Karen Scrivener, EPFL, Switzerland Vanderley John, USP ... · Global cement production Billion...
Transcript of Karen Scrivener, EPFL, Switzerland Vanderley John, USP ... · Global cement production Billion...
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Karen Scrivener, EPFL, Switzerland
Vanderley John, USP, Brazil
Ellis Gartner, Imperial College, UK
Can be downloaded free at multiple sites.
Just google
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Cement Based Materials:
cannot be replaced by alternatives
0 2000 4000 6000 8000 10000 12000 14000 16000 18000
Cementitious
Wood
Ceramic
Iron
Lime
Asphalt
Glass
Aluminium
Copper
Materials production (Mt/year)
Cementitious materials make up ~50%
of everything we produce.
In the light of this,
CO2 emissions of 5-10%
very good
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Concrete is an environmentally friendly material
Material MJ/kg kgCO2/kg
Cement 4.6 0.83
Concrete 0.95 0.13
Masonry 3.0 0.22
Wood 8.5 0.46
Wood: multilayer 15 0.81
Steel: Virgin 35 2.8
Steel: Recycled 9.5 0.43
Aluminium: virgin 218 11.46
Aluminium recycled 28.8 1.69
Glass fibre composites
100 8.1
Glass 15.7 0.85
ICE version 1.6a
Hammond G.P. and Jones C.I
2008 Proc Instn Civil Engineers
www.bath.ac.uk/mech-eng/sert/embodied/
Re
lative
en
erg
y, C
O2
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Growth in cement use in last 70 years
0
2000
4000
6000
8000
0
1000
2000
3000
4000
5000
1950 1970 1990 2010
Po
pu
lati
on
(M
)
Mat
eri
als
Pro
du
ctio
n (
Mt)
Cement Crude Steel World Population
3x
34x
population
steel
cement
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Cement Business as usual
CO2 Emission
Based on A blueprint for a climate friendly cement industry. WWF-Lafarge 2008
2oC - RPC 2.6 –
450ppm
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Forecast growth
We need solutions for people in developing countries
0
2000
4000
6000
8000
2015 2025 2035 2045
Pro
du
ctio
n (
Mt)
OECD
China
India
Other
11 10
54
32
8
22
2637
0%
20%
40%
60%
80%
100%
2015 2050
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How to meet this challenge sustainably
Solutions need to be:
◼Practical, usable by unskilled workers
◼Economically viable
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Paris
18 March 2015
Beijing
18 October
2015
Sao Paulo
4,5 April
2016
UNEP SBCI Working Group on Low-CO2 Eco-efficient Cement-based Materials
Report Launched November 2016,
also as Special Issue
Cement and Concrete Research
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IEA for CSI of WBCSD, 2009 road map
IEA = International Energy Agency
CSI = Cement Sustainability Initiative
WBCSD = World Business Council for
Sustainable Development
Target:
18% reduction
in cement sector
High demandLow demand
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Source Martin Schneider 14th ICCC Beijing
0
20
40
60
80
100
120
2020 2025 2030 long term
€/t
CO
2Carbon capture and storage: Cost estimates
oxy-fuel
process
post-
combustion
capture
su
cce
ssfu
l d
em
on
str
atio
n
pro
jects
CCS would
increase
cement costs
substantially
Not viable for
developing
countries
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The resources of the earth mean we do not have a lot of options!
11
Only 8 elements constitute >98% or the earth’s crustEven elements we regard as common are more than 1000 times LESS abundant that the elements found in cement – cost and geographical distributionThe composition of the Earth’s Crust limits the possible chemistriesBut the limited range mean we can explore all options
1/1000
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How cement works:
Cement grainwater hydrates
reaction with water increases solid volume,
joins grains together
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What about the different oxides
Na2O
K2O
Fe2O3
MgO
CaO
SiO2
Al2O3
Too soluble
Too low mobility in alkaline solutions
The most useful
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Al2O3CaO
Portland
Cement
14
Hydraulic minerals in the system CaO-SiO2-Al2O3
Calcium aluminate /calcium sulfo aluminate
SiO2
BUT, what sources of
minerals are there
which contain Al2O3 >>
SiO2 ?
Bauxite – localised,
under increasing
demand for Aluminium
production,
EXPENSIVE
Even if all current
bauxite production
diverted would still only
replace 10-15% of
current demand.
Less CaO > less CO2
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Portland based cement will continue to be dominant
◼ Incredible economy of scaleClinker very low cost
◼ Raw materials abundant nearly everywhere
◼ Easily to manipulate open time
◼ Robust
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Extending use of blended cements
16
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Evolution of Clinker substitution
17
2%4%
5% 5% 6% 6% 6% 6% 6% 7% 7% 7%4%
4%
4% 4%5% 5% 5% 5% 5% 5% 5% 5%
1%
2%
3%3%
3%4% 4% 4%
4%4% 4% 4%
1%
2%
2%2%
2%2%
2% 2% 2%2% 2% 2%
4%
2%
1%1%
1%1%
1% 1% 1%1% 1% 1%
0%
5%
10%
15%
20%
25%
1990 2000 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014
Limestone
Slag
Fly ash
Puzzolana
Others
• Almost no progress in last 5 years
• Only 3 substitutes used in quantity
Clinker substitution most successful strategy to reduce CO2
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0 2000 4000 6000
Calcined Clay
Filler
Portland cement
Fly ash
Slag
Natural Pozzolan
Vegetable ashes
waste glass
silica fume
Mt/yr
Used Available
limestone
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▪ Blended with SCMs will be best solution for sustainable cements for foreseeable future
▪ Only material really potentially available in viable quantities is calcined clay.
