Achievement success in the role of

Researcher in Transforming
Foundation Industries
(Dematerialisation)
University of Leeds
Based on my experience
Introduced by:
Dr. Mohamed Ali
PhD in physical chemistry and building materials
Ain Shams University, Cairo, Egypt
1. Introduction

- In fact, based on my experience in the cement industry whether as a quality manager in the local and
multinational cement companies (National cement company, Kar cement group, CIF Angola cimento,
Italcementi and Heidelberg cement) or as a lecturer and researcher, I believe you should hire me as a
researcher because I am someone who has immense passion for my career and I have several innovation
ideas to improve and develop the cement characteristics in a compliance and commitment with the
environmental directions. So, I feel you will be very satisfied with the results obtained if you choose to
hire me as one of your researchers team.

- Because the main aim from this role as a research assistant is to demonstrate the combined effect of
multiple marginal actions to reduce CO 2 emissions in the cement sector, therefore, I am sure that my
research skills, attributes and practical experience will perform a high standard in this role.

2. My research plan related to the role demands

- When I started my research plan in my master’s degree, I focused on elimination of cement production
cost and reduction of CO2 emission. Therefore, I was studying replacement of clinker with
supplementary cementing material such as (pozzolana and ground blast furnace slag) in order to obtain
blended cement. Such composite or blended cements are employed for their economic and ecological
benefits. Then, energy consumption as well as CO 2 emission will be reduced. Furthermore, the cement
hydration characteristics improved were investigated by XRD and DTA for some selected samples in
various ages of hydration (2, 8, 28 and 90 days).
- In my doctorate thesis, my research has been focused on the cement chemical additives named
“Grinding Aids” that are strongly adsorbed on the surface of cement ground particles, so that
preventing agglomeration and coating on ball and mill lining. The main purposes for their
addition are increasing the grindability of the cement and therefore reduce the energy and
electrical consumption required to grind the clinker into a given fineness, decrease the clinker
content, thus reduce CO2 emission. Furthermore, the physico-chemical and mechanical properties
of the cement will be improved.

- Grinding aids used in this study were propylene glycol (PG), ethylene glycol (EG), tri ethanol
amine (TEA) and commercial grinding aid (CG). The ratios of grinding aids added were 0.03,
0.04 and 0.05 wt. % with respect to the dry cement. X-ray diffraction analysis (XRD), differential
thermal analysis (DTA) and Scanning Electron Microscope (SEM) for some selected samples
were carried out to investigate the morphology and phase composition of the formed hydration
products.

- In my previous role as a postdoctoral researcher, I could utilize some wastes from food industry
to be used as an active ingredient when it was mixed with organic compound (glycol-based
derivative). This product has a powerful action in improvement and development the hydration
characteristics of cement and contributed in reduction of CO 2 emission.
3. Methodology of CO2 emission in cement industry and Overcome methods
In fact, the cement industry alone accounts for approximately 4.1-5.0 % of world’s anthropogenic CO 2
emissions. The calcination and the combustion of fossil fuels are the main processes contributing to
almost 90% of CO2 emitted from the cement manufacturing(The calcination process contributes to
around 50% of CO2 while combustion of fossil fuels contributes to around 40 % of CO 2 emissions ). The
remaining 10 % comes from the transport of raw material and some other production activities..

There are several measures in the cement industry, which can reduce CO 2 emissions significantly. One of
the measures is the reduction of clinker to cement ratio with different additives as the following:

(1) Replacement of clinker by supplementary cementing materials such as (GBFS, Pozzolana, Fly ash
and silica fume), this was the scope of my master’s degree.
(2) Addition of grinding aids that can help in reduction of electrical consumption and lead to decrease of
CO2 emission, this was the scope of my doctorate’s degree.
(3) Replacing fossil fuels with alternative fuels may play a major role in the reduction of CO 2 emissions.
For example: by using RDF and Biomass together with fossil fuels, a decrease in CO 2 emissions can be
achieved, due to biogenic part of the RDF. For the purpose of this study, it was assumed that the biogenic
part (wood, textile, paper, etc.) in RDF is 40 %. I have experience in dealing with these alternative fuels
(AF) during working in Heidelberg cement group
In Summary, the total CO2 emissions = Process -related emissions
+ Combustion -related emissions
+ Electricity -related emissions
Where each emission implies as given below:

Process-related emissions:

Raw materials (calcium oxide and other minerals such as silicon, aluminum and iron oxide) drying,
pyro processing; CKD and organic carbon also produce parts of emissions.

