New Markets for Magnesium Compounds

1. It is time to contemplate new technology paradigms, new products and new organisational structures New Markets for Magnesium Compounds TecEco are in the business of using MgO to solve sustainability problems economically. Sustainability will be the biggest business on the planet if we want to survive the future. Auguste Rodin “The Thinker” I will have to race over some slides but the presentation is always downloadable from the TecEco web site if you missed something. John Harrison B.Sc. B.Ec. FCPA.

2. The Mg Compounds Industry We have to be flexible- Tsoukatos, Michael, Magmin 2005 Obvious role is to be technical leaders- Bamas, Dominique, Magmin 2005We need to be proactive innovatorsHarrison, John, Magmin 2005 • Characterized as being. • Market acceptors not creators. • Mature but volatile markets • Not investing in innovation • Submissive • Dominique Bamas “A tough industry for tough guys” • Unidentified industry representative “Our investors do not want us to be innovative” • Misconception that the type of product is very much controlled by the type of ore • TecEco kiln technology will allow departure from this situation. • Failure to understand what reactive means • CCM is a catch all word for anything that is not DBM or FM • A new product category called “reactive magnesia” • Many pages on the net featuring TecEco • We hope to find yours there by the next industry conference if you can make genuine low temperature calcined reactive MgO • Largely oblivious as to how carbon taxes and energy shortages will impact. • The production of reactive magnesia could be the first major non fossil fuel driven industrial process.

3. Time to Innovate Leaders innovate. Managers react • Mining methods? • Production technologies • TecEco kiln technology will make it possible to efficiently make consistent product from a wide variety of ores using non fossil fuel energy in a closed system allowing the capture of CO2 (Carbon taxes will not be a burden using the technology) • Why then is it so hard to raise funds to develop the technology? • Product development • Most uses of MgO have not yet been invented or improved. (Bamas, Dominique, Magmin 2005 ) • TecEco tec, eco and enviro cements could be developed and deployed very quickly with the backing of the industry create substantial new markets using high silica or possible iron magnesia (often a waste stream) without much cost. • The construction market will grow significantly with TecEco technology – not shrink.

4. Time to Contemplate? • MagMin 2005 may be the first time ever that such a large group of magnesium compounds industry representatives have been together. • We should all thank Mike O’Driscoll and Industrial Minerals Magazine for this opportunity. • There are obviously common industry issues e.g. • Response to carbon taxes • Competition product associations and lobby groups e.g. • Portland cement industry putting out information to diffuse and confuse regarding TecEco technology, use of MgO for environmental remediation etc. • Lobby groups having a disproportionate say on government committees etc. • Research development and deployment. • To develop new markets (e.g Tec and Eco-Cements). • Energy issues. • Government policy issues. E.g. the EU on OH&S

5. Time to Form an Association? • Why not use this venue with so many of you together to form an association. • There should be three sub-groups representing: • Dead burned magnesia • Caustic calcined magnesia • Reactive magnesia. • Collectively you will • Counter the lobbying power of alternative competing industries such as the lime and Portland cement industries. • Move from being market acceptors to a leading industry creating your own future.

6. Opportunities for the Magnesium Compounds Industry • The Kyoto treaty came in to force on the 16th February, 2005. • Signatory countries are legally bound to reduce worldwide emissions of six greenhouse gases (collectively) by an average of 5.2% below their 1990 levels by the period 2008-2012. • Sequestration is just as important as emissions reduction. • Magnesium compounds are the ideal choice for mineral sequestration. • The magnesium compounds industry can play a vital role • Supplying reactive magnesia to the new sequestration market. • Developing new and innovative technologies to make reactive magnesia using non fossil fuel energy. • Championing the use of reactive magnesia for sequestration in eco-cements for the built environment and directly out of the air. • Helping their respective countries meet their Kyoto commitments. TecEco can help the industry adapt and grow its own future

7. Partners in the Business Opportunity • The magnesium compounds industry. • The power industry and others who will be seeking to reduce carbon taxes. • Global governments who can organize carbon credits. ****************************** • The role of the magnesium compounds industry • Pressing to remove standards banning reactive magnesia in Portland cement. • Advocating mineral sequestration. • Taking a stand in the sequestration debate pointing out the advantages of magnesium compounds. • Providing research Funds to develop TecEco technologies by. • Taking advance licences. • Buying a share in the company. R & D is not just about studying your competitors product or markets. It can be about creating new market space.

8. The Problem – A Planet in Crisis TecEco are in the BIGGEST Business on the Planet - Solving Sustainability Problems Economically A Planet in Crisis?