▪ Blend containing combination of calcined clay and limestone are particularly interesting: EPFL led LC3 project supported by SDC. Started 2013
There is no magic solution
19
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What is LC3
LC3 is a family of cements,
the figure refers to
the clinker content
0
10
20
30
40
50
60
70
PC LC3-50
Co
mp
ress
ive
str
en
gth
(M
Pa)
1 day
7 days
28 days
90 days
• 50% less clinker
• 30% less CO2
• Similar strength
• Better chloride resistance
• ASR resistant
0
20
40
60
80
100
PC PPC30 LC3-50 LC3-65
Mas
s p
rop
ort
ion
(%
)
Gypsum
Limestone
Calcined clay
Clinker
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Why are such high levels of substitution possible
21
◼ Calcination of kaolinite at 700-850°C gives metakaolin: much more reactive than glassy SCMs
» Synergetic reaction of
Alumina in metakaolin
with limestone to give
space filling hydrates
OPC
205 10 15 25Position [ 2Q ]
CHMs
Strät .Strät . C4AF AFtAFtAFt AFtHcMc
MsHc
1d
28d
LC3-50
205 10 15 25
Position [ ]
CHMs
Strät.Strät. C4AF AFtAFtAFt AFtHcMc
MsHc
2Q
1d
28d
silicon
aluminium
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Comparison of calcined kaolinitic clay, slag and fly ash
Binary systems 70% clinker
Ternary systems, with limestone 50% clinker
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Availability of suitable clays, yellow and pink regions, and others
23
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Suitable clays presently stockpiled as waste
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LC3 has been produced and used in full scale trials in Cuba and India
A company in Latin America will start full scale production in March/April
Uses existing technologyRotary kiln Flash calcineretc
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Cuba: Industrial block manufacture plant
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Prefabrication plant Cuba
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House built at Santa Clara, Cuba with LC3
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India: Evaluation in building materials
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India: Industrial production
KJS Concrete Pvt. Ltd., Dadri
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India: Demonstration structure
Around 15 tonnes of CO2 saved
Compared to existing solutions
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Key Advantages
• Chloride resistance• ASR mitigation
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Chloride ingress ASTM
Apparent diffusion coeffs.
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Porosity characterization by MIP
◼ Significant refinement of porosity already at 3 days of hydration
LC3-50 (95%) 3d
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Very dense
microstructure
Strong pore refinement
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Alkali silica reaction
Chappex 2012
Impact of alumina on aggregates
No alumina
Alumina in solution
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Global cement production
Billion tons/year
Clinker factor, global
average
%
Global SCM volume
Billion tones/year
Global CO2
reduction
Million tones/year
2006 2.6 79 0.5
2050 (CSI study)
4.4 73 1.2 200
2050 (with LCC)
4.4 60 1.8 600
Global potential of LC3
∆ = 400 million
tonnes per yr
Can replace
whole of need for CCS
in low demand scenario
> whole of CO2
emissions
of France
Potential impact of LC3 technology
IEA study for
CSI of WBCSD
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One part of the chain
Reduce CO2
from clinker production
• Efficient plants
• Waste fuels
• Alternate raw
materials
Reduce clinker in cement
Reduce cement
in concrete
Reduce concrete
in building
More efficient (re)use of buildings
• SCMs• Aggregate grading
• Good admixtures
• Use filler
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By working throughout the
value chain CO2 emissions
can be reduced by 80%
compared to 1990, without
huge extra costs and using
existing knowledge and
codes
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Efficiency of binder use in concrete(29 countries)
0
5
10
15
20
0 20 40 60 80 100
Bin
de
r In
ten
sity
(kg
/m³.
MP
a)
Compressive Strength (MPa)
250kg/m³
DAMINELI, et al . Measuring the eco-efficiency of cement use.
Cement and Concrete Composites, 32, p. 555-562, 2010
Site mixing
Ready-mixed
industrial
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Materials wastage
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Materials wastage
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Materials wastage
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Industrialization as mitigation tool
◼ Promote industrialized use of cement
◼ Dry-mix mortar
◼ Industrialized concrete
◼ Concrete components
◼ Ban commercialization of bagged cement in large cities (ex. China)
◼ Mitigation potential: 15% reduction?
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High filler, advanced performancewater & binder minimization technology
Good rheology min water
ParticleDispersion
MinimumBinder
Particle packing
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Filler without dispersion:agglomeration may increase water demand
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Filler + Dispersion: Low water demand for given rheology
Typical cementLEAP cement + filler
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Low-Binder concrete formulations(29 countries)
0
5
10
15
20
0 20 40 60 80 100
Bin
de
r In
ten
sity
(kg
/m³.
MP
a)
Compressive Strength (MPa)
250kg/m³
CBI/KTH - Sweden; USP – Brazil; U Darmastad, U Karlsrhue, VDZ - Germany
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Market Share at 2050 (%)
Efficient concrete
Extending use of SCMs:Calcined Clayand limestone
2 solutions have large potential to reduce CO2
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Geopolymer + Calcined clay
BYF
CCSC
Calcined Clayand limestone
Efficient concrete
CO2 mitigation potential of different technologies
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Concluding remarks
◼ Future cements will be based on Portland cement clinker with increasing levels of incorporation of SCMs
◼ Calcined clays are the only realistic option for extending the use SCMs
◼ Possible to obtain similar mechanical properties to OPC / CEM I with 50% clinker and clays with >40% kaolinite
◼ Calcined clays have very positive impact on:
◼ Chloride ingress
◼ ASR
◼ If we are serious about more sustainable concrete we need to use cements with lower CO2 emissions, e.g LC3 clinker/ calcined clay / limestone blends
◼ To go further we need to work through the whole value chain.
◼ Europe has an important role to play in facilitating uptake worldwide:standards and research
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THANK YOU!