So, the optimum way to reduce CO2 emissions from the calcination process is to use alternative raw
materials (*), which do not contain carbonates in their mineral structure. However, till now no
economically viable minerals have been found in comparison by quality to the current Portland-based
cements.

Combustion-related emissions:

Coal, petroleum coke, liquid and solid waste fuels, natural gas, other new waste streams
(wood, carpets, plastics, paint residue and sewage sludge etc.

Electricity-related emissions:

Motors, fans and blowers for whirling a kiln, drying, heating, grinding of materials, feeds or clinkers.
4. IPCC three tiers method

Three tiers methods for the process-related emission factors of cement production are recommended
by the IPCC . The Tier 1 method uses the default emission factor of 0.510 t CO 2/t clinker produced,
which is based on the fraction of lime in clinker, or 64.6% and incorporating a 2% correction factor
for discarded dust. The Tier 2 method is based on the average lime concentration in clinker by
collecting data on clinker production and lime fraction by type. The difference of both methods is
expected to be small. The Tier 3 method is a comprehensive method based on raw material inputs
but may not be practical for many cement facilities due to its extensive data requirements

The clinker emission factor (EF Clinker ) is the product of the fraction of lime in the clinker multiplied
By the ratio of the relative mass of CO2 released per unit of lime as below:

EF Clinker = Fraction CaO * 44/56= Fraction CaO Clinker × 0.785=

Because IPCC (Intergovernmental Panel of Climate Change) Guideline recommends the default value for
the fraction of lime in clinker could be 64.6%.

So, EF Clinker = 0.646 × 0.785= 0.5071

The IPCC also recommends that the above factor should be adjusted by the emission of the lost cement kiln
dust(CKD)with around 2–6%, which represents additional CO2 emissions not accounted for in the clinker
emissions estimate.
As a result, the correction factor= 1.02, So, EF clinker= 0.5071 × 1.02= 0.5172
- Other process-related emission factors are recommend by Emission Data base for Global Atmospheric
Research (EDGAR), Carbon Dioxide Information Analysis Center CDIAC to be 0.390 tCO 2/t cement and
0.499 tCO2/t cement, respectively.

The process-related CO2 emission factor includes the emission from calcinations of carbonates, non-carbonates
like bypass dust or CKD and organic carbon, which is expressed by the equation:
EFprc =R1+R2+R3

Where:
EFprc: theCO2 emission factor of carbonates calcinations (tCO2/t clinker)
R1: emission factor from calcinations of carbonates in the raw meal (tCO 2/t clinker)
R2: emission factor from calcinations of parts of carbonates in the kiln exhaust dust (tCO 2/t clinker)
R3: emission factor from calcinations of parts of carbonates in the kiln bypass dust(tCO 2/t clinker).

The calcinations CO2 emission factor (R1) is calculated based on the measured calcium oxide(CaO) and
magnesium oxide (MgO) content of the clinker as bellow:

R1 = Cc 44/ 56+Cm 44/40

In which:
Cc: the share of CaO content in the clinker,%;
Cm: the share of MgO content in the clinker,%;
44/56 : the conversion of the relative formula mass of CO2 and
44/40: the conversion of the relative formula mass of CO 2 and MgO.
5. Conclusion:

Because the CaO content is the main factor affects the CO 2 emission, so, I believe that we have to
recommend the stakeholders and the owners of the cement plants through scientific conferences to :

(1) Reduce the CaO content as soon as possible during the calcination of carbonates and this may be by
changing in the raw materials or in the cement type produced, this can be carried out by :
(a) Using of clay having high CaO content to decrease the limestone ratio. (*)
(b) Starting production of low heat of hydration clinker cement having low contents of C 3S and C3A
of highest hydration heat (510 and 1356 J/g respectively) while has higher content of C 2S of
247 J/g. This is due to the CaO content of low hydration clinker cement is around 48-52%< 64.6%
So, EF Clinker = 0.48 × 0.785= 0.3768

(2) Recycling the CO2 from the flue gases will reduce the emissions CO 2 notably.
(3) Using alternative raw materials that have low SO 3, Cl and alkali contents to reduce the
bypass quantity.

(4) Replacement of clinker to cement ratio by SCM that contributes in reduction of CO 2 emission.

(5) Using of grinding aids to reduce the electrical power consumption and clinker content that
will lead to CO2 emission reduction.

(*) Clay of high CaO content can contribute in reduction of limestone ratio in raw mix design from 80 to 64%.