Modern cements Colum McCague MPA Cement Concrete and Masonry Roadshow, Manchester, 15 th June 2017 Colum McCague MPA Cement Concrete and Masonry Roadshow, Manchester, 15 th June 2017 Contents • What is Portland cement? • Manufacture • Carbon reduction strategy • Low carbon cements • EN 197-1 cements • Novel cements • Current position and outlook • Conclusions Contents • What is Portland cement? • Manufacture • Carbon reduction strategy • Low carbon cements • EN 197-1 cements • Novel cements • Current position and outlook • Conclusions 15/06/2017 1
Transcript
Modern cements
Colum McCague MPA Cement
Concrete and Masonry Roadshow, Manchester, 15th June 2017
Colum McCague MPA Cement
Concrete and Masonry Roadshow, Manchester, 15th June 2017
Contents
• What is Portland cement?• Manufacture
• Carbon reduction strategy
• Low carbon cements• EN 197-1 cements
• Novel cements
• Current position and outlook
• Conclusions
Contents
• What is Portland cement?• Manufacture
• Carbon reduction strategy
• Low carbon cements• EN 197-1 cements
• Novel cements
• Current position and outlook
• Conclusions
15/06/2017
1
• What is Portland cement?• Manufacture
• Carbon reduction strategy
• Low carbon cements• EN 197-1 cements
• Novel cements
• Current position and outlook
• Conclusions
Contents
• What is Portland cement?• Manufacture
• Carbon reduction strategy
• Low carbon cements• EN 197-1 cements
• Novel cements
• Current position and outlook
• Conclusions
Contents
Manufacture• Limestone and shale
in kiln at 1450 C
• Significant thermaland electrical energyrequired for process
• CO2 emitted fromdecomposition oflimestone and burningof kiln fuel
What is Portland cement?
Energy andCarbon intensive!
Image source: Cement Technology Roadmap: Carbon emissions reductions up to 2050, WBCSD and IEA, 2009.
Manufacture• Limestone and shale
in kiln at 1450 C
• Significant thermaland electrical energyrequired for process
• CO2 emitted fromdecomposition oflimestone and burningof kiln fuel
What is Portland cement? t?
Energy andCarbon intensive!
Image source: Cement Technology Roadmap: Carbon emissions reductions up to 2050, WBCSD and IEA, 2009.
Source: Use of cement in concrete according to European standard EN 206-1, Müller, C. 2012
‘Hierarchy of standards’
Source: Use of cement in concrete according to European standard EN 206-1, Müller, C. 2012
EN 197-1 Cement
• European cement standardpublished in 2000
• Composition, specificationsand conformity criteria forcommon cements• E.g. CEM I, CEM II, CEM III..
EN 197-1 Cement
• European cement standardpublished in 2000
• Composition, specificationsand conformity criteria forcommon cements• E.g. CEM I, CEM II, CEM III..
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Extract from Table 1 of BS EN 197-1
Up to 95% clinker substitution
Up to 55% clinker substitution
Up to 20% clinker substitution
Up to 35% clinker substitution
EN 197-1 cements for UK concrete
Extract from Table 1 of BS EN 197-1
Up to 95% clinker substitution
Up to 55% clinker substitution
Up to 20% clinker substitution
Up to 35% clinker substitution
EN 197-1 cements for UK concrete
CEM I
CEM II/A
CEM II/B
CEM III/A
CEM III/B
CEM III/C
CEM II/A
LimestoneClinker
FA/Slag
CEM IV/B
EN 197-1 cements for UK concrete
• Narrow range of EN197-1 cementspermitted in BS 8500
• Rely heavily on FAand ggbs!
Can we optimise limestone??
CEM I
CEMM II/A
CCEM II/B
CEM III/A
CEM III/B
CEM III/C
CEM II/A
LimestoneClinkerr
FA/Slag
CEM IV/B
EN 197-1 cements for UK concrete
• Narrow range of EN197-1 cementspermitted in BS 8500
• Rely heavily on FAand ggbs!
Can we optimise limestone??
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CEM I
CEM II/A
CEM II/B
CEM III/A
CEM III/B
CEM III/C
CEM II/A
LimestoneClinker
FA/Slag
CEM IV/B
CEM II/B-M
CEM II/A-M
EN 197-1 cements for UK concrete
• Ternary ‘CEM II-M’cements are available!
