Sustainability Through People, Process and Product Innovation€¦ · The Sustainable attributes of...
Transcript of Sustainability Through People, Process and Product Innovation€¦ · The Sustainable attributes of...
SustainabilityThrough People, Process and Product Innovation
Jean-Claude Roumain FACICorporate Product Manager, Holcim (US) Inc.
o
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
Content
Concrete the material of choice
The impact of increase demand for cement andconcrete
The Sustainable attributes of concrete
People‘s role in Sustainability
How standards specifications and Codes affectsustainability
Performance specification the catalyst to Sustainability
Process Improvement in cement and concrete
Product Innovation
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
What are sustainability issues?
Sustainability is more than the high-profile issues of CO2 and climatechange; also included are the social, environmental, and economic(SEE) aspects of:
• Land• Water• Energy• Emissions (atmosphere)• Non renewable Materials and Resources• Indoor environmental quality
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
Population Growth & Cement Production Population Clock : 15:04 GMT (EST +5) Feb 9,2009
World Population
6,759,411,810
World Cement Production
2,700,000,000 mt
World Population Growth
1 Billion every 14 years
US Population
305,781,626
US Cement Production
90,000,000 mt
Cement Production Growth
130 million tonnes per year
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
Besides water Concrete is the most usedmaterial on this planet
Concrete is the material of choice
Availability
Versatility
Cost Effective
Low Ecological Cost
Superior life cycle cost
Can Be Durable
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
EXPANDING THECONCRETE MARKETPLACE
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
Sustainability
“ We do not inherit the earth from our ancestors;
We borrow it from our children. “
- Native American proverb
“ No civilization can survive the physical destruction of itsresource base.”
Bruce Sterling
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
Asphalt
Wood
Steel
Glass
Plastic
Aluminum
Competitive Alternate Materials
JC Roumain 1978
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
Asphalt
Bad concrete/Fragmentation
Environmental Impact
Wood
Steel
Glass
Plastic
Aluminum
Greatest competitive Threats to ConcreteGreatest competitive Threats to Concrete
JC Roumain 1978
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
Creating a balance in satisfying thetwo important needs of
society
Buildinginfrastructures to
support our desiredstandard of living
Protection of ourenvironment andefficient use of
our non renewablenatural resources
In BalanceJean-Claude Roumain(1998)
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
Sustainability Triple Bottom Line
TomorrowTomorrowTodayToday
SocialSocialEnvironmentalEnvironmental
EconomicEconomic
GlobalGlobal RegionalRegional
LocalLocal
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
Content: The three P’s
People : To communicate and establish a culture of “Sustainability” throughKnowledge transfer just like “Safety first” and the promotion of performancespecifications
Process: Durable Concrete is a Process. We must identify all barriers andeliminate them. We must facilitate the use of alternate materials to replacenon renewable resources. And promote efficiency in ManufacturingDelivering, and Application of Durable Quality concrete
Product Innovation: To create an environment that is conducive to innovation,value creation, and the ability to sustain successful utilization ofsustainable material such as Composite Cements and or concrete with highcontent of “Mineral Component”
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
WBCSD Cement Sustainability
In 1999, ten leading cement companies –representing one-third of the world’s cementproduction – embarked on the CementSustainability Initiative (CSI), a member-sponsoredprogram 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:
4 reducing the industry’s ecological footprint4 increasing stakeholder engagement4 understanding the industry's social contributions.
