Tackling industrial emissions is essential for the UK to deliver on its climate commitments and achieving economic and social prosperity from the transition to net zero. IDRIC was established in 2021 as part of the UKRI Industrial Decarbonisation Challenge to support the decarbonisation of industrial clusters. During this time, IDRIC has developed an influential and impactful network at a critical time and become an essential catalyst bringing together the research and innovation community to accelerate the pace and scale of industrial cluster decarbonisation. Funding for current IDRIC activities will cease in Spring 2024. However, the need for the functions IDRIC is delivering - the research work plus bringing together the relevant players in an environment that allows and encourages trust and collaboration, reduces barriers and accelerates progress - will continue for decades. The UK needs to take long term, multi-decadal decisions to providing long term commitment for industry emission reductions into the 2030s and IDRIC is exceptionally well placed to lead EPSRC activity towards the delivery of the UK's Industrial Decarbonisation Strategy. This proposal represents funding for a 12-month transitional period (April-2024 to March-2025), which will be crucial to support IDRIC in maintaining essential momentum and the community cohesion necessary to safeguard the knowledge, experience and relationships built at this critical time for industrial decarbonisation. The objectives have been co-created with industry and academia building upon the established sense of belonging and the long-term relationships and associated trust required to deliver: Continue to synthesise and disseminate learnings and impacts from the cluster focussed, challenge-led research delivered in 2021-2024. Foresight and horizon-scan of industry-informed research and innovation needs of decarbonisation to deliver towards targets of 2030, 2040 and 2050. Co-create and share knowledge by maintaining active networks and platforms to stimulate cross-learning and engender national/international collaborations for developing net zero solutions. Support policy, skills development and mission advocacy by providing evidence to policymakers, regulators, industry, the wider supply chain and the public to promote decarbonisation. To date, IDRIC have carefully considered that continued engagement is critical and also dependent on stakeholders gaining ongoing strategic benefit from their interaction. This has been key to IDRIC's current success, as shown by bringing together relevant players in an environment that allows and encourages trust and collaboration, reduces barriers and accelerates progress. Therefore, with this 12-month funding we will be prioritising key stakeholder engagement that are aligned with 3 workstreams; Clusters & Partnerships; KE & Synthesis; Cross-cutting Themes (Policy, Skills, EDI). The activities for this phase of IDRIC are designed to utilise IDRIC's unique convening power. They will deliver a suite of outputs e.g. (frontiers report, industry net-zero innovation roadmap) scoped through engagement with the community to ensure maximum impact from the current phase and strategic activities in support of a mapping a clear path for the critical steps required from 2025-2030 - crucial to enabling the realisation of the UKs first net-zero cluster by 2030.

Concrete is the most widely used construction material in the world. The construction industry annually uses 4.3 billion tons of ordinary Portland cement (OPC) as binder for concrete, accounting for around 7% of global CO2 emissions. To reduce the environmental impact of concrete industry in the UK, industrial by-products, such as pulverised fuel ash (PFA) and ground granulated blast-furnace slag (GGBS), are usually used for partial replacement of OPC. Although partial replacement of OPC can reach up to 50%, the total replacement of OPC in concrete with these wastes is not feasible without the addition of alkaline activating agents. Geopolymers, also called "alkali-activated materials", that are cement-free eco-friendly materials synthesized at ambient or elevated temperature by alkali activation of aluminosilicate source materials such as low-calcium PFA and GGBS, have been drawing a lot of attention as a promising alternative to OPC. GPC has many advantages over OPC concrete (OPCC), such as light weight, good fire resistance, low alkali-aggregate expansion, and good resistance to corrosion, acid attack and freeze-thaw cycles. Using geopolymer as the binder in concrete can help reduce embodied energy and carbon footprint by up to 80%. However, GPC is inherently brittle similar to OPCC and susceptible to cracking that would facilitate corrosion of reinforcing steel and impair durability of reinforced concrete (RC) structures, and thus hinder its widespread application. In addition, the resilience of concrete infrastructure that associates with the usability of RC structures is a major concern. It is essential for GPC to possess the capability to recover permanent deformation upon yielding (i.e., re-centring) or the ability to reduce residual crack sizes (i.e., crack closure) when subjected to cyclic loads in order to maintain the functionality and serviceability of a structure over its service life. As such, it is vital to develop strain hardening fibre reinforced GPC, also known as engineered geopolymer composite (EGC) to suppress the brittleness of GPC and improve its durability through multiple crack propagation with controlled crack widths. In this project, for the first time, a novel self-healing EGC that integrates the greenness potential of GPC and the energy absorption capacity of shape memory alloy (SMA) fibres without permanent deformation will be developed. The project involves the development of a novel mix design methodology that integrates micromechanical modelling, design of experiment and life cycle analysis. A range of advanced experimental techniques (e.g., in-situ X-ray computed tomography imaging, image volume correlation, and scanning electron microscope) and modelling approaches (e.g., multiscale lattice Boltzmann-finite element method, and multiscale fracture model) will be used to characterise microstructure and simulate engineering properties of EGC respectively, which will provide insight into the overall performance of EGC and its self-healing efficiency. This research will make it possible to develop a novel EGC with eminent mechanical properties and desired crack-healing capacity. It would expedite the use of GPC and SMA fibres in civil infrastructure applications, particularly for concrete structures subjected to dynamic loads and aggressive environments, which will help greatly enhance resilience, sustainability and durability of concrete infrastructure. The outcomes of this project are expected to result in direct benefits to society by extending the lifetime and by reducing the environmental impact, and repair and maintenance costs of RC structures.

