John Kline Kline Consulting

Charles Kline Kline Consulting

April 2014

data extracted from Hammond and Jones (2011), University of Bath, UK

The Cement Industry Technology Roadmap to

Reduce Carbon Emissions
In terms of specific emissions (kg of CO2 per ton of cement):

340
kg/t
= -50%
680
406
(-40%)

2006

Low Demand

338
(-50%)

High Demand

Blue Map

Main levers to reduce CO2 emissions

Plus a
New Lever
Clinker Reformulation

Energy Efficiency
Biogenic Fuels
Clinker Substitution

1. Energy Efficiency
Process

Theoretical consumption
Vertical Shaft Kilns

Typical Fuel
Consumption
(GJ/t)

Efficiency
(%)

1.75
~5

35%

5.9 - 6.7

25-30%

Long Dry Kilns

4.6

38%

2 Stages Pre-Heater (PH)

3.8

46%

4 Stages PH

3.3

53%

4 Stages PH + Pre-Calciner (PC)

3.1

56%

58%

Wet Kilns

Dry Kilns

5 Stages PH+PC (BAT)*

* Industrys Best Available Technology

Alternative Fuels used in clinker production

2. Alternative Fuels and Biomass

Achieve
50%
biomass
2006 data

Waste Source Summary

Manufacturing
Wastes

Agricultural
Wastes

Municipal Solid
Wastes (MSW)

Bio-Solids

Construction
Wastes

Availability

Industrial Areas

Rural Locations

Most Locations

Small & Large

Cities

Large Cities

Collection

Special

Special

In Place

In Place

In Place

H2O Content

Varies

High

Medium

High

Medium

Handling Issues

Varies

Medium

Medium

High if not dried

Medium

Separation
Required

No

No

Yes

No

Yes

Preprocessing
For Plant Centric

Varies

Drying, Baling

Compacting,
Baling

Drying

Size Reduction

Plant Centric
Processing

Varies

Drying, Size
Reduction, Firing

Drying, Size
Reduction, Firing

Firing

Drying, Size
Reduction, Firing

Most Likely
Future Model

Plant Centric

Plant Centric

Source Centric

Source Centric

Source Centric

Tougher Fuels Require More Processing

Combustion

Temperature

+/- 800 C

+/- 100 C

Torrefaction

Pyrolysis

Gasification

100%

Process

Raw

Oxidation

0%

Drying

Addition of
oxidant

Combustion

Achieve 50%
Substitution

Average Addition content in cement

3. Clinker Substitution
30%

25%
20%
15%
10%
5%
0%

26%

2006 data, CSI

26%
24%
22%

21%

20%
17%

16%

16%

Most Important Binder Materials

Legend
C-Ash ASTM Type C Flyash
F-Ash ASTM Type F Flyash
L Lime (Limestone - CaCO3)
MK Metakaolin
PC Portland Cement
SF Silica Fume
Slag Ground Blast Furnace

Hydraulic
Reactions
Faster
Early Strength

SiO2
SF

Pozzolanic
Reactions
Slower
Later Strength

F-Ash

C-Ash

MK

Slag

PC

CaO

Al2O3

Potential to Increase Additives

Today

Clinker
Gypsum
Flyash
Slag
Pozzolan

Potential

Limestone

2780
120
250
150
150
0
150

77.2%
3.3%
6.9%
4.2%
4.2%
0.0%
4.2%

2780
120
500
200
300
0
150

68.6%
3.0%
12.3%
4.9%
7.4%
0.0%
3.7%

Total Binder

3600

100.0%

4050

100.0%

Bt of CO2

The Cement Technology Roadmap (CSI+IEA)

How the Big Producers are Doing

Producers1

Lafarge
Holcim

Heidelberg
Italcementi

Cemex
Objective:

Alternative Fuel %2

Clinker in Cement
%

Specific Heat
Consumption Mj/t

13.9%

72.6%

3,653

13.0%

70.3%

3,495

21.7%

75.4%

3,342

6.5%

76.5%

3,820

27.1%

81.8%

3,876

Higher

Lower

Lower

Source: 2012 Sustainability Reports

New Clinkers
Clinker
Mineral

Normal
Portland

Lafarge

Italcementi Heidelberg

Buzzi

Vicat

CaO

43%

37%

31%

37%1

32%

SiO2

14%

12%

5%

17%

7%

Al2O3

4%

11%

28%

10%2

20%

Fe2O3

2%

5%

1%

3%

2%

N/A

SO3

1%

3%

11%

6%

9%

N/A

LOI

35%

29%

24%

24%

26%

N/A

McKinsey Evaluation of CO2 Costs

CO2 Capture Technologies

N2

Pre-Combustion

Fuel
Gasification &
Separation
Air Heat

H2

CO2
Process
Raw Materials

CO2

N2
Power

Oxy-Combustion

O2

Air Separation
Air

Fuel

Post-Combustion

Fuel
Process
Raw Materials

CO2 Separation

Process
Raw Materials

CO2
N2
CO2

Flue Gas
Direct Utilization
Products
CO2

Indirect Calcination

Heat

Limestone
Calcination
Raw Materials

N2
CO2

CO2 for
Sequestration,
Enhanced Oil
Field Recovery,
& Utilization

Potential Oxy-Calcination
To Drying +
Processing

Recycle CO2
+ H2O

To Raw
Mill for
Drying

Pure
Oxygen

Yield 3.5:1

Yield 5:1

Yield 1.3:1

1000

Nitrogen
Release

Low
N,
Low S
Fuel
oC

Air
Separation
Plant

1450 oC
Excess Air

100 oC

Yield = T-CO2 / T-Oxygen

Cooling Air

Comparison of Oxy Combustion Options

System

Kiln Oxy
Oxy
Combustion Calcination

Total Oxy
Combustion

Indirect
Calcination

CO2 Capture %

15%

85%

100%

65%

Yield: t-CO2 / t-O2

1.3

5.0

3.5

N/A

Leakage

Kiln Seals

Tower Only

Kiln + Tower

Precalciner
Only

Quality Impact

Potential

None

Potential

None

Cooler Issues

High

N/A

High

N/A

Efficiency Impact

High

Moderate

High

High

Refractory Impact

Potential

None

Potential

None

Technology Needs

Kiln Seals &

Cooler

None

Kiln Seals &

Cooler

None

Sorbent Technology
N2, O2
& H2O

Adsorber

Utilization Technology

CO2
Sorbent

Desorber

Exhaust
Gas

Exhaust
Gas

N2, O2
& H2O

CO2

Pressure

Vacuum

Products
Wastes

Energy

Energy

Membrane Technology

Exhaust
Gas

Process(es)

Cryogenic Technology
CO2
Exhaust
Gas

Exhaust
Gas
Energy

Energy
Compression
and Cooling

Liquid or
Solid
Separation
N2, O2
& H2O

Algae Projects - Overview

Led by

Project Type

Country

Partner

Status

Holcim
Italcementi
Heidelberg
Votorantim
Holcim

In-Plant Trial

Spain,
France,
US,
Canada,
Sri Lanka

Algae Firms

Ongoing

Lafarge
Heidelberg
Secil

In-Plant Trial

France,
US, Portugal

Algae Firms

Closed

Heidelberg
Argos
Intercement
Votorantim

Lab Trials

Sweden,
Columbia,
Brazil,
Argentina

Universities

Ongoing

Cemex

Lab Trials

UK

Consortium

Ongoing

Growing Algae in Flue Gas is only the 1st Step

Process
Extract from DOE Algal Roadmap

Market

Grow
Cultivate

Conclusions

Cement and Concrete are still the most

sustainable building materials
Carbon capture and sequestration remains
expensive and should be the last option
Carbon conversion shows promise, but not there
yet
The world does not need more clinker
Cement Manufacturers need to develop
strategies:
Sourcing and processing of alternative fuels
Sourcing and processing of cementitious materials

Recommendations
As an industry, we must work proactively together
to:
Actively promote the overall carbon efficiency of concrete;
Support the IEA roadmap and their sectorial approach;
Push for a common understanding and accounting for
traditional levers;
Develop and promote a common approach to carbon footprint
analysis;
Develop and promote a common accounting approach for
biomass;
Share the knowledge gained by the various carbon capture
projects

Ensure that everyone knows, that at least for today,

cement and concrete remain the best alternatives