Sustainability and Productivity Through People, Process ...p2infohouse.org/ref/50/49344.pdf9 2008...

Sustainability And Productivity Through People, Process and Product Innovation

Jean-Claude Roumain, Corporate Product Manager Holcim (US) Inc.

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2008 National Resource ConservationMarch 7th 2008Holcim (US) Inc

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EXPANDING THE CONCRETE MARKETPLACE

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AvailabilityVersatilityLow Maintenance CostSuperior Life Cycle CostLow Ecological Cost

Can Be Durable

Concrete is the Material of Choice

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Asphalt

Wood

Steel

GlassPlastic

Aluminum

Competitive Alternate Materials

6


Asphalt

Bad Concrete

Environmental Impact

Wood

Steel

GlassPlastic

Aluminum

Greatest competitive Threats to ConcreteGreatest competitive Threats to Concrete

7


Creating a balance in satisfying the two important needs of

society

Building infrastructures to

support our desired standard of living

Protection of our environment and efficient use of

our natural resources

In BalanceJean-Claude Roumain(1998)

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Holcim sustainability activitiesFoundation member of World business council for sustainable development (WBCSD) - Cement sustainability in 1999

In 2007 18 members including 8 of Top 10 companies

Sustainability issues coverClimate change Pollution Resource depletionWorker health and safety

Actions agreed to monitor and publish CO2 emissions from 2006 and to set up a climate change mitigation strategy

The Holcim Foundation for Sustainable Constructionpromotes innovative approaches to sustainable construction

Holcim Awards to promote interdisciplinary dialog, bring forward new ideas and examine potential solutions.

http://www.wbcsd.ch/

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WBCSD Cement sustainabilityIn 1999, ten leading cement companies – representing one-

third of the world’s cement production – embarked on the Cement Sustainability Initiative (CSI), a member-sponsored program of the WBCSD.

In 2008 18 member countries, including 8 of largest top ten

The objective was to find new ways to meet the sustainability challenge of: reducing the industry’s ecological footprint increasing stakeholder engagement understanding the industry's social contributions.

Cement production is energy-intensive - it accounts for 5 percent of global carbon dioxide emissions - and it touches on a wide range of sustainability issues including:

Climate change Pollution Resource depletionWorker health and safety

http://www.wbcsd.ch/

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2006 World Cement Production

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Portland Cement ConsumptionThousand Metric Tons

450

20,450

40,450

60,450

80,450

100,450

120,450

140,450

1995 1997 1999 2001 2003 2005 2007 2009 2011

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Natural Resourcesin cement and concrete production

1.7 to 2 ton of minerals per ton of clinker1.7 to 2 ton of minerals per ton of clinker

Cement consumes up to 5 billion ton of minerals per yearCement consumes up to 5 billion ton of minerals per year

Concrete consumes 16 billion ton of aggregate per yearConcrete consumes 16 billion ton of aggregate per year

Cement and concrete consume 600 to 700 billion gallons Cement and concrete consume 600 to 700 billion gallons of water per year of water per year

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Today’s Challenges

Concrete industry is fragmented and diverse

Antiquated standards / Limited acceptance of new standards

Slow to investigate and adopt new technology

Reluctance to change

Gap in product knowledge

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People’s Role

“Despite conventional wisdom, People – not Technology –play the biggest role in creating successful green buildings”

Tom Paladino, PE, AIA, LEED AP

USGBC, Board of Directors Vice Chairman

A simple assembly of “green” products is not an adequate solution for sustainability

LEED 3.0

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Who Are The Stake Holders?

Material Supplier

Cement

Admixtures

Aggregate

Immediate Customer Contractor Specifier Owner

Ready Mix

Paver

Precast

Prestress

Block

Pipe

General

Cement Finisher

Foundations, walls

Industrial Floors

Testing Labs

Architect

Engineer

DOT’s

City

County

FHWA

FAA

Corps.of Eng.

Bureau of Rec.

Developer

Taxpayer

User

“Incentives”

“COMFORT ZONE”

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AK

AL

AR

CT

DC

FL

GA

HI

ID

IN

KS

LA

MA

MD

MEMN

MO

MS

NC

ND

NH

NY

OK

OR

PARI

SC

SD

TN

TX

VA

VT

WA

AZ

CA CO

IA

IL

KY

MI

NENJ

NM

NV OHUT

WI

WV

WY

DE

MT

As of November 1, 2007

.45 limit .9 limit

.6 limit .95 limit

.7 limit 4#/cu. yard

None

Alkali Limits

MN

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AK

AL

AR

CT

DC

FL

GA

HI

ID

IN

KS

LA

MA

MD

MEMN

MO

MS

NC

ND

NH

NY

OK

OR

PARI

SC

SD

TN

TX

VA

VT

WA

AZ

CA CO

IA

IL

KY

MI

NENJ

NM

NV OHUT

WI

WV

WY

DE

MT

Status as of November 1, 2007DOT Allows C 1157 Cements

DOT Does Not Allow C 1157 Cements

DOT Approved for Cement Treated Base Work Only*

Not Known

DOTs that Allow C 1157 Cements

* Not Structural Concrete or Pavements

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Making it better - Cement

Reduced energy use / unit of cement > 33% since 1972

Industry has pledged another 10% reduction by 2020

Climate Vision - Voluntary reduction of CO2 of 10% by 2020

Reduce waste by 60% by 2020

Holcim Internal Goal “0” waste by 2012

Find these facts atwww.cement.org/smreport06

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Going to the concrete market