Portland cement is traditionally manufactured by heating limestone and clay at high temperature in a kiln. On a global scale, cement production is responsible for about 7% of the CO2 emissions that we suspect of causing climate change and consumes more than 5,000,000,000 tonnes of raw materials. In recent years, there has been an increasing trend towards replacing both the fuels and minerals used in cement production with industrial wastes. This practice helps to conserve both fossil fuels and natural mineral resources. In general, wastes now fed to the cement kiln contain mainly combustible materials and the same harmless elements that are present in natural cement raw materials, so there is no undesirable effect on cement quality or the environment. However, it has been suggested that some wastes containing toxic metals could be used in cement kilns, and we need to know more about what happens to these potential pollutants during cement production and use, to decide whether such wastes can safely be added in the cement kiln. This collaboration between researchers in Environmental Engineering at University College London in the UK and Materials Scientists at the China Building Materials Academy and South China University of Technology therefore aims to conduct a scientific study of the fate and behaviour of toxic metals from untreated wastes, through the cement kiln, to hydrated cement pastes and the environment. We will use advanced techniques for chemical analysis and materials characterisation, including x-ray absorption spectroscopy with high energy x-rays from the UK's Diamond Light Source, and the Beijing Synchrotron, to see how the form of metals changes as they pass through the kiln and when water is added to the cement, and to understand how much metal-bearing waste can safely be added before undesirable effects occur. The new understanding gained in this work will support decision-making by industry and the government, about the use of waste in making cement.

I will establish the underpinning scientific and technical knowledge to enable the UK cement industry and UK producers of alumina-containing waste to create new supply chains for the manufacture of high-performance low-CO2 cements. I will also develop a user-friendly process model that can optimise cement clinker manufacture from waste. Moreover, I will support the academic and industrial community by creating a much-needed centre for experimental thermodynamics in the UK and will become established and recognised as a leader in low-carbon cement production. Cement is the most manufactured product on the planet and is essential to the development of infrastructure and economy. Cement manufacture is responsible for 2% of the UK's carbon emissions where more than 8 Mt p.a. of, the generally employed, Portland cement (PC) clinker are produced. Globally, the manufacture of 4 Gt of cement p.a. is responsible for 8% of man-made CO2 emissions. Calcium sulfoaluminate (CSA) cements can achieve more than 30% reduction in CO2 emissions compared to PC, on a mass basis, when produced from virgin raw materials. The properties of CSA cements are often superior to those of PC and are therefore used in special applications such as fast-track rehabilitation of highways and airfields. Considering their savings in work-time and their higher performance, CO2 savings from CSA cement, compared to PC, are in fact greater. Moreover, CSA cement can be produced in existing PC plant configurations without major modifications; thus, low industrial capex. CSA cements are normally produced from bauxite, limestone, and clay. However, the use of CSA cements has been limited in the UK due to the lack of a raw alumina source (i.e., bauxite), which is required for CSA manufacture; any CSA cement currently used in the UK is imported. On the other hand, the UK industry produces significant volumes of waste material containing alumina which this Fellowship research aims to valorise. Two major waste streams are potable aluminium water treatment sludge (aWTS), and aluminium oxide residue (AOR) from secondary aluminium production and recycling. The UK produces ~90 kt of aWTS (dry) and ~70 kt of ALS per year which can be used as alumina sources, replacing bauxite, to produce ~1M tonnes of CSA cement p.a., and replacing up to 50% of virgin raw materials with waste. This translational research will create a new subindustry in the UK, by enabling CSA cement manufacture through an innovative process, valorising UK industrial residues, and creating new UK products. However, to develop and establish the manufacturing process for targeted cement clinkers, the presence and fluctuation of impurities in the wastes must be addressed. Industrially, the proportions of cement clinker phases produced through thermal processing of the raw materials are designed using empirical equations. This approach is not suitable to produce CSA clinker, especially when alternative raw materials (containing foreign elements) are used. A more flexible approach is required. Therefore, this Fellowship research will also derive necessary fundamental material data for the phases involved in CSA clinkering from waste and use the data to build a user-friendly pyro-processing simulator that will allow for rapid raw material mix and process design, optimisation, and troubleshooting. This simulator will also enable identification of other potentially useful feed sources for clinker manufacture; thus, a reduction in future experimental clinkering tests. As part of this Fellowship, I will also establish the first centre for experimental thermodynamics in the UK. I will leverage the successful completion of the Fellowship to lead research in low-carbon cement production and specialising in thermochemistry. I also aim to become an ambassador for CSA cement and concrete in the UK and to be involved in influencing policy and writing standards for CSA cement and concrete.