9. A Demographic Explosion ? Undeveloped Countries Developed Countries Global population, consumption per capita and our footprint on the planet is exploding.

10. Atmospheric Carbon Dioxide

11. Global Temperature Anomaly

12. The Techno-Process Earth Systems Atmospheric composition, climate, land cover, marine ecosystems, pollution, coastal zones, freshwater systems, salinity and global biological diversity have all been substantially affected. Our linkages to the bio-geo-sphere are defined by the techno process describing and controlling the flow of matter and energy. It is these flows that have detrimental linkages to earth systems. Detrimental affects on earth systems Move 500-600 billion tonnesUse some 50 billion tonnes

13. Ecological Footprint Our footprint is exceeding the capacity of the planet to support it. We are not longer sustainable as a species and must change our ways

14. Impact of the Largest Material Flow - Cement and Concrete • Concrete made with cement is the most widely used material on Earth accounting for some 30% of all materials flows on the planet and 70% of all materials flows in the built environment. • Global Portland cement production is in the order of 2 billion tonnes per annum. • Globally over 14 billion tonnes of concrete are poured per year. • Over 2 tonnes per person per annum TecEco Pty. Ltd. have benchmark technologies for improvement in sustainability and properties

15. Embodied Energy of Building Materials Concrete is relatively environmentally friendly and has a relatively low embodied energy Downloaded from www.dbce.csiro.au/ind-serv/brochures/embodied/embodied.htm (last accessed 07 March 2000)

16. Average Embodied Energy in Buildings Most of the embodied energy in the built environment is in concrete. But because so much is used there is a huge opportunity for sustainability by reducing the embodied energy, reducing the carbon debt (net emissions) and improving properties. Downloaded from www.dbce.csiro.au/ind-serv/brochures/embodied/embodied.htm (last accessed 07 March 2000)

17. Emissions from Cement Production • Chemical Release • The process of calcination involves driving off chemically bound CO2 with heat. CaCO3 →CaO + ↑CO2 ∆ • Process Energy • Most energy is derived from fossil fuels. • Fuel oil, coal and natural gas are directly or indirectly burned to produce the energy required releasing CO2. • The production of cement for concretes accounts for around 10%(1) of global anthropogenic CO2. (1) Pearce, F., "The Concrete Jungle Overheats", New Scientist, 19 July, No 2097, 1997 (page 14).

18. Cement Production = Carbon Dioxide Emissions

19. Sustainability • Sustainability is a direction not a destination. • Our approach should be holistically balanced and involve • Everybody, every process, every day. + + Eco-cements = Low Emissions ProductionMineral Sequestration + Waste utilization Emissions reductionthrough efficiency andconversion to non fossil fuels Geological Seques-tration TecEco’s Contribution

20. Sustainability = Culture + Technology Increase in demand/price ratio for sustainability due to educationally induced cultural drift. $ Supply Greater Value/for impact (Sustainability) and economic growth Equilibrium shift ECONOMICS Demand Increase in supply/price ratio for more sustainable products due to innovative paradigm shifts in technology. # Sustainability is where Culture and Technology meet. Demand Supply

21. Huge Potential for Sustainable Materials in the Built Environment C C Waste C Waste C C • The built environment is made of materials and is our footprint on earth. • It comprises buildings and infrastructure. • Building materials comprise • 70% of materials flows (buildings, infrastructure etc.) • 40-45% of waste that goes to landfill (15 % of new materials going to site are wasted.) • Reducing the impact of the take and waste phases of the techno-process. • By including carbon in materialsthey are potentially carbon sinks. • By including wastes forphysical properties aswell as chemical compositionthey become resources

22. Innovative New Technologies Vital • It is possible to achieve Kyoto targets as the UK are proving, but we need to go way beyond the treaty according to our chief scientists. • Carbon rationing has been proposed as the only viable means to keep the carbon dioxide concentration in the atmosphere below 450 ppm. • Atmospheric carbon reduction is essential, but difficult to politically achieve by rationing. • Making the built environment not only a repository for recyclable resources (referred to as waste) but a huge carbon sink is an alternative and adjunct that is politically viable as it potentially results in economic benefits. • Concrete, a cementitous composite, is the single biggest material flow on the planet with over 2.2 tonnes per person produced. • Eco-cements offer tremendous potential for capture and sequestration using cementitious composites. • Tec-Kiln technology vital to lower costs and make more reactive Mg compounds

