Title:
Calcium Sulfoaluminate Cement Manufacturing in India— Prospects and Prognosis of Environmental Impacts
Author(s):
Atul Sharma, Anusha S. Basavaraj, Piyush Chaunsali, and Ravindra Gettu
Publication:
Materials Journal
Volume:
120
Issue:
1
Appears on pages(s):
17-28
Keywords:
alternative raw materials; calcium sulfoaluminate (CSA) cement; carbon dioxide (CO2) emissions; energy consumption; life cycle assessment
DOI:
10.14359/51738456
Date:
1/1/2023
Abstract:
Calcium sulfoaluminate (CSA) cement is a low-CO2 binder exhibiting useful properties, such as shrinkage compensation and rapid hardening, which can be achieved by altering its phase composition. In this paper, a hypothetical scenario of CSA cement manufacturing at an existing Indian cement plant is investigated for the environmental consequences (that is, CO2 emissions and energy consumed) using the life cycle assessment methodology. Thirteen laboratory-scale studies from the literature were selected for potential upscaling to industrial level production. The analysis showed that the manufacturing of CSA clinker could result in a 15 to 55%
reduction in the CO2 emissions without a significant change in
energy consumption when compared to ordinary portland cement. The impacts of CSA cement manufacturing were comparable to those of blended cements, such as those with slag and fly ash.
Related References:
1. U.S. Geological Survey, “Mineral Commodity Summaries 2015: Mineral Commodity Summaries,” U.S. Geological Survey, Reston, VA, 2015, 196 pp.
2. IBEF, “Cement Industry in India,” India Brand Equity Foundation, New Delhi, India, 2022, https://www.ibef.org/industry/cement-india.aspx. (last accessed Jan. 10, 2023)
3. Olivier, J. G. J.; Janssens-Maenhout, G.; Muntean, M.; and Peters, J. A. H. W., “Trends in Global CO2 Emissions: 2016 Report,” PBL Netherlands Environmental Assessment Agency, The Hague, the Netherlands, 2016.
4. Schneider, M.; Romer, M.; Tschudin, M.; and Bolio, H., “Sustainable Cement Production—Present and Future,” Cement and Concrete Research, V. 41, No. 7, 2011, pp. 642-650. doi: 10.1016/j.cemconres.2011.03.019
5. Hendriks, C. A.; Worrell, E.; de Jager, D.; Blok, K.; and Riemer, P., “Emission Reduction of Greenhouse Gases from the Cement Industry,” Proceedings of the Fourth International Conference on Greenhouse Gas Control Technologies, IEA GHG R&D Programme, Interlaken, Switzerland, 1998, pp. 939-944.
6. Hanein, T.; Galvez-Martos, J.-L.; and Bannerman, M. N., “Carbon Footprint of Calcium Sulfoaluminate Clinker Production,” Journal of Cleaner Production, V. 172, 2018, pp. 2278-2287. doi: 10.1016/j.jclepro.2017.11.183
7. Damtoft, J. S.; Lukasik, J.; Herfort, D.; Sorrentino, D.; and Gartner, E. M., “Sustainable Development and Climate Change Initiatives,” Cement and Concrete Research, V. 38, No. 2, 2008, pp. 115-127. doi: 10.1016/j.cemconres.2007.09.008
8. CEMBUREAU, “Cementing the European Green Deal, Reaching Climate Neutrality along the Cement and Concrete Value Chain by 2050,” The European Cement Association, Brussels, Belgium, 38 pp.
9. Scrivener, K. L.; John, V. M.; and Gartner, E. M., “Eco-Efficient Cements: Potential Economically Viable Solutions for a Low-CO2 Cement-Based Materials Industry,” Report of a Working Group Initiated by UNEP's Sustainable Building and Climate Initiative, United Nations Environment Programme, Nairobi, Kenya, 2016, 64 pp.
10. Gartner, E., and Hirao, H., “A Review of Alternative Approaches to the Reduction of CO2 Emissions Associated with the Manufacture of the Binder Phase in Concrete,” Cement and Concrete Research, V. 78, Part A, 2015, pp. 126-142. doi: 10.1016/j.cemconres.2015.04.012
