Lafarge

7th CSI Forum - Vancouver
Innovative approaches to
reduce CO2 emissions
Gnther Walenta
Lafarge LCR
02/10/2013
LAFARGE & CO2 - Some Figures

In 2012, LAFARGE produced 153 Mt cement and emitted ~94 Mt CO2
About 65% of the CO2 related to decarbonation of limestone and 35%
from fuel combustion
Between 1990-2010, Lafarge decreased net CO2 emissions by 20%
(from 774 to 630 kg CO2/tcement ) i.e. a reduction of ~25 Mt CO2/yr
Since 2011 new commitment : minus 33% of net CO2 emissions
reduction from 1990 to 2020
Main conventional levers used to reduce CO2:
Reduce specific heat consumption of the cement kiln
Increase cementitious additions into the cement (slag, FA,
pozzolans, limestone)
Substitution of fuels (animal meal, tires, shredded wastes)
7th CSI Forum - CO2 reduction solutions G. Walenta - Lafarge Centre de Recherche
Date
Some potential non conventional solutions

Although the conventional industrial levers still need to be
developed, we think they will soon come to a limit and that we will
not be able divide our CO2 emissions by factor 4 (by year 2050)
Other non conventional means need to be developed:

Carbon Capture & Sequestration (CCS)
Carbon Capture & Transformation (CCT)

Micro- Algae
Low CO2 clinker development: AETHER
Date
Algae ponds Photo-bio-reactors (PBR)

Algae growing based on Photosynthetic reaction
+
Micro-algae
+ CO2 + H2O
Sunlight
Biomass + O2
Bio-fuels:
biodiesel / bioethanol / methanisation
High value products (omega-3)
Surface needed: ~4 km
485 /t CO2 avoided
(without CAPEX)
Total CO2 reduction:

50% CO2
But:
Business model not valid
Vertical tubular PBR

Significant technology breakthrough needed for industrial use
Date
Lafarges objectives for Aether :

A low CO2 clinker for all types of cement
Objective:
Develop a new class of clinkers for making cements with
similar mechanical performances to conventional OPCs, and
which can be produced in existing PC plants, while giving
significantly lower CO2 emissions (20%-30%) in production
Targeting Niche products & mainstream products
Not looking for specific applications, but looking to replace the ordinary
clinker
Ready mix, Precast
Date
What is AETHER?
Aether
is a new, patented* class of low-CO2
cements based on BCSAF clinkers containing:
Belite: C2S 40 75%
Calcium sulfoaluminate (yeelimite): C4A3$ 15 - 35 %
Ferrite : C2(A,F) 5 25%
*Gartner, E., and Li, G., 2006. World Patent Application WO2006/018569 A2
Date Page 66
Aether
cement: CO2 emissions and
manufacturing
Portland raw
mix
~35% LOI
~14% SiO2
~3% Al2O3
~3% Fe2O3
~43% CaO
~0.3% SO3
Portland
clinker
C3S
~65%
C3A
~6%
C2S
~15%
C4AF ~12%
Aether
clinker *
C4A3$
~25%
C2S
~55%
C2(A,F) ~20%
Aether
main characteristics vs. Portland:
Aether
raw
mix *
LOI
SiO2
Al2O3
Fe2O3
CaO
SO3
~29%
~12%
~11%
~5%
~37%
~3%
* a potential Aether
composition
Higher Alumina and SO3 content and lower LOI of the raw mix =
lower CaCO3
No C3S, but C4A3$ & higher C2S content
Date
Overview CSA and belite based

binder technologies
Different approaches (not exhaustive):
Buzzi (NEXT)
Heidelberger (BCT)
Italcementi (ALIPRE)
Vicat (ALPENAT)
Lafarge (AETHER)
Some common points:
Chemistry & mineralogy different from OPC
C3S is no longer major phase; C2S takes on more importance (15 to 75%)
Presence of C4A3$ (15% to 70%), C5S2$, C$
Raw materials similar to OPC, but generally higher alumina needs
higher raw material cost - use of alternative raw materials is preferred
Wide range of compositions, allowing a high variety of properties
Lower limestone & burning temperatures = lower CO2 emissions
Higher short term strength, etc,
Date
Aether industrial trial 2012 Le Teil (South of France)

