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LC3 For Cem Tech Oct 2020
LC3 For Cem Tech Oct 2020
ch
Mt/yr
There is no magic solution
§ Blended with SCMs will be best solution for sustainable cements for
foreseeable future
Compressive strength
100 Calcined clay 50
1 day
Clinker 40
80
Mass proportion (%)
7 days
(MPa)
30
60 20 28 days
10 90 days
40
0
20
PC LC3-50
0 • 50% less clinker
PC PPC30 LC3-50 LC3-65 • 40% less CO2
• Similar strength
LC3 is a family of cements, • Better chloride resistance
the figure refers to • Resistant to alkali silica reaction
the clinker content
Comparison of calcined kaolinitic clay, slag and fly ash
• (Kaolin-bearing rocks of
Sc
economic interest)
ien
• Mine tailings
% Kaolinite (>40%) is the most important • Uncharted kaolinitic clay
parameter for highly reactive pozzolans deposits
Slide Adrian Alujas
Three basic clay structures
Kaolinite (1:1) Montmorillonite (2:1) Illite (Micas)
(Smectites) (2:1)
aluminium
silicon
“Metakaolin”, sold as high purity product for paper, ceramic, refractory industries
Requirements for purity, colour, etc, mean expensive 3-4x price cement
0% 17.0% 35.0%
38.9% 50.3% 66.2% 79.4% 95%
• % Al2O3 > 18
• % Al2O3 / % SiO2 > 0,3
• % LOI > 7,0
19
World soil map gives a rough indication,
yellow pink and light green regions, very good
but other areas have also have good deposits
Suitable clays presently stockpiled as waste
Process to produce LC3 / LC2 LC3
Blend
/intergrind
calcined clay
with clinker
limestone
and gypsum
ideal
range
700-850
>1000
<600 600-700 850-1000 crystalline
Not reactive dehydroxlation Surface area phases
complete but reduced formed
reactivity reactivity no
increases decreases reactivity
Impact of calcination temperature
• Agglomeration occurs at 600°C
higher temperatures
Safe zone Danger
•
30 50
Specific surface zone 45
25
decreases (reactivity) 925°C
Specific Surface
40
Median diameter
• Above 950 oC 20
35
30
re-crystallization occurs 15 800°C 25
(BET)
(d50) 20
10
15
10
5
Ref. 5
0 0
-100 0 100 200 300 400 500 600 700 800 900 1000 1100 1200
Temperature (°C)
Calcination methods:
Rotary kiln Flash calcination
» Advantages » Advantages
» Robust » Reputed more energy efficient
» Tolerant to moisture content up to 20%
» Fairly large particles (few mm) can be calcined » Disadvantages
efficiently » Very low moisture (<5%)
» Easy colour control technology » Dryer and dry storage silo required
» Small particles
» Disadvantages » crusher
» Reputed to have higher energy consumption
Weight
Dehydroxilation 1200
The heat generated in the 1000
firing chamber is used to dry 800
the incoming material. 600
Flexibility for moisture content 400
200
(change rotation speed first
shaft) and output 1 5 10 15 20 25 30 35 40 min
New Calcination plant Ivory Coast
Colour control at Ivory Coast plant
Eco solution pilot plant for trial calcinations
Overview
» Introduction and context
» Processes in Manufacturing
» Clay selection
» Calcination process
» Performance Characteristics
» Potential for CO2 reduction
» Regulatory obstacles
» Challenges
Comparison of calcined kaolinitic clay, slag and fly ash
70 LC3-50 47%MK
LC3-35 63%MK
60
CemCL General Use 40%
50 CemCL High Strength 20%
Normo4 PPC50 Pozz
40
30
20
10
0
1 2 3 7 28 90
Sample Age (d)
Key Advantages
• Chloride resistance
• Suppression of alkali silica reaction
Chloride ponding ASTM
PC PC
PPC30 PPC30
LC3-50 LC3-50
CO2Ý +CO2
CaCO3
All CaO content can react with CO2,
not just portlandite
Leemann, et al(2015) :
Overview
» Introduction and context
» Processes in Manufacturing
» Clay selection
» Calcination process
» Performance Characteristics
» Potential for CO2 reduction
» Regulatory obstacles
» Challenges
CO2 reduction Cement: CSI System Calculations 2016 calcs
§ Only direct emissions are considered.
