Maximizing CO2 Reductions while Increasing Production and Improving Cement Quality

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Maximizing CO2 Reductions while Increasing
Production and Improving Cement Quality

• Al Vazquez
• AgCert International, TurboGreen
• Francisco Retondo
• W. R. Grace

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Agenda

• Carbon Cap-and-Trade Mechanisms
• Approved CDM Methodologies for Cement
• ACM0005 Cement Blending Methodology
• Required Steps to Register a Project through CDM
• Application of Quality Improvers and Grinding
  Aids
• Quality Improvers Case Examples
• Global Carbon - Cement Market Analysis
• Conclusions

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Greenhouse Gases
Carbon dioxide (CO2)
Methane (CH4)
Nitrous Oxide (N2O)
Hydro Fluorocarbons (HFCs)
per Fluorocarbons
Sulphur Hexafluoride (SF6)
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Carbon Cap-and-Trade Mechanisms

• EU Emissions Trading System (EUETS)
• Clean Development Mechanism (CDM)
• Joint Implementation Mechanism (JI)
• Voluntary Emission Reduction Systems (VER)

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CDM Process
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Approved CDM Cement Methodologies
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Approved CDM Cement Methodologies
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Approved CDM Cement Methodologies
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ACM0005 Cement Blending Methodology

• Applicable to projects that increase the share
  of Secondary Cementitious Materials (SCM)
  beyond current practices
• Condition 1 No shortage of SCM
• Condition 2 Domestic sold output only
• Condition 3 Adequate data on cement types in
  the market

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ACM0005 Cement Blending Methodology

• Baseline Emissions - First Step in prior to
  project evaluation (lowest value of the
  following criteria)
• Average mass percentage of clinker for the 5
  highest blend cements in the region.
• Production weighted average mass percentage of
  clinker of the top 20 of blended cements in the
  region.
• Mass percentage of clinker in the relevant
  cement type produced prior to the project.

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ACM0005 Required Registration Steps
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Step 1 Project Alternatives

• Most credible alternative evaluation
• Would the project have occurred without carbon?
  Has it been done elsewhere within your company
  without carbon?
• Has the project been initiated without carbon?

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Step 2 Investment Analysis

• Internal Rate of Return (IRR)
• Internal hurdle rate

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Step 3 Barrier Analysis

• Investment barriers (other than financial)
• Technological barriers
• Prevailing practice barriers

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• Cement Processing Additives Grinding Aids
• Improve grinding process efficiency increase
  tonnes/hour reduce specific energy consumption
• Cement Performance Additives Quality Improvers
• significantly improve cement performance and
  quality
• e.g. increased strength development,
  accelerated/delayed setting, reduced water
  demand, etc.
• allow higher clinker replacement levels
• Cement Functional Additives
• Masonry Cement Additives
• Chromium (VI) Reducing Additives

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Clinker Factor largely correlates with the CO2
emission factor

• Drivers
• lower cost of making blended cements
• mkt demand for specific cements w/ special
  properties (e.g. durability)
• reduced CO2 emission of manufacturing process

Production of Blended Cements is extremely
popular in Europe and South America CO2 Factor in
Western Europe 0.68 in 2003 - - - gt 0.62 by 2010
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Further drastic reduction of CEM I
production Significant shift towards CEM II CEM
III cements
Source J. Harder. Development of clinker
substitutes in the cement industry ZKG
International No. 2-2006 (Volume 59) pp. 58-64
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Quality Improvers Role in CO2 Reduction
Less CO2
Mill Output
Less Clinker
Less Fuel
Productivity Cement volume/ tonne of clinker
More Filler Materials
More Alternative Fuels
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EU Emissions Trading Scheme - Clinker Replacement
in Cement

• Clinker replacement in cement is an opportunity
• Consider 5 increase in SCM in the cement
• e.g. slag, fly ash, pozzolan, limestone, etc
• Will reduce 0.05 0.85t CO2/t cement 0.0425t
• For a 1mtpa cement plant 42,500t CO2
• At 15/t 0.638mm or 0.638/t cement
• This is in addition to usual process cost
  reduction
• CO2 value depends on level with reference to NAP
  and ability to sell/buy allocations

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• Possible Changes in Cement Performance
• from Clinker Substitution - Fly Ash

• Increase Blaine SSA, by 2m2/kg per 1 (_at_
  constant kWh/t)
• Reduce Packset
• Narrow cement PSD
• Decrease 28-day strength, above 5, by 0.2 - 0.7
  MPa per 1
• Decrease 2-day strength, above 5, by 0.5 - 0.9
  MPa per 1
• Extend setting time, 10-40 minutes (initial set)
• Reduce concrete water demand?