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BFS Class C fly ash

OPC

Metakaolin

Silica fume

Clays

CaO

SiO2

SiO2

AI2O3

CaO

Natural pozzolanas

Class F fly ash

Classification of OPC/MIC by Chemical Composition

Increasing hydraulic reactivity

AI2O3

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Recycled Content

Cement and concrete industries consumed 20.59 million metric tons of coal combustion products (fly-ash, bottom ash and FGD) in 2005 (American Coal Ash Assoc)

GGBFS Slag cement utilization in 2006 was 3.62 million metric tons (Slag Cement Assoc)

Electric Arc Furnace Slag

Silica Fume

Rice Husk Ash

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GGBFSGGBFSGround, granulated blast furnace slag (GGBFS) is another useful cementitious material, and is both hydraulic and pozzolanic. It is made by processing slag, the molten mineral byproduct of iron-making blast furnaces.

GGBFS

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Coal Combustion Products 2006

2004 14.1

2005 14.9

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US Fly Ash Penetration vs. Other Countries

Country Estimated Fly Ash Penetration

South Africa 6.0%

United Kingdom 4.5%

France 4.5%

Germany 11.0%

Spain 7.5%

Poland 8.5%

Greece 9.0%

USA 9.0%

A comparison with other countries where Fly Ash is plentiful suggests that the Penetration rate in the USA is already among the highest overall.

When looking at the US it is also important to keep in mind that the west coast, which accounts for close to 15% of the market, has virtually no Fly Ash

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Impacts of the cement production process

Quarrying and raw materials preparation

consumption of non-renewable resources

impacts on local landscape, ecology and communities

Clinker production

use of fossil fuels

atmospheric emissions, especially CO2

Cement grinding and distribution

use of raw materials and electricity

can have impacts on local communities

Cement production is an energy and resource intensive process.

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BUILDINGinfrastructure

NaturalResources

ENERGY fuels

Emissions CO2

Industrial Ecology - Eco-efficiency in the cement industry value-chain

QUARRYlimestone

QUARRYaggregates

MILLcement

KILNclinker

READY MIXconcrete

Operations

Substitutes Recycledbuilding materials

By-products from other industries

Alternative fuels / waste

materialsIndustrial Ecology

“Wastes of one industry are the

starting materials of

another”

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Calcium 60%Iron

10%

Silica

20%

Alumina

10%

Sulfate

Alkali waste

Aragonite

Calcite

Cement-kiln dust

Cement rock

Chalk

Clay

Fuller’s earth

Limestone

Marble

Marl

Seashells

Shale

Slag ( GGBFS-EAFS )

Blast-furnace flue dust

Clay

Iron ore

Mill scale

Ore washings

Pyrite cinders

Shale

Calcium silicate

Cement rock

Clay

Fly ash

Fuller’s earth

Limestone

Loess

Marl

Ore washings

Quartzite

Rice-hull ash

Sand

Sandstone

Shale

Slag

Traprock

Aluminum-ore refuse

Bauxite

Cement rock

Clay

Copper slag

Fly ash

Fuller’s earth

Granodiorite

Limestone

Loess

Ore washings

Shale

Slag

Staurolite

Anhydrite

Calcium sulfate

Gypsum

FGD Ash

SDA Ash

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Alternate Fuels - Tire Derived Fuel

Pound for pound, scrap tires have about 25% more energy than coal

Tires are also a raw material source for iron (steel belts)

Can have lower NOx emissions compared to some types of coal

Rubber Manufacturers Association reports that the cement industry consumed 53 million tires in

2004 (41% of total burned)

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Cement Formulation

2004 Product formulation change – ASTM C150 allows for up to 5% powdered limestone – used in Europe for decades

Energy Consumption reduced by 11.8 trillion Btu’s (10.14)

CO2 Emissions reduced by 2.5 million tons (equiv to 300,000 cars/year)

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Sustainable Product InnovationTechnological Innovation

Hybrid automobiles

Wind and solar power

How About Cement And Concrete?

