Ziel des Forschungsvorhabens war es, den Einfluss von Nebenoxiden aus Brennstoffaschen auf die Bildungstemperaturen der Klinkerschmelze und auf die damit verbundene Klinkermineralogie herauszuarbeiten. Ebenso sollten die Auswirkungen der verringerten Prozesstemperatur und der veränderten Eigenschaften der Klinkerschmelze auf die notwendige Bildung von Coatingschichten sowie die Feuerfestkorrosion und damit auf die Haltbarkeit der feuerfesten Zustellung in der Sinterzone des Drehrohrofens aufgeklärt werden.

Achieving climate neutrality in the cement and lime industries poses a particular challenge, given that the majority of CO₂ emissions are caused by raw material-related emissions from the decompo-sition of limestone. The capture and storage of CO₂ (carbon capture and storage, CCS) is therefore pivotal in enabling these industries to achieve climate neutrality. The selection of a suitable capture technology is contingent on site and plant-specific conditions. In many cases, multiple production lines or products exist which generate substantial CO₂ emissions.

The current requirements for low alkali cements mean that calcined clays can hardly be used as main constituent in such cements due to their alkali content. However, it is known that pozzolanic SCMs contribute to the prevention of ASR. The aim of the research project is therefore to systematically investigate the contribution of calcined clays to the prevention of ASR.

This research project serves to analyse the effects of various factors (especially chemistry and mineralogy of the raw clay, calcination temperature) on the effective alkali content of cements with calcined clays,

In this research project, IR spectroscopy in combination with mathematical tools (chemometrics) is going to be evaluated as an analytical method for the characterisation of silica based materials, primarily X-ray amorphous materials, with regard to the reliable determination of the composition of material mixtures with X-ray amorphous materials (e.g. ternary cements with calcined clay and/or recycled concrete fines). In a next step, the findings on the analytical method and evaluation routines developed for cement are going to be evaluated with regard to their transferability to siliceous aggregates for estimating its alkali sensitivity.

In this training you will become familiar with all relevant aspects concerning the use of alternative fuels in cement plants. Starting with the main political drivers such as the circular economy and the European waste fuel strategy, you will get a detailed insight into the current state-of-the-art-situation with regard to the use of alternative fuels in the EU. In this context, pre-treatment and suitable quality control of alternative fuels will be also explained and presented to you. You will focus on all the relevant aspects of the use of alternative fuels in the burning process (e.g. drivers and barriers of their use, available process technology and latest developments) and discuss them in the sessions. You will acquire knowledge about technical feasibility and optimisation potential, and have the possibility to discuss case studies.

Clinker production is the most energy-intensive process step in cement manufacturing. It can represent up to 90% of the total energy demand in a cement plant and is therefore a main focus not only with regard to cost optimisation and quality improvement of the final product, but also regarding emission control and the reduction of impacts on the environment. VDZ’s training will enable you as participant to obtain a deeper knowledge of the clinker production process and a better understanding of how the daily decisions can impact the overall performance of the plant (quality, electrical energy use, fuel consumption and emissions).

VDZ’s online seminar “Strategies for the decarbonisation of the cement industry” aims to train technical staff that will be involved in the development and implementation of decarbonisation strategies in the cement industry in the coming decades. As a participant, you will gain a broader perspective on the challenges, opportunities, uncertainties and technical solutions available to achieve the ambitious goal of net zero CO₂ emissions in the future. Starting with energy efficiency and utilisation of alternative fuels, you will learn about state-of-the-art technologies, technical limitations, identification of improvement potential and industrial case studies. You will also get an insight into the current regulatory framework and how the implementation of CBAM might influence investment strategies in cement plants in Europe and beyond over the next decade. You will look ahead and discuss innovative CO₂ reduction possibilities, such as calcined clays, use of artificial intelligence (AI) and CCUS. Calcined clays will be presented from a technology and materials perspective. You will also learn about different CC technologies and their operating principles, TRL evolution prospects and associated technological risks, selection criteria and critical techno-economic requirements. At the end of the online seminar, you will understand the fundamentals of machine learning and how AI can be used for process parameter prediction in the present, as well as for the development of autonomous systems for process control in carbon capture cement plants in the future.

The 9ᵗʰ International VDZ Congress took place in Düsseldorf on 6 – 8 November 2024. The VDZ Congress is the international scientific forum for the cement industry and its suppliers. Delegates from all over the world discuss the latest developments concerning the transformation of the industry on its way towards climate neutrality.