Lime Mortar Research Development Innovation Projects Contracts

Lime Mortar Research Development Innovation Projects Contract

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Current projects: (please feel free to add offers / update in comments below – and get promoted!)

Lime-based solid reactor for CO2 separation from exhaust gases with regenerative recovery of the enthalpy of reaction (2020-2022):

The lime and cement industries are responsible for around 5% of global CO2 emissions. About half of the CO2 comes from the product itself through the limestone decomposition CaCO3 -> CaO + CO2. This CO2 cannot be avoided through the use of renewable energies. Therefore the CO2 has to be captured. In the project, a solid reactor is being developed that works according to the calcium looping process. Here the exhaust gas is compressed for CO2 exothermic absorption (CaO + CO2 -> CaCO3) and the gas is expanded for endothermic calcination (CaCO3 -> CaO + CO2) with the release of CO2. As a result, the exothermic absorption (carbonization) takes place at a higher temperature level than the endothermic calcination. The heat released is stored regeneratively in the particles of the reactor and then used for calcination. In preliminary tests, 250 cycles were carried out according to this method without the material burning to death (continuously decreasing CO2 absorption). Compared to previous calcium looping processes, not only is dead burning avoided, but the enthalpy of reaction is also reused, so that oxyfuel firing for calcination and the inefficient generation of electricity for carbonization are no longer necessary. The FSt. 1 Reaction kinetic experiments carried out on an existing thermoreactor, the FSt. 2 develops a process model and the FSt. 3 shows the mode of operation with an existing semi-industrial shaft reactor.

L’AmmoRE – Ammonia Recovery with Lime / Ammonia recovery from fermentation products from biogas plants in the form of ammonia water using lime (2020-2022):

The biogas plants make a valuable contribution to the renewable energy mix in Germany. At the same time, however, they also face the problem of disposing of the nutrient-rich digestate. Due to tightening of the European and national legal situation, agricultural application without prior removal is only possible to a limited extent, which leads to increased costs for the plant operator. The problem is particularly pronounced in regions with high levels of livestock processing due to the already existing nutrient surplus. Above all, the high nitrogen content in the digestate has a limiting effect. This is where the presented project comes in. By means of a stripping system converted for the use of milk of lime, digestate of various compositions is denitrified, and thus a limed digestate is obtained, which can be used again as liquid farm manure. The ammonia obtained is processed directly into marketable ammonia water, which is used, for example, in analytical chemistry or in flue gas cleaning. As a result, SMEs (especially lime and cement manufacturers, biogas plant operators) benefit across all sectors from an increase in competitiveness, the development of new sales markets, the conversion / construction of stripping plants, the spreading of denitrified digestate and the expanded range of uses of lime milk. The concluding technology and economic feasibility study will address both a scale-up and the use of ammonia water in various industries.
By fully utilizing the digestate, the project makes a valuable contribution to the circular economy. At the same time, the production of ammonia is more energy-efficient and climate-neutral than conventional production using the Haber-Bosch process. The decentralized extraction of ammonia also helps to reduce the greenhouse gases caused by transport.

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We DO work on co2 reduction, older and current Projects:

Direct CO2 avoidance
LEILAC (Low Emissions Intensity Lime And Cement) has the potential of a technological breakthrough that can enable the European cement and lime industry to significantly reduce its emissions while maintaining or even increasing its international competitiveness. With the best technologies currently available in the cement and lime industries, there is no way to economically capture carbon. Therefore, the most practical approach to reducing these emissions for the cement and lime industries has been to increase the efficiency of the ovens and use alternative fuels. The direct CO2 separation offers a common platform for CCU and CCS in both the lime and cement industries and can make these industries future-proof.

The LEILAC technology should enable a direct separation of the carbon dioxide in order to efficiently separate the unavoidable process emissions that arise during the lime and cement production. This is made possible by the special shape of the furnace, in which the resulting process emissions from the limestone are separated from the remaining exhaust gas. This means that the technology has the potential to use renewable fuels to achieve the target reduction in emissions by 2050. There are already concrete plans to operate the LEILAC furnace purely electrically. This enables both direct avoidance of CO2 and efficient CO2 separation of the amount of CO2 that occurs.

