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Research and Technological Development in the
Cement and Concrete Industry
Sustainable Development: a Challenge for European Research
Parallel Session 7
Brussels, 26 May, 2009
Dr. Wolfgang Dienemann, HeidelbergCement Technology Center
Slide 2 - 26.05.2009Research and Technological Development in the Cement and Concrete Industry – W. Dienemann
The Cement and Concrete Industry
History
Cement like material already used by Romans (Opus Caementitum)
Development of hydraulic lime („Roman Cement“) late 18th / early 19th century
1843 – W. Aspdin develops Portland Cement
Since 1850s rapid industrial development
Slide 3 - 26.05.2009Research and Technological Development in the Cement and Concrete Industry – W. Dienemann
The Cement and Concrete Industry
Facts and Figures
Concrete is the world‘s most versatile, durable and reliable construction material
In the same time concrete is a very economical product
Around 2,9 billion tonnes of cement in 2007
Equals 7 billion m3 of
concrete per year
Next to water concrete is
the most used material
Slide 4 - 26.05.2009Research and Technological Development in the Cement and Concrete Industry – W. Dienemann
The Cement and Concrete Industry
Rising demand
Volumes are expected to more than double in the next decades
Infrastructure development in developing countries
China and India with high growth rates
Slide 5 - 26.05.2009Research and Technological Development in the Cement and Concrete Industry – W. Dienemann
The Cement and Concrete Industry
Cement and CO2
Cement manufacturing releases ~800 kg CO2 per ton of cement
Around 60% results from chemical reaction of limestone
~40% burning of fuels, 5% electrical energy
Globally 5-7% of manmade CO2 emission
Key industry challenge
Slide 6 - 26.05.2009Research and Technological Development in the Cement and Concrete Industry – W. Dienemann
Technical Developments – Process Optimization
Optimizing Energy Efficiency
Energy accounts for ~40% of production costs
Optimization of burning process
– Efficiency of preheater
– Efficiency of cooler
– Waste heat power
generation
Slide 7 - 26.05.2009Research and Technological Development in the Cement and Concrete Industry – W. Dienemann
Technical Developments – Process Optimization
Valorization of Waste as Alternative Fuel
The clinker burning process is ideally suited to use alternative fuels
Minimized emissions due to long residence time and high gas temperatures
No residues as ash is incorporated in clinker
Overall reduction
of CO2 emissions
and fossil fuel
consumption
Slide 8 - 26.05.2009Research and Technological Development in the Cement and Concrete Industry – W. Dienemann
Technical Developments – Process Optimization
Valorization of Waste as Alternative Fuel
Significant progress has been made in replacing fossil fuels
Individual plants already use 90%
alternative fuels
Burning technology optimized
0
10
20
30
40
50
60
1987 1995 1999 2001 2003 2005 2007
Sha
re o
f al
tern
ativ
e fu
els
in %
Slide 9 - 26.05.2009Research and Technological Development in the Cement and Concrete Industry – W. Dienemann
Replacement of clinker
Clinker manufacturing accounts for 90% of fuel and energy consumption and CO2 emissions
Can partly be substituted by latent hydraulic or pozzolanic materials– Blastfurnace slag from steel industry
– Fly ash from coal fired power plants
– Natural and artificial pozzolans
Wide range of composite cements covered by EN standards
Technical Developments – Process Optimization
Slide 10 - 26.05.2009Research and Technological Development in the Cement and Concrete Industry – W. Dienemann
Technical Developments – Process Optimization
Conclusions
Three main pathways successfully applied in cement industry
Enabled through RTD and innovations in engineering technology and material science
Optimization of concrete recipes and manufacturing technology further reduced embodied energy
European companies clearly at the forefront of this development
Slide 11 - 26.05.2009Research and Technological Development in the Cement and Concrete Industry – W. Dienemann
Sustainability – Challenges and Opportunities
Reducing the Environmental Footprint High pressure to further reduce CO2-emission significantly
(Emission Trading) requires additional improvements and radical changes
Reduction of emission limits require further technological developments in process and filter technologies
Rising prices for electricity and fossil fuels demand further process optimization
Potential through incremental development limited due to high level of optimization already achieved
Slide 12 - 26.05.2009Research and Technological Development in the Cement and Concrete Industry – W. Dienemann
Adaptation to Climate Change
Optimized use of concrete‘s inherent thermal mass enables design of energy efficient buildings
Sustainability – Challenges and Opportunities
Slide 13 - 26.05.2009Research and Technological Development in the Cement and Concrete Industry – W. Dienemann
Adaptation to Climate Change
Sustainability – Challenges and Opportunities
Durable and safe construction needed also in case of extrem events to protect humans and economic values
Slide 14 - 26.05.2009Research and Technological Development in the Cement and Concrete Industry – W. Dienemann
Adaptation to climate change
Optimized cements and concretes required to better exploit alternative energy sources
Sustainability – Challenges and Opportunities
Low-heat concrete for hydro dams
UHPC for offshore foundations
Special well cementfor deep drillings
Slide 15 - 26.05.2009Research and Technological Development in the Cement and Concrete Industry – W. Dienemann
Barriers to Change
Construction industry very conservative in general
High safety requirements for buildings and infrastructure, guaranteed longterm performance
High degree of regulation through Eurocodes, standards, etc
New products and applications must be scientifically sound and technically proven
This requires substantial investments in research and development
Sustainability – Challenges and Opportunities
Slide 16 - 26.05.2009Research and Technological Development in the Cement and Concrete Industry – W. Dienemann
New Approaches – How can R&D help?
