Manufacturing Efficiency

Develop phased array technology to enable “medical quality” imaging and characterization of thick reinforced concrete components. This early detection technology could prioritize maintenance to avoid macrocrack formation which could significantly increase the durability of existing concrete components, reducing lifecycle energy and emissions costs.

Develop a machine learning algorithm to guide the design of molecular additives that streamline the path for alternative binder chemistries concrete use in existing construction methods and equipment. The central goals are to increase the durability of US infrastructure by at least twofold and reduce the energy expended in producing this concrete by at least half.

Develop computational tools to evaluate the feasibility of using industrial by-product materials to make low energy cements. The objective is to reduce energy demand and greenhouse emissions related to the production of cements, to leverage the practical economic benefits of low-energy binder systems, and to produce highly durable concrete.

Develop process to enable low-temperature activation of precursor materials that are geologically sourced and/or that comprise alkaline industrial wastes. Approaches provide alternatives to ordinary Portland cement that have significantly lower energy intensity and greatly enhanced durability.

Develop ultralow-binder-content ductile concrete (UDC), a low-cost, highly durable, strong, energy-efficient, and low-emission infrastructural material. UDC will be lower cost, greater ductility, and longer lifetime than ordinary portland cement.

Develop extremely durable concretes with engineered foam glass aggregates that mimic the reactive volcanic glass of 2000-year-old Roman architectural and marine concretes. These innovative materials, mixtures and processing technologies, could improve durability at 4 times typical 50-year Portland cement concrete service life and reduce by up to 85% the energy and emissions associated with production and deployment.

Develop ultra-acid-resistant, low-calcium geopolymer cements that take advantage of reduced heat-curing and lower alkali conditions, for wastewater (i.e., sewer) and other infrastructure applications. The project aims to provide an alternative material technology solution that will extend the service life of concrete infrastructure and reduce total life cycle energy, economic, and environmental costs.

UHV Technologies will develop and demonstrate an innovative aluminum smelting technology that will significantly increase the range of aluminum alloys that can be manufactured from recycled scrap aluminum. This will reduce the need for primary aluminum with corresponding energy and environmental benefits. Using UHV’s patented high-throughput sorter, aluminum alloys will be pre-sorted, then melted in an energy-efficient vacuum furnace to avoid the typical 5% metal loss from molten metal oxidation, allowing for lower-cost production of high-value aluminum alloys. Currently ~60% of total U.S.

Develop an extremely durable belite-based cement alternative to ordinary portland cement that is low-energy consuming and low-carbon releasing. The material would use less energy, release less CO2 and excel in performance and durability over time.

Carbon mineralization, a promising carbon management technology, reacts CO2 gas with minerals containing magnesium and/or calcium. The reaction forms a stable, solid carbonate, which can be used in building materials. Community Energy will use minerals from the waste produced at mining facilities to enhance the rate of carbon mineralization, increase the amount of available minerals used to capture CO2, and produce building materials, such as aggregate for making cement, which can offset some of the carbon footprint associated with the cement industry.