Cement production is energy-intensive - it accounts for 3.8 to 5 percent of global carbon dioxideemissions - and it touches on a wide range of sustainability issues including:
4 Climate change4 Pollution4 Resource depletion4 Worker’s health and safety
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Cement Sustainability Initiative
4 Holcim: 80% of 1990 per-unit emissions by 20104 LaFarge: 80% of 1990 per-unit emissions by 2010; 90% of 1990 absolute
emissions by 2010 in industrialized countries4 Cemex: 75% of 1990 per-unit emissions by 20154 Heidelberg: 85% of 1990 per-unit emissions by 20104 Titan: 85% of 1990 per-unit emissions by 2010
PCA has published a voluntary target for its members: achieve90% of 1990 per-unit emissions by 2020
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
Content
Concrete the material of choice
The impact of increase demand for cement andconcrete
The Sustainable attributes of concrete
People‘s role in Sustainability
How standards specifications and Codes affectsustainability
Performance specification the catalyst to Sustainability
Process Improvement in cement and concrete
Product Innovation
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
2006 World Cement Production
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
World Cement Production by region - 2007
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
WORLD CEMENT PRODUCTION BY REGION (millionmetric tons) 2007 – 2017 (source: Freedonia Group)
Item 2007 2012 2017
World Cement Production 2762 3570 4490
North America: 149.6 173.5 195.5
United States 95.5 110 122
Canada & Mexico 54.1 63.5 73.5
Western Europe 230.1 251.5 274.5
Asia/Pacific: 1853.6 2463 3161.5
China 1348 1804 2300
Japan 73 75 77
Other Asia/Pacific 432.6 584 784.5
Other Regions: 528.7 682 858.5
Latin America 110.6 134.5 163
Eastern Europe 131.1 176.5 224.5
Africa/Mideast 287 371 471
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
Content
Concrete the material of choice
The impact of increase demand for cement andconcrete
The Sustainable attributes of concrete
People‘s role in Sustainability
How standards - specifications and Codes affectsustainability
Performance specification the catalyst to Sustainability
Process Improvement in cement and concrete
Product Innovation
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
The Sustainable Attributes of Concrete
locally derived- produced- placed and can be recycledas aggregate
once in place consumes CO2 from the atmosphere
is non toxic
is generally reinforced by 100%- recycled steel andgenerally incorporates other industrial by-products
is resource efficient: the ingredients require littleprocessing and generate little waste
is exceptionally strong in uses where resistance to fireprogressive collapse- seismic disturbance or blast areconcerned
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
The Sustainable Attributes of Concrete
in roadways- reduces rolling resistance and thus fuelconsumption
can be made pervious to water- thus preventing run-off
is reflective- therefore cool- safe and saves on artificiallighting
is exceptionally durable when properly designed andplaced to last a century or more
provides excellent thermal mass that can enablesubstantial reductions in heating and cooling costs
has natural beauty in architectural applications
Provides great flexibility in design options
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
Today’s Challenges
Concrete industry is fragmented and diverse
Limited acceptance of new performance standards
Slow to investigate and adopt new technology
Reluctance to change
Gap in product knowledge
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
Content
Concrete the material of choice
The impact of increase demand for cement andconcrete
The Sustainable attributes of concrete
People‘s role in Sustainability
How standards - specifications and Codes affectsustainability
Performance specification the catalyst to Sustainability
Process Improvement in cement and concrete
Product Innovation
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
People’s Role
“Despite conventional wisdom, People – not Technology –play the biggest role in creating successful greenbuildings”
Tom Paladino, PE, AIA, LEED AP
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Who Are The Stake Holders?
MaterialSupplier
Cement
Mineral &
Chemical
Admixtures
Aggregate
ImmediateCustomer 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”JC Roumain 1992
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
Who Are The Stake Holders?
MaterialSupplier
Cement
Mineral &
Chemical
Admixtures
Aggregate
ImmediateCustomer 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”JC Roumain 1992
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
A ranking of 250 jobs according to “ Job Rated Almanac “
1. Web site manager
2. Actuary
3. Computer systems analyst
4. Software engineer
5. Mathematician
6. Computer programmer
7. Accountant
8. Industrial engineer
9. Hospital administrator
10. Web developer
Top 10
Where Does your job rank?
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
A ranking of 250 jobs, according to “Jobs Rated Almanac”
Bottom 11 240 Garbage Collector
241. Seaman
242. Roofer
243. Taxi Driver
244. Sheet metal worker
245. Dancer
246. Cowboy
247. Construction worker
248. Fisherman
249. Lumberjack
250. Roustabout/Oil field laborer
Where does your job rank?