CO2 capture
Responsible use of natural resources and climate protection are central elements of a climate-neutral lime industry in 2050. As an indispensable basic industry, the lime industry is responsible for around 1.5% of the CO2 emissions of the German energy and industrial sector (UBA inventory report, 2017). About ⅔ of the CO2 is due to the raw material and cannot be avoided by using renewable energies in the combustion process. A CO2 separation with subsequent recycling (CCU) according to the idea of ​​the circular economy or – if unavoidable – CO2 storage (CCS) is the declared goal for fulfilling the German climate protection plans.

To achieve this goal, a fixed bed reactor is being developed as part of an AiF-IGF project, with which CO2 can be separated from exhaust gases in a much more energy-efficient manner than with known processes. The new approach is that the exothermic carbonization (CO2 absorption: CaO + CO2 → CaCO3) is carried out at overpressure and the endothermic calcination (CaCO3 → CaO + CO2) at negative pressure. As a result, the carbonization takes place at a higher temperature level than the calcination. The enthalpy of reaction released during carbonization is stored regeneratively in the solid reactor and used for calcination. In preliminary tests, up to 250 cycles were carried out without a decrease in CO2 absorption. Compared to previous calcium looping processes, this dead burning is avoided and the enthalpy of reaction is reused, so that oxyfuel firing for calcination and the inefficient generation of electricity during carbonization are no longer necessary. Calculations show that only approx. 10 to 20% of the energy of oxyfuel combustion is required. In further project steps, after successful CO2 concentration and separation, the focus is on the identification of the most suitable CCU application, e.g. B. CO2 mineralization or methanation.

 

Carbonation and mineralization
As part of the AiF research project “ECO 2: Development of the limestone powder CO2 washing process – practical optimization and ecological assessment” (AiF-IGF No. 18560N), the CO2 separation at a coal-fired power station in Wilhelmshaven was investigated with the help of a semi-technical demonstration system. The CO2 scrubber simulated the naturally occurring carbonate weathering in a process-technically accelerated manner. The CO2 exhaust gas is passed through a limestone powder-water suspension inside the scrubber, whereby the CO2 is converted into water-soluble hydrogen carbonate. The mineralized water produced can then be used directly for water restoration and buffering. As part of the project, long-term simulations were also carried out to evaluate the permanent storage of carbon dioxide in water and the chemical-ecological effects on flora and fauna. The ECO-2 process thus contributes on the one hand to climate protection by avoiding CO2 emissions and on the other hand to environmental protection and sustainability through the component of water remediation through the introduction of the mineralized water.

In the planned follow-up project ECO 3, this process is to be used for sustainable water restoration of the newly created open-cast mining lakes in Lusatia. Most of these lakes are currently characterized by increased acid input from the surrounding rock and very low pH values, which prevents both tourist and normal use of the water. Our limestone meal CO2 washing process makes it possible to supply the lakes with acid buffers, enable sustainable use and permanently bind CO2 as hydrogen carbonate.

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Lignite Brown Coal Research Development contract innovation update

Lignite Brown Coal Research Development contract innovation update

currently no new projects listed

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older Projects:

Optimization of the dynamic behavior of slewing mechanisms for bucket wheel excavators
Swivel mechanisms enable the targeted control of a rotary movement. This is between
two ball races arranged a plurality of rolling elements, which have a bearing function
of the rotatable system part. The slewing ring is driven by a
Pinion-ring gear system, whereby the drive power necessary for the rotary movement is over
several swivel drives arranged on the circumference of the ring gear are provided.
During the digging process, the bucket wheel excavator’s superstructure is lifted over the slewing mechanism
pivoted about its vertical axis, so that a large area of ​​the slope from the paddle wheel
can be covered without moving the device. However, due to the
mechanical coupling with the wheel arm, the digging forces in the slewing gear and in the
Swivel gear. Various process-specific effects contribute to the fact that the
The nominal loads of the digging and swiveling process are superimposed on dynamic loads. The
Dynamic additional loads limit the service life of those involved in the digging process
Machine elements, as every load cycle leads to partial damage to the components. In addition, will
the inherent behavior of the system is addressed, so that excess resonance occurs and
further promote component fatigue.
With the help of the simulation models to be developed, the overall system is coordinated
in terms of improved dynamics. As a suitable method of achieving this
The aim is to develop an optimized motor control for the swivel drives.
Linked to this is the analysis of the influence of the individual drive train components on
the dynamic behavior of the pan and dig process. This enables the delivering
SMEs integrate their partial deliveries into a coordinated system so that in