I will establish the underpinning scientific and technical knowledge to enable the UK cement industry and UK producers of alumina-containing waste to create new supply chains for the manufacture of high-performance low-CO2 cements. I will also develop a user-friendly process model that can optimise cement clinker manufacture from waste. Moreover, I will support the academic and industrial community by creating a much-needed centre for experimental thermodynamics in the UK and will become established and recognised as a leader in low-carbon cement production. Cement is the most manufactured product on the planet and is essential to the development of infrastructure and economy. Cement manufacture is responsible for 2% of the UK's carbon emissions where more than 8 Mt p.a. of, the generally employed, Portland cement (PC) clinker are produced. Globally, the manufacture of 4 Gt of cement p.a. is responsible for 8% of man-made CO2 emissions. Calcium sulfoaluminate (CSA) cements can achieve more than 30% reduction in CO2 emissions compared to PC, on a mass basis, when produced from virgin raw materials. The properties of CSA cements are often superior to those of PC and are therefore used in special applications such as fast-track rehabilitation of highways and airfields. Considering their savings in work-time and their higher performance, CO2 savings from CSA cement, compared to PC, are in fact greater. Moreover, CSA cement can be produced in existing PC plant configurations without major modifications; thus, low industrial capex. CSA cements are normally produced from bauxite, limestone, and clay. However, the use of CSA cements has been limited in the UK due to the lack of a raw alumina source (i.e., bauxite), which is required for CSA manufacture; any CSA cement currently used in the UK is imported. On the other hand, the UK industry produces significant volumes of waste material containing alumina which this Fellowship research aims to valorise. Two major waste streams are potable aluminium water treatment sludge (aWTS), and aluminium oxide residue (AOR) from secondary aluminium production and recycling. The UK produces ~90 kt of aWTS (dry) and ~70 kt of ALS per year which can be used as alumina sources, replacing bauxite, to produce ~1M tonnes of CSA cement p.a., and replacing up to 50% of virgin raw materials with waste. This translational research will create a new subindustry in the UK, by enabling CSA cement manufacture through an innovative process, valorising UK industrial residues, and creating new UK products. However, to develop and establish the manufacturing process for targeted cement clinkers, the presence and fluctuation of impurities in the wastes must be addressed. Industrially, the proportions of cement clinker phases produced through thermal processing of the raw materials are designed using empirical equations. This approach is not suitable to produce CSA clinker, especially when alternative raw materials (containing foreign elements) are used. A more flexible approach is required. Therefore, this Fellowship research will also derive necessary fundamental material data for the phases involved in CSA clinkering from waste and use the data to build a user-friendly pyro-processing simulator that will allow for rapid raw material mix and process design, optimisation, and troubleshooting. This simulator will also enable identification of other potentially useful feed sources for clinker manufacture; thus, a reduction in future experimental clinkering tests. As part of this Fellowship, I will also establish the first centre for experimental thermodynamics in the UK. I will leverage the successful completion of the Fellowship to lead research in low-carbon cement production and specialising in thermochemistry. I also aim to become an ambassador for CSA cement and concrete in the UK and to be involved in influencing policy and writing standards for CSA cement and concrete.