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
Agricultural field work (42% of all work related deaths)
Construction work (3rd leading cause of deaths)
Outdoor jobs in landscaping, grounds keeping andlawn services
Work involving tractors and all terrain vehicles
Travel door-to-door selling
The 5 most dangerous jobs for teens
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
Content
Concrete the material of choice
The impact of increase demand for cement andconcrete
The Sustainable attributes of concrete
People‘s role in Sustainability
How standards specifications and Codes affectsustainability
Performance specification the catalyst to Sustainability
Process Improvement in cement and concrete
Product Innovation
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
Cement specifications
ASTM C150 adopted in 1940
ASTM C 595 adopted in 1967
ASTM C 1157 adopted in 1992
Limestone addition first proposed in 1985
Limestone addition adopted in 2004
4 Clinker factor reduced from 95 to 92
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
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
NVOH
UT
WI
WV
WY
DE
MT
DOTs that Allow C 1157 Cements
Status as of January 1, 2008
DOT Allows C 1157Cements
DOT Does Not AllowC 1157 Cements
DOT Approved for CementTreated Base Work Only*
Not Known* Not Structural Concrete or Pavements
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State Alkali Limits
As of December 1, 2006
.4 limit .9 limit
.45 limit .95 limit
.6 limit None
.7 limit 4#/cu. yard
WA
OR
CA
NV
AZ
UT CO
NM
ID
MT
WY
ND
SD
NE
KS
OK
TX
IA
MO
AR
LA
WI
IL IN
KY
TN
MS AL GA
FL
SC
NC
VA
MI
OH
WV
PA
NY
MEVT
NH
CT
MA
RI
NJDE
MD
MN
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
Low Alkali Clinker
Selective quarrying
Higher energy consumption
Potential reducing condition
Use calcium chloride
Harder to grind
Higher CKD production
Environmental implication (Nox)
Energy/Costs
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
Cement Formulation
2004 Product formulation change – ASTM C150allows for up to 5% powdered limestone – usedin Europe for decades
Energy Consumption reduced by 11.8 trillionBtu’s (10.14)
CO2 Emissions reduced by 2.5 million tons(equiv to 300,000 cars/year)
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
Content
Concrete the material of choice
The impact of increase demand for cement andconcrete
The Sustainable attributes of concrete
People‘s role in Sustainability
How standards specifications and Codes affectsustainability
Performance specification the catalyst to Sustainability
Process Improvement in cement and concrete
Product Innovation
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
Sustainability
Performance specification is the catalyst
Technological change or Innovation does not occur in avacuum. It frequently sparks a response from the legal,political or social environment
Sustainability is the objective
Innovation
Sustainability
ASTM C1157P2P
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
Content
Concrete the material of choice
The impact of increase demand for cement andconcrete
The Sustainable attributes of concrete
People‘s role in Sustainability
How standards specifications and Codes affectsustainability
Performance specification the catalyst to Sustainability
Process Improvement in cement and concrete
Product Innovation
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
34%
3%6%
17%
40%
4%
16%
80%
U.S. CO2 Emissions
Electricity Generation
Coal
Nat. Gas
other
Transportation
Industrial
Residential Other
6 Billion Tons CO2 2.4 Billion Tons CO2EIA 2007, Energy-related CO2
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
Cementmanufacturers
contributed1.5% of the
Industrial total
34%
3%6%
17%
40%
4%
16%
80%
U.S. Men made CO2 Emissions
ElectricityGeneration
Coal
Nat. Gas
other
Transportation
Industrial
Residential Other
6 Billion Tons CO2
EIA 2007, Energy-related CO2
2.4 Billion Tons CO2
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
The Facts – A Symbiotic Relationship
Cement
85 M ton clinker
1 ton CO2 per ton clinker fromenergy and calcination
85 M tons of CO2 per year
Byproduct
1 M ton of cement kiln dust(CKD)
Fly Ash
52% of energy from coalcombustion
2 ton CO2 per ton coal
1 kg CO2/kwh
2000 M ton CO2 per year
Byproduct
55 M ton of fly ash per year
15 M ton of fly ash used inconcrete last year
40 M ton of fly ash land filledin 2007
GGBFS
1 ton of CO2 per ton steel
2 to 4 tons material needed toproduce 1 ton steel
Byproduct
5.5 M ton air cooled slag
4.5 M ton GBFS
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
CO2 - Sources and How much?