Timing:
06/12/2012 to 18/12/2012
Rotary kiln
Length ~70m
~100 Participants
2 times 5000t of good AETHER clinker produced
Date Page 99
Aether: Experiences from Industrial trials:

CO2 emissions and manufacturing facts
Aether clinkers can be produced:
in kilns designed for Portland production (Lepol 2011 & Dry 2012)
using similar process parameters and fuels
using mainly conventional raw materials
at lower temperatures (1225 -1300C) than for Portland cement
clinker (1400 1500C)
with significantly lower energy than Portland cement clinker
Aether cement grinding energy is lower than for OPC (based on lab
grinding -must be confirmed industrially)
The manufacturing of Aether generates 20 to 30%
less CO2 per tonne of cement than pure Portland
cement (CEM (I) type)
Date
10
Ongoing & next steps
Evaluate clinker & cement properties

Mineralogy & Chemistry
Standard motar & Concrete testing
Durability testing
Creation of suitable standards
Identify most promising AETHER applications
Date
11
Results AETHERTM Concrete tests

Precast Concrete application
Slump life: 45 min -1 hour Slump Class:
S3-S4
Strenghts:
6 hours: 20 MPa (without heating
24 hours: 27 MPa
7 days: 41 MPa
28 days: 48 MPa
Date
12
Durability Results AETHERTM

Concrete
Strength development and dimensional variations
Ongoing study with Lafarge - BRE (British Research Establishment)
with European Union support (Life+ project)
Strength development (will continue for 10 years)
in water (40, 68, 95F, ie: 5, 20, 35C),
o in air (68F / 20C, 65%RH)
o
All results comparable to OPC (6 months)

0
dl/l
Dimensional variations
Results (1year):
Drying shrinkage reduced
50%
time
1y
Aether
-250
-500
m/m
Portland
Typical mix
for wet precast
W/C=0.4
Date
13

Concrete
Resistance to agressive medium
Wear rating
o Class 5 sulfate at 5C
o 3% citric acid at 20C
min. equivalent to OPC

(still in progress)
Use of alkali reactive aggregates:

In progress
Possibility to use embedded steel reinforcement:

Protective passivating layer on the surface of embedded steel rebar
confirmed
further study foreseen (PhD)
Date
14

Concrete
Risk of corrosion of embedded steel corrosion
Resistance to carbonation for laboratory & natural exposure
Carbonation equivalent to a blended Portland cement with
similar CO2 saving
Resistance to chloride
ingress
Matches equivalent
OPC concretes
Date
15
Aether: Conclusion
AETHER cements based on clinkers containing belite, calcium
sulfoaluminate and ferrite seem to be a promising alternative to
Portland cements.
20%-30% Reduction of CO2 emissions relative to Portland cements
Use of similar raw materials and production possible in existing
industrial installations
Similar concrete performance to Portland cements
But more research is needed on process, hydration

and durability, in order to develop appropriate standards,
before Aether cements can be considered a largescale alternative to Portland cement.
Date
16
2011 Team AETHER TM before returning to the individual working groups:

Nationalities:
Brazil, Canada, China, Germany, England, France, Austria, Spain
Date
17
Thank you !
Discussion
Date
18

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7th CSI Forum - Vancouver

LAFARGE & CO2 - Some Figures

Some potential non conventional solutions

Other non conventional means need to be developed:

Carbon Capture & Transformation (CCT)

Low CO2 clinker development: AETHER

Algae ponds Photo-bio-reactors (PBR)

Total CO2 reduction:

Vertical tubular PBR

Lafarges objectives for Aether :

Overview CSA and belite based

Aether industrial trial 2012 Le Teil (South of France)

Aether: Experiences from Industrial trials:

Ongoing & next steps

Evaluate clinker & cement properties

Results AETHERTM Concrete tests

Durability Results AETHERTM

All results comparable to OPC (6 months)

Durability Results AETHERTM

min. equivalent to OPC

Use of alkali reactive aggregates:

Possibility to use embedded steel reinforcement:

Durability Results AETHERTM

But more research is needed on process, hydration

2011 Team AETHER TM before returning to the individual working groups:

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