FERROCK
FERROCK
FERROCK
A SEMINAR REPORT
Submitted by
MEENAKSHI S (ATP19CE018)
BACHELOR OF TECHNOLOGY
IN
CIVIL ENGINEERING
Mr.JAYAKRISHNAN.R
OCTOBER 2022
DEPARTMENT OF CIVIL ENGINEERING
CERTIFICATE
Guide/Supervisor Co-Guide/Co-Supervisor
MEENAKSHI S
ABSTRACT
Concrete is the most used building material for construction works, which is
responsible for 70 percent of the industrial carbon dioxide emission. From this
perspective, the green concrete concept has evolved and more researches have been done
on replacement by green materials.
In this study we discuss about Ferrock as a carbon negative concrete. It shows
the best usage of Iron ore waste Powder obtained from mining process which causes air
pollution, health hazards and also consuming large areas. Ferrock is a binder that is a
blend of Iron Powder, Flyash, Lime Powder, Metakaolin and Oxalic acid. Oxalic acid
acts as a catalyst and on reaction with CO2 and water produces Iron Carbonates, which is
the hardened product. It can enhance the environment by absorbing the atmospheric CO2
for its hardening process.
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CONTENTS
ACKNOWLEDGMENT i
ABSTRACT ii
LIST OF FIGURES v
ABBREVIATIONS vi
1 INTRODUCTION 1
1.1 HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 WHY CHOOSE FERROCK OVER CONCRETE? . . . . . . . . . . . . 3
2 LITERATURE SURVEY 4
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6 CONCLUSION 17
REFERENCES 18
iv ASET
LIST OF FIGURES
v
ABBREVIATIONS
vi
Chapter 1
INTRODUCTION
1.1 HISTORY
Ferrock was invented by Dr.David Stone, founder and owner of Iron Shell Media
Technologies, and former University of Arizona Ph.D student in the Department of Soil,
Water, and Environmental Science Department.Stone accidentally made Ferrock while he
was working on project back in 2002. At the time, he was researching ways to prevent
iron from rusting and hardening.
At first, he didn‘t think much of the material he created and abandoned the test.
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However, he soon changed his mind and decided to focus on finding a material with
the same physical capabilities of concrete, but in an eco-friendly version. To test his
new idea, he worked with Tohono O‘odham Nation Reservation in Southern Arizona to
source the silica he needed to his test. He also received 200,000 dollars in grants by
the Environmental Protection Agency (EPA), which allowed him to create demonstrative
projects, along with assistance from the tribe. Once Stone had the Ferrock manufacturing
process figured out, he entered his eco-friendly alternative to concrete in a competition,
which he won.
In 2013, the US Patent and Trademark Office issued patent for the invention.
Although Stone is one who invented Ferrock, the copyright belongs to University of
Arizona, since he was working for them at the time of his discovery. A year later, Stone
worked out a contract to hold a license that allowed him to commercialize his invention.
This license was done in collaboration with Tech Launch Arizona (TLA).
1.2 GENERAL
Concrete is the most utilized structural ingredient in all places. Roughly 1 ton of
cement is created every year from each person on the planet. In view of the broad use, it
is critical to assess the effects of this material in the environment precisely. These days,
a material’s ecological effect is assessed with its individual impact on ozone harming gas
discharges and environmental change. From this perspective, the Green concrete idea
was evolved. Globally, cement production is in charge of 5 to 7 percent of carbon dioxide
generated.
David Stone, a former Ph.D student at the University of Arizona (UA) Department
of Soil, Water and Environmental Science has developed an alternative to Portland cement
known as Ferrock.
Ferrock is a binder that is a blend of Iron Powder, Flyash, Lime Powder,
Metakaolin and Oxalic acid. Oxalic acid acts as a catalyst and on reaction with CO2 and
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water produces Iron Carbonates, which is the hardened product. It can enhance the
environment by absorbing the atmospheric CO2 for its hardening process. From studies,
it is found that the optimum molarity of oxalic acid as catalyst was 10 moles and ferrock
also absorbs considerable amount of CO2 from the atmosphere and reduces the amount
of CO2 emitted from the industries. It’s giving promising suggestions as a choice to
concrete and a far greener construction material. Being environment friendly,Ferrock
uses all the materials from scratch, waste metal powder, Limestone, Metakaolin and
Flyash. This concreting technology is far greener, stronger and durable compared to its
predecessor.
Concrete is a tried and true product that has been used around for hundreds of
years. But despite the extensive use of concrete, there is a good reason we should want to
fit other possible building materials.
Manufacturing concrete and cement-which is produced separately and is added to
the concrete to make it firm up and bind together to form a hard shape-, releases a ton
of carbon dioxide into the air. The reason why there‘s so much CO2 is that cement has
to be heated to extremely high temperature in order to break down the limestone, as in
scorching 2,800°F (1537.778°C). That is, for 1000 kilograms of cement, 900 kilograms
of carbon dioxide is released from the factories and into the air.