 

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Iron Steel Research Development contract innovation update

Iron Steel Research Development contract innovation update

currently no new projects listed

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older Projects:

Co- ordination of EU- Funding is essential for maintaining international competitiveness

The steel industry will play a key role on the way to a climate-neutral economy in 2050. Since a significant part of the industrial CO2 emissions in steel production occurs via the blast furnace-converter route, the use of climate-friendly technologies could have an enormous impact on climate protection. Various possibilities are known and available for this, from the direct avoidance of CO2 in the production process (Carbon Direct Avoidance CDA) to the chemical processing of the CO2 (Carbon Capture and Usage CCU), to the circular economy. They must now be quickly researched in demonstration and pilot processes for their industrial feasibility. An even stronger focus on the circular economy offers further potential for more sustainability and climate protection.

Funding required for investment and operating costs
The conversion to green production processes is associated with massive investments for steel companies. For the locations in Germany, this will amount to around 30 billion euros by 2050. In addition, there are significantly higher operating costs for climate-friendly processes. The transformation therefore requires full funding of investment costs and additional operating costs in the case of large-scale implementation. On the part of the state, European and national funding programs exist or are being set up for which steel companies can apply.

It is also important that steel companies in Germany can apply for and receive funding from the ETS Innovation Fund, which is intended to support the implementation and demonstration of low-carbon steel production. This includes that companies using this program can receive additional funding from other funding programs (“sequencing”). In the 9th EU framework program for research and innovation and the achievement of the “Clean Steel” partnership, Germany should at least participate in proportion to its share in EU steel production.

 

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Glass Industry Research Development innovation update

Glass Industry Research Development innovation update

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older Projects:

Niels v. Bülow Foundation The foundation is named after Niels von Bülow (1894-1983), the chairman of the HVG and DGG from 1948 to 1963 and the initiator of the foundation. The foundation was set up in 1964 and came about thanks to a generous donation from Gerresheimer Glashüttenwerke, Düsseldorf. The sole purpose of the foundation is the non-profit promotion of vocational training and advanced training for young professionals for the glass industry. The aim is to give the scholarship holders the opportunity to study, to continue a course they have started, or to do a doctorate after completing their main examination through a one-off financial aid or financial aid extending over a longer period of time.

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Gypsum Industry Research Development innovation update

Gypsum Industry Research Development innovation update

 

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older Projects:

Bauhaus 2019 Competition:
“We congratulate the winners and awardees on their great work and their success in the competition.

The recognition in the 2019 university competition was announced on November 14th. awarded at the Bauhaus University in Weimar. All award-winning works are documented in the competition catalog

https://www.gips.de/fileadmin/user_upload/Web_Wettbewerbskatalog_2019.pdf

Within the scope of the EPD, the totality of released volatile organic compounds and especially the formaldehyde emissions were examined and evaluated in the test chamber experiment. These substances are suspected of causing allergic and carcinogenic (carcinogenic) effects after prolonged exposure, as is typical for interior rooms in apartments. However, gypsum boards and their varieties (damp room, fire protection, perforated and dry screed boards) and gypsum fiber boards (also known as dry screed boards) do not have any of these negative effects on indoor air quality. The indoor emissions values measured and shown in the EPD meet all safety requirements according to the recognized test scheme of the Committee for the Health Assessment of Building Products (AgBB test scheme for interior emissions.
….

It is also important that steel companies in Germany can apply for and receive funding from the ETS Innovation Fund, which is intended to support the implementation and demonstration of low-carbon steel production. This includes that companies using this program can receive additional funding from other funding programs (“sequencing”). In the 9th EU framework program for research and innovation and the achievement of the “Clean Steel” partnership, Germany should at least participate in proportion to its share in EU steel production.”