23. TecEco Technologies • Silicate → Carbonate Mineral Sequestration • Using either peridotite, forsterite or serpentine as inputs to a silicate reactor process CO2 is sequestered and magnesite produced. • Proven by others (NETL,MIT,TNO, Finnish govt. etc.) • Tec-Kiln Technology • Combined calcining and grinding in a closed system allowing the capture of CO2. Powered by waste heat, solar or solar derived energy. • To be proved but simple and should work! • Direct Scrubbing of CO2 using MgO • Being proven by others (NETL,MIT,TNO, Finnish govt. etc.) • Tec and Eco-Cement Concretes in the Built Environment. • TecEco eco-cements set by absorbing CO2 and are as good as proven. TecEco EconomicunderKyoto? TecEco

24. The TecEco Total Process Olivine Mg2SiO4 This reaction is how most MgCO3 came to be formed anyway so why are we not using it to also sequester carbon? Serpentine Mg3Si2O5(OH)4 Crushing Crushing CO2 from Power Generation or Industry Grinding Grinding Waste Sulfuric Acid or Alkali? Screening Screening Silicate Reactor Process e.g. Mg2SiO4 +2CO2 =>2MgCO3 + SiO2 Magnetic Sep. Gravity Concentration Heat Treatment Fe, Ni, Co. Silicic Acids or Silica Magnesite (MgCO3) Simplified TecEco ReactionsTec-Kiln MgCO3 → MgO + CO2 - 118 kJ/moleReactor Process MgO + CO2 → MgCO3 + 118 kJ/mole (usually more complex hydrates) Solar or Wind Electricity Powered Tec-Kiln CO2 for Geological Sequestration Magnesium Thermodynamic Cycle Magnesite MgCO3) Magnesia (MgO) Oxide Reactor Process Other Wastes after Processing CO2 from Power Generation, Industry or CO2 Directly From the Air MgO for TecEco Cements and Sequestration by Eco-Cements in the Built Environment

25. Why Magnesium Compounds? • Because of the low molecular weight of magnesium, magnesium oxide which hydrates to magnesium hydroxide and then carbonates, is ideal for scrubbing CO2 out of the air and sequestering the gas into the built environment: • More CO2 is captured than in calcium systems as the calculations below show. • Magnesium minerals are relatively abundant. • Magnesium minerals are potential low cost. New kiln technology from TecEco will enable low cost simple non fossil fuel calcination with CO2 capture of magnesium carbonate. • Because large quantities of carbonates (the binder in eco-cements) are produced from not much MgO. (The volumetric expansion from MgO to MgCO3.5H2O is 811% )

26. Why Magnesium Compounds (2)? • At 2.09% of the crust magnesium is the 8th most abundant element. • Magnesium oxide is easy to make using non fossil fuel energy using TecEco kiln technology. • Reactive, low lattice energy forms of magnesium oxide are most suitable as they are • Easier to get into solution • Efficiently absorb CO2 • A high proportion of CO2 and water means that a little MgO goes a long way. • In terms of sequestration or binder produced for starting material in cement, eco-cements are nearly six times more efficient. • Use for sequestration directly and in the built environment would result in new and exciting markets for the magnesium compounds industry.

27. MgO Production at 10% of PC Portland Cement Production Possible Reactive Magnesia Production At 10% substitution of PC by MgO 2005 world production would have been 210 million tonnes which is more than 100 times greater than current production The MgO could come from abundant silicates not necessarily carbonates. A carbon credit would apply for first carbonating a silicate then calcining the resulting carbonate without emitting CO2 to the atmosphere.

28. TecEco Kiln Technology • Grinds and calcines at the same time. • Runs 25% to 30% more efficiency. • Can be powered by variable non fossil fuel energy. • Theoretically capable of producing much more reactive MgO • Even with ores of high Fe content. • Captures CO2 for bottling and sale to the oil industry (geological sequestration). • Runs at low temperatures. • Can be run cyclicly as part of a major process to solve global CO2 problems. • Will result in new markets for ultra reactive low lattice energy MgO (e.g. paper and environment industries) • TecEco need your backing to develop the kiln

29. More Consistently Reactive MgO Particle Size => A narrower distribution of reactivity is desirable The current state of the art is a broad distribution of reactivity Reactivity =>

30. More Consistently Ground MgO The current state of the art is a broad distribution of particle size. Particle Size => A narrower distribution of particle size is desirable Particle Size =>

31. A Post – Carbon Age The magnesium industry can be uniquely responsible for helping achieve this transition “Molecular Biomimicry”

32. Drivers for TecEco Cement and Kiln Technology Government Influence Carbon Taxes Provision of Research Funds Environmental education TecEco kiln technology could be the first non fossil fuel powered industrial process Consumer Pull Environmental sentimentFear of climate changeCost and technical advantagesCompetition Huge Markets Cement 2 billion tonnes. Bricks 130,000 million tonnes Producer Push The opportunity cost of compliant waste disposal Profitability and cost recovery Technical merit Resource issues Robotics Research objectives TecEco cements are the only binders capable of utilizing very large quantities of wastes based on physical property rather than chemical composition overcoming significant global disposal problems, and reducing the impact of landfill taxes. TecEco eco-cements can sequester CO2 on a large scale and will therefore provide carbon accounting advantages.

