GREEN CEMENT A TALK OF TODAY’S ECO-FRIENDLY INDUSTRY

The cement industry is fronting many encounters in the 21st century owing to reducing natural
fuel capitals, scarcity of mineral deposits, proliferate cement demand and climate related
ecological alarms. Every single ton of ordinary Portland cement (OPC) formed discharges a
corresponding quantity of carbon dioxide to the atmosphere. In this respect, cement
manufactured from nearby existing reserves and industrial waste that merged with OPC as
auxiliary or complete replacement with original clinkers to decrease the energy necessities
vigorously needed.

Lessening in energy exhaustion and carbon releases throughout cement manufacturing attained
by presenting substitute cements. The prospective of alternative cements as a replacement of
predictable OPC completely understood through full study of binder properties with up-to-date
expertise.

INTRODUCTION

Cement is a solid binding mediator or bonding agent, which helps as the major element in
concrete. Concrete shows an uncomplicated part in building as an acute constituent in
foundations, structures, roads, bridges, highways, embankments. Agreed its crucial part in
construction and urban development, the manufacture intensities of cement remain to rise every
single day.
Concrete is the second peak used material globally, behind only water. According to the U.S.
Geological Survey, national manufacture of Portland cement augmented to additional 80 million
tons in 2014 and 4.5 billion tons global. Most of that manufacture is in China, which used up
more cement in the previous four years than the United States consumes in 100 years.
At present-day, the annual report manufacture levels of Ordinary Portland Cement (OPC) total to
nearby 3.6 billion metric tons. According to Columbia University’s Earth Institute, the yearly
growing percentage of cement production is 2.5%. According to current results, the cement
manufacturing industry yields additional 2.55 billion tons each year. By 2050, it remains
expected that the produce of cement will exceed 4.5 million tons.
As significant as cement is, the method to fabrication it is also a main reason of industrial air
contamination. The manufacture of clinker, an important element in cement, is a leading cause of
discharge of harmful fumes, particularly carbon dioxide.
Cement manufacturing is a chief basis of greenhouse gases. However, cutting emissions means
grasping one of the utmost multipart constituents well known.
MANUFACTURING PROCESS
In the cement built-up process, a combination of limestone and clayey ingredients nurtured to a
kiln operational at 1400⁰C. Next, the thermal process, the treated solid is crushed, establishing a
lump-filled and solid material known as clinker. Finally, gypsum assorted with clinker,
forming cement. The clinker manufacture process is extremely energy demanding and discharges
gaseous emissions. For 1 tons of cement, manufactured, 0.6 to 1 tons of carbon dioxide free. In
addition to clinker manufacture, other methods in cement production contribute off CO2.
However, cement is so crucial in all occupations; it is firm to conjure up/imagine a world devoid
of cement production.
 GREEN CEMENT A TALK OF TODAY’S ECO-FRIENDLY INDUSTRY

PORTLAND CEMENT REPLACEMENTS

Around are numerous goods in the market that are replacements to OPC, which are
manufacturing to improve performance but lessening impact on the atmosphere. Lower-carbon
cements are a case in point. This proficiency includes lessening the amount of clinker used to
produce ordinary Portland cement (OPC). Meanwhile clinker is ready with limestone and
manufactured in kilns, a smaller amount clinker means fewer emissions and less energy.
Derivatives from other productions, including slag and fly ash used as alternates for clinker.

Limestone calcites clay cement is likewise innovative products that declare to decrease
CO2 emissions by 30% versus OPC. Researchers in Switzerland established this expertise, also
referred to as LC3. Other lower-carbon cements established using magnesium silicates. The
subsequent material heated at lesser temperatures than limestone.

Market developments in green cement

Many novel expertise’s in the cement manufacturing that comprise of better methods of taking
on the customary cement manufacture process as well as completely innovative methods of
future cement production.

In 2005, The Cement Sustainability Initiative shaped 'Strategies for the Assortment and Usage of
Fuels and Minerals in the Cement Manufacturing Process'. It is important for several reasons:

1. It offers a benchmark for cement enterprises to keep ensuring uniformity of manufacture

and unambiguousness of practices.
2. It provides a technique of evaluating even if a material is too unsafe for use in the
cement manufacture procedure
3. It moderates the fears of investors over the safety and consistency of the use of substitute
materials, mainly wastes.

According to the study, by 2020, as surroundings-pleasant cement turn out to be extensively

accessible, it will consume to variable grades for diverse functions. The rising eco-friendly
awareness of publics global has right now directed various to modification their procurement
ways. Commercial structure is the second best probable marketplace for green cement.
Companies passionate to exhibit themselves as ecologically answerable make sure the reserves to
procurement greener raw material, still if they are extra costly than old-style cement.

