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Research and Technological Development in the Cement and Concrete Industry

Slide 2 - 26.05.2009Research and Technological Development in the Cement and Concrete Industry W. Dienemann. The Cement and Concrete Industry. HistoryCement like material already used by Romans (Opus Caementitum)Development of hydraulic lime (Roman Cement) late 18th / early 19th century1843

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Research and Technological Development in the Cement and Concrete Industry

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    1. Research and Technological Development in the Cement and Concrete Industry Sustainable Development: a Challenge for European Research Parallel Session 7 Brussels, 26 May, 2009

    2. Slide 2 - 26.05.2009 Research and Technological Development in the Cement and Concrete Industry – W. Dienemann The Cement and Concrete Industry History Cement like material already used by Romans (Opus Caementitum) Development of hydraulic lime („Roman Cement“) late 18th / early 19th century 1843 – W. Aspdin develops Portland Cement Since 1850s rapid industrial development

    3. Slide 3 - 26.05.2009 Research and Technological Development in the Cement and Concrete Industry – W. Dienemann The Cement and Concrete Industry Facts and Figures Concrete is the world‘s most versatile, durable and reliable construction material In the same time concrete is a very economical product Around 2,9 billion tonnes of cement in 2007 Equals 7 billion m3 of concrete per year Next to water concrete is the most used material

    4. Slide 4 - 26.05.2009 Research and Technological Development in the Cement and Concrete Industry – W. Dienemann The Cement and Concrete Industry Rising demand Volumes are expected to more than double in the next decades Infrastructure development in developing countries China and India with high growth rates

    5. Slide 5 - 26.05.2009 Research and Technological Development in the Cement and Concrete Industry – W. Dienemann The Cement and Concrete Industry Cement and CO2 Cement manufacturing releases ~800 kg CO2 per ton of cement Around 60% results from chemical reaction of limestone ~40% burning of fuels, ? 5% electrical energy Globally 5-7% of manmade CO2 emission ? Key industry challenge

    6. Slide 6 - 26.05.2009 Research and Technological Development in the Cement and Concrete Industry – W. Dienemann Technical Developments – Process Optimization Optimizing Energy Efficiency Energy accounts for ~40% of production costs Optimization of burning process Efficiency of preheater Efficiency of cooler Waste heat power generation

    7. Slide 7 - 26.05.2009 Research and Technological Development in the Cement and Concrete Industry – W. Dienemann Technical Developments – Process Optimization Valorization of Waste as Alternative Fuel The clinker burning process is ideally suited to use alternative fuels Minimized emissions due to long residence time and high gas temperatures No residues as ash is incorporated in clinker Overall reduction of CO2 emissions and fossil fuel consumption

    8. Slide 8 - 26.05.2009 Research and Technological Development in the Cement and Concrete Industry – W. Dienemann Technical Developments – Process Optimization Valorization of Waste as Alternative Fuel Significant progress has been made in replacing fossil fuels Individual plants already use ? 90% alternative fuels Burning technology optimized

    9. Slide 9 - 26.05.2009 Research and Technological Development in the Cement and Concrete Industry – W. Dienemann Replacement of clinker Clinker manufacturing accounts for 90% of fuel and energy consumption and CO2 emissions Can partly be substituted by latent hydraulic or pozzolanic materials Blastfurnace slag from steel industry Fly ash from coal fired power plants Natural and artificial pozzolans Wide range of composite cements covered by EN standards Technical Developments – Process Optimization

    10. Slide 10 - 26.05.2009 Research and Technological Development in the Cement and Concrete Industry – W. Dienemann Technical Developments – Process Optimization Conclusions Three main pathways successfully applied in cement industry Enabled through RTD and innovations in engineering technology and material science Optimization of concrete recipes and manufacturing technology further reduced embodied energy European companies clearly at the forefront of this development

    11. Slide 11 - 26.05.2009 Research and Technological Development in the Cement and Concrete Industry – W. Dienemann Sustainability – Challenges and Opportunities Reducing the Environmental Footprint High pressure to further reduce CO2-emission significantly (Emission Trading) requires additional improvements and radical changes Reduction of emission limits require further technological developments in process and filter technologies Rising prices for electricity and fossil fuels demand further process optimization Potential through incremental development limited due to high level of optimization already achieved

    12. Slide 12 - 26.05.2009 Research and Technological Development in the Cement and Concrete Industry – W. Dienemann Adaptation to Climate Change Optimized use of concrete‘s inherent thermal mass enables design of energy efficient buildings Sustainability – Challenges and Opportunities

    13. Slide 13 - 26.05.2009 Research and Technological Development in the Cement and Concrete Industry – W. Dienemann Adaptation to Climate Change Sustainability – Challenges and Opportunities