33. Drivers for Change – Robotics • Using Robots to print buildings is all quite simple from a software, computer hardware and mechanical engineering point of view. • The problem is in developing new construction materials with the right flow characteristics so they can be squeezed out like toothpaste, yet retain their shape until hardened • Once new materials suitable for the way robots work have been developed economics will drive the acceptance of robots for construction • Concretes for example will need to evolve from being just a high strength grey material, to a smorgasbord of composites that can be squeezed out of a variety of nozzles for use by a robotic workforce for the varying requirements of a structure • TecEco cement concretes have the potential of achieving the right shear thinning characteristics required

34. Benefits of Adopting TecEco Technology • We can meet Kyoto objectives and at the same time reduce our footprint and make money. • There are a number of opportunities for improved sustainability that are relatively easily achieved with MgO: • Utilizing wastes to make concretes. • Fly ash, bottom ash, industrial slags etc. (Tec and Eco-Cements.) • Reducing energy and emissions during the production of cements. • Sequestering carbon by allowing MgO to re-carbonate. The biggest business on the planet is going to be the sustainability business

35. The Role of the Magnesium Compounds Industry • The use of reactive MgO for sequestration directly (as magnesium hydroxide used to scrub CO2 out of the air) and as tec, eco and enviro cements in the built environment could potentially increase the market to in the order of millions of tonnes especially for lower purity grades (e.g. High SiO2). • Players in the magnesium compound industry of the future will need to understand and get involved in sustainability issues and what TecEco are doing. Making sure: • Mineral sequestration research, development and deployment remain on track as the physical outcome – the supply of large amounts of magnesium carbonate – will reduce mining costs considerably. • The development of tec and eco-cements occurs as large quantities of reactive reactive MgO will be required for this purpose. • Enabling technologies such as the TecEco kiln are developed as they will allow production of the highly reactive magnesia required and reduce the cost base of manufacture. • There are significant outcomes requiring significant commitment and a vision for the future.

36. TecEco Cements More information at www.tececo.com More slides on web site

37. TecEco Cements SUSTAINABILITY PORTLAND + or - POZZOLAN Hydration of the various components of Portland cement for strength. Reaction of alkali with pozzolans (e.g. lime with fly ash.) for sustainability, durability and strength. TECECO CEMENTS DURABILITY STRENGTH MAGNESIA Hydration of magnesia => brucite for strength, workability, dimensional stability and durability. In Eco-cements carbonation of brucite => nesquehonite, lansfordite and an amorphous phase for sustainability. TecEco concretes are a system of blending reactive magnesia, Portland cement and usually a pozzolan with other materials and are a key factor for sustainability.

38. The Magnesium Thermodynamic Cycle

39. TecEco Cements - Sustainability in The Built Environment • The CO2 released by calcined carbonates used to make binders can be captured using TecEco kiln technology. • Tec-Cements Develop Significant Early Strength even with Added Supplementary Materials. • Around 25 = 30% less total binder is required for the same strength. • Eco-cements carbonate sequestering CO2 • Both tec and eco=cements provide a benign low pH environment for hosting large quantities of waste overcoming problems of: • Using acids to etch plastics so they bond with concretes. • sulphates from plasterboard etc. ending up in recycled construction materials. • heavy metals and other contaminants. • delayed reactivity e.g. ASR with glass cullet • Durability issues

40. TecEco Formulations • Tec-cements (Low MgO) • contain more Portland cement than reactive magnesia. Reactive magnesia hydrates in the same rate order as Portland cement forming Brucite which uses up water reducing the voids:paste ratio, increasing density and possibly raising the short term pH. • Reactions with pozzolans are more affective. After all the Portlandite has been consumed Brucite controls the long term pH which is lower and due to it’s low solubility, mobility and reactivity results in greater durability. • Other benefits include improvements in density, strength and rheology, reduced permeability and shrinkage and the use of a wider range of aggregates many of which are potentially wastes without reaction problems. • Eco-cements (High MgO) • contain more reactive magnesia than in tec-cements. Brucite in porous materials carbonates forming stronger fibrous mineral carbonates and therefore presenting huge opportunities for waste utilisation and sequestration. • Enviro-cements (High MgO) • contain similar ratios of MgO and OPC to eco-cements but in non porous concretes brucite does not carbonate readily. • Higher proportions of magnesia are most suited to toxic and hazardous waste immobilisation and when durability is required. Strength is not developed quickly nor to the same extent.