11. Mehta, P. K., “Investigations on Energy-Saving Cements,” World Cement Technology, V. 11, No. 4, 1980, pp. 166-177.
12. Hanein, T.; Galan, I.; Elhoweris, A.; Khare, S.; Skalamprinos, S.; Jen, G.; Whittaker, M.; Imbabi, M. S.; Glasser, F. P.; and Bannerman, M. N., “Production of Belite Calcium Sulfoaluminate Cement Using Sulfur as a Fuel and as a Source of Clinker Sulfur Trioxide: Pilot Kiln Trial,” Advances in Cement Research, V. 28, No. 10, 2016, pp. 643-653. doi: 10.1680/jadcr.16.00018
13. Glasser, F. P., and Zhang, L., “High-Performance Cement Matrices Based on Calcium Sulfoaluminate–Belite Compositions,” Cement and Concrete Research, V. 31, No. 12, 2001, pp. 1881-1886. doi: 10.1016/S0008-8846(01)00649-4
14. Su, D.; Yue, G.; Li, Q.; Guo, Y.; Gao, S.; and Wang, L., “Research on the Preparation and Properties of High Belite Sulphoaluminate Cement (HBSAC) Based on Various Industrial Solid Wastes,” Materials (Basel), V. 12, No. 9, 2019, Article No. 1510. doi: 10.3390/ma12091510
15. Shenbagam, V. K.; Cepuritis, R.; and Chaunsali, P., “Influence of Exposure Conditions on Expansion Characteristics of Lime-Rich Calcium Sulfoaluminate-Belite Blended Cement,” Cement and Concrete Composites, V. 118, 2021, Article No. 103932. doi: 10.1016/j.cemconcomp.2021.103932
16. Chaunsali, P., and Vaishnav, K., “Calcium-Sulfoaluminate-Belite Cements: Opportunities And Challenges,” Indian Concrete Journal, V. 94, No. 2, 2019, pp. 18-25.
17. Chatterjee, A. K., “Re-Examining the Potential of Calcium Sulphoaluminate Cements from the Perspective of Versatility, Durability and GHG Emission,” Indian Concrete Journal, V. 84, No. 11, 2010, pp. 7-19.
18. Phair, J. W., “Green Chemistry for Sustainable Cement Production and Use,” Green Chemistry, V. 8, No. 9, 2006, pp. 763-780. doi: 10.1039/b603997a
19. Hanein, T.; Galvez-Martos, J.-L.; and Bannerman, M. N., “Carbon Footprint of Calcium Sulfoaluminate Clinker Production,” Journal of Cleaner Production, V. 172, 2018, pp. 2278-2287. doi: 10.1016/j.jclepro.2017.11.183
20. Ren, C.; Wang, W.; Mao, Y.; Yuan, X.; Song, Z.; Sun, J.; and Zhao, X., “Comparative Life Cycle Assessment of Sulfoaluminate Clinker Production Derived from Industrial Solid Wastes and Conventional Raw Materials,” Journal of Cleaner Production, V. 167, 2017, pp. 1314-1324. doi: 10.1016/j.jclepro.2017.05.184
21. Miller, S. A., and Myers, R. J., “Environmental Impacts of Alternative Cement Binders,” Environmental Science & Technology, V. 54, No. 2, 2020, pp. 677-686. doi: 10.1021/acs.est.9b05550
22. Gettu, R.; Pillai, R. G.; Santhanam, M.; Basavaraj, A. S.; Rathnarajan, S.; and Dhanya, B. S., “Sustainability-Based Decision Support Framework for Choosing Concrete Mixture Proportions,” Materials and Structures, V. 51, No. 6, 2018, Article No. 165. doi: 10.1617/s11527-018-1291-z
23. Palou, M. T., and Majling, J., “Preparation of the High Iron Sulfoaluminate Belite Cements from Raw Mixtures Incorporating Industrial Wastes,” Ceramics-Silikáty, V. 39, No. 2, 1995, pp. 63-67.
24. El-Alfi, E. A., and Gado, R. A., “Preparation of Calcium Sulfoaluminate-Belite Cement from Marble Sludge Waste,” Construction and Building Materials, V. 113, 2016, pp. 764-772. doi: 10.1016/j.conbuildmat.2016.03.103
25. Ren, C.; Wang, W.; and Li, G., “Preparation of High-Performance Cementitious Materials from Industrial Solid Waste,” Construction and Building Materials, V. 152, 2017, pp. 39-47. doi: 10.1016/j.conbuildmat.2017.06.124
26. Wu, K.; Shi, H.; and Guo, X., “Utilization of Municipal Solid Waste Incineration Fly Ash for Sulfoaluminate Cement Clinker Production,” Waste Management, V. 31, No. 9-10, 2011, pp. 2001-2008. doi: 10.1016/j.wasman.2011.04.022
27. Marroccoli, M.; Montagnaro, F.; Nobili, M.; Telesca, A.; and Valenti, G. L., “Hydration Properties of Calcium Sulphoaluminate Cements Made from Coal Combustion Wastes,” Proceedings of the 30th Meeting of the Italian Section of The Combustion Institute, Ischia, Italy, June 2007, 6 pp.