    14. Slide 14 - 26.05.2009 Research and Technological Development in the Cement and Concrete Industry – W. Dienemann Adaptation to climate change Optimized cements and concretes required to better exploit alternative energy sources Sustainability – Challenges and Opportunities

    15. Slide 15 - 26.05.2009 Research and Technological Development in the Cement and Concrete Industry – W. Dienemann Barriers to Change Construction industry very conservative in general High safety requirements for buildings and infrastructure, guaranteed longterm performance High degree of regulation through Eurocodes, standards, etc New products and applications must be scientifically sound and technically proven This requires substantial investments in research and development Sustainability – Challenges and Opportunities

    16. Slide 16 - 26.05.2009 Research and Technological Development in the Cement and Concrete Industry – W. Dienemann New Approaches – How can R&D help? Increasing Biodiversity Quarries are ideally suited to even increase biodiversity through dynamic and rare habitats Rocks, steep faces Wetland Grasland Standing water R&D needed to develop biodiversity indicators and management plans

    17. Slide 17 - 26.05.2009 Research and Technological Development in the Cement and Concrete Industry – W. Dienemann Increase use of Alternative Fuels even further Valorization of waste only realistic possibility to reduce fossil fuel consumption (plus CO2-savings) Assimilating more and new types of fuels requires RTD in Burner technology (including O2-enrichment) Control of manufacturing process Impact on product quality Environmental performance (e.g. leaching) New Approaches – How can R&D help?

    18. Slide 18 - 26.05.2009 Research and Technological Development in the Cement and Concrete Industry – W. Dienemann Further reduce Clinker Content Increasing the ratio of cementitious materials beyond today‘s values still is the most promising route short- and midterm. Extending the use of conventional and new cementitious materials requires a better understanding of fundamental mechanisms that control performance: Structural / mechanical behaviour Corrosion resistance Durability Environmental performance (e.g. leaching) New Approaches – How can R&D help?

    19. Slide 19 - 26.05.2009 Research and Technological Development in the Cement and Concrete Industry – W. Dienemann Developing new low-CO2 materials For radical changes new materials are needed that have lower inherent CO2 content, i.e. less Calcium, e.g.: Supersulfated cements, based on slag Alkali-activated alumosilicates („geopolymers“) New, low Ca clinker, Belite, Ca-Sulfoaluminate MgO-based systems … Significant R&D activities required to understand their reaction mechanism and predict their performance New Approaches – How can R&D help?

    20. Slide 20 - 26.05.2009 Research and Technological Development in the Cement and Concrete Industry – W. Dienemann Knowledge based Development and Innovation R&D in cement and concrete technology has been very fragmental, incremental and often trial-and-error based. Needs to be converted into knowledge based approach: Develop fundamental understanding of reaction mechanisms Develop and employ appropriate analytical tools Develop models to predict field performance Validate models vs field conditions Holistic approaches needed to create confidence in new materials and overcome barriers in standardization; shorten time to market. Cradle-to-Cradle concept might lead to new, creative approaches to develop positive footprint. New Approaches – How can R&D help?

    21. Slide 21 - 26.05.2009 Research and Technological Development in the Cement and Concrete Industry – W. Dienemann Conclusion Significant improvements have been made to reduce environmental footprint of cement and concrete industry Potential of current optimization pathes almost exploited Substantial RTD investments needed to further improve sustainability of the industry. In applied research, product development, innovation In basic research / fundamental understanding Potential to develop a positive footprint Research and Technological Development in the Cement and Concrete Industry

    22. Slide 22 - 26.05.2009 Research and Technological Development in the Cement and Concrete Industry – W. Dienemann for better building

    23. Slide 23 - 26.05.2009 Research and Technological Development in the Cement and Concrete Industry – W. Dienemann The Cement and Concrete Industry Cement and Concrete manufacturing

    24. Slide 24 - 26.05.2009 Research and Technological Development in the Cement and Concrete Industry – W. Dienemann Technical Developments – Process Optimization Replacement of clinker

    25. Slide 25 - 26.05.2009 Research and Technological Development in the Cement and Concrete Industry – W. Dienemann Cradle-to-Cradle Concept for Building Materials Ensure optimal recycability of concrete Positive list of concrete constituents Develop new recycling technologies Valorization of wastes and by-products from other industries Turn the footprint positive / Eco-Effectiveness New Approaches – How can R&D help?

    26. Slide 26 - 26.05.2009 Research and Technological Development in the Cement and Concrete Industry – W. Dienemann Cradle-to-Cradle Products Develop products with positive environmental contribution New Approaches – How can R&D help?

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