Translation. Region: Russian Federal
Source: Novosibirsk State University –
An important disclaimer is at the bottom of this article.
A team of researchers from NSU has created a new environmentally friendly building material that could potentially replace traditional cement. The first prototypes are already ready, and plans call for industrial production of the new material. The project, led by a graduate student, Faculty of Geology and Geophysics Stepan Denisov, a professor at NSU's Department of Geology and Geophysics, "Development of a Single-Component Binding Material Based on Industrial Ash and Slag Waste," won the federal Student Startup competition. The amount of support provided for the coming year will amount to 1 million rubles.
The project is unique in that the new building material is made entirely from industrial waste, specifically coal ash—the residue generated by the combustion of solid fuels (coal, peat, and oil shale) in thermal power plants, boiler houses, and other industrial installations. Thus, waste that had accumulated in landfills for years, polluting the environment, is transformed into a useful, high-quality construction product.
"The project's idea arose at the intersection of two major issues. First, there's the waste problem: Russia has accumulated approximately 2 billion tons of ash and slag waste alone, and it's growing by 60 million tons every year. Only a small portion—about 15%—is recycled. These waste dumps occupy vast areas. Second, there's the environmental issue of the cement industry: conventional cement production is a highly energy-intensive process, accounting for approximately 8% of all global CO₂ emissions. Our project addresses both issues simultaneously: recycling waste and simultaneously creating a "green" alternative to cement, reducing the carbon footprint," explained Stepan Denisov.
Work on the project began over a year ago and is being conducted at the NSU Climate Center. The scientific director, responsible for the overall development and also a member of the startup team, is Georgy Lazarenko, PhD, Director of the NSU Climate Center. The startup team also includes Matvey Trutnev, a master's student at the Faculty of Geology and Geophysics, Dmitry Goryainov, a PhD student at the Faculty of Geology and Geophysics, and Yakov Ermolov, PhD, in Engineering.
A laboratory technology has now been developed, and the first prototypes of the material have been produced. The technology consists of ash and slag, crushed into powder, mixed with special activators. Then, when mixed with water, a chemical reaction—geopolymerization—is initiated. The result is a durable stone with properties similar to cement, but with its own advantages.
Preliminary tests of samples have already been conducted, the results of which have shown that in terms of such indicators as strength and water absorption, the new material fully complies with the stated requirements.
"In terms of strength (50 MPa), it is comparable to high-grade M500 cements, and its frost resistance can reach 300 cycles. Furthermore, the product has low water absorption (less than 5%), while most competitors' rates range from 5% to 18%. Furthermore, it offers flexible setting times—from 5 minutes to 7 hours—covering both quick repairs and standard construction needs. At the same time, its cost is among the lowest on the market, competing with standard M300-M400 Portland cements while offering the quality and properties of significantly more expensive specialized materials," added Stepan Denisov.
Similar materials to this material currently available on the market are so-called geopolymer binders, which are produced both in Russia and abroad. However, the key advantages of the material developed at NSU are its price and environmental friendliness, achieved through the use of 100% ash as a raw material and complete waste recycling.
The development will find application in various construction sectors—anywhere cement is used—for floor screeds, bricklaying, plastering, building block production, etc. Potential users include large industrial enterprises addressing waste disposal issues, as well as construction companies and individuals seeking a more affordable and environmentally friendly material.
The funds the team receives from the Student Startup competition will be used to conduct further, more in-depth testing of samples against all construction standards (frost resistance, corrosion resistance, etc.), purchase the necessary reagents and materials, patent the design, and manufacture the first batch of prototypes in commercial packaging (5, 10, and 25 kg bags). Future plans include launching industrial production of the construction mixture and processing up to 100,000 tons of ash and slag per year.
Please note: This information is raw content obtained directly from the source. It represents an accurate account of the source's assertions and does not necessarily reflect the position of MIL-OSI or its clients.
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