Syncrude Kaolin Recovery Project

This report is an appendix to the EcoSmart Project s Metakaolin Feasibility Study. Syncrude Canada Ltd has initiated a project to recover a kaolin rich slurry from oil sands tailings. The recovered product has been identified as a potential pozzolanic supplement in specialty cements. This report describes the laboratory and pilot plant work which produced a bulk sample of slurry. The slurry sample was sent to ECC in Georgia for calcining and product evaluation.

The report also contains a description and cost estimate of a commercial plant to generate the initial annual quantity of product required by ECC.

Technical Report Author: Tynebridge Technologies Ltd

Analysis of the NLK Project EA 2860 EcoSmart Concrete Project Metakaolin Pre-Feasibility Study

This report is an appendix to the EcoSmart Concrete Project s Metakaolin Study. The report presents INSA s technical economical and environmental analysis of the report prepared for EcoSmart by NLK consultants.

The report concludes that NLK s arguments are acceptable but have to be verified by a pilot-scale production of metakaolin in a multiple-hearth furnace then supplied to ready mix concrete plants to determine industrial acceptability.

Technical Report Author: Jean Pera

NLK Project EA 2860: EcoSmart Concrete Project Metakaolin Pre-Feasibility Study

This report is an appendix to the EcoSmart Project s Metakaolin Study. The report presents the results of NLK s metakaolin pre-feasibility review of the potential for developing metakaolin from the oil sands operations for use in concrete as a supplementary cementing material. The report covers the technical economic and environmental aspects of recovering and converting kaolin to metakaolin and of using metakaolin as a SCM.

The report concludes that metakaolin produced from the oil sands tailings is comparable to silica fume as an additive and is about 85-90% as reactive as commercially available metakaolin. It is technically viable for use as an SCM in concrete although its slight colouration precludes some uses. A precondition to considering the viability of extracted metakaolin is that it can be supplied at a low enough cost to provide economic benefits to ready mix concrete suppliers with resulting demand that it is adequate to justify an extraction plant.

Technical Report Author: NLK Consultants Inc.

Metakaolin Study: Pre-Feasibility Review of the Potential for Developing Metakaolin from Oil Sands Operations for Use in Concrete

This report evaluates the potential of metakaolin recuperated from oil sands tailing ponds in North Alberta as a supplementary cementing material -SCM- for concrete. Oil sands operations produce vast quantities of tailings containing extremely fine clays that prevent the reuse of process water from the tailings ponds. Preliminary research has indicated that this fine material can be processed into a product similar to metakaolin -MK- . Metakaolin is a valuable product with many commercial uses including as a high performance SCM. Extracting the fine clay from the ponds to produce SCM would have two benefits: clarifying the process water for reuse in the operations while producing a valuable product from a by-product.

The study finds however that while it is technically feasible the concept is uneconomical for many reasons. The material that can be produced from the pond – called calcined mature fine tailings or CMFT – while similar to MK has lower quality and performance than the products currently on the market. Another shortcoming is that CMFT is grey while metakaolin from virgin kaolin is white. Therefore in performance and appearance CMFT cannot compare to MK. Rather it is more like fly ash -FA- another SCM abundantly available in Alberta but at a much lower price than MK. Furthermore the oil sand region is isolated landlocked and far from the market for concrete. Because of the cost of extracting drying calcining and transporting the material CMFT cannot compete against FA and the study concludes on the non-feasibility of the concept. The oil sand industry still wants to resolve its water and pond issues and continues to investigate ways to process the fine tailing. If this research is successful and CMFT with improved quality color and cost can be produced then it will be worthwhile to reexamine the case and see if the product can be used in concrete.

Technical Report Author: EcoSmart Concrete Project

Current Situation of Supplementary Cementitious Materials (SCMs) in Canada

The report details the current situation of supplementary cementing materials -SCMs- in Canada specifically in terms of production cost availability usage potential areas for increasing usage local barriers and relevant guidelines and specifications. The purpose of the study is to determine a strategy to increase the use of SCMs in Canada.

The data show that approximately 524 000 347 000 and 37 000 tonnes of fly ash Ground Granulated Blast Furnace Slag -GGBFS- and silica fume were used in cement and concrete applications in 2001. These amounts represent 11 90 and 185% of the quantity produced respectively. Thus fly ash appears to be the only material that is underused and that represents a potential for increased use of SCMs in Canada.

The investigation also shows that there are policy technical and economic barriers to the increased use of SCMs in Canada. The report suggests several solutions to overcome these barriers.

Includes an extensive list of tables.

Technical Report Author: Nabil Bouzoubaa, Benoit Fournier