developments in cementium cement additives and value …challenges and opportunities of the african...
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Developments in CEMENTIUM Cement Additives and Value for the Cement Industry
5th Africa CemenTradeDar Es Salaam, 26-27 February 2013
Lorenzo Ambrosini
Global Segment Manager Cement Additives
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Breaking the paradigm of ‘developing country’
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Challenges and opportunities of the African Cement Industry
Globalization• Faster information sharing• Standardization
Efficiency
Growth• Capturing opportunity window• Financial risks / ROIC• CAPEX / Flexibility
Applications• Segmenting the market • Adapting prod. performance• Differentiation
Production• SCM availability & drawbacks• Clinker Factor / CO2• Grinding capacity
Logistics• Reliable distribution• Safety issues• Electicity & water supply
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Keeping pace with the growth rate….
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…but
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…growth is not for ever….
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Sub-Saharan AfricaSouth Africa (w/o fly ash)
N. Africa
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And growth may implicate some risks, too.
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Maturity curve
Overcapacity
Market volatility
Market demand
Supply capacity
New projects
Supply capacity
Market demand
Market demand When to invest?Where to invest?How much to invest?
Flexibility is needed!
Cement Additives, while extending capacity, can contribute to delay investments and so to mitigate financial risks
Improvement of RONOA, ROIC
Supply capacity
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New business models have to be considered… Example ‘Plug & Grind’ by Cemengal
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Performance monitoring of a Grinding Aid in BASF pilot mill: reduction of specific energy (kWh/t)
Main Power(Amp)
Filter Power(Amp)
Elevator Power (Amp)
Reference grinding aid CEMENTIUM “A” CEMENTIUM “B”
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Validation of results in industrial mill trials in a cement plant: increase of production capacity (t/h)
Reference grinding aid CEMENTIUM “A” CEMENTIUM “B”
Mill Feed increase
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Improvement of granulometry (narrower laser PSD)Example: industrial tests in a Ball Mill
Laser Granulometry – Cumulative Distribution
Laser Granulometry – Frequency Distribution
ReferenceCEMENTIUMCEMENTIUM
ReferenceCEMENTIUMCEMENTIUM
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Mechanism of action of Grinding Aids
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Ball Mills Vertical Roller Mills
Particle dispersion:avoiding ball coating,
increasing separator efficiency
A) Compaction on table, andB) Dispersion in separator
More challenging application
In general, still less performance of cement additives than in BM
Water injection is used (vibrations)
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CEMENTIUM Case Study160 tph Vertical Roller Mill in West Africa
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+10% +5%
Ongoing industrial tests on-site with new CEMENTIUM 2121 ES
Relevant improvement of grinding efficiency achieved Energy cost saving / increase of production capacity by 16 tph
~30% less dosage than common additives reduced logistics & storage required
+
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Overview cement applications
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Typical application segmentation of an African cement market
Housing: ‘Formal’ and ‘Informal’ construction (bag)
Ready-mix producers
Precast producers / block manufacturers
Infrastructure / projects100%
0%
Cementsales
(qualitative)
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Knowing applications requirements is fundamental for differentiation & positioning
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• Workability• Setting time• Branding!
‘Informal’ construction
Ready-mix producers
Precast / Block producers
Infrastructure,Projects
• 28d-strength• Fulfill Standards• No slump loss
• Early strength• ‘Green’ strength• Low stickiness
• Specifications, e.g. w/c ratio,
• Durability (S, Cl), low-heat
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Overview cement applications
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Also the ‘informal’ market can be further segmented into different applications
SlabsBrick layingFoundations Plastering
Workability,extended setting
Early strength Adhesion,crack-free
Low strength
Overview cement applications
04.11.200415
Ready-mix producers
Precast producers / block manufacturers
Infrastructure / projects100%
0%
Cementsales
(qualitative)Housing: ‘Formal’ and ‘Informal’ construction (bag)
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Cement Additives are an important tool to adapt cement perfomance to customer’s needs
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‘Designing’ cement according to application requirements(optimization of performance and costs)
Tailor-made solutions can be developed for a high variety of requirements
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Example: Chloride-free Early Strength EnhancerCEMENTIUM 2102 ES
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The challengeAn independent cement producer was using atraditional early strength enhancer in its CEM II42.5R cement. Due to the increasing pressure onplant optimization, he was seeking superiorperformance, but without cost increase.
