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Sustainability Through People, Process and Product Innovation Jean-Claude Roumain FACI Corporate Product Manager, Holcim (US) Inc. o

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Page 1: Sustainability Through People, Process and Product Innovation€¦ · The Sustainable attributes of concrete People‘s role in Sustainability How standards specifications and Codes

SustainabilityThrough People, Process and Product Innovation

Jean-Claude Roumain FACICorporate Product Manager, Holcim (US) Inc.

o

Page 2: Sustainability Through People, Process and Product Innovation€¦ · The Sustainable attributes of concrete People‘s role in Sustainability How standards specifications and Codes

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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

Page 3: Sustainability Through People, Process and Product Innovation€¦ · The Sustainable attributes of concrete People‘s role in Sustainability How standards specifications and Codes

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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

Page 7: Sustainability Through People, Process and Product Innovation€¦ · The Sustainable attributes of concrete People‘s role in Sustainability How standards specifications and Codes

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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

Page 9: Sustainability Through People, Process and Product Innovation€¦ · The Sustainable attributes of concrete People‘s role in Sustainability How standards specifications and Codes

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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

Page 10: Sustainability Through People, Process and Product Innovation€¦ · The Sustainable attributes of concrete People‘s role in Sustainability How standards specifications and Codes

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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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Holcim (US) IncMinnesota Pavement Conference February 12, 2009

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

Page 26: Sustainability Through People, Process and Product Innovation€¦ · The Sustainable attributes of concrete People‘s role in Sustainability How standards specifications and Codes

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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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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

Page 28: Sustainability Through People, Process and Product Innovation€¦ · The Sustainable attributes of concrete People‘s role in Sustainability How standards specifications and Codes

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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?

Page 30: Sustainability Through People, Process and Product Innovation€¦ · The Sustainable attributes of concrete People‘s role in Sustainability How standards specifications and Codes

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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

Page 33: Sustainability Through People, Process and Product Innovation€¦ · The Sustainable attributes of concrete People‘s role in Sustainability How standards specifications and Codes

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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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Holcim (US) Inc

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

Page 39: Sustainability Through People, Process and Product Innovation€¦ · The Sustainable attributes of concrete People‘s role in Sustainability How standards specifications and Codes

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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

Page 41: Sustainability Through People, Process and Product Innovation€¦ · The Sustainable attributes of concrete People‘s role in Sustainability How standards specifications and Codes

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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

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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Holcim (US) IncMinnesota Pavement Conference February 12, 2009

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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Holcim (US) IncMinnesota Pavement Conference February 12, 2009

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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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

Technological Innovations

Hybrid automobiles

Wind and solar power

How about Cement And Concrete?

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Holcim (US) IncMinnesota Pavement Conference February 12, 2009

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Holcim (US) IncMinnesota Pavement Conference February 12, 2009

Four AcesFour Aces

Cost effective

Ease of use

Sustainable

Robust And

Durable material

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Holcim (US) IncMinnesota Pavement Conference February 12, 2009

Why SCC Concrete?

….Just to avoid this mess at the jobsite…

48 men…. Who is doing what?…

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Holcim (US) IncMinnesota Pavement Conference February 12, 2009

Why SCC Concrete? Productivity-Durability

Improve the working environment “Productivity” And above allconcrete durability

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Holcim (US) IncMinnesota Pavement Conference February 12, 2009

The Evolution of Concrete Finishing

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Holcim (US) IncMinnesota Pavement Conference February 12, 2009

The Equipment revolution Today : Laser Screed

Placing and finishing 50,000ft2 (4,645 m2) of concrete per day

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Holcim (US) IncMinnesota Pavement Conference February 12, 2009

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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Holcim (US) IncMinnesota Pavement Conference February 12, 2009

The Evolution of Concrete Paving

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Holcim (US) IncMinnesota Pavement Conference February 12, 2009

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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Holcim (US) IncMinnesota Pavement Conference February 12, 2009

Can we predict the future?

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Holcim (US) IncMinnesota Pavement Conference February 12, 2009

Yes, we can predict the future

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Holcim (US) IncMinnesota Pavement Conference February 12, 2009

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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Holcim (US) IncMinnesota Pavement Conference February 12, 2009

Biosilica

Renewable cementitious material

Rice Husk

Oats

Bagasse

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Holcim (US) IncMinnesota Pavement Conference February 12, 2009

Low Energy Cements?

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Holcim (US) IncMinnesota Pavement Conference February 12, 2009

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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Holcim (US) IncMinnesota Pavement Conference February 12, 2009

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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Holcim (US) IncMinnesota Pavement Conference February 12, 2009

University in NL

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Holcim (US) IncMinnesota Pavement Conference February 12, 2009

Bio-Concrete – Calcitic Concrete

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Holcim (US) IncMinnesota Pavement Conference February 12, 2009

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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Holcim (US) IncMinnesota Pavement Conference February 12, 2009

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?.

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Thank you

A firm commitment

for a Sustainable Future

Jean-Claude Roumain FACI

Corporate Product Manager

Holcim (US) Inc.

[email protected]