Mastertitelformat bearbeiten Research and Technological Development in the Cement and Concrete Industry Mastertitelformat bearbeiten Dr. Wolfgang Dienemann, HeidelbergCement Technology Center Master-Untertitelformat bearbeiten Sustainable Development: a Challenge for European Research Parallel Session 7 Brussels, 26 May, 2009

The Cement and Concrete Industry History Cement like material already used by Romans (Opus Caementitum) Development of hydraulic lime („Roman Cement“) late 18th / early 19th century 1843 – W. Aspdin develops Portland Cement Since 1850s rapid industrial development Slide 2 - 26.05.2009 Research and Technological Development in the Cement and Concrete Industry – W. Dienemann

The Cement and Concrete Industry Facts and Figures Concrete is the world‘s most versatile, durable and reliable construction material In the same time concrete is a very economical product Around 2,9 billion tonnes of cement in 2007 Equals 7 billion m3 of concrete per year Next to water concrete is the most used material Slide 3 - 26.05.2009 Research and Technological Development in the Cement and Concrete Industry – W. Dienemann

The Cement and Concrete Industry Rising demand Volumes are expected to more than double in the next decades Infrastructure development in developing countries China and India with high growth rates Slide 4 - 26.05.2009 Research and Technological Development in the Cement and Concrete Industry – W. Dienemann

The Cement and Concrete Industry Cement manufacturing releases ~800 kg CO2 per ton of cement Around 60% results from chemical reaction of limestone ~40% burning of fuels,  5% electrical energy Globally 5-7% of manmade CO2 emission  Key industry challenge Slide 5 - 26.05.2009 Research and Technological Development in the Cement and Concrete Industry – W. Dienemann

Technical Developments – Process Optimization Optimizing Energy Efficiency Energy accounts for ~40% of production costs Optimization of burning process Efficiency of preheater Efficiency of cooler Waste heat power generation Slide 6 - 26.05.2009 Research and Technological Development in the Cement and Concrete Industry – W. Dienemann

Technical Developments – Process Optimization Valorization of Waste as Alternative Fuel The clinker burning process is ideally suited to use alternative fuels Minimized emissions due to long residence time and high gas temperatures No residues as ash is incorporated in clinker Overall reduction of CO2 emissions and fossil fuel consumption Slide 7 - 26.05.2009 Research and Technological Development in the Cement and Concrete Industry – W. Dienemann

Technical Developments – Process Optimization Valorization of Waste as Alternative Fuel Significant progress has been made in replacing fossil fuels Individual plants already use  90% alternative fuels Burning technology optimized Slide 8 - 26.05.2009 Research and Technological Development in the Cement and Concrete Industry – W. Dienemann

Technical Developments – Process Optimization Replacement of clinker Clinker manufacturing accounts for 90% of fuel and energy consumption and CO2 emissions Can partly be substituted by latent hydraulic or pozzolanic materials Blastfurnace slag from steel industry Fly ash from coal fired power plants Natural and artificial pozzolans Wide range of composite cements covered by EN standards Slide 9 - 26.05.2009 Research and Technological Development in the Cement and Concrete Industry – W. Dienemann

Technical Developments – Process Optimization Conclusions Three main pathways successfully applied in cement industry Enabled through RTD and innovations in engineering technology and material science Optimization of concrete recipes and manufacturing technology further reduced embodied energy European companies clearly at the forefront of this development Slide 10 - 26.05.2009 Research and Technological Development in the Cement and Concrete Industry – W. Dienemann

Sustainability – Challenges and Opportunities Reducing the Environmental Footprint High pressure to further reduce CO2-emission significantly (Emission Trading) requires additional improvements and radical changes Reduction of emission limits require further technological developments in process and filter technologies Rising prices for electricity and fossil fuels demand further process optimization Potential through incremental development limited due to high level of optimization already achieved Slide 11 - 26.05.2009 Research and Technological Development in the Cement and Concrete Industry – W. Dienemann

Sustainability – Challenges and Opportunities Adaptation to Climate Change Optimized use of concrete‘s inherent thermal mass enables design of energy efficient buildings Slide 12 - 26.05.2009 Research and Technological Development in the Cement and Concrete Industry – W. Dienemann

Sustainability – Challenges and Opportunities Adaptation to Climate Change Durable and safe construction needed also in case of extrem events to protect humans and economic values Slide 13 - 26.05.2009 Research and Technological Development in the Cement and Concrete Industry – W. Dienemann

Sustainability – Challenges and Opportunities Adaptation to climate change Optimized cements and concretes required to better exploit alternative energy sources Low-heat concrete for hydro dams UHPC for offshore foundations Special well cement for deep drillings Slide 14 - 26.05.2009 Research and Technological Development in the Cement and Concrete Industry – W. Dienemann

