CEMENT AND LIME, UPDATE

Eemeli Tsupari, VTTMarkus Hurskainen, VTT

Sampo Mäkikouri, VTT

BACKGROUND: PRESENTATION IN 7TH

RESEARCHERS’ SEMINAR

Eemeli Tsupari, VTTMarkus Hurskainen, VTT

24-25.1.20177th RESEARCHERS’ SEMINAR

CO2 emissions from cement productionTHE MOST IMPORTANT INDUSTRIAL CO2 SOURCE!!!

• Ca. 55% of the emissions are process emissions (from CaCO3), 35% comes from the burning of the fuels to heat the kiln, and ca. 10% comes from electricity use and transportation.

• The total CO2 emissions are estimated to be around ~3 Gt/a, which equals to ~8% of total man-made emissions.• By extrapolating from the CSI GNR data* (which covers 21% of world’s cement

production)

55%35%

10%

CO2 emissions from cement production

Process

Fuel

Electricity

Sources: *Cement Sustainability Initiative - Getting Numbers Right databasehttp://www.wbcsdcement.org/GNR-2014/index.html

More than the C needed to replace global aviation fuels!

Experiments at VTT (CCSP 2016)

• Successful pre-calcination of lime mud (from pulp mill)• Production of 95%..98% pure (biogenic) CO2

• Avoiding CO2 from fossil fuels

• Next: Funding for CFD studies and scale-up

UPDATE /SEPTEMBER2017

Demonstration of indirectcalcination

• Preparation on-going with Tekes and companies

• The core of the project will be investmentand experiments with small scaleindirectly heated rotating kiln

• CO2 output ~22 kg/h

Calcination by electricity

• Economic feasibility with different scale factors– WACC 10%, 20 years– CO2 selling by 50 €/t

* Incl. costs of CO2 allowances, fossil fuel taxes etc.

Scale factor

Electrification in Sweden

https://corporate.vattenfall.com/press-and-media/press-releases/2017/vattenfall-and-cementa-focusing-on-zero-emissions/

Visit @ Finnsementti Parainen 21.8.2017

• Realised CO2 emissions 2016 492 kt– 13th largest CO2 point source in Finland – Lappeenranta plant 335 kt CO2/a

• Finnsementti interested on NeoCarbon– Please propose collaboration for e.g. review of

scenario assumptions, reports, articles, etc.

• Letter-of-intent to participate on demonstration of indirect precalcination

– High volume in cement industries but morefeasible in pulp and lime plants

Picture: Finnsementti

• So far, the focus has been in alternative (low-C) fuels and blended cements– At present, fuel based CO2 only 30% of Finnsementti’s total CO2

• In general, there are several possibilities for significant CO2 reductions:

– Finally dependent on customers (old, important and proven product, no risks in building safety and speed)

• Standards are important

Feedback from Finnsementti(full memo at the end of this presentation)

Fuels CaCO3

CO2

• Efficiency improvement- O2 enrichment (note link to electrolysis)- Calcinier

• Biogenic fuels• Lower C fuels (NG, LNG, waste)

• Blending• Alternative raw materials

In European cement standard EN 197-1, the 27 products are grouped into five main cement types as follows:

– CEM I Portland cement (>95% clinker)– CEM II Portland-composite cement (65-94% clinker)– CEM III Blastfurnace cement (5-64% clinker)– CEM IV Pozzolanic cement (45-89% clinker)– CEM V Composite cement (20-64% clinker)

Classifications enabling highblend cements already exists

http://www.finnsementti.fi/files/pdf/FS_Suomalainen_sementti_kirjanen_071112.pdf

~85% market share in the EU!

Rethinking Cement -report

Five strategies:1. Supplying 50% of cement

demand with geopolymer cement2. Supplying 50% of cement

demand with high-blend cements3. Mineral carbonation4. Using less cement5. Carbon negative cements

– Based on e.g. MgO

Global annual availability of rawmaterials (million tonnes)

Source: Rethinking cement -report

CEMBUREAU visionhttps://cembureau.eu/media/1226/cembureau_2050roadmap_lowcarboneconomy_2013-09-01.pdf

(EU, Mt CO2)

Ashes from lignite or coal,

blastfurnace slag, concrete crusher

sand, aerated concrete meal and

fractions from demolition waste

(also sludge)

Highlighting CCS

15

CO2 addition in conventional concreteConcrete masonry (CarbonCure)

• Purified CO2 fed into concrete in mixing

• CO2 reacts forming nano-scale CaCO3particles

• Improved compressive strength leading to material savings

13.12.2017

http://carboncure.com/Source: Monkman, S. CO2 for Better Ready Mixed Concrete Production. CarbonCure Technologies Inc. Ohio Concrete - 78th AGM, Columbus, Dec 10, 2015.

Figure: CO2 addition leads to higher compressive strength in concrete masonry products.

16

CO2 addition in conventional concreteReady-mixed concrete (CarbonCure)

• CO2 can be fed also into ready-mixed concrete in the mixing phase

• CO2 feeding equipment can be retro-fitted to the plant

Source: Carbon Cure – Ready mixed concrete

13.12.2017

Figure: Conclusion of the CarbonCure case studies. CO2 addition enabled a reduction in the amount of cement in the concrete mix by 5-8 % without losing compressive strength.