BASF solution• Assessing benchmark performance• Developing the new Chloride-free Early Strength
Enhancer CEMENTIUM 2102 ES• Lab tests and industrial trials
Customer‘s benefits• Higher performance: strength: +7% at 1d, +6%
at 28d, mortar flow +5% vs. benchmark• Much better pack-set: +18%• Keeping the same cost per ton cement
„….I gave BASF the task to work on performance increase, but I made it clear from the beginning that I was not ready to assume higher cost per ton cement.”
The company owner
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Example:CEMENTIUM 5000 AE for masonry cement
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Indicated for cements / binders with high filler content and very low Clinker Factor
Tailor-made approach to fulfill specific needs:
• Rheology
• Adhesion
• Water retention
• Setting time
• Mechanical (low) strength
• Mill productivity (Grinding Aid action)
• Coloring
Attention: low-strength cements implicate risks of missuse in structures!
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Latests innovation: Cement Tracer
Background
Deficiencies in construction threaten life
Cement producers may bear liability risks
Difficult to track cement origin and provide evidence in case of damages
So far, there is no reliable method to determine cement content in concrete, particularly in case of use of composite cements. Standards cannot be verified! Minneapolis, August 2007
‘Coding’ cements. High number of color combinations are possible. Colors are only visible with analytics (spectro-photometry).
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Cement Tracer:Possible applications
Dosing on clinker mill feed
Cement production process Cement tracing within cement plant in order to investigate flows, retention times, silo management, mixing efficiency, …
Cement distributionCement tracing to track distribution channels, imports, shippings, blending….
MarketingTracing special cement and prove its application (e.g. ‘eco-cement’)
Cement application in concreteProving cement type or supplier used in concrete (qualitative). Possibility to assess cement content in concrete (e.g. to fulfill Standards or specifications) Analysis of cement or concrete
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BASF analytical capabilities: quantitative clinker & cement analysis
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Mineralogists / Crystallographers with more than 30 years of experience in Rietveld refinement of cements
Quantification of clinker / cement phases
Quantification of supplementary materials in binders (e.g. amorphous slag, Round Robin VDZ, 2008)
Crystallographic parameters, site occupancy factors, crystallite size
QXRD in hydrating systems, degree of hydration, crystallography of hydrates
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BASF Construction ChemicalsR&D Centre, Trostberg, Germany
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Modeling the grinding process for implementation of Cement Additives
Labjar mill
Heated lab mill
Real plant
Chemical reaction
Technical KPI comparison
realitymodel
Addition in mortar water
Particle Size Distribution
Comminution effect
Temperature control
Gas phase simulation ()
„big step“
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Modeling a grinding process for implementation of cement additives
Labjar mill
Heated lab mill
Real plant
Pilot mill
Chemical reaction
Technical KPI comparison
realitymodel
Particle Size Distribution
Comminution effect
Temperature control
Gas phase simulation ()
Addition in mortar water
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New equipment for additives development:The BASF pilot mill located in Treviso, Italy
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Technical data: 1:10-scale grinding plant in a dedicated building Closed circuits, two-chamber ball mill Dynamic separator Mill temperature regulation Airflow rate regulation Mill performance evaluation and automatic feed
control by noise measurement PLC in a separate, noise-isolated control room
New equipment for additives development:The BASF pilot mill located in Treviso, Italy
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Availability of SCMs in Africa(main constituents for composite cement only*)
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GBSF (Granulated Blast Furnace Slag)Possible slag imports
Fly Ash (from coal-fired power plants)
Natural pozzolan(major deposits)
Limestone is widely available (wherever clinker is produced)
*Does not include minor constituents (e.g. silica fume) or alternative raw meal materials (e.g. steel slag), or materials requiring calcination (e.g. calcinated clays)
Copper slag(use as aggregate only)
Used by ‘blenders’
Rift Valley
e.g. from Japan
e.g. from Brazil
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Differentiation opportunities by integration of SCMs in cement and role of Cement Additives
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• Late stregth• Durability
Blast furnace slag Fly Ash Natural Pozzolan Limestone
• Workability• Durability
• Low cost / avail.• (Diverse)
• Low cost / avail.• Workability
• Early strength• Grinding en.