 

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Cement Concrete Innovation Project Research Development Contract

Content may NOT be published without permission!

https://www.vdz-online.de/fileadmin/user_upload/PDFs/AGB.pdf

Concrete technology
Durability of concretes with clinker-efficient cements under changed concrete technological boundary conditions
Proof of durability of chemically stressed concretes and concrete components: Proofs on concrete in the event of attack by carbon dioxide
Differentiation of E III-S aggregates and derivation of concrete technical measures
Testing of the frost-thawing salt resistance of concrete for exposure class XF2
Testing and evaluation of the effective alkali content of cements
Environmentally friendly railway sleepers with calcium sulfoaluminate cements

Knowledge transfer in construction
Chemistry & Mineralogy
Effects of pre-hydration on the performance of cements, taking various clinker properties into account
Performance of ternary cements with portland cement clinker, blast furnace slag and calcined clay as the main component
Optimization of the X-ray analysis of dusts from clinker production as a basis for their utilization and for process control
Cement chemical optimization of cements containing fly ash

Cement manufacture
Accelerating CO2 capture with oxyfuel technology in cement production
CO2 separation by means of an integrated calcium looping process
Emission reduction in the stone and earth industry through model-based process optimization (EMREDPRO)
Advanced Indirectly Heated Carbonate Looping Process (ANICA)
Optimization of the sorbent-assisted dust discharge to further reduce the Hg loads from Zemen rotary kilns
Organic reduction in catalysts

Investigation of the interaction between fuel particles and cement clinker with the aim of increasing the use of substitute fuels
Investigation of the influence of alternative fuels on the formation of deposits in rotary kilns in the cement industry
Improvement of the energy efficiency in the grinding of composite cements by means of separate fine grinding on a semi-industrial scale
Procedure for the rapid testing of the quality of airworthy substitute fuels for use in the clinker burning process
Cement clinker production with simultaneous power generation

Asphalt Meta Research Programs

“Incoming inspection of reclaimed asphalt by means of FTIR spectroscopy for optimised reuse in the asphalt mixing plant”.
Research objective and working hypothesis
The aim of the proposed research project is to develop and test a method for the
characterisation of road paving materials, which allows the identification of problematic
This will enable the identification of problematic constituents and modifications originally used in asphalts. If the analytical method investigated is suitable, the
At the end of the project, a test method will be available that can be used in the asphalt mixing laboratory, which will enable the FTIR measurement and the quantitative evaluation of the measurement in a user-friendly way.
Solution
The proposed solution for the development and testing of a method for the for the FTIR analysis of reclaimed asphalt to improve the reuse in asphalt mixtures comprises a total of nine work packages:
1. construction of an asphalt-specific spectral library for the identification of problematic constituents (e.g. PAHs) as well as common modifiers and additives. 2,
2. optimisation of the procedure for obtaining representative asphalt mortar samples from reclaimed asphalts for FTIR analysis,
3. laboratory conception of the FTIR analysis methodology on samples with known and defined
and defined composition,
4. validation of the FTIR analysis on representative asphalts with known composition with parallel analysis using conventional
methods,
5. practical testing of the FTIR analysis in an asphalt mixing plant.

finished by 28.2.2021  “Durability of the layer composite when using viscosity-changing organic additives in the asphalt”

finished by 31.1.2021 “Determination and parameterization of the cavity distribution in asphalt specimens using asphalt petrological methods”

Working hypothesis
The aim of the planned project is to design a preparation and analysis procedure for the differentiated
description of the void distribution of asphalts, which will mature to practical suitability in the medium
and less time-consuming implementation, this method will mature to practical suitability in the medium term.
Compared to conventional methods for determining the void content, a higher informative value with regard to the void distribution can be achieved. The knowledge gained can then contribute to the understanding of the interactions of asphalt constituents, as well as to the optimisation of mixtures and paving processes.
For example, the effects of small deviations in the grading curve or the binder content, but also those of the temperature on the cavity structure. It is possible that small parameters can lead to a significantly better structure and thus a longer durability of the asphalt pavement.

 

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