In comparison, Ferrock which has been found to absorb carbon dioxide and fuse
it into the matrix. The more CO2 it consumes, the stronger it becomes. It seems like a
no-brainer that we would want to use more of a product that can do the same things as
concrete, but that cleans up our air too.
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Chapter 2
LITERATURE SURVEY
2. Alejandro Lanuza, Garcia et al (2017): In this paper, Life Cycle Analysis (LCA)
is utilized to look at the natural effects of Ferrock and Ordinary Portland Cement,
concentrating on the amount of carbon contamination, water usage. This
procedure incorporates a top to bottom natural evaluation of Ferrock generation,
from the purpose of its materials extraction to all its steps. The outcomes are
contrasted with a past life-cycle investigation of Ordinary Portland Cement (OPC).
This examination finds that Ferrock has both the possibility to supplant OPC, and
contribute essentially to the advancement of an feasible future.
3. Balraj More, Pradeep Jadhav, Vicky Jadhav (2014): In this paper the amount of
CO2 absorbed by the concrete using the Zeolite powder and Zeolite sand as a
supplementary material is determined. They found that the Zeolite Concrete
absorbs around 1 mole of CO2 from atmosphere in 50 days. Concrete with Zeolite
as a supplement material can absorb large quantity of CO2. Introducing Zeolite
material into concrete absorbs CO2 from the atmosphere, hence it will be
eco-friendly. Zeolite absorbs CO2 and reduces the air pollution, keeping
environment clean and full of oxygen.
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6. Robbie M Andrew (2018): In this study the required data for estimating
emissions from global cement production are collected, and it is observed that
some global estimates are significantly inflated. Here they assembled a large
variety of available data sets and prioritised official data and emission factors,
including estimates submitted to the UNFCCC plus new estimates for China and
India, to present a new analysis of global process emissions from cement
production. It show that global process emissions in 2016 were 1.45±0.20GtCO2,
equivalent to about 4% of emissions from fossil fuels. Cumulative emissions from
1928 to 2016 were 39.3±2.4GtCO2, 66% of which have occurred since 1990.
Emissions in 2015 were 30% lower than those recently reported by the Global
Carbon Project were studied.
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7. Laurent Barcelo, John Kline, Gunther Walenta, Ellis Gartner (2013): In this
paper design of a new clinkers that requires less limestone is studied.The volume
of Portland cement required for concrete construction makes the cement industry a
large emitter of CO2. Most of the CO2 footprint of cement is due to the
decarbonation of limestone during the clinkering process. Designing new clinkers
that require less limestone is one means to significantly reduce the CO2 footprint
of cement and concrete. A new class of clinkers is described in this paper that can
reduce CO2 emissions by 20 to 30% when compared to the manufacture of
traditional PC Clinker.
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Chapter 3
Although the structural applications for both materials are very similar, the
manufacturing and chemical processes involved are vastly different. Cement is a binding
material, a substance used for construction that hardens and adheres to aggregates to
bind them together to form concrete. Cements used in construction are usually inorganic,
often with a lime or calcium silicate base and can be characterized as either hydraulic or
non-hydraulic, based on its ability to set in the presence of water.
Portland cement which is largely used in the construction industry is an example
of hydraulic cement. They set and become adhesive due to an exothermic chemical
reaction between the cement and the water due to the hydration of the principal chemical
components of cement, namely, tricalcium (Ca3) and dicalcium silicate (Ca2SiO4),
tricalcium aluminate (Ca3AI2O6), and tetracalcium aluminoferrite
(Ca4AI2Fe2O10).The chemical reaction also called as hydration of cement results in
mineral hydrates. This reaction results in the hardening and strength gaining of cement.
Cement also finds its application as a soil stabilizer in geo-technical engineering, and
stabilizer for environmental applications.
The raw materials used in the manufacturing of cement mainly consists of lime,
silica, alumina and iron oxide. The oxides interact with one another in the kiln at high
temperature to form more complex compounds. The relative proportions of these oxide
compositions are responsible for influencing the wide range of properties of cement. The
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table below shows the approximate oxide composition limits of ordinary Portland cement.
In comparison, Ferrock also uses clay and limestone as part of its composition,
but the ratio of clay and limestone used is much smaller compared to OPC, eight and ten
percent respectively. The majority of the mixture, totaling 80 percent, is composed of low-
value waste products. The main ingredient is metallic iron powder, which is a byproduct
of shot blasting, a finishing technique for steel manufacturing. During the shot blasting
process the iron powder is ground to a micro-particle scale ( 19.03µm), which becomes
a considerable nuisance to the blasting facility because of its ineffectual applicability and
the inherent respiratory hazard associated with working with such a fine material. These
ingredients are combined as a dry-mix with a source of silica, such as fly ash or recycled
glass. Oxalic acid is also added to facilitate the chemical process and then blended to
create a uniform mixture.