• Early strength• Quality
• Strength• Water demand
• Late strength
+- ES Enhancers ES+LS Enhancers ES+ES+SW LS Enhancers
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Attractive opportunities to use pozzolans in the Rift Valley
Cement Additives can mitigate strength loss and water demand in puzzolanic cements (e.g. CEMENTIUM 4000 SW)
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The challengeIncreasing cost pressure on cement manufacturershas forced them to seek ways to reduce theirclinker factor. A well-known cement manufacturerin Turkey asked for a tailor-made additive thatwould enable them to increase SCM content intheir CEM II A 42,5 R.
BASF solution• Development of the tailor-made CEMENTIUM
3102 LS• Beside late strength enhancement, working on
improving concrete properties• Lab and on-site tests
Customer‘s benefits• Reduced 3% pts. of clinker in CEM II A 42,5• Added value to cement users, thanks to
improved concrete rheological properties
“BASF has proved itself to be a valid solution partner by responding to our specific request, and meeting it with our full satisfaction…„
Production Manager
Example: Late Strength improver CEMENTIUM 3102 LS
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Distribution issues of African markets. Importance to have a reliable partner
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Long distribution distances, especially if products are sourced from Europe
Availability of port / jetty
Handling facilities at ports
Storage / warehouses in the country
Infrastructure network (road, rail, water)
Bureaucracy, paperwork
Piracy, robberies
Safety
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BASF locations and supply footprint for Cement Additives
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Preferred supply route
Existing BASF Construction Chemicals production sites
TurkeyGermany Italy
Local action radius
Considered location of new plants
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Conclusions
Challenges of Cement Industry
Implications / Opportunities
Contribution of Cement Additives
Market demand growth
Application requirements
Production conditions
Logistics
• CAPEX / risks• Missed opportunities
• Fulfilling market needs• Differentiation
• SCM availability• Clinker limitations
• Power shortages• Product supply issues
Extending capacitiesProduction flexibiltiy
Adapting product performance to needs
Increasing production & mitigating drawbacks
Saving electrical powerHaving reliable partner
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Cementing a better future.CEMENTIUM®
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BASF – The Chemical Company
Our chemicals are used in almost all industries
We combine economic success, social responsibility and environmental protection.
Sales 2011: €73,497 million
EBIT 2011: €8,586 million
Employees (as of December 31, 2011): 111,141
In 2011, BASF filed for around 1,050 new patents worldwide
6 integrated plants (‘Verbund‘) and around 370 production sites
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Structure of BASF’s segments
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Chemicals Performance Products
Functional Solutions
AgriculturalSolutions Oil & Gas
Intermediates
Monomers
Petrochemicals
Dispersions & Pigments
Care Chemicals
Nutrition & Health
Paper Chemicals
PerformanceChemicals
Catalysts
ConstructionChemicals
Coatings
PerformanceMaterials
Crop Protection Oil & Gas
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BASF Group worldwide
Asia Pacific
Europe
SÃOPAULOSÃOPAULO
GEISMARGEISMAR
FLORHAMPARKFLORHAMPARK
North America
South America, Africa, Middle East
FREEPORTFREEPORT
ANTWERPANTWERP LUDWIGSHAFENLUDWIGSHAFEN
SINGAPORESINGAPORE
HONG KONGHONG KONG
KUANTANKUANTAN
NANJINGNANJING
“Verbund” site(integrated plant)
Selected production siteP
Regional headquarter
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Production Site in Ludwigshafen, Germany:World’s largest integrated chemical complex
10 km2 surface200 production plants2,000 km pipelines33,000 employees
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CEMENTIUM®Cementing a better future.