Sustainability – Challenges and Opportunities Barriers to Change Construction industry very conservative in general High safety requirements for buildings and infrastructure, guaranteed longterm performance High degree of regulation through Eurocodes, standards, etc New products and applications must be scientifically sound and technically proven This requires substantial investments in research and development Slide 15 - 26.05.2009 Research and Technological Development in the Cement and Concrete Industry – W. Dienemann

New Approaches – How can R&D help? Increasing Biodiversity Quarries are ideally suited to even increase biodiversity through dynamic and rare habitats Rocks, steep faces Wetland Grasland Standing water R&D needed to develop biodiversity indicators and management plans Slide 16 - 26.05.2009 Research and Technological Development in the Cement and Concrete Industry – W. Dienemann

New Approaches – How can R&D help? Increase use of Alternative Fuels even further Valorization of waste only realistic possibility to reduce fossil fuel consumption (plus CO2-savings) Assimilating more and new types of fuels requires RTD in Burner technology (including O2-enrichment) Control of manufacturing process Impact on product quality Environmental performance (e.g. leaching) Slide 17 - 26.05.2009 Research and Technological Development in the Cement and Concrete Industry – W. Dienemann

New Approaches – How can R&D help? Further reduce Clinker Content Increasing the ratio of cementitious materials beyond today‘s values still is the most promising route short- and midterm. Extending the use of conventional and new cementitious materials requires a better understanding of fundamental mechanisms that control performance: Structural / mechanical behaviour Corrosion resistance Durability Environmental performance (e.g. leaching) Slide 18 - 26.05.2009 Research and Technological Development in the Cement and Concrete Industry – W. Dienemann

New Approaches – How can R&D help? Developing new low-CO2 materials For radical changes new materials are needed that have lower inherent CO2 content, i.e. less Calcium, e.g.: Supersulfated cements, based on slag Alkali-activated alumosilicates („geopolymers“) New, low Ca clinker, Belite, Ca-Sulfoaluminate MgO-based systems … Significant R&D activities required to understand their reaction mechanism and predict their performance Beton-prüfung Slide 19 - 26.05.2009 Research and Technological Development in the Cement and Concrete Industry – W. Dienemann

New Approaches – How can R&D help? Knowledge based Development and Innovation R&D in cement and concrete technology has been very fragmental, incremental and often trial-and-error based. Needs to be converted into knowledge based approach: Develop fundamental understanding of reaction mechanisms Develop and employ appropriate analytical tools Develop models to predict field performance Validate models vs field conditions Holistic approaches needed to create confidence in new materials and overcome barriers in standardization; shorten time to market. Cradle-to-Cradle concept might lead to new, creative approaches to develop positive footprint. Slide 20 - 26.05.2009 Research and Technological Development in the Cement and Concrete Industry – W. Dienemann

Research and Technological Development in the Cement and Concrete Industry Conclusion Significant improvements have been made to reduce environmental footprint of cement and concrete industry Potential of current optimization pathes almost exploited Substantial RTD investments needed to further improve sustainability of the industry. In applied research, product development, innovation In basic research / fundamental understanding Potential to develop a positive footprint Slide 21 - 26.05.2009 Research and Technological Development in the Cement and Concrete Industry – W. Dienemann

for better building Slide 22 - 26.05.2009 Research and Technological Development in the Cement and Concrete Industry – W. Dienemann

The Cement and Concrete Industry Cement and Concrete manufacturing Sand Clay Gypsum Gravel Lime Kiln Clinker Mill Cement Mixer Iron Additions Admixtures Water Slide 23 - 26.05.2009 Research and Technological Development in the Cement and Concrete Industry – W. Dienemann

Technical Developments – Process Optimization Replacement of clinker Slide 24 - 26.05.2009 Research and Technological Development in the Cement and Concrete Industry – W. Dienemann

New Approaches – How can R&D help? Cradle-to-Cradle Concept for Building Materials Ensure optimal recycability of concrete Positive list of concrete constituents Develop new recycling technologies Valorization of wastes and by-products from other industries Turn the footprint positive / Eco-Effectiveness Slide 25 - 26.05.2009 Research and Technological Development in the Cement and Concrete Industry – W. Dienemann

New Approaches – How can R&D help? Cradle-to-Cradle Products Develop products with positive environmental contribution Air-cleaning concrete Fine dust reducing concrete Slide 26 - 26.05.2009 Research and Technological Development in the Cement and Concrete Industry – W. Dienemann