§ Emissions and energy consumption during extraction and transportation of raw materials (other than
limestone) and all fuels are excluded.
§ Emissions and energy consumed due to the production of electricity (both purchased and produced) is
excluded.
§ Provides data for comparison with CSI database
§ Based on measurable quantities at the plant level and avoids almost all assumptions that are not
relevant to local conditions and materials.
§ The energy cost of calcination assumed was
higher than the real energy seen in the Ivory Coast plant
0.16 0.20
M30 M50
0.14 0.18
0.16
0.12 Others Others
0.14
0.10 Electricity Electricity
0.12
kg COշ eq./kg
kg COշ eq./kg
0.08 Transportation
0.10 Transportation
0.06 Aggregates
0.08 Aggregates
0.06
GGBS GGBS
0.04
0.04
Sand Sand
0.02 0.02
Cement Cement
0.00 0.00
OPC OPC with LC³ OPC with OPC OPC with LC³ OPC with
30% fly ash 15% GGBS 30% fly ash 15% GGBS
Potential global impact of LC3 technology
Global cement
Clinker
factor,
Global SCM Global CO2 IEA: International Energy
production volume reduction
global
average
Agency study for
Billion
tons/year
Billion
tones/year
Million
tones/year CSI: Cement Sustainability
%
Initiative
2006 2.6 79 0.5
of WBCSD: World Business
2050
(CSI study)
4.4 73 1.2 200 Council for Sustainable
2050
4.4 60 1.8 600 Development
(with LC3)
2050 with LC3
4.4 45 2.4 1000
2009
Developped
> 10 x entire
emissions
of Switzerland
Overview
» Introduction and context
» Processes in Manufacturing
» Clay selection
» Calcination process
» Performance Characteristics
» Potential for CO2 reduction
» Regulatory obstacles
» Challenges
Regulation: Cement
» EN 197
» Currently CEM II B category allows down to 65% clinker
with substitution by a combination of calcined clay and limestone CEM II B-M(Q-LL) – LC3-65
» New extension in a few months will allow CEM II C with down to 50% clinker – LC3-50
» ASTM C595
» Pozzolan content: ≤ 40%
» Limestone content: ≤ 15%
» Minimum clinker content: 45%
» Allows LC3-50
» But strength requirement is at constant slump with very fine sand and without admixture
» Even so successful conformity with LC3-50
35 OPC ref
US $ / tonne
30
25
20
15
10
Report available:
5
https://lc3.ch/wp-
0 content/uploads/2020/10/2019-
Integrated Plant Grinding Plant LC3FinancialAttractiveness-WEB.pdf
Overview
» Introduction and context
» Processes in Manufacturing
» Clay selection
» Calcination process
» Performance Characteristics
» Potential for CO2 reduction
» Regulatory obstacles
» Challenges
Challenges
» Finding the right clays – the TRCs are there to help you
» Evaluating financial feasibility – contacts available to help
» Calcination equipment – Many suppliers
» Use in Concrete – Increasing experience in the TRCs
» Changing standards and codes – also possibilities for collaboration
Concluding remarks
@LC3Cement
LC3 Project Office
@LC3Cement EPFL STI IMX LMC MXG 233
Station 12
LC3-Low Carbon Cement Swiss Federal Institute of Technology
Lausanne
LC3-Low Carbon Cement 1015 Lausanne, Switzerland
LC3@epfl.ch
LC3-Limestone Calcined Clay Cement