Cement Kiln
Raw Materials -Limestone,Shale, Clay, etc.
Fuel –Burning coal andfossil fuels
Cementgrinding &blendingClinker
0.96 t CO2per t clinker
Gypsum(calciumsulfate)
CementASTM C 150
0.92 t CO2per t cement
CompositeCementASTM C 595 orASTM C 1157
0.65 to 0.80 tCO2 per tcement
ConcretePlant0.15 t CO2/yd3concrete
SandGravelWater
ConcreteUses0.135 t CO2from cementper yd3
concrete0.178 t CO2/yd3 concreteincludingconcrete plantandtransportation
Fly ash
Slag
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
Going to the concrete market
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
Name of Presentation/Event
Going to the concrete market
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
Change is good - Evolution of process and product
Leaders in Continuous Improvement
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
Sustainability in Cement Manufacturing
Efficient Management of our Non Renewable Mineral Resources
The Use of Byproducts from Industry
US cement mfg. accounts for < 1.5% of man-made CO2
World Cement Mfg. accounts for 5% of man-made CO2
CO2 from:
4 Material decomposition CaCO3 → Calcination→ CaO → CO2
4 Fossil fuel consumption
Efficiency in the Pyroprocess
The Use of Alternate Fuel
The Use of Byproducts as SCM
Holcim internal goal “0” Solid Waste Landfilled by 2012
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
Impacts of the cement production process
Quarrying and raw materials preparation
consumption of non-renewableresources
impacts on local landscape, ecologyand communities
Clinker production
use of fossil fuels
atmospheric emissions,especially CO2
Cement grinding anddistribution
use of raw materialsand electricity
can have impacts onlocal communities
Cement production is an energy and resourceintensive process.
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
Alkali waste
Aragonite
Calcite
Cement-kilndust
Cement rock
Chalk
Clay
Fly ash
Fuller’s earth
Limestone
Marble
Marl
Seashells
Shale
Slag (GGBFS-EAFS)
Calcium 60%
Blast-furnaceflue dust
Clay
Iron ore
Mill scale
Ore washings
Pyrite cinders
Shale
Iron10%
Calcium silicate
Cement rock
Clay
Fly ash
Fuller’s earth
Limestone
Loess
Marl
Ore washings
Quartzite
Rice-hull ash
Sand
Sandstone
Shale
Slag
Traprock
Silica20%
Aluminum-orerefuse
Bauxite
Cement rock
Clay
Copper slag
Fly ash
Fuller’s earth
Granodiorite
Limestone
Loess
Ore washings
Shale
Slag
Staurolite
Alumina 10%
Anhydrite
Calcium sulfate
Gypsum
FGD Ash
SDA Ash
Sulfate
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
Impacts of the cement production process
Quarrying and raw materials preparation
consumption of non-renewableresources
impacts on local landscape, ecologyand communities
Clinker production
use of fossil fuels
atmospheric emissions,especially CO2
Cement grinding anddistribution
use of raw materialsand electricity
can have impacts onlocal communities
Cement production is an energy and resourceintensive process.
