Case study: The Italcementi TX ACTIVE story

Transcription

1 Case study: The Italcementi TX ACTIVE story Cristal Global Conference London, 17 Nov. 2011

2 Table of contents Research and Innovation in Photocatalysis in cement-based materials: some milestones Some scientific issues Old and recent outstanding projects Final considerations and future trends 2

3 Innovation: one of our flags Innovation has a flag, i.nova, under which gathers the best talents, resources and multidisciplinary competencies. These significant elements permit to achieve excellence in the building sector and in the economic performance without forgetting the environmental protection and the improvement of the communities living conditions. 3

4 Research and Innovation s innovation operates through 2 major laboratories of Bergamo and Paris, where the daily work of about 170 researchers - chemists, geologists and engineers allowed to file over 60 patents in the last decade. closely cooperates with an international scientific network consisting of research centers, universities and companies of the building and building material industry. s new innovation centre - i.lab, Innovation and Technology Central Laboratory - is rising on the Kilometro Rosso site in Bergamo. The new construction will boast a surface area of 11,000 sq.m, of which over 7,000 are totally devoted to research laboratories. 4

5 Photocatalytic cements: short history R&D program on photocatalysis in cement-based systems First (Italian) patent application First publications First concrete trials 5

6 1995: Photocatalysis of cement-based materials The photocatalysis of cement-based materials is a recent matter. It has been launched for the first time on the basis of an intuition of Luigi Cassar (past Director of R&D Department Italcementi Group), in the Ideal City First Italian Patent was filed in BASIC PATENT MI96A

7 : first results with cement-based materials 1995: the decomposition of coloured/colourless organic compounds by means photocatalytic cement-based materials was demonstrated and quantified (pollutants: cigarette smoke derived, candle carbon black, phenantroquinone, cholorophenol) 1996: the NOx decomposition was also verified 7

8 1997: first publication by Italcementi The first official publication on such products was presented (by L. Cassar et al.) in an Italian Congress on Innovative Materials, in 1997 ("Materiali cementizi e fotocatalisi" FAST Congress, Milan November 1997). Since that period, the development of photocatalytic cements has been carried out with increasing innovative solutions, passing from the self-cleaning performance to depolluting effect. 8

9 1998: first trials of photocatalytic concrete The first meaningful application of the photocatalytic cement-based materials has certainly been the church "Dives in Misericordia" in Rome for which, on demand of the arch. Richard Meier, CTG Laboratories developed a white concrete possessing a prolonged maintenance of color along the time. First panels (prototypes) Size 1:4 1 st panels prototypes Size 1:1 3x2 m 9

10 Photocatalytic cements: short history R&D program on photocatalysis in cement-based systems First (Italian) patent application First publications First concrete trials First project: Dives in Misericordia Church, Rome Rhodamine-B (discoloration) test (CSTB, France) 10

11 Dives in Misericordia Church in Rome White precast concrete panels preserving aesthetics 11

12 Dives in Misericordia Church in Rome sail 1 sail 2 sail 3 northern wall Colorimetric measurements sail1 external wall sail 2 external wall sail 3 external wall sail1 internal wall sail 2 internal wall sail 3 internal wall 12

13 Colorimetric measurements 13

14 Cité de la Musique et des Beaux-Arts Chambéry (France) Grey precast concrete preserving aesthetics 14

15 Colorimetric measurements V V O O V O L V O L L V V V OO O V O V O V V V 15

16 Photocatalytic cements: short history R&D program on photocatalysis in cement-based systems First (Italian) patent application First publications First concrete trials First project: Dives in Misericordia Church, Rome Rhodamine-B (discoloration) test (CSTB, France) Start of PICADA Project ( ) Street canyon experience Pilot depollution tests in Segrate, Calusco, Bergame Launch of first version of photocatalytic cement (TX Millennium ) Development of Laboratory Test methods 17

17 PICADA Project: from the lab to the real world Photocatalytic Innovative Covering Applications for De-pollution Assessment Objective: Develop and assess coverings for depollution based on photocatalysis Duration:

18 PICADA Project: street canyon (1:5) Guerville, near Paris (France) Experimental photocatalytic coating applied on walls Measurement Parameters Gas velocity, temperature, and composition from the pollution source. Continuous NOx measurements on both treated and reference canyons. VOC s sampling twice daily. Pollution source (engine) Monitoring equipment Background NOx and O 3 measurements at the top of the canyons. Meteorological parameters (WD, WS, T, RH, solar irradiation). 19

19 PICADA Project: NOx results Photocatalytic coating reduced NOx levels by 20% to 80 %. Several factors affect abatement rates including: Solar irradiation Pollutant concentration Wind speed Wind direction relative to the structure Pollutant residence time 20

