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