Concrete cement and circular economy Jesper Sand Damtoft

Concrete, cement and circular economy Jesper Sand Damtoft Director R&D, Quality and Technical Sales Support Cementir Holding 1

Aalborg Portland, the only cement producer in Denmark 2

Chalk - a unique natural resource 3

Sale of cement 1994 -2016 4 Grey cement: 1. 525. 000 tons Denmark: 1. 264. 000 tons (83%) Export: 261. 000 tons (17%) White cement: 705. 000 tons Denmark: 71. 000 tons (10%) Export: 634. 000 tons (90%) Turnover: 1, 8 billion DKK

Cementir Holding - parent company of Aalborg Portland 18 Overskrift 5

The Cementir Group has established its global research centre in Aalborg Overskrift 6

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Concrete - an artificial rock type 8

Invented by the Romans, re-invented in the 18 th century 9

5 km 3 concrete produced annually - 12 billion tons 10

Production of cement at Aalborg Portland Chalk and sand Fly ash Cement kiln 1500 o. C Gypsum Clinker SCM Grinding Cement 11

Cement clinker 12

Recycling and synergies with the society utilised by Aalborg Portland today Energy • District heating 1. 200. 000 GJ – (ca. 25. 000 households) • • Dried sewage sludge Fuel from waste (RDF) Meat and bone meal Saw dust 3. 000 tons 95. 000 tons 6. 000 tons 10. 000 tons Raw materials • Gypsum from power plant 45. 000 tons • Fly ash 200. 000 tons • Hals Barre Sand 80. 000 tons 13

Activities at Aalborg Portland • Increase use of alternative fuels – Investment: ca. 14 million EUR in 3 steps. – Goal: increase substitution of fossil fuels from ca. 40% to 60% in the production of grey – CO 2 reduction: 27. 000 t pr. year • Establishment of windfarm – Investment: ca. 14 million EUR – 18% substitution of electricity production – Reduction of CO 2 emission from coal fired power production: 28. 000 tons pr. year • Increased production of district heating – Investment: ca. 6 - 10 million EUR – District heating for 7. 000 -10. 000 households – Reduction of CO 2 emission from coal fired power production: ca. 30. 000 t pr. year 14

Further synergies with the society • District cooling – The water in the bottom of the chalk quarry is always cold – Can be used for district cooling – Supplies agreement with new hospital – Capacity for other purposes • Power production – Conversion of heat from kiln shells to electricity – Aalborg University is developing thermoelectric materials which converts heat to electricity – Still basic research 15

Environmental Product Declarations and Life Cycle Analyses as development tool • How do we prioritise our environmental improvements to give the optimum benefit? • Creating a full LCA model of cement production • How to better use Environmental Product Declaration and Life Cycle Analyses (LCA) to develop our business Kg of CO 2 eq per Mpa, as per producers declared strength 16

Cooperation with Aalborg University: “Smart” systems thinking and integration 17 http: //www. slideshare. net/internationalenergyagency/tcep 2014 -pres

Cement production as part of ”smart” systems thinking and integration 18 Solid waste Fuel Energy (not realized yet) Refuse derived fuel (1, 391 TJ/year) Cooling Nyt Aalborg Universitetshospital Other industries (132, 000 tons) Waste processing facility Chalk slurry (29, 000 tons/year) Wood chips (9, 2 TJ/year) Wood waste Sludge (36 TJ/year) Desulfurization Gypsum (27, 000 tons/year) Nordjyllandsværket Organic waste Fly ash (200, 000 tons/year) Municipal waste Organic waste Heat (1, 128 TJ/year) Fish waste Organic waste Meat and bone meal (154 TJ/year) Heat

Aalborg Portland is moving beyond cement…. • A resource handling company – – • Kusk og Dahl: Aggregate Aalborg Portland: Cement Unicon: Ready-mix concrete Neales: Waste management (UK) Resources from waste – – Municipal solid waste Industrial waste Recycling of plastic and metal Solid Recovered Fuel for the cement production with reduced CO 2 -footprint 19

Concrete for a sustainable society • Concrete production – Green concrete – Value-added concrete – Utilising the potential of concrete • Use of concrete – Concrete for energy savings – Energy storage by concrete – Sustainable infrastructure. • End-of-life – Concrete recycling – CO 2 uptake in concrete 20

Cement and concrete as part of the circular economy District heating District cooling Electricity Alternative fuels Alternative raw materials Fly ash Cement production Concrete recycling Demolition CO 2 uptake in concrete Fly ash Concrete production Use of concrete Long durability Energy savings by use of thermal mass 21

22 “The two most important global challenges today are poverty and climate change. ” Gro Harlem Brundtland

Fighting poverty means constructing…. . 23

Huge growth, an opportunity for the cement industry……. 24 Eco-efficient cements: Potential, economically viable solutions for a low-CO 2, cement based materials industry Karen L. Scrivener, Vanderley M. John, Ellis M. Gartner

……. . but also a challenge 5% of global CO 2 emissions 25 Rest of World India China OECD etc.

Cement industry roadmap for 80% reduced CO 2 emissions in 2050 26 34% Carbon Capture and Storage The role of cement in the 2050 low carbon economy, CEMBUREAU 2013

Why not substitute more clinker in cement? ? 27 34% Fuel Ca. CO 3 Ca. O + CO 2 The role of cement in the 2050 low carbon economy, CEMBUREAU 2013

Cement example illustrate the limiting factor of circular economy: Shortage of recyclable materials 28 Eco-efficient cements: Potential, economically viable solutions for a low-CO 2, cement based materials industry Karen L. Scrivener, Vanderley M. John, Ellis M. Gartner

Synergetic effect between calcined clay and limestone presents an opportunity to overcome this shortage • Clay calcined at 700 -800 o. C becomes reactive when blended with cement • No process CO 2 • Normally, calcined kaolinite (1: 1 clay) is preferred – High reactivity • Good results have been obtained with smectitic clay (2: 1 clay, “bentonite”) Control cement Blended cements with calcined 2: 1 clay and limestone Blended cements with inert material (Aplite) and limestone 29

Danish raw materials are suitable for limestone-calcined clay cement technology • 30 Chalk – Median grain size: 2. 5 mm – High reactivity – Already used to produce high early strength limestone cement • Clay – Large deposits of smectiitic clay in Denmark

Green Concrete II • Research project: 2014 -2018 • Budget: 3. 5 million EUR • New cement types and concrete types with reduced environmental footprint • Increased use of recycled materials and new binders in concrete • Demonstration projects – 2 road bridges – 1 rail bridge – House 31

Huge potential in developing economies 32

Use of limestone-calcined clay technology overcomes shortage of industrial by-products 33 Eco-efficient cements: Potential, economically viable solutions for a low-CO 2, cement based materials industry Karen L. Scrivener, Vanderley M. John, Ellis M. Gartner

Cement industry roadmap for 80% reduced CO 2 emissions in 2050 34 34% Limestone-Calcined Clay Cement technology reduce need for Carbon Capture and Storage The role of cement in the 2050 low carbon economy, CEMBUREAU 2013

35 Conclusions • Huge opportunities in synergies and circular economy • Recycled materials are not an unlimited resource, we still needs natural raw materials 20/10/2021