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Knowledge transfer


Current

Reduction of green house gases by process innovations in the primary Industry, SP 6: Development of a methodology for cross-project and ecological potential assessment, cement industry

The transfer and networking project ReInvent aims to provide technical and organisational support for the BMBF funding measure KlimPro-Industrie.

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Completed

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.

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Completed

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.

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Cement production


Completed

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.

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Completed

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.

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Completed

CEMCAP – CO₂ capture from cement production

Taking into account the experimental results and a techno-economic analysis, CEMCAP has developed a decision basis for CO₂ capture technologies in the cement industry. This should enable European cement producers to perform plant-specific CCS economic analyses and adapt to a world with limited carbon emissions. From a European perspective, CEMCAP aims to expand the portfolio of cost- and resource-efficient options for CCS and thus the possibilities for reducing greenhouse gas emissions.

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Completed

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.

Learn more

Completed

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

The aim of this research project was to investigate the issue of high-temperature corrosion in the hot area of the preheater and the rotary kiln.

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Completed

Investigation on the interaction of fuel particles and cement clinker with the aim of increasing the use of alternative fuels

The aim of the research project was to identify those fuel particles which potentially cause the greatest disturbances and to determine their rate of conversion in the flame and in the clinker bed. A further goal was to derive quality criteria for AF, to elaborate recommendations for the optimisation of fuel feeding systems and to develop a tool to estimate the suitability of an AF.

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Concrete technology


Completed

New functionalities of textile-reinforced concrete through titanium dioxide modifications Subsidiary project: fine-grained concrete and cement-bound adhesive

The working plan of the Research Institute of the Cement Industry was aimed at systematic investigation of the mix formulation and workability of a nano-based cement-bound adhesive.

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Completed

ASR performance testing: extending the database to include the 60 °C concrete test with particular reference to cements with several main constituents

In the IGF (Cooperative Industrial Research) project the framework conditions for a possible performance test method for evaluating the alkali reactivity of concrete was calibrated on the basis of the requirements of the German regulations.

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Completed

Reducing the environmental impact of concrete construction through new types of cement and the concrete produced from them using starting materials that are available in adequate quantities

The aim of this research project was the laboratory and industrial production and testing of cements that contain levels of limestone above the maximum content described in DIN EN 197-1.

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Completed

Procedures for E II aggregates

VDZ and the Brandenburg Technical University Cottbus-Senftenberg (BTU) investigated whether it is possible to define an alkali sensitivity class E II-S on the basis of the 40 °C concrete test with cloud chamber storage. In addition, criteria for the rapid test procedure and the 60 °C concrete test as well as the BTU-SP rapid test were also derived.

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Completed

Determination of characteristic values based on the degree of hydration for predicting the durability of concrete

Mortar and concrete trials were used to determine characteristic parameters, such as the void filling of the cements, their hydration characteristics, the porosity of the mortars and concretes made with these cements, and the durability of the concretes.

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Completed

Boundary conditions for accurately achieving projected concrete properties in the modern 5-material system of diverse concrete constituents

Within the framework of the research project, the intention was to identify the most important influence parameters that are responsible for showing unscheduled properties such as changed consistency, signs of sedimentation, or an accelerated or decelerated strength development in certain cases of fresh concretes which are produced over prolonged periods.

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Chemistry and mineralogy


Current

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.

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Current

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.

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Completed

Use of X-ray fluorescence analysis to determine trace element contents in cements

The aim of the research project was to develop a procedure for analysing trace elements on cements using X-ray fluorescence analysis. In addition, precision data and application limits were to be determined, which are essential in order to be able to classify the results.

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Completed

Resource-efficient use of sulphate-containing process dusts for sulphate optimisation using isothermal heat flow calorimetry

The research project analysed 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 was to be determined whether isothermal heat flow calorimetry can be used as a fast and cost-effective investigation method for this purpose.

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Current

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.

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Current

Influences of two-stage mixing on the hydration behaviour of Portland-composite cements and composite cements as well as on the concrete performance

The research project was 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 of clinker-efficient cements.

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Environmental protection


Current

CaLby2030 – Calcium Looping to capture CO2 from industrial processes by 2030

In CaLby2030, the deployment of Calcium Looping technology (CaL) using Circulating Fluidised Bed reactors (CFB) in the cement industry will be investigated, aiming at efficient CO₂-Capture without compromising clinker production or product quality. A technology scale-up will be also evaluated in a German cement plant by exploring different retrofit possibilities. Besides the cement sector, the deployment of CFB-CaL technology in other relevant sectors will also be investigated.

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