics of the innovation - description of the products, services, and technology to be used; b) Analysis of innovation process components; c) Research of similar processes and products - Success Cases.
The concrete block industry is one of the links in the construction sector production chain, which includes cement companies, construction companies, equipment manufacturers, real estate companies linked to works and maintenance. The eco-friendly concrete block industry sector, in an unconventional way, embeds CO2 suppliers.
Producing concrete blocks that store CO2 is innovative. Through accelerated carbonation curing technology, carbon dioxide is chemically converted into a mineral, calcium carbonate, which definitively precipitates in the concrete pores [10]10 A. Neves Jr., "Captura de CO2 em materiais cimentcios atravs de carbonatao acelerada". Ph.D. dissertation. Univ. Fed. Rio de Janeiro, Rio de Janeiro, RJ, Brasil, 2014.. It is sustainable, as it meets the need to reduce greenhouse gases in the atmosphere, minimizing the consequences of global warming. To the authors knowledge, technology is non-existent in the Brazilian market.
Some factors make concrete blocks ideal candidates for storing an CO2. The block hollow geometry and thin walls facilitate the diffusivity of CO2 inside the unit. Also, this is a large-scale product with increasing use in medium and large urban centers.
It is a fact that non-reinforced cementitious precast can absorb CO2 and gain strength prematurely when subjected to CO2 curing. Fortunato [6]6 L. R. Fortunato, "Captura de CO2 em peas de concreto para pavimentao atravs da cura por carbonatao acelerada", M.S. thesis, Univ. Fed. So Carlos, So Carlos, SP, Brasil, 2019. found that concrete paving pieces, when subjected to curing with carbon dioxide, stored 5.10% of the CO2 present in the chamber atmosphere. Considering the consumption of cement by the Brazilian unreinforced precast industry in 2019 of 5.66 Mton [12]12 Sindicato Nacional da Indstria do Cimento, Relatrio Annual, Rio de Janeiro: SNIC, 2019., it would have been possible to capture approximately 290,000.00 ton of CO2 if all production had been cured with CO2. This value corresponds to the CO2 sequestration of 36,250,000.00 trees in a year, since, according to the Totum Institute, a tree sequesters approximately eight kilograms of CO2 in a year [13]13 Instituto Totum, "Cada rvore da Mata Atlntica chega a retirar 163 kg de CO2 da atmosfera". -verificacao-de-inventarios-de-gases-de-efeito-estufa/135-cada-arvore-da-mata-atlantica-chega-a-retirar-163-kg-de-co2-da-atmosfera (accessed: June 8, 2021).
. In addition, the carbonated concrete paving pieces showed superior axial compressive strength at 2-days age than the reference pieces (non-carbonated), although the 28-days were equivalent [6]6 L. R. Fortunato, "Captura de CO2 em peas de concreto para pavimentao atravs da cura por carbonatao acelerada", M.S. thesis, Univ. Fed. So Carlos, So Carlos, SP, Brasil, 2019..