The new method, outlined in Carbon Capture Science and Technology, reduces carbon emissions in cement production - a material linked to about 8% of global CO2 emissions, or 1.6 billion metric tonnes annually. By integrating captured CO2 and steam directly into the concrete mix, the process enhances both the environmental and structural performance of printed concrete.
The 3D printing system injects CO2 and steam into the concrete as it is printed. The CO2 chemically reacts with concrete components, converting into a solid form and becoming sequestered within the material. Simultaneously, the steam boosts CO2 absorption, strengthening the final structure.
Tests showed that the concrete's mechanical properties improved substantially, with up to 36.8% greater compressive strength and 45.3% better flexural strength compared to standard 3D-printed concrete. Printability also rose by 50%, streamlining construction processes. Additionally, the method trapped 38% more CO2 than traditional 3D printing methods.
Professor Tan Ming Jen, principal investigator at NTU's School of Mechanical and Aerospace Engineering and the Singapore Centre for 3D Printing (SC3DP), said: "The building and construction sector causes a significant portion of global greenhouse gas emissions. Our newly developed 3D concrete printing system offers a carbon-reducing alternative by not only improving the mechanical properties of concrete but also contributing to reducing the sector's environmental impact. It demonstrates the possibility of using CO2 produced by power plants or other industries for 3D concrete printing. Since traditional cement emits a lot of carbon, our method offers a way to plough back CO2 through 3D concrete printing."
The research team believes the innovation aligns with global sustainability goals by reducing the carbon footprint of construction while advancing greener technologies. The work builds upon NTU's prior 3D printing advancements and international collaborations.
PhD candidate Lim Sean Gip, the study's first author, stated: "We are at a critical time where the world is accelerating efforts to meet climate change targets. We believe our technology could contribute to making the construction industry more sustainable."
Co-author Dr. Daniel Tay, Research Fellow at NTU's School of MAE, added: "Our proposed system shows how capturing carbon dioxide and using it in 3D concrete printing could lead to stronger, more eco-friendly buildings, advancing construction technology."
The team has filed a US patent application for the process and plans to enhance efficiency further. Future research may explore using waste gases instead of pure CO2 for increased sustainability.
Research Report:Carbon capture and sequestration with in-situ CO2 and steam integrated 3D concrete printing
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