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
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
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
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Global Cement Producers
GoalsProviding environmentally friendly sustainable productsLower Fuel ConsumptionLower Operating CostsLower Capital Costs
BarriersTraditional methods have limitations
UsageEstimated 10-15% consists of SCMs
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Limitations
Natural SCMsLimited quantitiesRegional variability
Synthetic SCMsKnowledgeExperienceTechnology
Waste MaterialsFluctuating chemistriesUnwanted components
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fly Ash
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fly Ash
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Clays - Kaolins
ConsiderationsWet “Lumpy” materialSpecific temperatures“Off-color” productsInconsistent quality
Traditional TechnologyInefficient coolingNot evenly heatedDiscoloration
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Clays - Kaolins
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Synthetic Pozzolan Productions
ProductHigh pozzolonic activityColor similar to cementLower fuel consumption
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
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
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Further ImplementationsPatent Pending
13-08-30
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
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
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
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
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
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:
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
CO2 Reduction by Making Pozzolan Cement
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%
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
CO2 Reduction by Making Pozzolan Cement
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%
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Direct Substitution
17
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
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
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
30 August 2013Titel 19
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%)
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
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
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Proof of Concept
13-08-30
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
30 August 2013Titel 22
Thank You
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