Presentation made by Dr Soumen Maity from Development Alternatives at the "Low Carbon Options in South Asia" workshop held in Nepal in August 2014.

1. LOW CARBON DEVELOPMENT
- Development of Low Carbon Cement
TARA
CANSA Workshop
26 August 2014

2. Concrete and sustainable development
• There are a lot of misconceptions about cement and concrete
TARA
with respect to sustainable development.
• If we want to improve things we have to start from a correct
assessment of the situation
• We hear a lot about the fact that cement and concrete account
for some 5-8% of man-made CO2
• What we don’t realise is that this is amazingly good for a
material which makes up around half of everything produced.

3. TARA
The Global Scenario

4. Concrete: The most used material in the world
TARA
The amount of concrete that a person
Metals
Ceramics
Polymers
consumes per year
Steel
Wood
Bricks / Masonry
Concrete
Aluminium
Titanium
Polyamide
Polythelyne
Annual production (t/yr)
Source: INTRODUCTION à LA SCIENCE DES MATÉRIAUX, Kurz,Mercier, Zambelli,. PPUR , 3rd ed 2002
Price ($/t)
105
104
103
102
10
103 105 107 109 1011

5. Concrete: Low intrinsic environmental impact
TARA
ICE version 1.6a
Hammond G.P. and Jones C.I
2008 Proc Instn Civil Engineers
www.bath.ac.uk/mech-eng/sert/embodied/
Despite being intrinsically
low energy materials,
The enormous volumes of
concrete used mean that
Cement production
accounts for 5-8% of
global CO2 emissions

6. Concrete: Comparison based on functional unit
TARA
Energy of producing 1m
of column to support
1000 tonnes
40
190
Energy of
producing 1m
of pipe
350
350
300
250
200
150
100
50
0
concrete PVC polyethylene
Energy (kWh)

7. Forecasted demand
TARA

8. TARA
The Indian Perspective

9. Indian scenario - present
Characteristic of Indian Cement Industry
• One of the most efficient in the world
 0.719 T of CO2/ T of cement
(0.65 – 0.90 T of CO2)
• Per capita consumption 191 kg
 World average – 500 kg
 China – 1581 kg
• Produced 137 million tons of CO2
 Approx. 7% of India’s total man-made CO2
emissions
TARA
WBCSD: Cement
Technology Roadmap 2009

10. Indian scenario – 2050
The Indian Cement Industry
• Increase in population
TARA
 1.2 billion to 1.7 billion
• Rapid urbanization
 380 million to 675 million (UN DESA, 2011)
• GDP is expected to increase from
 USD 4,060 billion to USD 37,721 billion
‒ Large scale infrastructure development
‒ Increased demand for concrete
WBCSD: Cement
Technology Roadmap 2009

11. Indian scenario
Major concerns:
• Energy consumption and costs
• Environmental emission
• Availability of raw materials
• Market based competition
TARA
WBCSD: Cement
Technology Roadmap 2009

12. TARA
Chemistry of Cement

13. Cement chemistry
TARA
Cement Gypsum
• 3-5%
1450OC
+
Limestone Clay
CaCO3
Al2O3
SiO2
Fe2O3
Clinker
C3S, C2S, C3A
C4AFe
Water
Portlandite,
Ettringite,
Monosulphate
Grinding
and mixing

14. Origin of CO2 emissions in cement production
1 tonne of cement leads to the emission of 650 – 900 kg CO2
TARA
60
40
CaCO3
decomposition
(CHEMICAL)
Fuel
CaCO3  CaO + CO2
The production process
is highly optimised
Around 80% of
thermodynamic limit.
it is estimated that < 2%
further savings can be
made here
Use of waste fuels,
which can be > 80%
reduces the demand
for fossil fuels

15. TARA
Low carbon chemistries

16. The current approach: Reducing clinker factor
Process optimisation ↓ clinker factor
Limestone Slag
Often by-products or wastes from other industries
TARA
↓ CO2
Clinker
Gypsum Cement
SCMs – Supplementary Cementing Materials
Fly ash Silica fume Natural pozzolan

17. Why India
 Facilitate uptake of PC / calcined clay / limestone blends
 Create capacities for technology transfer to developing countries
 Huge rise in consumption forecast in India
 How to keep up with projected demand
TARA
 Only 25% of capacity needed in 2050 exists today
 Need for range of blending materials
 High level producers in free market economy
 Excellent blend of research and application partnership
 1st Country with national road map for sustainability
under Cement Sustainability Initiative, CSI of
World Business Council for Sustainable Development, WBCSD
 Target for clinker factor 0.58 by 2030

18. TARA
Low Carbon Cement Project
- Entry Phase (2013-2014)

19. Results achieved till date
• Trial grinding and blending in a commercial mini-cement unit
Composition:
TARA
50% clinker
15% limestone
30% calcined clay
5% gypsum
Blends:
B0: PPC
B1: LSA + CA + gypsum + clinker
B2: LSA + CB + gypsum + clinker
B3: LSB + CA + gypsum + clinker
B4: LSB + CB + gypsum + clinker

20. Results achieved till date
TARA

21. Results achieved till date
TARA

22. Results achieved till date
TARA

23. Results achieved till date
TARA
Clinker Limestone
Calcined clay Gypsum

24. Results achieved till date
TARA

25. Results achieved till date
TARA

26. Results achieved till date
TARA

27. Results achieved till date
TARA

28. Results achieved till date
TARA

29. Results achieved till date
TARA

30. Results achieved till date
TARA

31. Results achieved till date
TARA

32. Results achieved till date
TARA

33. Results achieved till date
TARA
Standard MCR tiles
vibration time range
of 30-35 sec/tile

34. TARA
Low Carbon Cement Project
- 2014 - 2020

35. The Project
TARA
 Research and development (IITD)
 Technology application (TARA)
 Environmental assessments (TARA)
 Economic assessment and tools (TARA)
 Policy dialogue and influencing (TARA)
 Technology packaging (TARA)
 Knowledge sharing platform (IITD)
 Project management and co-ordination (IITD/TARA)

36. Major stakeholders
UNEP Lead partners
TARA
IIT Delhi
Research
TARA
Application
EPFL
(Research and EU standards)
- IIT, Chennai
- IIT, Mumbai
- Major cement
companies
- Mini cement
producers
- Consumers
SDC
Cuba (Grants)
Dalmia Cements
India Cements
Madras Cements
Holcim
Denmark
Brazil
Thailand
WBCSD
L&T
ACC
TATA
Housing

37. Rationale to South Asia
TARA
 Contributes to carbon emission reduction
 Utilization of waste materials
 Waste clay (no top soil)
 Waste limestone (mine rejects)
 Resource efficiency
 Local cement production units

38. TARA
Thanks