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Yes, we can predict the future

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Fly ash quality and availability trendsWestern US

High share in PRB coal and Class C ashIn case DeSOx required SDA technology of choice (water demand)Due to cap and trade emission reduction system it is not known which plant will finally install DeSOx

Eastern USMainly bituminous coal but PRB increasingSome plants might achieve SO2 limit just by coal switch to PRBIn case of DeSOx installation required FGD wet scrubber systems technology of choiceWhen FGD installed it’s possible that switch back to bituminous coal in case PRB coal was fired before due to cost

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Geographical trends on fly ash quality

Impact factor Impact on fly ashquality/availability

SDA preferred Mainly negative but depending on location in plant

No landfillrestrictions

No utilizationpressure

Impact factor Impact on fly ashquality/availability

FGD preferred Option to change fromPRB to bit coal

Landfillrestriction

Promotes useof fly ash

SIP call states Stricteremission limits

Increasing installation of emission control systems forSOx and NOx moving from East to West coast

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Triboflow unit, 2 cells 1 t/h capacity each

+-Carbon +Mineral -

Charging byinterparticle frictionthrough velocity

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Dry scrubber location options

Bottom Ash

Coal

Furnace

Fly ash not usable Fly ash usable

Desulphurization (DeSOx)

ESP

Lime

Lime

SDA

SDA

SDA product

+

Baghouse

SDA productincl. fly ash

Fly ash separate

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SDA in US

Volumes increasing, implementation more depending on water availability

PRB coals have already low sulfur so less need forreduction of SOx

Volume increase 2002 0.9 mio t/y, 2003 1.4 mio/y, 2004 1.9 mio/y, 2005 1.4 t/y

10 mio expected in 2010 t/y

Implementation strongly depending on new limits and cap and trade mechanism

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Properties of SDA/DSI product

SiO2

Al2O3

Fe2O3

CaO

MgO

SO3

Na2O

K2O

TiO2

Cl

F

1- 40

1 - 15

0.1 - 5

20 - 60

0.5 - 5

1 - 17

0.1 - 0.5

0.1 - 0.2

0.05 - 1

0.5 - 6

0.1 - 1

CaSO3

CaSO4

CaCO3

Ca(OH)2

CaCl2

CaF2

Fly ash

Moisture

SDA/DSIproduct

15 - 75

2 - 30

1 - 30

1 - 25

1 - 15

0.1 - 1

1 - 70

1 - 10

SDA/DSIproductChemistry Mineralogy

Note: High variation because of different location of reactor and ash content

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Biosilica

Renewable cementitious material

Rice Husk

Oats

Bagasse

Transformation of Binders for Concrete

Disruptive technologies

Revolu

tion

CogenerationRHA, Oil ShaleSelf calcination

Limestone + Sub bituminous coal

CO2 Utilisation

Power generation

Activated Diatomaceous, Volcanicnatural pozzolan, Earth (DE) ASH

ActivatedSlag, fly ash

Catalyst

Performance specification

Sustaining technologies

Evolution

SDA Ash, Beneficiated Ash, HC Biosilicas, Hydrophobic Powders

New binders

Cementindustry

Others

Ground or DustLimestone

GroundGlass RHA Internal Curing minerals

Composite cement(Limestone)

SUSTAINABILITY

Ternary blends Quaternary blends(Slags + FA).Silica fume, Metakaolin

SCC Cements (high filler content)

CRADLE TO CRADLE

Jean-Claude Roumain , 2007

Transformation of the Concrete Industry

Disruptive Technology

Revolu

tion

In Situ Modular RM Plants

Cellular concrete

Covercrete IPCF

Synthetic foaming agent

CSH Nucleation & GrowthVolume, density ,set Modifier

Rheology, strength ModifierP2P

FromPrescriptive to Performance Specification

Sustaining Technology

Evolution

Composite Members Hydrophobic concrete

Ready Mix

Precast

prestress

Steel – Carbon – Glass –cellulose fibers

SUSTAINABILITY

RecarbonationPrecast

Biologically Growing Concrete

Abalone, Shells, Eggs,Teeth

Thinner, lighter members

SCC – Productivity – Performance Taller, Thinner concrete

Day to Night placement -Versatility – New Shape-Geometry Structure

RM Industry Challenges• Logistic • Local Aggregate Supply • Water Management • Noise

Jean-Claude Roumain (2007)

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Goal:

development of concrete

with high self-crack-healing capacity

using bacteria as self-healing agent

Bio-mineral production

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Biology Grown Concrete – Calcitic Concrete

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As the old saying goes. . .

There are those who make things happen

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Those who watch things happen

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Those who watch things happen

And those who wonder what the !!!! happened.

Thank you

A firm commitment

for a Sustainable Future

Jean-Claude Roumain FACI

Holcim (US) Inc.

[email protected]

TEL: 303 810 5227

mailto:[email protected]

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Triboflow - Process diagrams and flow chart

Modular set up of 1 t/h cells– flexible sizing

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Triboflow plant layout

11 m

14 m

4.6 m

Surge hopper

Bag houses

Charging unitProcessing cells

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Spray Dry Absorption (SDA) processUsualy used for smaller units <200 MWe, larger units require 2 SDA reactors and as retrofit of existing plantsLower SO2 reduction levels 60-80% than FGD systemsLime(CaO)/Limestone(CaCO3)-water-slurry is sprayed in a reactor to bind SO2 in the flue gases forming mineral phasesWater is evaporated, a dry SDA product is producedComposition of SDA product dependent on location of reactorReactor before Electrostatic precipitator ESP produces a mix of fly ash and desulphurization productsSDA product usually a mix of Calciumsulfates and -sulfites, unreacted absorbent (CaCO3), Ca(OH)2, CaCl2 and fly ashReactor behind ESP produces pure desulphurization product and has no effect on fly ash

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