28. Rungchet, A.; Chindaprasirt, P.; Wansom, S.; and Pimraksa, K., “Hydrothermal Synthesis of Calcium Sulfoaluminate–Belite Cement from Industrial Waste Materials,” Journal of Cleaner Production, V. 115, 2016, pp. 273-283. doi: 10.1016/j.jclepro.2015.12.068
29. Telesca, A.; Marroccoli, M.; Tomasulo, M.; Valenti, G. L.; Dieter, H.; and Montagnaro, F., “Low-CO2 Cements from Fluidized Bed Process Wastes and Other Industrial By-Products,” Combustion Science and Technology, V. 188, No. 4-5, 2016, pp. 492-503. doi: 10.1080/00102202.2016.1138736
30. Rungchet, A.; Poon, C. S.; Chindaprasirt, P.; and Pimraksa, K., “Synthesis of Low-Temperature Calcium Sulfoaluminate-Belite Cements from Industrial Wastes and Their Hydration: Comparative Studies Between Lignite Fly Ash and Bottom Ash,” Cement and Concrete Composites, V. 83, 2017, pp. 10-19. doi: 10.1016/j.cemconcomp.2017.06.013
31. Pace, M. L.; Telesca, A.; Marroccoli, M.; and Valenti, G. L., “Use of Industrial Byproducts as Alumina Sources for the Synthesis of Calcium Sulfoaluminate Cements,” Environmental Science & Technology, V. 45, No. 14, 2011, pp. 6124-6128. doi: 10.1021/es2005144
32. Iacobescu, R. I.; Pontikes, Y.; Koumpouri, D.; and Angelopoulos, G. N., “Synthesis, Characterization and Properties of Calcium Ferroaluminate Belite Cements Produced with Electric Arc Furnace Steel Slag as Raw Material,” Cement and Concrete Composites, V. 44, 2013, pp. 1-8. doi: 10.1016/j.cemconcomp.2013.08.002
33. Canbek, O.; Shakouri, S.; and Erdoğan, S. T., “Laboratory Production of Calcium Sulfoaluminate Cements with High Industrial Waste Content,” Cement and Concrete Composites, V. 106, 2020, Article No. 103475. doi: 10.1016/j.cemconcomp.2019.103475
34. Chen, I. A., and Juenger, M. C. G., “Incorporation of Coal Combustion Residuals into Calcium Sulfoaluminate-Belite Cement Clinkers,” Cement and Concrete Composites, V. 34, No. 8, 2012, pp. 893-902. doi: 10.1016/j.cemconcomp.2012.04.006
35. Gálvez‐Martos, J.-L.; Valente, A.; Martínez‐Fernández, M.; and Dufour, J., “Eco‐Efficiency Assessment of Calcium Sulfoaluminate Clinker Production,” Journal of Industrial Ecology, V. 24, No. 3, 2020, pp. 695-706. doi: 10.1111/jiec.12967
36. Shen, Y.; Qian, J.; Huang, Y.; and Yang, D., “Synthesis of Belite Sulfoaluminate-Ternesite Cements with Phosphogypsum,” Cement and Concrete Composites, V. 63, 2015, pp. 67-75. doi: 10.1016/j.cemconcomp.2015.09.003
37. Beretka, J.; de Vito, B.; Santoro, L.; Sherman, N.; and Valenti, G. L., “Utilisation of Industrial Wastes and By-Products for the Synthesis of Special Cements,” Resources, Conservation and Recycling, V. 9, No. 3, 1993, pp. 179-190. doi: 10.1016/0921-3449(93)90002-W
38. Singh, M.; Kapur, P. C.; and Pradip, “Preparation of Calcium Sulphoaluminate Cement using Fertiliser Plant Wastes,” Journal of Hazardous Materials, V. 157, No. 1, 2008, pp. 106-113. doi: 10.1016/j.jhazmat.2007.12.117
39. Singh, M.; Upadhayay, S. N.; and Prasad, P. M., “Preparation of Special Cements from Red Mud,” Waste Management, V. 16, No. 8, 1996, pp. 665-670. doi: 10.1016/S0956-053X(97)00004-4
40. Basavaraj, A. S., and Gettu, R., “Life Cycle Assessment as a Tool in Sustainability Assessment of Concrete Systems: Why and How?” Indian Concrete Journal, V. 96, No. 4, 2022, pp. 1-20.
41. ISO 14040:2006, “Environmental Management—Life Cycle Assessment—Principles And Framework,” International Organization for Standardization, Geneva, Switzerland, 2006.
42. ISO 14044:2006, “Environmental Management—Life Cycle Assessment—Requirements and Guidelines,” International Organization for Standardization, Geneva, Switzerland, 2006.
43. Gettu, R.; Patel, A.; Rathi, V.; Prakasan, S.; Basavaraj, A. S.; Palaniappan, S.; and Maity, S., “Influence of Supplementary Cementitious Materials on the Sustainability Parameters of Cements and Concretes in the Indian Context,” Materials and Structures, V. 52, No. 1, 2019, Article No. 10. doi: 10.1617/s11527-019-1321-5
44. Chitvoranund, N.; Winnefeld, F.; Sinthupinyo, S.; and Lothenbach, B., “Phase Assemblage Study of Alite-Calcium Sulfoaluminate Cement Blended with Supplementary Cementitious Materials,” