Increasing energy efficiency in the cement industry through training by means of virtual reality (VR)
The aim of IGF project 21619 is to develop a training simulator with which learners can independently solve typical process engineering tasks within a virtual reality (VR) environment, particularly in connection with ball mills.
BetonQuali - information and qualification platform
"BetonQuali - information and qualification platform", a joint project of VDZ gGmbH and its project partners, aimed to develop and test a training method for semi-skilled and unskilled employees in the concrete industry.
Development of a high-efficiency SNCR process with staged combustion for reducing NOₓ and NH₃ emissions in cement industry rotary kiln plants with precalcination
The aim of the research project was to obtain general NOₓ emission abatement to 200 mg/m³ with a minimal NH₃ slip of max. 30 mg/m³ in cement industry rotary kiln plants with precalcination.
Improving the selection and service life of metallic materials in the high-temperature range of rotary cement kilns, taking into account the relevant gas atmosphere
Investigation and optimisation of catalytic methods of reducing carbon monoxide and organic components in the exhaust gas of rotary kiln plants in the cement industry
As part of the IGF research project 17364 N funded by the AiF, studies were performed in conjunction with the research institute of the cement industry (FIZ) and the Institute of Chemical and Electrochemical Process Engineering at Clausthal University (ICVT) on the catalytic reduction of CO and organic components in the rotary kiln exhaust gas of cement plants.
Stabilisation of processes with high secondary fuel use through the injection of oxygen in rotary kiln plants in the cement industry
The main aim of the research project was to evaluate the influence of oxygen enrichment on the clinker, on kiln operation and on the use of alternative fuels as well as on the composition of the exhaust gas.
Sustainable education for cement industry workers in Russia (BIRUZEM)
At the request of VDZ members with business interests in Russian-speaking regions, VDZ therefore got together with other service providers and universities in early 2013 to work on creating a platform for training courses in Russian in the field of cement production and utilisation.
Reducing mercury loads in rotary cement kilns using sorbents
The research project was investigating the extent to which the different types of mercury bond, the alkaline atmosphere and high dust loading influence the effectiveness of possible additives such as activated charcoal, open-hearth coke or other calcium compounds and mixtures of these.
CARBON CONCRETE COMPOSITE – C³-Environment: Characterisation and leaching tests for the determination of the environmental safety of C³
Goal of the research project was to generate a broad, scientific verified data base via corresponding leaching and shower tests (laboratory and outdoor tests) on carbon-concrete test specimen with different concrete covering of the carbon-fibres as well as with different percentages of the carbon-fibres to evaluate the environmental compatibility of the new, innovative composite building material “carbon-concrete”.
CARBON CONCRETE COMPOSITE – C³: Acceleration of standardisation and approval procedures in the context of test-based design and performance testing for C³ products (CarbonSpeed)
The aim of the C³ CarbonSpeed project was to create a guideline to complement the existing verification procedures of the building authorities (approval in individual cases, national technical approval) with a view to shortening the time required for the introduction of solutions with carbon concrete.
CARBON CONCRETE COMPOSITE – C³: Proofs and testing concepts for standards and technical approvals
In the course of the project, VDZ planned, inter alia, to work together with the ibac, Aachen, to develop a data base for the environmental compatibility of the new composite construction carbon concrete, by leaching and irrigation trials.
Advanced initial testing for air-entrained concrete with superplasticiser considering conditions in construction practice
Resource-saving concrete – The next-generation material
Optimisation of concrete compositions based on their serviceability limit state: A step towards a further reduction of CO₂ emissions of concrete production
The target of this research project was to develop a comprehensive database regarding the material parameters carbonation and chloride resistance for different cement types and concrete compositions. The investigations focused on concrete compositions that contain cements with low clinker/cement factors.
Chemistry and mineralogy
Clinker burning with alternative fuels at low process temperatures - effects on coating formation and on the corrosion of refractory products in the cement rotary kiln as well as on the performance of cement
The replacement of primary fuels by alternative fuels is of great economic and ecological importance for the cement industry and is to be increased in the future. The fuel ashes are used as raw material in the cement clinker and influence its properties as well as the coating formation on the refractory lining in the kiln. Exact knowledge of these effects is indispensable for the further increase of the alternative fuel rate and the simultaneous optimisation of the kiln operation as well as for the maintenance of the clinker quality and the service life of the refractory lining.
Calcined Clays from mineral secondary raw materials
The aim of the research project is to investigate the suitability of previously largely unused mineral secondary raw materials from the stone and earth industry as a resource-conserving and climate-friendly main cement constituent. The use of cal-cined clays from secondary raw materials instead of conventional main cement constituents or high-quality primary clays can make an important contribution to the production of climate-friendly and resource-efficient cements.
Use of X-ray fluorescence analysis to determine trace element contents in cements
The aim of the research project is to develop a procedure for analysing trace elements on cements using X-ray fluorescence analysis. In addition, precision data and application limits are to be determined, which are essential in order to be able to classify the results.
Resource-efficient use of sulphate-containing process dusts for sulphate optimisation using isothermal heat flow calorimetry
The research project analyses whether sulphate-rich process dusts can be used to optimise the sulphate content of cements, thereby saving anhydrite/gypsum and, in particular, improving the early strength of cements with several main constituents. Furthermore, it is to be determined whether isothermal heat flow calorimetry can be used as a fast and cost-effective investigation method for this purpose.
Interactions of accelerating admixtures and clinker-efficient cements with several main constituents to improve the early compressive strength of concrete
The acceptance of resource-efficient cements with significantly reduced specific CO₂ emissions is still too low in construction practice. The main reason for this is that early strength is not high enough for economical production processes and also competitive construction with concrete. Accelerating admixtures can improve the early strength of concrete. The research project investigates interactions between concrete admixtures that accelerate the strength development and cements with several main constituents.
Influences of two-stage mixing on the hydration behaviour of Portland-composite cements and composite cements as well as on the concrete performance
The acceptance of resource-efficient cements with significantly reduced specific CO₂ emissions is still too low in construction practice. The main reason is that the early strength is not high enough for economical production processes and competitive construction with concrete. The research project is investigating the extent to which more intensive mixing and further cement constituents besides clinker increase the mixing energy input and can increase the early cement hydration and thus the strength development.