• MPA currently workingwith BSI to haveCEM II-M cementsapproved in BS 8500
CEM I
CEMM II/A
CCEM II/B
CEM III/A
CEM III/B
CEM III/C
CEM II/A
LimestoneClinkerr
FA/Slag
CEM IV/B
CEM II/B-M
CEM II/A-M
EN 197-1 cements for UK concrete
• Ternary ‘CEM II-M’cements are available!
• MPA currently workingwith BSI to haveCEM II-M cementsapproved in BS 8500
CEM I
CEM II/A
CEM II/B
CEM III/A
CEM III/B
CEM III/C
CEM II/A
LimestoneClinker
FA/Slag
CEM IV/B
CEM II/B-M
CEM II/A-M
CEM VI
CEM II/C-M
EN 197-1 cements for UK concrete
• Ternary ‘CEM II-M’cements are available!
• MPA currently workingwith BSI to haveCEM II-M cementsapproved in BS 8500
CEM I
CEMM II/A
CCEM II/B
CEM III/A
CEM III/B
CEM III/C
CEM II/A
LimestoneClinkerr
FA/Slag
CEM IV/B
CEM II/B-M
CEM II/A-M
CEM VI
CEM II/C-M
EN 197-1 cements for UK concrete
• Ternary ‘CEM II-M’cements are available!
• MPA currently workingwith BSI to haveCEM II-M cementsapproved in BS 8500
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• What is Portland cement?• Manufacture
• Carbon reduction strategy
• Low carbon cements• EN 197-1 cements
• Novel cements
• Current position and outlook
• Conclusions
Contents
• What is Portland cement?• Manufacture
• Carbon reduction strategy
• Low carbon cements• EN 197-1 cements
• Novel cements
• Current position and outlook
• Conclusions
Contents
• Burning of limestone is reduced• Partial replacement in kiln with other minerals
e.g. bauxite (calcium aluminate cement)
• Burning of limestone is eliminated• Full replacement in kiln with other minerals
e.g. magnesite (magnesia cements)
• Chemical activation of cementitious materialse.g. alkali activated slag cements
What are novel cements?
• Burning of limestone is reduced• Partial replacement in kiln with other minerals
e.g. bauxite (calcium aluminate cement)
• Burning of limestone is eliminated• Full replacement in kiln with other minerals
e.g. magnesite (magnesia cements)
• Chemical activation of cementitious materialse.g. alkali activated slag cements
What are novel cements?
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Alkali-activated slag invented in 1895
Magnesia cement invented in 1866
Calcium aluminate cement invented in 1908
Novel cements?
Alkali-activated slag invented in 1895
Magnesia cement invented in 1866
Calciumaluminate cementinvented in 1908
Novel cements?
Lower CO2 than Portland basedcements
Good efficiency of plant andprocesses
Good availability of raw materials
Similar performance andcharacteristics to Portland cement
What are we looking for?
Lower CO2 than Portland basedcements
Good efficiency of plant andprocesses
Good availability of raw materials
Similar performance andcharacteristics to Portland cement
pp
What are we looking for?
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CEM I
SiO2
CaO Al2O3
• Portland cement
• Manufacture• Limestone + shale
in kiln at up to 1450 C
To recap..
PC
CEM I
SiO2
CaO Al2O3
• Portland cement
• Manufacture• Limestone + shalee
in kiln at up to 14500 CC
To recap..