Furthermore, numerous administrations now need a larger level of ecological consciousness in

ventures they finance, indicating to additional obligation on building corporations to purchase
green building supplies as well as cement. There will be some saturation of green cement into the
inhabited accommodation industry. This will upsurge if additional nations pursue the UK's lead
in implementing firm housing structure regulations demanding all fresh structures to be carbon
neutral.
 GREEN CEMENT A TALK OF TODAY’S ECO-FRIENDLY INDUSTRY

Currently green cement production credits for 3.5% of worldwide cement, but predicted to
nurture to above 13% of the market by 2020.

While green cement production will mainly be limited to technologically advanced countries,
China and India will get closer quickly set their authority on the world cement prospect.

Established on broad principal study and market understanding, the study also discloses how
request for substitute cement-like materials will develop from virtually nil to just under 17
million tons over the next ten years.

FLY ASH IN GREEN CONCRETE

Flash is a product collected from the burning of coal and is made of silica aluminum iron and
calcium.

Two types of fly ash exist.

 Type F and
 Type C

TYPE F

Is a flash with low calcium that has carbon contents around 5%.

TYPE C

is a flash with higher calcium contents and carbon contents less than 2%

HISTORY

Of flash and concrete pozzolanic ash used in concrete for thousands of years as it was collected
from volcanic ash that is similar to fly ash.

MAJOR USE

It was in the Hoover Dam as used to repair a tunnel since the 1980s. Use of fly ash in concrete
has been encouraged for various reasons to follow to begin the comparison between concrete's
containing only Portland cement and those containing a mixture.

PHYSICAL AND CHEMICAL PROPERTIES

Fly ash particles are slightly finer than those of Portland cement
their distributions within a cement matrix are similar chemically
The two share many of the same chemical compounds however,
the proportions of these compounds differ.
 GREEN CEMENT A TALK OF TODAY’S ECO-FRIENDLY INDUSTRY

HYDRATION PROCESS

fly ash has a notable effect on the hydration process of concrete

fly ash reacts slowly with water the slower less intense reaction
causes less heat to be produced
more fly ash is added the slower the reaction lower the heat
released
this event is different from Portland cement which has a very
quick reaction

COMPRESSIVE STRENGTH

addition of any amount of fly ash will reduce the early strength
it requires approximately 91 days for fly ash concrete to reach 80
percent of its maximum strength reached in roughly 10 days with
Portland cement concrete
concrete fly ash is a final hydrated product a large crystalline
Network that provides superior long term compressive strength up
to 50 percent of cement replacement will result in an increase of
ultimate strength

WORKABILITY

particles of fly ash of a spherical shape

added to a cement matrix they act as ball bearings
addition of fly ash will cause is in regard to the workability of the
concrete mix

LONG TERM STRENGTH

Addition of fly ash will decrease the shear strength of concrete

appreciably.
Fly ash concrete has a continued appreciable strength gained even
years after its original pouring doing - due to the drawn-out
hydration process.
 GREEN CEMENT A TALK OF TODAY’S ECO-FRIENDLY INDUSTRY

ABRASION RESISTANCE AND CORROSION RESISTANCE OF FLY ASH

CONCRETE

the abrasion resistance is based entirely on the aggregate properties

and the strength of the concrete itself
fly ash may not directly impact the abrasion resistance if the mix is
designed to have a higher strength this will increase the abrasion
resistance of the concrete
corrosion resistance hub is based on the permeability of the concrete
fly ash with its much finer particles and large crystalline Network
makes the concrete much less permeable and using an electric
conductivity test
REDUCED EMISSIONS

Portland cement concrete cycled product obtained from collecting

material from the combustion of coal as concrete one of the largest
used construction materials
Produce flash always as long as coal power always being produce.
Reduce the amount of production of Portland cement the result is
less co2 emissions going into the atmosphere
Portland cement contributes to environmental damage and co2
emissions

FLYASH USAGE AD. & DISAD.