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
Process Steps Clinker Burning
Drying
Preheating
Calcining
Sintering
Cooling
Input: Raw Meal
Output: Clinker
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
CC-99064.dsf / Kma 22.2.99 Process Technology
400 600 800 1000 1200 1400 1400 1200°C
Heating Calcining Sintering Cooling
CaCO3
CaCOfree C3S
C2S
C3AC2AS
C3A
C4AFC2F ! C4AFCA ! C12A7
Clays
Quarz
Spurrite
Liquid phase
Qua
ntity
200
Heat exchangers in a kiln system
Drying
Process Requirements and Technical Solutions
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
Holcim Kiln Systems: Process Types and Installed Capacity
Holcim Kiln Systems:Total Installed Capacity per Process Type
0
20
40
60
80
100
120
140
1983 1985 1987 1989 1991 1993 1995 1997 1999 2001 2003
Mio
t/y
clin
ker
(inst
alle
d)
wetsemi wetsemi drydry
wet
dry
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
PI’s of Wet Process Kiln System pre 1970
CapacityDiameterLengthLength/DiameterKiln load (inside lining)BZ load (inside lining)
::::::
100 2.5 40 30 0.4 40
------
3600 7.5 230 38 0.8 100
t/dmm
t/m3dt/m2d
Kiln feedKiln circumferential speedKiln slopeTotal chain weightDust lossesSpec.heat consumption
::::::
slurry, 28 10 2.5 10 0.05 5000
------
43 20 4 15 0.257000
% H2Om/min%% rel. to capacitykg/kg clikJ/kg cli
35 % H2O20 °C
gas : 900°Cmeal : 400°C
5500kJ/kg
dust : 0.15 kg/kg
0.9 Nm3/kg, 180°C
1 kg cli80°C
200 °C- 10 mbar 2 %O23.0 Nm3/kg
installed : 3.0 Nm3/kg, 20°Coperation: 2.3
clinker : 1kg cli, 1400°Csecondary air : 1.4Nm3/kg, 670°C
20mbar 50mbar
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
PI’s of Long Dry Process Kiln System up to 1975
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
Dry process kiln ( with 4-stage SP)
CC-99073.dsf / Kma 17.2.99
CapacityDiameterLengthLength/DiameterKiln load (inside lining)BZ load (inside lining)
::::::
500 3.5 50 14 1.5 100
------
3200 5.5 90 16 2.2 180
t/dmm
t/m3dt/m2d
Kiln speedKiln slopeSpec.heat consumption
:::
1.5 3 3150
---
2.0 3.5
3500
rpm%kJ/kg cli
3250kJ/kg
1.45 Nm3/kg, 240°C
360 °C-50 mbar3,5 %O21,41 Nm3/kgdust: 0.1kg/kg
550°C
720°C
830°C
1.65kg/kg50 °C
1050 °C- 3 mbar 2 %O2 1,2 Nm3/kg
= 30%jclinker : 1kg cli, 1400°Csecondary air: 0.9 Nm3/kg, 860°C
20mbar 50mbar
1kg cli,80°C
installed: 3.0Nm3/kg, 20°Coperation: 2.3
Dry Process Kiln with 4 Stage Preheater (1970–1985)
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
CC-99079.dsf / Kma 17.2.99
CapacityDiameterLengthLength/DiameterKiln load (inside lining)BZ load (inside lining)
::::::
1500 3.5 40 10 3 185
------
10'000 6.2 105 16 5.5 350
t/dmm
t/m3dt/m2d
Kiln speedKiln slopeSpec.heat consumption
:::
2.5 3.5 2900
---
4.5 4 3500
rpm%kJ/kg cli
1,65 kg/kg50°C
500°C
650°C
770°C
870°C2%O2
0.5Nm3/kg, 1100°C
1800 kJ/kg (60%)
310 °C-50 mbar 3 %1.30 Nm3/kgStaub: 0.1 kg/kg
1.45Nm3/kg, 240°C
1100 °C -3 mbar 2 % O2 0,43 Nm3/kg
= 90%
1200 kJ/kg(40%)
clinker : 1kg cli, 1400°Csecondary air: 0.35 Nm3/kg, 1100°C
1kg cli,110°C
Installed: 2.0Nm3/kg, 20°Coperation: 1,8
20mbar50mbar
Dry process kiln (with 5-stage SP and PC)
Dry Process Kiln (with 5-stage SP and PC ( 1990-)
