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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

Testing and assessment of effective alkali content in cements

The IGF project 19295 N intended to devise a testing and assessment system that better reflects the cements’ material properties.

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Completed

Optimal compaction of concretes with high workability and high robustness

The aim of this research project was to create basic knowledge on the results of different processing and compaction measures in correlation with the properties of the fresh concrete.

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Completed

Behaviour of different aggregates under accelerating conditions in ASR testing methods

The research project should generate essential knowledge on the behaviour of different aggregates under accelerated conditions within ASR testing methods. The target was to obtain with different testing methods a consistent assessment of the alkali sensitivity of aggregates and concretes respectively and to clearly identify expansive reactions that are not caused by ASR.

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Completed

DURAFOR - Forecast of durability properties of concrete with new clinker based cements

In a CORNET (Collective Research Networking) research project, the project partners CRIC (Belgium), Smart minerals (Austria) and VDZ (Germany) had combined under the consortium leadership of the VDZ to determine characteristic variables for cement and mortar samples and correlate them with the results of concrete durability tests.

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Completed

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”.

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Completed

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.

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Chemistry and mineralogy


Current

Effects of pre-hydration on the performance of cements and the influence of different clinker properties

The research project has two objectives. The first is to investigate whether certain chemical / mineralogical properties can make clinker more robust against pre-hydration effects. Secondly, it will be investigated which measures can be taken to counteract possible negative effects, in particular by adjusting the sulphate carrier composition.

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Current

Process atmosphere during clay calcination – effects on emissions and product properties

Calcined clays as the main cement constituent are an essential part of the cement industry's decarbonisation strategy. Many clay deposits have iron-rich impurities that form hematite during calcination, which colors the product, the cement and ultimately the concrete red. A reducing atmosphere during calcination and/or cooling can prevent the formation of hematite. Systematic findings on the influence of secondary constituents in clays on their reactivity, emissions and cement-technical properties have hardly been available to date and are to be systematically investigated in the project.

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Current

Calcined Clays from mineral secondary raw materials

The aim of the research project was to investigate the suitability of largely unutilised mineral secondary raw materials from the stone and earth industry as a resource-conserving and climate-friendly main cement constituent. The utilisation of calcined clays from secondary raw materials instead of conventional cement main constituents or high-quality primary clays can make an important contribution to the production of climate-friendly and resource-efficient cements. This means that the transformation process of the cement industry can be shaped in a way that is not only cli-mate-friendly but also resource-efficient.

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Current

Performance of ternary cements with Portland cement clinker, calcined clay and limestone as the main constituents

The project systematically investigates the performance and hydration behaviour of ternary cement (KQL) with clinker (K), calcined clay (Q) and limestone (L) as well as key durability aspects of concretes produced with these materials.

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Current

High-quality recycling of crushed concrete sand

In the ZIM research project, used concrete is processed in such a way as to improve the usability of all fractions generated, in particular the crushed sand and the fine fraction. To this end, tests are also being carried out on the pozzolanic reactivation of the recycled concrete fines.

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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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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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