sustainability and development in the cement …...2014/05/20 · a superb global cement market 0...

Sustainability and Development in the Cement Industrial Complex

Vanderley M. John

Rafael G Pileggi

(almost) infinite number of

technical solutions

For any given problem

technical solutions

Economically viable solutions

Economy (private)

(

technical solutions

Environment (common)

Green solutions

Tragedy of the commons

G Hardin

(

technical solutions

Society (common)

Socially Responsible Solutions

(almost) infinite number of

technical solutions

Environment (common)

Eco-Efficient Solutions

Economy (private)

technical solutions

Society

Sustainable Solutions

Economy

Environment Society

Sustainable Solutions

solve the problems, whitin the budget,

making society happy.

A Superb Global Cement Market

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rld

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Mt)

cement

steel

A Superb Global Cement Market

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Cement Demand Forecast

IEA/WBCSD

One environmental side-effect

A partir de Bonde, T. Global CO2 Emissions from Fossil-Fuel Burning Cement Manufacture, and Gas Flaring: 1751-2009 LBL, Sept 2012

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CO2 Concentration

IPCC - Climate Change 2007: The Physical Science Basis - Summary for Policymakers http://www.ipcc.ch/

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CO

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pp

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CO2 Emission Forecast

A blueprint for a climate friendly cement industry. WWF-Lafarge 2008

CO2 Emissions Forecast

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(WWF-Lafarge)


SCM AVAILABILITY High CO2 Emissions forecast: one reason

Ferrous slag generation

(Smiters Pira, 2011).

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Landfill, slag piles

Internal steelworks recycling

Glass, fertiliser, slagwool, ect.

Aggregates, road material, ect.

Cement and clinker

Blast Furnace Slag in Cement

Year BFS (Mt) Cement (Mt) BFS (%)

2010 200 3.000 6,5

2020 280 3.800 7,4

Production is growing in China (~60% of total).

Mineral Coal Consumption

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Co

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S. & C. America, Africa, Asia, Middle East Europe & Eurasia Major Exporters South Africa Australia India China Russia USA

Fly ash in cement

• Total ash content ~11% (ACAA 2011)

• Fly ash content ~8,50%

• WBCSD 2020 - 14% cement production

– 500 Mt

– 80% recycling rate

• Decrease is projected after 2030!

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Other

Slag

Fly ash

Other Pozzolan

SCM in cement - WBCS CSI Data

GNR (2010 data)

http://www.wbcsdcement.org/GNR-2010/index.html

Slag+ Fly ash Availability

• Base scenario: WBCSD (2009)

• Maximum possible: – All slags and ashes recycled in cement

SCM 2010 2020 2050

Effective

CSI

Most

Probable

Maximum

Possible

BFS 4,6% 7,5% 14% ?

Fly ash 4,3% 14% 25% Decrease

Total 8,9% 21,5% 39% ?

Fly ash and slag will not be enough!

• Local availability

• Global shortage

• CO2 allocation reduces benefit

CEMENT INDUSTRY STRATEGIC PLANNING

WBCSD & IEA Cement Technology Roadmap 2009

CO2 Emissions Forecast

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Blue (WBCSD IEA)



WBCSD/IEA CO2 MITIGATION Energy

Efficiency 10%

Renewable Fuels 24%

Clinker Substitution

10%

Carbon Capture and

Storage 56%


COST WBCSD/IEA CO2 MITIGATION

US $354 a 843 billion


Carbon Capture and Storage Cost

USD $40–170/t CO2

Cement cost will increase


Economic Viability

Cement will loose competitiveness!

Heavy investment.

Higher operational costs.

Social equity

Gross National Income per capita, PPP ($)

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1975 1980 1985 1990 1995 2000 2005 2010 2015 Argentina Brazil Colombia Switzerland United Kingdom United States

World Bank, 2013

WE NEED A SUSTAINABLE SOLUTION!

Option: Increase binder use efficiency

• Produce more cement-based products with the same amount of binder.

Wastage rate of materials at building sites (Brazil)

Coarse aggregates

Sand Cement Ready-mix concrete

Mat

eri

als

was

tage

rat

e (

%)

Low Binder Content

Low content of reactive, high-temperature, scarce material (Clinker, Slag, pozzolans) and

high content of inert abundant materials.

• Binder: reactive materials – clinker, gypsum, slag, pozzolans – No limestone filler

• Performance: – Compressive strength – CO2 footprint – ...

Binder Intensity

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-1)

Compressive strenght (MPa)

Literature - Brazil

Literature - International

Ready-mix concrete 1


250kg/m³

Binder Intensity (kg.m-³.MPa-1) Benchmark 29 Countries

DAMINELI, B. L. KEMEID, F. M. AGUIAR, P. S.; JOHN, VANDERLEY M. Measuring the eco-efficiency of cement use. Cement and Concrete Composites, v. 32, n. 8, p. 555-562, 2010.

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Literature - Brazil




Série6

250kg/m³

DAMINELI, B. L. KEMEID, F. M. AGUIAR, P. S.; JOHN, VANDERLEY M. Measuring the eco-efficiency of cement use. Cement and Concrete Composites, v. 32, n. 8, p. 555-562, 2010.


