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):
2006 Low Demand High Demand
680
406 338
Blue Map
(-40%) (-50%)
340
kg/t
= -50%
Main levers to reduce CO2 emissions
Clinker Reformulation
Energy Efficiency
Biogenic Fuels
Clinker Substitution
Plus a
New Lever
1. Energy Efficiency
Process Typical Fuel
Consumption
(GJ/t)
Efficiency
(%)
Theoretical consumption 1.75
Vertical Shaft Kilns ~5 35%
Wet Kilns 5.9 - 6.7 25-30%
Dry Kilns
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%
5 Stages PH+PC (BAT)* 3 58%
* Industry’s Best Available Technology
2. Alternative Fuels and Biomass A
lte
rna
tive
Fue
ls u
se
d in
clin
ke
r p
rod
uctio
n
2006 data
Achieve
50%
biomass
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
+/- 100 ºC +/- 800 ºC
Raw Oxidation
Drying
Torrefaction
Combustion
GasificationPyrolysis
Temperature
Process
Addition of oxidant
100%
0%
3. Clinker Substitution
2006 data, CSI
0%
5%
10%
15%
20%
25%
30% 26% 26%
24% 22%
21% 20%
17% 16% 16%
Avera
ge A
dd
itio
n c
on
ten
t in
cem
en
t Achieve 50%
Substitution
Most Important Binder Materials
C-Ash
SiO2
CaO Al2O3
PC
Slag
SF
F-Ash
MK
L
LegendC-Ash – ASTM Type C FlyashF-Ash – ASTM Type F FlyashL – Lime (Limestone - CaCO3)MK – MetakaolinPC – Portland CementSF – Silica FumeSlag – Ground Blast Furnace
PozzolanicReactions
Hydraulic Reactions
SlowerLater Strength
FasterEarly Strength
Potential to Increase Additives
Today Potential
Clinker 2780 77.2% 2780 68.6%
Gypsum 120 3.3% 120 3.0%
Flyash 250 6.9% 500 12.3%
Slag 150 4.2% 200 4.9%
Pozzolan 150 4.2% 300 7.4%
0 0.0% 0 0.0%
Limestone 150 4.2% 150 3.7%
Total Binder 3600 100.0% 4050 100.0%
The Cement Technology Roadmap (CSI+IEA) B
t o
f C
O2
How the Big Producers are Doing
Producers1 Alternative Fuel %2 Clinker in Cement %
Specific Heat Consumption Mj/t
Lafarge13.9% 72.6% 3,653
Holcim13.0% 70.3% 3,495
Heidelberg21.7% 75.4% 3,342
Italcementi6.5% 76.5% 3,820
Cemex27.1% 81.8% 3,876
Objective:Higher Lower Lower
Source: 2012 Sustainability Reports
New Clinkers
ClinkerMineral
NormalPortland
Lafarge Italcementi Heidelberg Buzzi Vicat
CaO 43% 37% 31% 37%1 32%
SiO2 14% 12% 5% 17% 7% N/A
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%
McKinsey Evaluation of CO2 Costs
CO2 Capture Technologies
Gasification & Separation
Fuel
Air Separation
Process
Fuel
Raw Materials
CO2 Separation
Direct Utilization
Products
CO2 for Sequestration,Enhanced Oil
Field Recovery,& Utilization
Air
Air
Power
Process
Process
Limestone Calcination
Heat
H2
O2Fuel
N2
N2
N2
N2
Flue Gas
CO2
CO2
CO2
CO2
CO2
CO2
Pre-Combustion
Oxy-Combustion
Post-Combustion
Indirect CalcinationRaw Materials
Raw Materials
Raw MaterialsHeat
Potential Oxy-Calcination
To Raw
Mill for
Drying
Air
Separation
Plant
To Drying +
Processing
Pure
Oxygen
Nitrogen
Release
Recycle CO2
+ H2O
Low
N,
Low S
Fuel
Cooling Air
Excess Air
1450 oC
1000 oC
100 oC
Yield 1.3:1
Yield 5:1 Yield 3.5:1
Yield = T-CO2 / T-Oxygen
Comparison of Oxy Combustion Options
System Kiln Oxy
Combustion
Oxy
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
Adsorber Desorber
Exhaust
Gas
Exhaust
Gas
Exhaust
Gas
CO2
Products
CO2 CO2
N2, O2
& H2O
N2, O2
& H2O
Energy
Wastes
N2, O2
& H2O
Sorbent
Energy Energy
Energy
Pressure Vacuum
Sorbent Technology
Membrane Technology Cryogenic Technology
Exhaust
Gas
Liquid or
Solid
Separation
Compression
and Cooling
Process(es) Exhaust
Gas
Utilization Technology
Algae Projects - Overview
Led by Project Type Country Partner Status
HolcimItalcementiHeidelbergVotorantimHolcim
In-Plant Trial Spain, France,US,Canada,Sri Lanka
Algae Firms Ongoing
LafargeHeidelbergSecil
In-Plant Trial France,US, Portugal
Algae Firms Closed
HeidelbergArgosIntercementVotorantim
Lab Trials Sweden, Columbia, Brazil, Argentina
Universities Ongoing
Cemex Lab Trials UK Consortium Ongoing
Growing Algae in Flue Gas is only the 1st Step
Extract from DOE Algal Roadmap
Grow Cultivate
Process
Market
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