5.5
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
Kiln Fuel Requirement per short ton of clinker
Reduced energy use / unit of cement > 33% since 1972
Wet process 6,491,000 BTU 2.4 tons of clinker Upto 3,6000t/d (7,550 Kj/Kg) Pert ton of coal
Dry Process 5,449,000 BTU TypicalLong Dry Kiln (6,338 Kj/Kg)
Preheater / Precalciner 4,562,000 BTU (3,884 Kj/Kg)
Larger kiln as low as 3,240,000 BTU 7 tons of clinker (3,617 Kj/Kg) per ton of coal
Or even Much larger Kiln 2,700,000 BTU
Up to 10,000 t/d (3,140 Kj/Kg)
To make 1 ton of clinker we used to use 833lb of coal, now we only need 317lb
We are presently able to replace 20 % of our coal with Tire Derived Fuel 600 to 800tires/hour
We can replace 1.2 ton of coal per ton of TDF
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
Holcim Ste. Genevieve Plant Mo.
4 million metric tons
Energy efficient single kiln pyro processing line
Low heat consumption (< 3000 kJ/kg)
Low power consumption (< 15 kWh/t clinker)
4 finish mills
Will receive and ship over 90%of materials through own harboron the Mississippi River
Opening August 2009
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
Today’s Kilns
The cement kiln is one of the largest piece of movingequipment in the world
Kiln flame 3400°F (1870°C ) ⅓ the temperature of thesun surface
Raw meal in the kiln melting at 2700°F (1480 °C)
Average kiln today produces 60 to 70% more clinker atless than half the energy
“Wet process” 254 plants (1970) down to 54 plants77% reduction
81% of US production is “Dry Process”
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
Drivers of CO2 reduction
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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 (steelbelts)
Can have lower NOx emissions compared tosome types of coal
Rubber Manufacturers Association reports that thecement industry consumed 53 million tires in 2004
(41% of total burned)
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
Impacts of the cement production process
Quarrying and raw materials preparation
consumption of non-renewableresources
impacts on local landscape, ecologyand communities
Clinker production
use of fossil fuels
atmospheric emissions,especially CO2
Cement grinding anddistribution
use of raw materialsand electricity
can have impacts onlocal communities
Cement production is an energy and resourceintensive process.
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
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)
Diatomaceous Earth – Zeolite
Silica Fume – Metakaolin- Rice Husk Ash
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24%
9%
7%
16%
11%
27%
2%1%
0%0%
3%
2 4 %
9 %
7 %
1 6 %1 1 %
2 7 %
2 %1 %0 %
0 %3 %
Holcim Cement Types (1995 - 2007) *
56%
2%
8%
9%
4%
7%
11%2%
<1%0% 1%
S
P
F
L
M
1995 (~57 mio t)
46%
1%
9%
9%
4%
10%
15%
4%<1%
<1% 2%
S
P
F
L
M
2000 (~96 mio t) 2007 (~195 mio t)
* All ATR Plants
Ordinary Portland Cement Slag Cement (S)
(P)Pozzolan Cement
(F)Fly Ash Cement
(L)Limestone Cement
(M)Multiple Comp Cement
Masonry Cement
Oilwell Cement
White Cement
Special Binder
MIC & Other Cementit. Mat.