PC
SiO2
CaO Al2O3
• Calcium aluminate cement• (e.g. ciment fondu)
• Manufacture• Less limestone + bauxite
in kiln at up to 1600 C
• CEM I alternative?x CO2 savings are negligible x Bauxite availability
Novel cements (in brief)
PCCAC
SiO2
CaO Al2O3
• Calcium aluminate cement• (e.g. ciment fondu)
• Manufacture• Less limestone + bauxite
in kiln at up to 1600 C
• CEM I alternative?x CO2 savings are negligible x Bauxite availability
Novel cements (in brief)
PCCAC
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SiO2
CaO Al2O3
• Calcium silicate cement• (e.g. Solidia cement)
• Manufacture• Less limestone + quartz in kiln at 1200 C• Cured by reaction with CO2
• CEM I alternative?30% reduction in CO2
up to 70% after sequestration!~ Limited to precast
Novel cements (in brief)
PC
CSC
CAC
SiO2
CaO Al2O3
• Calcium silicate cement• (e.g. Solidia cement)
• Manufacture• Less limestone + quartz in kiln at 1200 C• Cured by reaction with CO2
• CEM I alternative?30% reduction in CO2
up to 70% after sequestration!~ Limited to precast
Novel cements (in brief)
PC
CSC
CAC
SiO2
CaO Al2O3
• Calcium hydrosilicate cement• (e.g. Celitement)
• Manufacture• Less limestone in kiln at 1000 C• Lime + quartz interground and
treated in autoclave
• CEM I alternative?50% reduction in CO2
~ Slow production rate
Novel cements (in brief)
PC
CHC
CSC
CAC
SiO2
CaO Al2O3
• Calcium hydrosilicate cement• (e.g. Celitement)
• Manufacture• Less limestone in kiln at 1000 C• Lime + quartz interground and
treated in autoclave
• CEM I alternative?50% reduction in CO2
~ Slow production rate
Novel cements (in brief)
PC
CHC
CSC
CAC
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SiO2
Al2O3
• Calcium sulfoaluminate cements• (e.g. Aether, ALI CEM)
• Manufacture• Less Limestone, bauxite + gypsum
in kiln at 1300 C
• CEM I alternative?25-30% reduction in CO2
Identical plant/processes to PC~ Up to 10% more alumina required
Novel cements (in brief)
PC
CHC
CSAC
CSC
CAC
CaO
SiO2
Al2O3
• Calcium sulfoaluminate cements• (e.g. Aether, ALI CEM)
• Manufacture• Less Limestone, bauxite + gypsum
in kiln at 1300 C
• CEM I alternative?25-30% reduction in CO2
Identical plant/processes to PC~ Up to 10% more alumina required
Novel cements (in brief)
PC
CHC
CSAC
CSC
CAC
CaO
SiO2
CaO Al2O3
• Alkali activated materials• (e.g. Cemfree)
• Manufacture• Calcium and silicon-rich (e.g. ggbs)
or aluminium and silicon-rich (e.g.pfa) materials combined withalkali activator
• CEM I alternative?9 - 80% reduction in CO2 [3]
~ Raw material availability
Novel cements (in brief)
[3] Handbook of Alkali-Activated Cements, Chindaprasit, P. and Leonelli, C. (eds), 2014.
mkggbs
PC
CHC
CSC
CACCSAC
SiO2
CaO Al2O3
• Alkali activated materials• (e.g. Cemfree)
• Manufacture• Calcium and silicon-rich (e.g. ggbs)
or aluminium and silicon-rich (e.g.pfa) materials combined withalkali activator
• CEM I alternative?9 - 80% reduction in CO2
[3]
~ Raw material availability
Novel cements (in brief)
[3] Handbook of Alkali-Activated Cements, Chindaprasit, P. and Leonelli, C. (eds), 2014.
mkggbs
PC
CHC
CSC
CACCSAC
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SiO2
CaO Al2O3
• Alkali activated materials• (e.g. Cemfree)
• Manufacture• Calcium and silicon-rich (e.g. ggbs)
or aluminium and silicon-rich (e.g.pfa) materials combined withalkali activator
• CEM I alternative?9 - 80% reduction in CO2 [3]
~ Raw material availability
Novel cements (in brief)
[3] Handbook of Alkali-Activated Cements, Chindaprasit, P. and Leonelli, C. (eds), 2014.
mkggbs
PC
CHC
CSC
CACCSAC
SiO2
CaO Al2O3
• Alkali activated materials• (e.g. Cemfree)
• Manufacture• Calcium and silicon-rich (e.g. ggbs)
or aluminium and silicon-rich (e.g.pfa) materials combined withalkali activator
• CEM I alternative?9 - 80% reduction in CO2
[3]
~ Raw material availability
Novel cements (in brief)
[3] Handbook of Alkali-Activated Cements, Chindaprasit, P. and Leonelli, C. (eds), 2014.
mk
PC
CHC
CSC
CACCSAC
SiO2
CaO Al2O3
PC
• Geopolymer cement• (e.g. BanahCEM, E-crete)
• Manufacture• Low-calcium alkali activated
system[3]
• CEM I alternative?9 - 80% reduction in CO2
[3]
~ Raw material availability
Novel cements (in brief)
CHC
[3] Handbook of Alkali-Activated Cements, Chindaprasit, P. and Leonelli, C. (eds), 2014.
