sustainability and development in the cement …...2014/05/20 · a superb global cement market 0...
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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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1950 1960 1970 1980 1990 2000 2010 2020
Wo
rld
Po
pu
lati
on
Mat
eri
als
Pro
du
ctio
n (
Mt)
cement
steel
A Superb Global Cement Market
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1950 1955 1960 1965 1970 1975 1980 1985 1990 1995 2000 2005 2010 2012
Ce
men
t (k
g/ye
ar.i
nh
ab)
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1950 1970 1990 2010 2030 2050
Glo
bal
Ce
me
nt
Pro
du
ctio
n (
Mt)
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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1950 1970 1990 2010 2030 2050
CO
2 f
rom
ce
me
nt
(% t
ota
l)
CO2 Concentration
IPCC - Climate Change 2007: The Physical Science Basis - Summary for Policymakers http://www.ipcc.ch/
240
260
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380
8000 6000 4000 2000 0 2000
CO
2 (
pp
m)
year
1750
CO2 Emission Forecast
A blueprint for a climate friendly cement industry. WWF-Lafarge 2008
CO2 Emissions Forecast
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25
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35
2010 2020 2030 2050
CO
2 f
rom
ce
me
nt
(% t
ota
l) BAU
(WWF-Lafarge)
A blueprint for a climate friendly cement industry. WWF-Lafarge 2008
SCM AVAILABILITY High CO2 Emissions forecast: one reason
Ferrous slag generation
(Smiters Pira, 2011).
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2008 2009 2010 2011 2012 2013 2020
Sla
g (
Mt)
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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1980 1990 2000 2010 2020 2030 2040 2050 2060 2070 2080 2090 2100
Co
al (M
t)
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!
0
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8
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16
1990 2000 2005 2006 2007 2008 2009 2010
Co
nte
nt
in C
em
en
t (%
)
Other
Slag
Fly ash
Other Pozzolan
SCM in cement - WBCS CSI Data
GNR (2010 data)
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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35
2010 2020 2030 2050
CO
2 f
rom
ce
me
nt
(% t
ota
l) BAU (WWF-Lafarge)
Blue (WBCSD IEA)
A blueprint for a climate friendly cement industry. WWF-Lafarge 2008
WBCSD & IEA Cement Technology Roadmap 2009
WBCSD/IEA CO2 MITIGATION Energy
Efficiency 10%
Renewable Fuels 24%
Clinker Substitution
10%
Carbon Capture and
Storage 56%
WBCSD & IEA Cement Technology Roadmap 2009
COST WBCSD/IEA CO2 MITIGATION
US $354 a 843 billion
WBCSD & IEA Cement Technology Roadmap 2009
Carbon Capture and Storage Cost
USD $40–170/t CO2
Cement cost will increase
WBCSD & IEA Cement Technology Roadmap 2009
Economic Viability
Cement will loose competitiveness!
Heavy investment.
Higher operational costs.
Social equity
Gross National Income per capita, PPP ($)
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60000
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
0,0
2,5
5,0
7,5
10,0
12,5
15,0
17,5
20,0
0 20 40 60 80 100 120
BI (k
g.m
-3.M
Pa
-1)
Compressive strenght (MPa)
Literature - Brazil
Literature - International
Ready-mix concrete 1
Ready-mix concrete 2
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.
0,0
2,5
5,0
7,5
10,0
12,5
15,0
17,5
20,0
0 20 40 60 80 100 120
BI (k
g.m
-3.M
Pa
-1)
Compressive strenght (MPa)
Literature - Brazil
Literature - International
Ready-mix concrete 1
Ready-mix concrete 2
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.
Binder Intensity (kg.m-³.MPa-1) Benchmark 29 Countries
0,0
2,5
5,0
7,5
10,0
12,5
15,0
17,5
20,0
0 20 40 60 80 100 120
BI (k
g.m
-3.M
Pa
-1)
Compressive strenght (MPa)
Literature - Brazil
Literature - International
Ready-mix concrete 1
Ready-mix concrete 2
250kg/m³
Ready mix plastic
Site mixing
Waste
Rolled
Binder Intensity (kg.m-³.MPa-1) Benchmark 29 Countries
0,0
2,5
5,0
7,5
10,0
12,5
15,0
17,5
20,0
0 20 40 60 80 100 120
BI (k
g.m
-3.M
Pa
-1)
Compressive strenght (MPa)
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
0,0
2,5
5,0
7,5
10,0
12,5
15,0
17,5
20,0
0 20 40 60 80 100 120
BI (k
g.m
-3.M
Pa
-1)
Compressive strenght (MPa)
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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CI (k
g/m
3.M
Pa
)
Clinker fraction
Literature - International
Literature - Brazil
Laboratory results
CO2 Intensity (USP results)
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CI (k
g/m
3.M
Pa
)
Clinker fraction
Literature - International
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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Co
mp
ressiv
e s
tren
gth
(M
pa)
Calcium carbonate Dolomite Quartz Granite
Cri
sto
bali
te
Nefe
lin
e
Sie
nit
e
Cem
en
t
DAMINELI, B. L. - D.Sc. Thesis, 2013. Slump> 150mm
Adhesion in Rendering Mortars (water/solids 16.5% + dispersant)
0,00
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Pu
ll o
ut
(MP
a)
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
0
3
6
9
12
15
0,1 10 1000
Vo
lum
e (
%)
Diâmetro (µm)
0
3
6
9
12
15
0,1 10 1000
Vo
lum
e (
%)
Diameter (µm)
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.
Muito obrigado pela atenção!