ADVANTAGE
improve the long term strength of
concrete
increases the work ability of a
concrete mix
reduce the rate of heat produced
during the hydration process
provides resistance to chloride ion
penetration lower permeability less
penetration
resistance to alkali silica reaction
expansion
DISADVANTAGE
low early strength
elimination of bleeding
reduction of shear strength
with the addition of fly ash
reduction in bonding
strength between the
concrete and embedded
steel
if it's class-f there will be an
increase in the requirement
for air entrainment
 GREEN CEMENT A TALK OF TODAY’S ECO-FRIENDLY INDUSTRY

GREEN CEMENT PRICES BREAKDOWN

Break down of material price in green cement (1 sq. ft. -CMUs)

MATERIAL PRICE ($/TON)

FLY ASH 50-80
NaOH 280-490
Na2SO4 80-150
Silica 380-600

Break down of material Price for Masonry Unit made with Portland cement

Material Price Usage Price ($/lb) Total

Sand 9.85 2480 0.0049 12.20
Aggregate 24.60 1360 0.0123 16.72
Cement 95.74 500 0.0478 23.90
Limestone 11.55 600 0.0057 3.46
56.28

(National block company)

Coal Resources Of Pakistan

The existence of coal sums in Pakistan recognized earlier independence, but its financial worth
emphasized in 1980 when huge stashes of coal revealed in the Lakhra and Sonda regions of
Sindh Province. The unearthing of one more vast coal sum of 175.5 billion tons in a space of
10,000 sq. km in Tharparkar Constituency of Sindh has delivered a significant upsurge in the
coal possessions of Pakistan. Later this finding, Pakistan is now the sixth richest country of the
sphere in admiration of coal assets. Pakistan did not look even on the grade of coal-rich nations
earlier the unearthing of Thar Coal. Coal means accessible to Pakistan be in entirely four
provinces and in AJK. The overall coal assets assessed at 185.5 billion tons.

PAKISTAN COAL RESOURCES-SINDH (As on June 2003)

 GREEN CEMENT A TALK OF TODAY’S ECO-FRIENDLY INDUSTRY

Thar Coal

Map showing location of coalfields of Sindh

The Thar coalmine is situated in the south-eastern portion of Sindh. The British stated the most
important signal of the presence of coal underneath
the silts of the Thar Barren region although boring
H2O boreholes overseas Development Agency
(ODA) in bringing together with the Sindh Arid
Zone Development Authority (SAZDA), in 1991.
The Thar coalmine, with a reserve likely of 175.5
million tons of firewood, shields a zone of 9000 sq.
km. in the Tharparkar Wilderness. The mineable
firewood assets assessed to be 1,620 million tons. In
mandate to create the coal means in the designated
four blocks (Map 3), an entire of 167 pits were bored
at one-kilometer gaps.

Map Showing Blocks of

Thar Coalfield
 GREEN CEMENT A TALK OF TODAY’S ECO-FRIENDLY INDUSTRY

THAR COAL QUALITY & RESERVES

Chemical analysis of the coal samples

Thar coal reserves

COST ANALYSIS

Cement = 320/50kg

Coarse aggregate = 625/MT

Fine aggregate = 750/MT

% silica % brick aggregate total cost

(IRs.)
0 0 4061.15/-
5 50 3654.50/-
10 50 3517.10/-
15 50 3380.10
20 50 3242.10/-
Cost of production of 1m3 of concrete
 GREEN CEMENT A TALK OF TODAY’S ECO-FRIENDLY INDUSTRY

CEMENT BUSINESS-EXISTING DYNAMICS AND FORTHCOMING SCENARIOS

Constant growth in trade and industry goings-on and venture in numerous infrastructure
developments in PSDP and CPEC, joined with augmented request from private accommodation
arrangements have strengthened building segment in previous years. Growing call and strong
limits has also persuaded cement industrialists to increase their manufacture volumes hostilely,
as of 49.4 million tons to 72.8 million tons in the following years. This capability can
supplementary develop if new minor companies too combined the movement of keeping market
portion.

Cement Production Capacity of Pakistan

The cement production is vital on behalf of the budget. Furthermore creating a straight impact of
7.5 percent to large-scale trade, manufacturing impacts development in the associated sections
(e.g., chemicals, wood etc.).
 GREEN CEMENT A TALK OF TODAY’S ECO-FRIENDLY INDUSTRY

Synopsis of the cement production

List North zone South zone

Total production capacity and 80% 20%
sales
Number of export markets Less More
Total Players/Companies 19 5
Zone Parts Punjab, KPK, AJK, GB Sindh and Baluchistan
key export markets Afghanistan and India Nigeria, Tanzania, Mozambique,
Iraq, Ethiopia and DR Congo

Cement Per CapitaConsumption in Pakistan (2017)

Demand Needed to Absorb Production Capacity million tons

GREEN CEMENT A TALK OF TODAY’S ECO-FRIENDLY INDUSTRY