41. TecEco Cement Technology • Portlandite (Ca(OH)2) is too soluble, mobile and reactive. • It carbonates, reacts with Cl- and SO4- and being soluble can act as an electrolyte. • TecEco generally (but not always) remove Portlandite using the pozzolanic reaction and • TecEco add reactive magnesia • which hydrates forming brucite which is another alkali, but much less soluble, mobile or reactive than Portlandite. • In Eco-cements brucite carbonates The consequences of need to be considered.

42. Why Add Reactive Magnesia? • To maintain the long term stability of CSH. • Maintains alkalinity preventing the reduction in Ca/Si ratio. • To remove water. • Reactive magnesia consumes water as it hydrates to possibly hydrated forms of brucite. • To reduce shrinkage. • The consequences of putting brucite through the matrix of a concrete in the first place need to be considered. • To make concretes more durable • Because significant quantities of carbonates are produced in porous substrates which are affective binders. Reactive MgO is a new tool to be understood with profound affects on most properties

43. Overcoming Dogma • In 1917 the US National Bureau of Standards (now the National Bureau of standards and Technology) and the American Society for Testing Materials established a standard formula for Portland cement which excluded MgO in any form. • We now know that it is lattice energy that causes the difference between amorphous magnesia and periclase • TecEco have proved that amorphous magnesia, having no lattice energy to overcome, is safe to use in hydraulic binder cement systems • Standards still ban any form of MgO in concretes to the detriment of the industry. • This perception is something the magnesium compounds industry must overcome .

44. Lattice Energy Destroys a Myth • Magnesia, provided it is reactive rather than “dead burned” (or high density, crystalline periclase type), can be beneficially added to cements in excess of the amount of 5 mass% generally considered as the maximum allowable by standards prevalent in concrete dogma. • Reactive magnesia is essentially amorphous magnesia with low lattice energy. • It is produced at low temperatures and finely ground, and • will completely hydrate in the same time order as the minerals contained in most hydraulic cements. • Dead burned magnesia and lime have high lattice energies • Crystalline magnesium oxide or periclase has a calculated lattice energy of 3795 Kj mol-1 which must be overcome for it to go into solution or for reaction to occur. • Dead burned magnesia is much less expansive than dead burned lime (Ramachandran V. S., Concrete Science, Heydon & Son Ltd. 1981, p 358-360 )

45. Summary of Reactions Involved We think the reactions are relatively independent. Notice the low solubility of brucite compared to Portlandite and that nesquehonite adopts a more ideal habit than calcite & aragonite

46. Strength with Blend & Porosity Tec-cement concretes Eco-cement concretes High Porosity Enviro-cement concretes High Magnesia High OPC STRENGTH ON ARBITARY SCALE 1-100

47. Tec-Cement Concrete Strength Gain Curve • Concretes are more often than not made to strength. • The use of tec-cement results in • 20-30% greater strength or less binder for the same strength. • more rapid early strength development even with added pozzolans. • Straight line strength development for a long time strength gain with less cement and added pozzolans is of great economic and environmental importance.

48. Reasons for Strength Development in Tec-Cements. • Reactive magnesia requires considerable water to hydrate resulting in: • Denser, less permeable concrete. • A significantly lower voids/paste ratio. • Higher early pH initiating more effective silicification reactions? • The Ca(OH)2 normally lost in bleed water is used internally for reaction with pozzolans. • Super saturation of alkalis caused by the removal of water? • Micro-structural strength due to particle packing (Magnesia particles at 4-5 micron are a little over ½ the size of cement grains.) • Slow release of water from hydrated Mg(OH)2.nH2O supplying H2O for more complete hydration of C2S and C3S? • Formation of MgAl hydrates? Similar to flash set in concrete but slower?? • Formation of MSH??

49. Water Reduction During the Plastic Phase Water is required to plasticise concrete for placement, however once placed, the less water over the amount required for hydration the better. Depending on grind size magnesia consumes more water as it hydrates than is required because of its fineness. Less water results in less shrinkage and cracking and improved strength and durability. Concentration of alkalis and increased density result in greater strength.

50. Tec-Cement Compressive Strength Graphs by Oxford Uni Student