20 Depolluting (NOx) laboratory tests Flow-through test (continuous) UNI (CEN draft standard) Recirculation test draft UNI standard 21

21 Depolluting applications: from the laboratory to the real situation The problem is to evaluate in a real situation/scale the effect induced by the use of products, whose photocatalytic performances have been already assessed at laboratory scale. PICADA European Project Street Canyon Segrate, Calusco, Bergamo (Italy) Porte de Vanves (Paris) Rome (Tunnel) Others 22

22 Main results of monitoring campaigns On the basis of long monitoring campaigns carried out in different pilot projects it was possible to demonstrate the in situ efficacy of TX products. For example: PAVING BLOCK PAVEMENT in BERGAMO, ITALY ( ) Differences of NOx values between those of photocatalytic zone and those of asphalt zone (reference) vary between 20% and 60%, as a function of both weather and traffic conditions. UMBERTO I TUNNEL in ROME (only vaults) (2007) NOx abatement higher than 20% (ante/post operam) as absolute values, but corresponding to about 50% if referred to the pollution situation in the city of Rome, in the same days 23

23 From pilot scale to real projects In these more recent years, some demonstration projects have been completed and some corresponding monitoring campaigns were carried out, in order to confirm photocatalytic performances of installed materials. Bergamo (2006-7) Rome (2007) Paris (2007-9) 24

24 Photocatalytic cements: short history R&D program on photocatalysis in cement-based systems First (Italian) patent application First publications First concrete trials First project: Dives in Misericordia Church, Rome Rhodamine-B (discoloration) test (CSTB, France) Start of PICADA Project ( ) Street canyon experience Pilot depollution tests in Segrate, Calusco, Bergame Launch of first version of photocatalytic cement (TX Millennium ) Development of Laboratory Test methods Launch of TX Active Cements (Italy, France, Spain, USA, ) Publication of first UNI standards (Italy) Umberto I Tunnel (Rome) (2007) License agreement with Heidelberg Cement Group (2008) Projects: i.lab, Bergamo - Vodafone Village, Milan 25

25 TX Active: Italcementi current market UK: Hanson (Tiocem ) USA-Canada Guatemala over m 2 of total surfaces installed within the 2010 year UK France - Belgium Spain China Italy Greece Morocco Egypt India Export Arabian Peninsula UAE already launched ready for the launch / projects Korea Thailand Australia + other 12 Countries with Heidelberg Cement Group (license agreement): Tiocem 26

26 TX Active: some examples of current R&D topics Health, safety and Life Cycle Analysis (LCA) Photocatalytic performances vs. durability Assessment of the reduction of urban heat island effects 27

27 Studies on health/safety and LCA Processing steps Production of photocat. cement Production of photocat. manufact Exposure Possible free TiO 2 Possible free TiO 2 + liquid/solids containing TiO 2 Physical evaluation: agglomeration of TiO2 particles, adhesion to cement particles Utilization of photocat. product Removal or demolition Possible consumption (e.g. abrasion) Possible free powder containing TiO 2 Studies in progress, for the determination of particles release due to abrasion: French national project: CLEAN dedicated study by INERIS 28

28 Titanium dioxide particles Nanoparticles Microparticles The normal condition of Titanium dioxide particles is the aggregate form by means of a covalent bonding. 29

29 Health/safety studies EDS-1 EDS-2 EDS-1 Sample preparation consists of graphite deposition on the cement powder SEM analysis EDS analysis (elementary microanalysis) EDS-2 NO FREE NANOPARTICLES! 30

30 Durability of photocatalytic products ISO standard evaluation of NOx abatement colorimetric data (CIELab) physical aging for the coating pre-standardization activity description of the cycle A c % A C ( CB C 100 C B L ) I I N S S N 31

31 Cool surfaces to reduce urban heat island effects Photocatalysis, for: - depolluting (pavements) - self-cleaning effect (buildings) Cool pavements in addition: - Clear (white or grey) materials - Cool surfaces Urban Heat Island Mitigation: - High albedo (reflectance) - evaporation, - lower surface temperature - lower CO2 emissions (lower energy consumption, for air conditioning) EPA Cool roofs and façades 32

32 Ongoing EU funded projects photocatalysis in indoor environment Clean buildings along with resource efficiency enhancement using appropriate materials and technology (3 years - 21 partners) in-field measurements, modelization PhotoPaq: Demonstration of Photocatalytic Remediation Processes on Air Quality (4 years - 9 partners) 33

33 TX Active : two product lines Products containing the principle TX Active reduce the harmful substances present in the air and preserve the aesthetic quality of buildings over time. Preserving aesthetics Abating Pollution 34

34 Photocatalytic cement-based products Hydraulic binders (cements and natural limes) Precast and ready-mix concrete Wall coatings (pre-mix mortars, paints) 35

