FUTURECEMTM a sustainable solution

for cement and concrete.

Picture by Torben Eskerod

2

https://commons.wikimedia.org/wiki/File:Nordjyllandsv%C3%A6rket.jpg

…For UE to lead the world in climate action, it means achieving net-zero greenhouse gas emissions by 2050…..

Mette Quinn - European Commission. DG CLIMA

Not only cement sector…...

to support the sustainable transition of the cement industry.

Paris Agreement: reducing emissionsKeep temperature increase below 2°C and pursue effort to limit to 1.5°C

New measures to reduce the supply of emissions allowances (EUA, or EU allowance) from 2019, combined with plans for a tighter system from 2021.

Pursuing clinker substitution as CO2 emission strategy

Mineral additions are key factor for clinker substitution

The most commonly used mineral additions, fly ash and slag are becoming in short supply

• Coal fired power stations shut down because of green transformation to reduce CO2

• Steel production in EU is under pressure for CO2 reduction and new technology reduce production of slag

• Clinker replacement is oscillating.

New solutions to reduce clinker content needed

https://www.wbcsdcement.org/GNR-2016/EU28/GNR-Indicator_12AG-EU28.html3

Huge resources of clay and limestone on a global scale.

Synergy between limestone and calcined clay enables higher strength and larger clinkerreplacement than using only calcined clay• Calcined clay is clay, burned at around 800oC

Limestone-calcined clay technology to support Greener transitions

Kaolinite from Europe &Limestone (step2)

Danish smectitic clay &Limestone (step1)

Danish smectitic clay

28D strength Reference : CEM I

Cements with clinker substitution within standards

Synergy

4

FUTURECEMTM – The cement/binder of the future

Green Sustainable

Innovative and

validated Innovative Concept validated in operation with full scale trials

CO2 EmissionCaring …

Earth ResourcesRespecting

5

Developed by

Global Availability of mineral addition compared to Portland cement (1)

Sustainability as main challenge

(largely available materials)

FUTURECEMTM: Limestone-calcined clay

Reducing clinker content so more greener cement

More than - 30% CO2 emission

Innovative technology which enables production of durable concrete with reduced clinker content (greener) and exploiting synergies of two largely available materials on earth (sustainable)

6

Clay calcination is a well-known technology……

Flash calciner• High temperature• Fast heating rate• Short retention time (s)• Fine raw meal (mm)• Low moisture content of raw

meal• Very precise calcination

possible

Rotary kiln

Flash Calciner (FLSmidth)

Rotary kiln• Low temperature• Slow heating rate• Long retention time (min)• Coarse raw meal (cm)• High moisture content of raw

meal• Existing equipment can be

used

…..Just a matter of choosing what fits your needs

7

A very strong and consistent technology base, developed by Aalborg Portland over the years…..

1990-1991: Synergy effect discovered by Aalborg Portland• Objective was to develop a high-strength cement with low clinker content.

Calcined kaolin or smectite and limestone mixtures were tested• Development of BASIS Cement (CEM II/A-LL) fulfilled the project targets. The

calcined clay was therefore not needed to obtain high clinker replacement

2008-2011: FUTURECEM Project• Increased focus on CO2 reduction prompted this project. The basic technology

was documented and further developed. Patent application was submitted.

2011-2014: SCM Project• Development of production equipment together with FLSmidth. Production of

pilot-scale cement used to construct demo wall in RMC.

2014-2019: Green Concrete II Project• Durability testing and testing in full-scale RMC constructions: a rail

bridge, a road bridge and indoor wall and floor

8

Cement producer Aalborg Portland A/SConcrete producers Unicon A/S Dansk Beton FabriksbetongruppenContractor MT Højgaard A/SConsulting Engineers Sweco A/S Rambøll Danmark A/SKnowledge institutions Danish Technical University Danish Technological Institute Four schools and collegesPublic building owners Danish Road Directorate Danish Rail Authority Femern Link

Green Concrete II

Green Transformation of Cement and Concrete Production• Budget: EUR 3.9 million, 50% funded by the Danish Innovation Fund• Duration: 2014-2019• Partners from the entire value chain of construction• Focus on infrastructure and residential building.

Main Objectives:Further development of cement with reduced CO2 footprint, making Full-scale demo constructions testing :

1. Production and casting of concrete with new cement types2. Durability of concrete with new cement type with long term Exposure Sites

9

Real Construction in place

Torben EskerodTorben Eskerod

Torben Eskerod

10

Two Bridges Building

Durability tests in the laboratory and in the field

• In order to evaluate durability in aggressive environments, along with testing program in the lab at DTI and Cementir Holding R&Q centre, exposure sites have been established for long term detection.

Durability testing in the laboratory Long-term durability testing in field exposure sites

11

Lesson learned from demos….Concretes made with FUTURECEM systems is suitablefor concrete industry, while maintaining conventionalproduction and execution technologies.Same performances as conventional concrete for keyparameters (workability, strengths etc.)

From durability side, FUTURECEM is highly resistant tocorrosion by chloride from sea water or freeze-thaw salt.No degradation by sulphate attack has been detected in realapplication over long time.

Ongoing long-term durability testing in field exposure sites

12

FUTURECEMTM – The cement/binder of the future

Green Sustainable

Innovative and

validated

Synergy between limestone and calcined clay enables clinker replacement. Full scale trial in Denmark in Green Concrete II Project

Reducing more than - 30%CO2 emission through clinkerreplacement.

Relying on natural raw materialsreadily available on the Earth

13

Developed by

Do not Forget!

Limestone-calcined clay cement is an efficient andimplementable part of the solution

• Needed in a future with fewer industrial mineral additions

• Improved financial/economical feasibility than other solutions

• Huge potential: up to 400 million tons CO2 annually saved 1)

2) Cumulative CO2 emissions reductions (expressed in % of 7.7 GtCO2) refer to the period from 2020 to 2050 and are based on the low-variability case of the scenarios. (compared to RTS)2)

48%

37%

12%3%

Innovative Technologies(incl. Carbon Capture)

Reduction of clinekr tocement ratio

Fuel Switching

Thermal energy Efficiency

Electricity intensity

1) Eco-efficient cements. Potential, economically viable solutions for a low-CO2, cement based materials industry. United Nations Environment Programme, Paris 2016

Not possible without limestone-calcined clay.Reductions could be even higher by applying thistechnology

Technology Roadmap. Low-carbon Transition in the CementIndustry- Cumulative CO2 emissions reductions (%) 2)

14

Cementir Group: Building a Sustainable Future within circular economy (few examples)

Alternative Fuelalternative fuel used for thermalenergy production in place of non-renewable fossil fuels. Over 45%in CCB

Renewable Energy - Wind PowerOwn production of electricity in Aalborg-plant,Denmark covering around 18% consumption withCO2 saving ~28 Ktons per year

Energy RecyclingDistrict Heating covering22% of the heat consumptionin Aalborg city, Denmark.

Greener and Sustanaible Cement InnovationFutureCemTM greener and sustainable technologyto cuts more than 30% CO2 emission during thecement production by exploiting largely availablematerial on the earth.

15

Sustainable ConcreteReducing environmental impact in every phasewith solar panels, zero water reject, logistics withlower CO2 emission (barges and fleet euro code6). Upcoming process sustainability certificationIntegration into city activities.

Stefano ZampalettaCorporate Product Development

Cementir HoldingSales, Marketing and Commercial Development

Corso di Francia, 20000191 Rome, Italy

Phone: +39 3355768442E-mail: s.zampaletta@cementirholding.it

Thank you for your Attention!