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Potential Influence of Quality Improvers

• Reduce coating and Reduce Packset
• Increase Mill Output, by 5 - 30
• Narrower cement PSD (Increase RRN)
• Increase 28-day strength, 5-15 or say 2 - 10 MPa
• Increase 2-day strength, 10-30 or say 2 - 10 MPa
• Reduce setting time, 10-40 minutes (initial set)
• Extend setting time, 10-40 minutes (initial set)
• Reduce water demand (concrete), by 2 - 5 or 20
  - 70mm (_at_75mm)

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Grace TDA CBA ESE Quality Improvers

• Q.I.s increase cement performance
• this allows lower clinker factor to maximise use
  of secondary materials
• (slag, fly ash, pozzolan, limestone, etc.)
• this provides economic benefit from
• process benefits
• lower compositional cost
• lower CO2/tonne of cement
• increased cement volume per tonne of clinker

• ENERGY AND CLINKER FACTOR SOLUTIONS
• Allow higher clinker replacement levels
• lower energy consumption
• reduction in the associated CO2 emissions

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Global Carbon Market Analysis

• Joint Implementation (March 08 Report)
• 114 Project in the pipeline
• 112 projects at validation (1 cement)
• 1 project registered (cement)
• 1 project rejected
• 1 Registered Project Podilsky Cement, Ukraine
• Wet to dry kiln conversion 756,000 tCO2/yr
• 1 Cement Project at Validation
• Fuel switch Savinsky Cement 225,000 tCO2/yr

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Global Carbon Market Analysis

• Clean Development Mechanism (March 08 Report)
• gt 3000 Project in the pipeline
• 987 projects registered 198,400,817 tCO2/yr
• 84 projects requesting registration 13,435,408
  tCO2/yr
• Approximately 100 cement projects in pipeline
• Much more potential

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CDM Cement Analysis

Totaling gt 10.5 MtCO2/yr
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CDM Cement Blending (ACM0005)

• 37 projects
• 14 registered
• 8 rejected
• 16 at validation

• Average Project
• 138,000 tCO2/yr

• Total Market Size (excludes rejected)
• 4,000,000 tCO2/yr

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CDM de-Carbonated Materials (ACM015)

• 6 projects
• 0 registered
• 0 rejected
• 6 at validation

• Average Project
• 211,000 tCO2/yr

• Total Market Size (excludes rejected)
• 1,270,000 tCO2/yr

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CDM Alternative Fuels (ACM0003)

• 16 projects
• 9 registered
• 0 rejected
• 8 at validation

• Average Project
• 144,000 tCO2/yr

• Total Market Size (excludes rejected)
• 2,300,000 tCO2/yr

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CDM Industrial Fuel Switch (ACM0009)

• 13 projects
• 2 registered
• 1 rejected
• 10 at validation

• Average Project
• 169,000 tCO2/yr

• Total Market Size (excludes rejected)
• 2,200,000 tCO2/yr

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CDM Waste Heat Recovery (AM024)

• 12 projects
• 3 registered
• 0 rejected
• 9 at validation

• Average Project
• 60,000 tCO2/yr

• Total Market Size (excludes rejected)
• 720,000 tCO2/yr

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CDM Small Scale Energy Efficiency (AMS II.D)

• Projects Include Upgrades to clinker coolers,
  upgrades to grinding mills, use of grinding
  aids, etc.
• 12 projects submitted, 2 registered, 2 rejected,
  8 at validation
• Average project size 20,000 tCO2/yr

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Conclusions

• Evaluate all options before the projects
  start!
• Carbon offsets quality improver costs IRR is
  changed
• Investment and barrier analyses are critical!
• Time is against us Kyoto Phase II ends in 2012
• De-bottleneck operations through cement blending
• Evaluate all methodologies and all options
• THANK YOU

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Maximizing CO2 Reductions while Increasing
Production and Improving Cement Quality

• Al Vazquez
• AgCert International, TurboGreen
• Francisco Retondo
• W. R. Grace