It is necessary to point out that the Oxalic Acid, while small in percentage,
represents an important ingredient of the mixture since it promotes the precipitation and
mineralization of iron. It is in fact a well-known chemical promoter commonly used in
the iron industry due to its characteristics as an iron dissolvent, which prevents
oxidization and has the capacity to absorb CO2 (by creating iron oxalate). While
reacting with the Ferrock mixture, it chemically reacts with the compound and
transforms it into a bonded carbonate molecule and therefore has no further threat as an
emitting greenhouse gas (GHG).With the introduction of additional aggregates, water
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and compressed carbon dioxide, the iron oxide begins to chemically react yielding a new
compound, iron carbonate,and emits hydrogen gas as a by-product.
Fe(O)+ CO2 + H2 O = FeCO3 + H2
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Chapter 4
Besides its unique chemical properties as a carbon sink that emits valuable
hydrogen gas as a byproduct, Ferrock additionally presents technical characteristics that
have potential to make it a promising substitute for cement. Ferrock has similar
functional properties in terms of its fresh-state behavior and workability.
In addition, the iron-based binder requires a fractional amount of time to cure
compared to OPC; 4 days of carbonation compared to the 28 days of hydration that is
required for cement to cure. The curing process for Ferrock also has the theoretical
potential to be further expedited based on the purity of the compressed carbon dioxide.
Additional characteristics can be defined by a comparison with the pore structure of
28-day cured OPC pastes. The value of permeability of Ferrock after 4 days of
carbonation (k = 2.5 x 10-16 m2) is significantly higher than 28-day cured cement paste
(k = 6.17 x 10-20 m2).
Research studies also show that the iron-based binder is chemically stable in
marine environments and does not break down upon exposure to salt waters. In fact,
results show that Ferrock has the capacity to incorporate some of the salt, especially the
chlorine ions into the mineral structure. This trapping capacity seems to extend to some
toxic contaminants such as arsenic.
The addition of oxalic acid increases the production of iron carbonate which
respectively reflects in increased strength.
Ferrock has a bit of flexibility to it, it can withstand more pressure and movement.
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Concrete is completely solid, so any slight movement can cause cracks that weaken the
entire structure. Ferrock, on the other hand, can withstand some movement without
damage. This feature makes it great to use in areas where there is active seismic activity
such as earthquakes. In flexural tests, it is found that Ferrock is four times harder than
Portland cement.
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Chapter 5
• Greenhouse gas emission-As CO2 is used during the hardening process it helps
reduce one of the most dangerous of greenhouse gases.
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• Ferrock involves high cost- It is believed that the material is more suitable for
niche products but will not be a cost-effective solution for large-scale projects such
as roads and highway developments.
Many industry believe that if the steel dust goes directly from being a waste to being
a useful building material, the cost of producing Ferrock will be exponentially high,
which makes the construction process all the more costlier.
As of now, Ferrock is not a popular construction material in India, going forward
it is expected to become one of the crucial building materials with its multiple
advantages surpassing its debated high-cost.
• Availability of raw materials-Ferrock needs steel dust waste and silica, both of
which are the byproducts or leftover scraps of another process. Therefore both of
these product are in limited supply. It takes a lot of silica and metal shavings to
make Ferrock, which makes it challenging to do large projects.
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Chapter 6
CONCLUSION
While Ferrock has been used in smaller construction sites, it has a long way to go
to become widely adopted. Many field experiments have been and are presently being
conducted to test and demonstrate the strength and capability of Ferrock in commercial
projects. However, the large-scale adoption of these alternative materials remains an
uphill battle. Considering concrete and cement have been in use for over 200 years, they
have stood the test of time, and unfortunately there just isn’t enough data to prove that
alternative materials - no matter how sustainable - can survive in the long term.
In the face of rapid real estate and infrastructure expansion, sustainable
construction is the only way to preserve deteriorating environmental resources. Though,
as of now, Ferrock is not a popular construction material in India, going forward it is
expected to become one of the crucial building materials with its multiple advantages
surpassing its debated high-cost.
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REFERENCES
[3] Balraj More, Pradeep Jadhav, Vicky Jadhav, ”CO2 Absorbing Concrete Block.”
(July 2015)
https://issuu.com/ijteee/docs/co2-absorbing-concrete-block
[5] Altwair Nurdeen, ”Green concrete structures by replacing cement with pozzolanic
materials to reduce greenhouse gas emission for sustainable environment.” (June
2010)
https://www.researchgate.net/publication/273445439
[6] Robbie M Andrew, ”Global CO2 emission from cement production.” (July 2018)
https://doi.org/10.5281/zenodo.831455
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[7] Laurent Barcelo, John Kline, Gunther Walenta, Ellis Gartner, ”Cement and carbon
emissions.” (June 2013)
https://link.springer.com/article/10.1617/s11527-013-0114-5
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