Continuous reduction of clinker content in cements in Holcim
L
F
P
S
M
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Holcim (US) IncMinnesota Pavement Conference February 12, 2009
Holcim Envirocore™ Product Family
New Classification Qualifying Criteria
Envirocore™ Portland/Slag Portland/Slag Blend with > 5% Slag
Envirocore™ Portland/Limestone Portland/Limestone Cement with > 10% Limestone
Envirocore™ Pozzolans Pozzolans
Envirocore™ Portland/Fly Ash Portland/Fly Ash Blended Cement with Fly Ash (F or C)
Envirocore™ Multiblend 3 or More Cementitious Materials
Envirocore™ Special Binders Special Binders
Description Qualifying Criteria
Envirocore™ Slag Slag Granules
Envirocore™ Fly Ash Fly Ash (F or C)
Description Qualifying Criteria
Envirocore™ Masonry Type N, Type S, Type M
Envirocore™ Mortar Type N, Type S, Type M
Envirocore™ Stucco Type S, Type M
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Content
Concrete the material of choice
The impact of increase demand for cement andconcrete
The Sustainable attributes of concrete
People‘s role in Sustainability
How standards specifications and Codes affectsustainability
Performance specification the catalyst to Sustainability
Process Improvement in cement and concrete
Product Innovation
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Technological Innovations
Hybrid automobiles
Wind and solar power
How about Cement And Concrete?
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Four AcesFour Aces
Cost effective
Ease of use
Sustainable
Robust And
Durable material
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Why SCC Concrete?
….Just to avoid this mess at the jobsite…
48 men…. Who is doing what?…
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Why SCC Concrete? Productivity-Durability
Improve the working environment “Productivity” And above allconcrete durability
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The Evolution of Concrete Finishing
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The Equipment revolution Today : Laser Screed
Placing and finishing 50,000ft2 (4,645 m2) of concrete per day
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The Equipment revolution
From Hand Finishing to Walk Behind trowel to Ride on Power trowel
4 to 5 riders can do the job of 25 to walk behind or 125 to 150 hand finishers
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The Evolution of Concrete Paving
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The Equipment Revolution
Today’s New pavers
CMI SF-550 Concrete SlipformPaver
4 4 Tracks4 Multi-Position Swing Legs4 Paving Depth to 24 in (61cm)4 Paving Width to 50 ft (15.24m)
Commonly Pave 1 mile (1.6 km) or more of 24 ft (7.3m) wideconcrete pavement/day
New Pavers can pave up to 50 ft (15 m) wide but 40ft (12 m) isrecommended for better pavement smoothness
Up to 1.9 mile (3 Km), 24 ft (7.3 m) has been paved in one day
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Can we predict the future?
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Yes, we can predict the future
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The future is here today
• At our universities• Upstart companies• Someone’s garage • Someone’s head
Black Hole
Academia IndustryK
NO
WLE
DG
E
INNOVATIONIs only limited by the extent of
OUR IMAGINATIONACADEMIAInterdisciplinary groupOrganic and inorganic chemistryBiologist, Botanist, PhysicistCeramic Engineers
Dialogue INDUSTRY
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Biosilica
Renewable cementitious material
Rice Husk
Oats
Bagasse
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Low Energy Cements?
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Insitu Non-Destructive MonitoringInsitu Non-Destructive Monitoring
computerconcrete
Steel plate embedded in concrete
Shear wave transducer (2.25 MHz)
Pulser / receiver
Test setup for laboratory evaluation: The wave reflection factor (WRF) is measured at the steel -concrete interface.
Am
plitu
de
Amplitude(arbitrary
units)
Computer
Wave Reflection Factor (WRFWave Reflection Factor (WRF))
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Goal:
development of concrete
with high self-crack-healingcapacity
using bacteria as self-healing agent
Bio-mineral production
Biologically grown concrete (University in NL))
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University in NL
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Bio-Concrete – Calcitic Concrete
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Sustainable Concrete Pavement of the future
100 to 300 life pavement
Presently 300 year life bridges are under construction
Composite pavements on a Solid Concrete foundation
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As the old saying goes. . .
✔There are those who make things happen
✔Those who watch things happen
✔And those who wonder what the heck happened?.
Thank you
A firm commitment
for a Sustainable Future
Jean-Claude Roumain FACI
Corporate Product Manager
Holcim (US) Inc.