mkggbs
CSC
CACCSAC
SiO2
CaO Al2O3
PC
• Geopolymer cement• (e.g. BanahCEM, E-crete)
• Manufacture• Low-calcium alkali activated
system[3]
• CEM I alternative?9 - 80% reduction in CO2
[3]
~ Raw material availability
Novel cements (in brief)
CHC
[3] Handbook of Alkali-Activated Cements, Chindaprasit, P. and Leonelli, C. (eds), 2014.
mkggbs
CSC
CACCSAC
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SiO2
CaO Al2O3
PC
• Geopolymer cement• (e.g. BanahCEM, E-crete)
• Manufacture• Low-calcium alkali activated
system[3]
• CEM I alternative?9 - 80% reduction in CO2
[3]
~ Raw material availability
Novel cements (in brief)
CHC
[3] Handbook of Alkali-Activated Cements, Chindaprasit, P. and Leonelli, C. (eds), 2014.
mkggbs
‘Geopolymer’ cement
CSC
CACCSAC
SiO2
CaO Al2O3
PC
• Geopolymer cement• (e.g. BanahCEM, E-crete)
• Manufacture• Low-calcium alkali activated
system[3]
• CEM I alternative?9 - 80% reduction in CO2
[3]
~ Raw material availability
Novel cements (in brief)
CHC
[3] Handbook of Alkali-Activated Cements, Chindaprasit, P. and Leonelli, C. (eds), 2014.
mkggbs
‘Geopolymer’cement
CSC
CACCSAC
• What is Portland cement?• Manufacture
• Carbon reduction strategy
• Low carbon cements• EN 197-1 cements
• Novel cements
• Current position and outlook
• Conclusions
Contents
• What is Portland cement?• Manufacture
• Carbon reduction strategy
• Low carbon cements• EN 197-1 cements
• Novel cements
• Current position and outlook
• Conclusions
Contents
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CO2e of common cements vs. alternatives
CEM I CEM II/A-L CEM II/B-V CEM III/A CEM IV/B-V SABC C C CHC AAM
CO2e of common cements vs. alternatives
CEM I CEM II/A-L CEM II/B-V CEM III/A CEM IV/B-V SABC C C CHC AAM
• Drafting of European standardsfor SABC (e.g. Aether) nowunderway
• PAS 8820 (UK) for alkaliactivated and ‘geopolymer’cement published in April 2016• Sponsored by HS2
Standards development
http://www.ecobinder-project.eu
• Drafting of European standardsfor SABC (e.g. Aether) nowunderway
• PAS 8820 (UK) for alkaliactivated and ‘geopolymer’cement published in April 2016• Sponsored by HS2
Standards development
http://www.ecobinder-project.eu
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• UK cement companies are currentlyconsidering uptake/implications ofemerging alternative cements
• However until standards are devisedthe main focus is to further reduceemissions through improvements tocurrent PC production processes
MPA outlook..
• UK cement companies are currentlyconsidering uptake/implications ofemerging alternative cements
• However until standards are devisedthe main focus is to further reduceemissions through improvements tocurrent PC production processes
MPA outlook..
• What is Portland cement?• Manufacture
• Carbon reduction strategy
• Low carbon cements• EN 197-1 cements
• Novel cements
• Current position and outlook
• Conclusions
Contents
• What is Portland cement?• Manufacture
• Carbon reduction strategy
• Low carbon cements• EN 197-1 cements
• Novel cements
• Current position and outlook
• Conclusions
Contents
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• Modern Portland cements are becoming more sustainabledue to ongoing improvements in plant and processes
• Development of Codes and Standards will encourage UKcement companies to develop alternative/novel cementsfor their product portfolios
• It is very unlikely that alternative cements will replacecommon Portland based cements but.. the cementindustry is eager to embrace these new innovationswhere possible
Conclusions
• Modern Portland cements are becoming more sustainabledue to ongoing improvements in plant and processes
• Development of Codes and Standards will encourage UKcement companies to develop alternative/novel cementsfor their product portfolios
• It is very unlikely that alternative cements will replacecommon Portland based cements but.. the cementindustry is eager to embrace these new innovationswhere possible
