"Green" Cement

Back when Stanford Professor Brent Constantz was 27 he created a high-tech cement that revolutionized bone fracture repair in hospitals worldwide. People who might have died from the complications of breaking their hips lived. Fractured wrists became good as new.

Constantz says he has invented a green cement that could eliminate the huge amounts of carbon dioxide spewed into the atmosphere by the manufacturers of the everyday cement used in concrete for buildings, roadways and bridges.

His vision of eliminating a large source of the world's greenhouse CO{-2} has gained traction with both investors and environmentalists.

Already, venture capitalist Vinod Khosla is backing Constantz's company, the Calera Corp., which has a pilot factory in Moss Landing (Monterey County) churning out cement in small batches.

And Carl Pope, executive director of the Sierra Club, says it could be "a game changer" if Constantz can do it quickly, on a big scale and at a decent price.

"It changes the nature of the fight against global warming," said Pope, who has talked with Constantz about his work.

That might sound like hyperbole, but the reality is that for every ton of ordinary cement, known as Portland cement, a ton of air-polluting carbon dioxide is released during production. Worldwide, 2.5 billion tons of cement are manufactured each year, creating about 5 percent of the Earth's CO{-2} emissions.

When Constantz learned about the high CO{-2} levels, he thought he could do better. After all, the majority of his 60 patents have to do with medical cement.

He claims his new approach not only generates zero CO{-2} , but has an added benefit of reducing the amount of CO{-2} power plants emit by sequestering it inside the cement.

To make traditional cement, limestone is heated to more than 1,000 degrees Celsius, which turns it into lime - the principal ingredient in Portland cement - and CO{-2}, which is released into the air.

Constantz uses a different approach, the details of which remains secret pending publication of his patent.

At his pilot factory, a former magnesium hydroxide facility that made metal for World War II bombs, magnesium crunches underfoot as Constantz, wearing a pressed, blue button-down shirt with rumpled shorts and sandals, outlines how the process works.

He pointed to two enormous smokestacks billowing flue gases full of carbon dioxide next door at Dynegy, one of the West's biggest and cleanest power plants.

Constantz takes that exhaust gas and bubbles it through seawater pumped from across the highway. The chemical process creates the key ingredient for his green cement and allows him to sequester a half ton of carbon dioxide from the smokestacks in every ton of cement he makes.

Constantz believes his cement would tackle global warming on two fronts. It would eliminate the need to heat limestone, which releases CO{-2}. And harmful emissions can be siphoned away from power plants and locked into the cement.

The same process can also be used to make an alternative to aggregate - the sand and gravel - that makes up concrete and asphalt, which would sequester even more carbon dioxide from power plants.

"The beauty here is we're taking this old industrial polluting infrastructure and turning it into something that will save the environment," Constantz said....

As far as cost, Constantz estimates his cement would retail for $100 a ton versus roughly $110 for Portland.