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LOW CARBON DEVELOPMENT- Development of Low Carbon Cement

CANSA Workshop26 August 2014

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Concrete and sustainable development

• There are a lot of misconceptions about cement and concrete with respect to sustainable development.

• If we want to improve things we have to start from a correct assessment of the situation

• We hear a lot about the fact that cement and concrete account for some 5-8% of man-made CO2

• What we don’t realise is that this is amazingly good for a material which makes up around half of everything produced.

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The Global Scenario

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Concrete: The most used material in the world

Source: INTRODUCTION à LA SCIENCE DES MATÉRIAUX, Kurz,Mercier, Zambelli,. PPUR , 3rd ed 2002

Metals

Ceramics

Polymers

Concrete

Bricks / Masonry

Aluminium

Titanium

SteelPolyamide

WoodPolythelyne

Annual production (t/yr)

Pri

ce (

$/t

)

10

102

103

104

105

103 105 107 109 1011

The amount of concrete that a person consumes per year

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Concrete: Low intrinsic environmental impact

ICE version 1.6aHammond G.P. and Jones C.I 2008 Proc Instn Civil Engineerswww.bath.ac.uk/mech-eng/sert/embodied/

Despite being intrinsically low energy materials,

The enormous volumes of concrete used mean that

Cement production accounts for 5-8% of global CO2 emissions

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Concrete: Comparison based on functional unit

40

190

350

0

50

100

150

200

250

300

350

concrete PVC polyethylene

Energy of producing 1m of column to support 1000 tonnes

Energy of producing 1m of pipe

En

erg

y (

kW

h)

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Forecasted demand

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The Indian Perspective

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Indian scenario - present

Characteristic of Indian Cement Industry

• One of the most efficient in the world 0.719 T of CO2/ T of cement

(0.65 – 0.90 T of CO2)

• Per capita consumption 191 kg World average – 500 kg China – 1581 kg

• Produced 137 million tons of CO2

Approx. 7% of India’s total man-made CO2

emissions

WBCSD: Cement Technology Roadmap 2009

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Indian scenario – 2050

The Indian Cement Industry

• Increase in population 1.2 billion to 1.7 billion

• Rapid urbanization 380 million to 675 million (UN DESA, 2011)

• GDP is expected to increase from USD 4,060 billion to USD 37,721 billion

‒ Large scale infrastructure development‒ Increased demand for concrete

WBCSD: Cement Technology Roadmap 2009

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Indian scenario

Major concerns:

• Energy consumption and costs

• Environmental emission

• Availability of raw materials

• Market based competition

WBCSD: Cement Technology Roadmap 2009

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Chemistry of Cement

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Cement chemistry

Cement Gypsum• 3-5%

1450OCClayLimestone

CaCO3

+Al2O3

SiO2

Fe2O3

ClinkerC3S, C2S, C3AC4AFe

Water

Portlandite, Ettringite, Monosulphate

Grinding and mixing

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Origin of CO2 emissions in cement production

1 tonne of cement leads to the emission of 650 – 900 kg CO2

60

40

CaCO3 decomposition (CHEMICAL)Fuel

CaCO3 CaO + CO2

The production process is highly optimised Around 80% of thermodynamic limit.it is estimated that < 2% further savings can be made here

Use of waste fuels, which can be > 80% reduces the demand for fossil fuels

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Low carbon chemistries

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The current approach: Reducing clinker factor

↓ CO2

Clinker

Natural pozzolanSilica fumeFly ash

Process optimisation ↓ clinker factor

Gypsum Cement

SCMs – Supplementary Cementing Materials

SlagLimestone

Often by-products or wastes from other industries

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Why India

Facilitate uptake of PC / calcined clay / limestone blends Create capacities for technology transfer to developing

countries Huge rise in consumption forecast in India

How to keep up with projected demand Only 25% of capacity needed in 2050 exists today

Need for range of blending materials High level producers in free market economy Excellent blend of research and application partnership 1st Country with national road map for sustainability

under Cement Sustainability Initiative, CSI of World Business Council for Sustainable Development, WBCSD Target for clinker factor 0.58 by 2030

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Low Carbon Cement Project- Entry Phase (2013-2014)

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Results achieved till date

• Trial grinding and blending in a commercial mini-cement unit

Composition:50% clinker15% limestone30% calcined clay5% gypsum

Blends:

B0: PPCB1: LSA + CA + gypsum + clinkerB2: LSA + CB + gypsum + clinkerB3: LSB + CA + gypsum + clinkerB4: LSB + CB + gypsum + clinker

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Results achieved till date

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Results achieved till date

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Results achieved till date

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Results achieved till date

Clinker Limestone

Calcined clay Gypsum

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Results achieved till date

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Results achieved till date

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Results achieved till date

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Results achieved till date

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Results achieved till date

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Results achieved till date

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Results achieved till date

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Results achieved till date

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Results achieved till date

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Results achieved till date

Standard MCR tiles vibration time range

of 30-35 sec/tile

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Low Carbon Cement Project

- 2014 - 2020

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The Project

Research and development (IITD) Technology application (TARA) Environmental assessments (TARA) Economic assessment and tools (TARA) Policy dialogue and influencing (TARA) Technology packaging (TARA) Knowledge sharing platform (IITD) Project management and co-ordination (IITD/TARA)

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Major stakeholders

IIT DelhiResearch

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EPFL(Research and EU standards)

- IIT, Chennai

- IIT, Mumbai

- Major cement companies

- Mini cement producers

- Consumers

SDC(Grants)Cuba

Dalmia Cements

India Cements

Madras Cements

Holcim

Denmark

Brazil

Thailand

WBCSD

UNEP

Lead

par

tner

s

L&T

TATA Housing

ACC

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Rationale to South Asia

Contributes to carbon emission reduction Utilization of waste materials

Waste clay (no top soil) Waste limestone (mine rejects)

Resource efficiency Local cement production units

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Thanks