17

Cement developed for CO2 curing(Lafarge SolidiaTM)

• A new non-hydraulic cement composed of low-calcium silicate compounds

Does not react with waterCuring based on reactions with CO2

High CO2 absorption (~300 kg CO2/t)

• Fuel savings of 30 %– Lower kiln temperature (1200 °C)– Less calcium carbonate

• Concrete product cures in 24 hours

• For pre-cast applications

13.12.2017

Source: Atakan, V., Sahu, S., DeCristofaro, N. Sustainable alternatives. Solidia Technologies, USA. International Cement Review, Feb 2015.

http://solidiatech.com/

18

Alternative binders in construction productsFrom slag to construction material (Carbstone Innovation NV)

• High value construction materials from unutilised steel slag

• Carbonation (CO2 curing) in an autoclave at high temperature and pressure

• No need for other binders, e.g. cement

• Pilot plant under construction in Farciennes, Belgium

Source: https://www.carbstoneinnovation.be/en

Summary of CO2 reduction options

Fuels CaCO3

CO2

• Efficiency improvement- Incl. O2 enrichment

• Biogenic fuels• Lower C fuels• - NG, LNG, waste• SNG• Electricity

• Blending• Alternative raw materials

• Recycling of products• Long life cycles• Resource efficiency in consumption (design, alternative

binders in construction, etc.)• Process heat recovery (e.g. district heat, ORC)• CCU/S• CO2 curing

Technical CO2 reduction potentials

Fuels CaCO3

CO2

• Efficiency improvement- Incl. O2 enrichment

• Biogenic fuels• Lower C fuels• - NG, LNG, waste• SNG• Electricity

• Blending• Alternative raw materials

~30%

50..100%

~80%~100%

• Recycling of products• Long life cycles• Resource efficiency in consumption (design, alternative

binders in construction, etc.)• Process heat recovery (e.g. district heat, ORC)• CCU/S• CO2 curing

Additional material

GLOBAL CO2 EMISSIONSUPDATE ON PRESENTATION GIVEN IN NCE

WORKSHOP “STRATEGIC ROADMAP - FUTURE ELECTRICITY NEED AND CO2 RECYCLING” 7.3.2017

Eemeli Tsupari, VTT

Global GHG emissions

Original data: IPCC 2014Picture source https://www.epa.gov/ghgemissions

Based on data published in https://www.iea.org/publications/freepublications/publication/CO2EmissionsFromFuelCombustionHighlights2015.pdf

Finland’s GHG emissions

Why?

> 15 000 TWh electricity

> 20 000 TWh heat

~5 000 Mt cement and lime

> 1 600 Mt steel

Driving, travelling, transporting consumables...

Low-C solutions

> 15 000 TWh electricity

> 20 000 TWh heat

~5 000 Mt cement and lime

> 1 600 Mt steel- Synthetic fuels for ships and aviation- Electric cars, busses etc.

- DRI by H2

- Electric calcination

- Solar heat- Heat pumps- Bioenergy- WtE

- PV, CSP, wind…

Driving, travelling, transporting consumables...

Several options in previous slides

Need for new low-C electricity

> 15 000 TWh

New electricity, TWh/a

> 13 000 TWh~ 4 000 TWh

> 6 000 TWh

~ 4 000 TWh

~ 6 500 TWh

- Synthetic fuels for ships and aviation- Electric cars, busses etc.

- DRI by H2

- Electric calcination

- Solar heat- Heat pumps- Bioenergy- WtE

- PV, CSP, wind…

Note: 2013 global consumption levels!(no growth, no efficiency improvements)

2 Gt CO2 from CaCO3

1.1 x C needed for synthetic fuels for shipsand aviation

> 48 000 TWh new renewable power!

Several options in previous slides 1000..5000 TWh

>45 000

Feedback from Finnsementti• So far, the focus has been in alternative (low-C) fuels and blended cements

– At present, fuel based CO2 only 30% of Finnsementti’s total CO2

• In general, there are several possibilities for significant CO2 reductions:– Oxygen enrichment (already commercial). Typically in the case of low quality fuels

• Note: Large and new consumer for O2 if surplus production in future– Adding calcinier on those existing kilns where not yet utilised. About 25% energy savings +

enabling low quality biogenic and waste-based fuels– Replacing coal and petcoke by natural gas, LNG, biogas or SNG– Increased blending

• Finally dependent on customers (old, important and proven product, no risks in building safety and speed)• Blast furnace slag is available even for higher shares• Also ashes can be blended, but should be from burner fired processes

Amounts decreasing, especially Finland• Other blends, e.g. CaCO3 and rice husk. General agronymn for blends is SCM• Standards are important

– Other raw materials: For example pozzolans (e.g. clays) and kaolin– Decreasing emissions indirectly by heat recovery

• District heating (already utilised in Parainen)• Electricity from waste heat by ORC if electricity is more expensive

• Recycling as materials for new cement is difficult but recycling of completeconcrete elements is done

New low-C cement typesSeveral parallel novel cement types are being developed including:

– Magnesium silicates rather than limestone (calcium carbonate)– Calcium sulfo-aluminate belite binders– A mixture of calcium and magnesium carbonates and calcium and magnesium

hydroxides– New production techniques, using an autoclave instead of a kiln and a special

activation grinding that requires far less heat and reduces process emissions– Dolomite rock rapidly calcined in superheated steam, using a separate CO2 -

scrubbing system to capture emissions– Geopolymers using by-products from the power industry (fly ash, bottom ash),

steel industry (blastfurnace slag), and concrete to make alkali-activated cements. Geopolymer cements have been commercialised in smallscale facilities, but havenot yet been used for large-scale applications.

https://cembureau.eu/media/1226/cembureau_2050roadmap_lowcarboneconomy_2013-09-01.pdf

More information

• http://bze.org.au/rethinking-cement-plan/

• www.wbcsdcement.org/technology

• https://cembureau.eu/media/1226/cembureau_2050roadmap_lowcarboneconomy_2013-09-01.pdf

• http://www.finnsementti.fi/files/pdf/FS_Suomalainen_sementti_kirjanen_071112.pdf