Increasing Biodiversity
Quarries are ideally suited to even increase biodiversity through dynamic and rare habitats– Rocks, steep faces– Wetland– Grasland– Standing water
R&D needed to develop biodiversity indicators and management plans
Slide 17 - 26.05.2009Research and Technological Development in the Cement and Concrete Industry – W. Dienemann
Increase use of Alternative Fuels even further
Valorization of waste only realistic possibility to reduce fossil fuel consumption (plus CO2-savings)
Assimilating more and new types of fuels requires RTD in– Burner technology (including O2-enrichment)
– Control of manufacturing process
– Impact on product quality
– Environmental performance (e.g. leaching)
New Approaches – How can R&D help?
Slide 18 - 26.05.2009Research and Technological Development in the Cement and Concrete Industry – W. Dienemann
Further reduce Clinker Content
Increasing the ratio of cementitious materials beyond today‘s values still is the most promising route short- and midterm.
Extending the use of conventional and new cementitious materials requires a better understanding of fundamental mechanisms that control performance:– Structural / mechanical behaviour
– Corrosion resistance
– Durability
– Environmental performance (e.g. leaching)
New Approaches – How can R&D help?
Slide 19 - 26.05.2009Research and Technological Development in the Cement and Concrete Industry – W. Dienemann
Developing new low-CO2 materials
For radical changes new materials are needed that have lower inherent CO2 content, i.e. less Calcium, e.g.:
– Supersulfated cements, based on slag
– Alkali-activated alumosilicates („geopolymers“)
– New, low Ca clinker, Belite, Ca-Sulfoaluminate
– MgO-based systems
– … Significant R&D activities required to understand their reaction
mechanism and predict their performance
New Approaches – How can R&D help?
Beton-prüfung
Slide 20 - 26.05.2009Research and Technological Development in the Cement and Concrete Industry – W. Dienemann
Knowledge based Development and Innovation
R&D in cement and concrete technology has been very fragmental, incremental and often trial-and-error based.
Needs to be converted into knowledge based approach:– Develop fundamental understanding of reaction mechanisms
– Develop and employ appropriate analytical tools
– Develop models to predict field performance
– Validate models vs field conditions
Holistic approaches needed to create confidence in new materials and overcome barriers in standardization; shorten time to market.
Cradle-to-Cradle concept might lead to new, creative approaches to develop positive footprint.
New Approaches – How can R&D help?
Slide 21 - 26.05.2009Research and Technological Development in the Cement and Concrete Industry – W. Dienemann
Conclusion
Significant improvements have been made to reduce environmental footprint of cement and concrete industry
Potential of current optimization pathes almost exploited Substantial RTD investments needed to further improve
sustainability of the industry.– In applied research, product development, innovation
– In basic research / fundamental understanding Potential to develop a positive footprint
Research and Technological Development in the Cement and Concrete Industry
Slide 22 - 26.05.2009Research and Technological Development in the Cement and Concrete Industry – W. Dienemann
for better building
Slide 23 - 26.05.2009Research and Technological Development in the Cement and Concrete Industry – W. Dienemann
The Cement and Concrete Industry
Cement and Concrete manufacturing
Lime
Clay
Iron
Kiln
Gypsum
Clinker
Additions
Mill
Gravel
Cement
Admixtures
Sand
Water
Mixer
Slide 24 - 26.05.2009Research and Technological Development in the Cement and Concrete Industry – W. Dienemann
Technical Developments – Process Optimization
Replacement of clinker
0%
10%
20%
30%
40%
50%
60%
1999 2000 2001 2002 2003 2004 2005 2006
CEM I
CEM II
CEM III
CEM IV
CEM V
Slide 25 - 26.05.2009Research and Technological Development in the Cement and Concrete Industry – W. Dienemann
Cradle-to-Cradle Concept for Building Materials
Ensure optimal recycability of concrete
Positive list of concrete constituents
Develop new recycling technologies
Valorization of wastes and by-products from other industries
Turn the footprint positive / Eco-Effectiveness
New Approaches – How can R&D help?
Slide 26 - 26.05.2009Research and Technological Development in the Cement and Concrete Industry – W. Dienemann
Cradle-to-Cradle Products Develop products with positive environmental contribution
New Approaches – How can R&D help?
Air-cleaning concrete Fine dust reducing concrete
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