35 Two basic remarks Photocatalytic materials are not a total solution for the elimination of the pollution in urban environments, but can contribute for an effective reduction of gas concentration. Photocatalytic cements can be used as substitutes of traditional Portland cements, with no modifications in rheology, mechanical strength and structural performances of concrete products. 36

36 TX Active horizontal applications Roads Walkways Pavements Roundabouts Parkings Squares 37

37 TX Active vertical applications Coatings Cementitious paints Renders Plasters Building façades Tunnel Umberto I Rome, Italy Coverings Precast panels Bricks and concrete blocks Hotel de Police Bordeaux, France 38

38 International references Recent projects 39

39 Commercial building - Italy Vodafone Village Milan 5 buildings (h max = 60 m) for about 3,000 people 15,000 m 2 Precast concrete façade panels 3,300 m 2 Paving blocks (courtyards) Fine coatings for other concrete walls 40

40 Commercial building - Italy Vodafone Village Milan Precast concrete façade panels 41

41 Commercial building - Italy Vodafone Village Milan Thin precast concrete façade panels (thickness: 20 mm) 42

42 i.lab: Italcementi Research Innovation Centre Bergamo - Italy Architect: R. Meier Precast panels and RMC elements (columns and walls) Rendering - north and east views Job site - September

43 i.lab: Italcementi Research Innovation Centre Precast panels and RMC elements (columns and walls) about 1200 m 3 of photocatalytic concrete 44

44 i.lab: Italcementi Research Innovation Centre Precast roofing panels 45

45 i.lab: Italcementi Research Innovation Centre Precast façade panels 46

46 i.lab: Italcementi Research Innovation Centre Precast panels and RMC elements (columns and walls) 47

47 High quality in architecture graphic concrete architectural concrete molten stones Photos: courtesy of Styl-Comp Group - Italy 48

48 Recent buildings in France Centre hospitalier de Niort (79) Concrete precast panels: 4,000 m 2 49

49 Completed projects in U.S.A. Louisiana State University (LSU) Basketball Practice Facility precast concrete panels 50

50 Completed projects in Spain Iesu church in Riberas de Loiola Architect: Rafael Moneo The final façade is composed of a special white TX Aria mortar, which has been applied onto approximately 10,500 square metres of exterior and interior walls. 51

51 Completed projects in India Pranidhan Chapel at Kalamassery Ernakulum White cement-based paint 52

52 Possible solutions for roads and pavements TX ACTIVE FOR ROADS PAVING BLOCKS LARGE PRECAST SLABS SLURRY-PERCOLATED ASPHALT READY-MIX CONCRETE RMC PRODUCTS THIN OR ULTRA-THIN WHITETOPPING PERVIOUS CONCRETE ROLLER COMPACTED (RCC) CAST IN PLACE TECHNOLOGIES ONE - LIFT PAVING TWO - LIFT PAVING 53

53 Two-lift paving application Route 141 in Chesterfield (St. Louis area) Missouri (USA) The first application of a photocatalytic concrete for a road (MoDOT Highway) 2011/2012 innovative section of two-lift concrete paving, whose upper lift produced with photocatalytic cement photocatalytic pervious concrete for a shoulder section. dedicated monitoring campaign MO This project was officially presented in occasion of the national two-lift concrete paving open house, hosted by the National Concrete Pavement Technology Center (NCPTC) in Chesterfield, MO USA (September 27-28, 2010) 54

54 Two-lift paving demonstration test National two-lift concrete paving open house September 28, 2010 Chesterfield, MO - USA photocatalytic whitetopping conventional concrete sub-base road cross-section 55

55 Slurry infiltrated asphalt concrete photocatalytic binder, for complete percolation of an open-grade asphalt (voids: 18-30%), using a slurry semi-rigid pavement no joints thickness of asphalt: mm casting open-grade asphalt final product 56

56 Easy technology self-percolating no vibration needed easy preparation fast application - Pilot test on A14 highway (Ancona Italy) September Pilot test in Carpiano, Milan (Italy) December

57 Final considerations One of the most innovative solution in cement industry Sustainable materials, for the future Green technology for high quality solutions Depolluting technology for urban environments Durable materials for long lasting buildings Increasing market (about 3,500 tons of TX cements in 2010 year) Over 2,000,000 m 2 of active surfaces Several already approved new, large projects 65

58 Italcementi actions (ITC): Strong R&D activity for strengthening in the photocatalytic products in the building sector International networking with other Industries, Universities, and R&D Centers Continuous market survey to check possible infringements in defense of ITC patents portfolio Active participation to International and National standardization works 69

59 Mutated panels by R. Meier Arch. with Italcementi (2010) Thank you for your attention!