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Literature - Brazil




250kg/m³

Ready mix plastic

Site mixing

Waste

Rolled


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Literature - Brazil Literature - International Ready-mix concrete 1 Ready-mix concrete 2 Laboratory of Microstructure - USP Starkast Betong Low resistance / low impact

250kg/m³

Low BI Concrete Formulation (USP)

DAMINELI, B. L. - D.Sc. Thesis, 2013 Slump> 150mm

Low BI Concrete Formulation (USP + Darmstad + KTH/CBI)

DAMINELI, B. L. - D.Sc. Thesis, 2013. Slump> 150mm Proske et al. Approach for eco-friendly concretes with reduced water and cement content. ICCS 2013. p288 . Slump> ~55mm

VOGT, C. Ultrafine particles in concrete:. KTH Dr. Eng. Thesis 2010. 155 p

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Literature - Brazil Literature - International Ready-mix concrete 1 Ready-mix concrete 2 Laboratory of Microstructure - USP Starkast Betong Low resistance / low impact

250kg/m³ 250kg/m³

CO2 Intensity (USP results)

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Clinker fraction


Literature - Brazil

Laboratory results

T Proske’s (TU Darmstadt) Concretes

CS (MPa)

Paste kg/m³ w/c Bi Reduction

(%) Binder Filler Water

20 (15,5) 90 270 141 1,57 5,8

59 220 199 0,90 14,2

40 (37,8) 145 269 123 0,85 3,9

45 265 185 0,70 7,2

70 (67,6) 225 225 114 0,51 3,3

32 330 164 0,50 4,9

Proske et al. Approach for eco-friendly concretes with reduced water and cement content. ICCS 2013. p288 .

Slump ~55mm, CEM I 52,5 R, Paste volume 0,270m³/m³

50% Filler Substitution in Cement (w/c = 0.5 + optimum dispersant content)

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DAMINELI, B. L. - D.Sc. Thesis, 2013. Slump> 150mm

Adhesion in Rendering Mortars (water/solids 16.5% + dispersant)

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Binder content reduction (%)

Eliane B. C. Costa PhD Thesis 2014 – CONSITRA - Projeto FAPESP

Low Binder Concrete Advantages

• Lowers concrete cost

• Very low CO2 footprint

• Low hydration heat

• Possible reduction of shrinkage and creep

Low binder concrete difficulties

• Water content control (sand humidity)

• Need to combine several materials in a batch

• Compatibility binder – dispersant

• Mixing equipment

• Long-term performance

HOW IT IS DONE

Low-Binder Basics

• Packing aggregates (coarse and sand) lower paste volume (binder, filler, water) needed to fill de voids and give mobility

• Dispersion of paste particles reduces the amount of water needed to good rheological behavior

• Packing paste with ultrafine particles reduces amount of water to fill the voids and good rheological behavior

• Control of rheological behavior

• Reactive binder

Packing reduces water demand for workability

Packing reduces porosity and increase strength

Packing

• Control of particle size distribution

– Air classification

• Particle shape (image analysis)

– Process + raw material

• Surface area (BET)

– Process + raw material

• Not all fillers are good!

Packing and porosity

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Diâmetro (µm)

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Conventional: cement, fine and coarse aggregate

Optimized: cement + 3 fillers + 2 fine + coarse

Design the rheological behavior of paste and concrete

Concrete Planetary mixing rheometer design: Rafael Pileggi (USP) Paste rheometer

Binder content and durability

Binder content and Carbonation

• Equivalent carbonation depth for binder > 150-170kg/m³

• Proske et all. (2013)

Society

Low binder: A Sustainable Solution

Economy

Environment Society

Low-binder: two routes

Filler mix on site

Reduction cement sales

Feasible for technically capable consumers

CO2 reduction for the cement users only

Cement production costs will rise

Fillers mixed at the cement plant

Cement demand not affected

Large scale: all consumers included

Significant CO2 emissions reduction for all

Cement production costs might be reduced

Low-binder: two routes

Filler mix on site

Reduction cement sales

Feasible for technically capable consumers

CO2 reduction for the cement users only

Cement production costs will rise

Fillers mixed at the cement plant Cement demand not affected

Large scale: all consumers included

Significant CO2 emissions reduction for all

Cement production costs might be reduced

sustainable solution

Low-binder cement: the good

• Calcination replaced by grinding and separation

• Reduction of thermal energy

• Increase yield from limestone quarry

– CO2 is part of the product (44%)

– Use of “low-quality” limestone

– Other sources of filler can be explored

Low-binder cement: the good

• CO2 mitigation without increasing costs

• Might reduces the capital cost

• Preserve industry’s investment

Low-binder cement: the tricky

• Requires developing new knowledge

• Need better control of water in concrete

– Dry sand?

– Better “on line” sensors

• Increase electricity consumption

• Dispersants will become a raw material

• In mature markets it might imply in a increase of production capacity

Conclusion

• Low-Binder concrete will succeed in the market

– Low cost

– Low environmental impact (CO2, Energy)

– Socially responsible

• Who is going to capture the value?

– Cement industry?

– Filler producers?

Conclusion

• Vision: Reduce 50% the binder content by

– Engineered fillers

– Better aggregates

– Dispersant in cement bags

Sources

• DAMINELI, B. L. KEMEID, F. M. AGUIAR, P. S.; JOHN, V. M. Measuring the eco-efficiency of cement use. Cement and Concrete Composites, v. 32, n. 8, p. 555-562, 2010 (DOI:10.1016/j.cemconcomp.2010.07.009)

• Damineli, Pileggi, John Low binder eco-efficient concretes. In: Pacheco- Torgal, Jalali, Labrincha e John, Eco-efficient concrete. Woodhead 2012.

http://dx.doi.org/10.1016/j.cemconcomp.2010.07.009




Eco-efficient concrete



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