Sustainable Growth Supplementary Cementitious Materials · Rotary Kiln 70% Cement 30% Clay Rotary...

The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.

SCM

upplementaryementitiousaterials

Sustainable Growth

By James Ballan

Manager of Supplementary Cementitious Materials


30 August 2013Titel 2

What are SCM?Supplementary Cementitious Materials

Substitution of clinker in cement by another material which has Cementitious properties

Image reprinted with permission from the Portland Cement Association


Global Cement Producers

GoalsProviding environmentally friendly sustainable productsLower Fuel ConsumptionLower Operating CostsLower Capital Costs

BarriersTraditional methods have limitations

UsageEstimated 10-15% consists of SCMs


Limitations

Natural SCMsLimited quantitiesRegional variability

Synthetic SCMsKnowledgeExperienceTechnology

Waste MaterialsFluctuating chemistriesUnwanted components


Fly Ash


Clays - Kaolins

ConsiderationsWet “Lumpy” materialSpecific temperatures“Off-color” productsInconsistent quality

Traditional TechnologyInefficient coolingNot evenly heatedDiscoloration


Clays - Kaolins


Synthetic Pozzolan Productions

ProductHigh pozzolonic activityColor similar to cementLower fuel consumption


Advantages to This Approach

Product quality allows for increased use of pozzolan in cement blends

Color similar to cement

Lower fuel consumption than existing methods

Few moving parts – Lower Maintenance / Operating costs

Compact design – less than 1500 m2

footprint of Pyro Process Equipment

13-08-30


Further ImplementationsPatent Pending

13-08-30


EFFECT OF DIFFERENT CALCINING PROCESSES

Cement strengths after 28 days by substitute 30% of cement with limestone and calcined clay.

12

Ref Sample

100% Cement

Ref Sample

100% Cement

Hydraulic Index

after 28 days

100

Hydraulic Index

after 28 days

100

70% Cement30%

Limestone

70% Cement30%

Limestone

6060

Clay SizeClay Size

CoarseCoarse

FineFine

Flash Calciner

70% Cement30% Clay

Flash Calciner

70% Cement30% Clay

8686

8787

Flash Calciner

70% Cement30% Clay

Flash Calciner

70% Cement30% Clay

9696

100100

Rotary Kiln

70% Cement30% Clay

Rotary Kiln

70% Cement30% Clay

8585

9191

Rotary Kiln

70% Cement30% Clay

Rotary Kiln

70% Cement30% Clay

7777

8686


Side-By-Side

KilnEquipment - $16 M USDInstallation - $ 16 M USD

680 kcal/kg12 kw/tMaintenance - $3 per ton

20-25% Substitution

18-24 months

ROI – 3.5 years

CalcinerEquipment - $12 M USDInstallation - $12 M USD

640 kcal/kg15 kw/tMaintenance - <$1 per ton

35-40% Substitution

15-18 months

ROI – 2.5 years

13-08-30


CO2 Reduction by Making Pozzolan Cement

0.893

0.94 X

=

Kg clinker

Kg CO2

Kg Cement

Kg CO2

Assume: 0.94 Kg CO2/Kg Clinker, and 0.256 Kg CO2/Kg Pozzolan

0.95 + 0.0 XKg clinker

Kg CO2 0.05

0.601

(0.256 X

=

Kg Pozzolan

Kg CO2

Kg Cement

Kg CO2

0.4 + 0.94 XKg Clinker

Kg CO2 0.6).95

CO2 OPC:

CO2 POZ:



0.893

0.94 X

=

Kg clinker

Kg CO2

Kg Clinker

Kg CO2

Assume: 0.94 Kg CO2/Kg Clinker, and 0.256 Kg CO2/Kg Pozzolan

0.95 + 0.0 XKg clinker

Kg CO2 0.05

0.601

(0.256 X

=

Kg Pozzolan

Kg CO2

Kg Cement

Kg CO2

0.4 + 0.94 XKg Clinker

Kg CO2 0.6).95

CO2 OPC:

CO2 POZ:

A reduction of 33%



64

X

=

Kg Clinker

700 Kcal

Kg Clinker

Kcal

Assume: We use 700 Kcal/Kg Clinker in the process

0.6 + XKg Pozzolan

540 Kcal 0.4

Fuel Savings:

Kg Clinker

700 Kcal -

A savings of 9.1%


Direct Substitution

17


Blended Cements

Clinker is engineered for Ordinary Portland Cement

Blended Cement can mimic Ordinary Portland Cement

High substitution rates require different parameters

Optimization of physical and chemical properties required

Blended Cements ~ Ordinary Portland Cement

13-08-30



Pozzolan Testing

Laboratory Study – Synthetic Pozzolan With the objective of identifying potential to produce a synthetic pozzolan

from a given clay, FLSmidth will perform/provide the following:Sample PreparationChemical and mineralogical characterizationPhysical testingActivation utilizing calciner processColor control of productGrinding and physical testing of synthetic pozzolan

Compressive strength testing at three substitution rates (20, 30 and 40%)


Concept / Advancement

13-08-30

Mobile PlantPilot scale Pozzolan Calciner System5 MTPD capacityFully integrated / Self-sustainable (Plug-and-Play concept)Simple set-up & operation

AdvantageHands-on experienceProduct produced with available raw materialsCapacity to achieve consumers acceptance

InvestmentWeekly Rental - ~$45,000 USDInvestment credited to purchase of full-scale system


Proof of Concept

13-08-30



Thank You

Sustainable Growth Supplementary Cementitious Materials · Rotary Kiln 70% Cement 30% Clay Rotary...

Documents

Transcript of Sustainable Growth Supplementary Cementitious Materials · Rotary Kiln 70% Cement 30% Clay Rotary...