FMRG: Eco: CAS-Climate: Reimagining Cement Manufacturing for Carbon Neutrality (NeutraCEM)

波特兰水泥是每年用于建造几乎所有形式的有形基础设施的数十亿吨混凝土的主要粘结剂。其全球年产量达45亿吨，占人为二氧化碳排放量的约8%，占所有工业二氧化碳排放量的约25%。水泥制造业是最难脱碳的行业之一，因为二氧化碳排放是基本化学反应(例如，石灰石脱碳以生产石灰和二氧化碳)和高温过程(由二氧化碳密集型化石燃料燃烧提供动力)不可避免的结果。随着美国开始实施百年一遇的基础设施复兴计划，同时承诺到2030年将二氧化碳排放量削减50%(根据《巴黎协定》，将全球变暖控制在1.5摄氏度以内)，迫切需要颠覆性地改变水泥制造业，特别是考虑到波特兰水泥的生产和使用有望在2030年增长到6GT。该项目通过端到端技术突破重塑水泥生产，其特点是太阳能驱动的两阶段工艺：一种新的电化学脱碳工艺，以生产石灰，而不会伴随二氧化碳释放；以及通过一种新的高温合成工艺超高速生产水泥。两个阶段的工艺实现了前所未有的制造能力；成本、能源和二氧化碳效率大大高于现代制造技术。该项目由数学和物理科学局(MPS)的材料研究部(DMR)支持，并由MPS的化学部(CHE)、工程部(ENG)的土木、机械和制造创新部(CMMI)以及教育和人力资源局(EHR)的本科生教育部共同资助。该项目的总体目标是以碳中性和节能的方式生产波特兰水泥和其他石灰基水泥。为了实现这一目标，该项目推进了几项技术创新：(1)低温、碳中性分解石灰石成石灰；(2)通过高温合成程序，超快生产物理和化学上与商业同行相似的水泥；(3)使用可再生能源取代化石燃料，为水泥生产的所有子过程提供动力；以及(4)协同利用先进实验、热力学和多物理模拟以及人工智能来优化制造过程，从而生产出一系列可持续的下一代水泥。预计这项工作的结果将大大促进对影响制造过程两个阶段的产品的动力学、效率和质量的过程参数的理解。将开发一个简单易用的软件，带有硬连接的热力学和机器学习引擎，以帮助制造商根据他们的水泥生产目标确定最佳配方。综合教育和劳动力发展计划强调通过传统模式培训下一代可持续制造研究人员和工程师，以及训练营和针对熟练技术工人(STW)和行业专业人员的高级技能培训研讨会等新方法。该奖项反映了NSF的法定使命，并通过使用基金会的智力优势和更广泛的影响审查标准进行评估，被认为值得支持。

Portland cement is the primary binding agent in billions of tons of concrete used every year for construction of nearly all forms of physical infrastructure. Its worldwide production, amounting to 4.5 billion tons per year, is responsible for ~8% of anthropogenic carbon dioxide emissions and ~25% of all industry carbon dioxide emissions. Cement manufacturing is among the hardest industries to decarbonize because the carbon dioxide emissions are unavoidable results of essential chemical reactions (e.g., decarbonation of limestone to produce lime and carbon dioxide) and high-temperature processes powered by carbon dioxide -intensive combustion of fossil fuels. As the U.S. embarks on a once-in-a-century infrastructure revival program, while also committing to slash carbon dioxide emissions by 50% by 2030 (to limit global warming to 1.5 degree Celsius, as per the Paris Agreement), there is an urgent need to disruptively transform cement manufacturing, especially considering that the production-and-use of Portland cement is poised to grow to 6 Gt by 2030. This project reimagines cement production through end-to-end technological breakthroughs that features a solar energy-powered, two-stage process: a novel electrochemical decarbonation process to produce lime without attendant carbon dioxide release; and ultrafast production of cement via a novel high temperature synthesis procedure. The two-stage process enables unprecedented manufacturing capabilities; with cost-, energy-, and carbon dioxide -efficiencies substantially better than those of contemporary manufacturing technologies. The project is supported by the Division of Materials Research (DMR) in the Directorate for Mathematical and Physical Sciences (MPS), and co-funded by the Division of Chemistry (CHE) in MPS, the Division of Civil, Mechanical and Manufacturing Innovation (CMMI) in the Directorate for Engineering (ENG), and the Division of Undergraduate Education in the Directorate for Education and Human Resources (EHR).The overarching goal of this project is to enable the production of Portland cement, as well as other lime-based cements, in a carbon -neutral and energy-efficient manner. To achieve this goal, the project advances several technological innovations: (1) Low-temperature, carbon-neutral decomposition of limestone into lime; (2) Ultrafast production of cements, that are physically and chemically similar to their commercial counterparts, via a high temperature synthesis procedure; (3) Use of renewable energy, in lieu of fossil fuels, to power all sub-processes of cement manufacturing; and (4) Synergistic use of advanced experiments, thermodynamic and multiphysics simulations, and artificial intelligence to optimize the manufacturing process, that results in a family of sustainable, next-generation cements. Outcomes of this work are expected to substantially advance understanding of process parameters that influence the kinetics, efficiency, and quality of the products from both stages of the manufacturing process. A simple, easy-to-use software, with hardwired thermodynamics and machine learning engines, will be developed to aid manufacturers in ascertaining optimal recipes based on their cement production targets. The integrated education and workforce development plan emphasizes training of next generation of sustainable manufacturing researchers and engineers through conventional modalities, as well as novel means such as bootcamps, and workshop for advanced-skills training of skilled technical workers (STWs) and industry professionals.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.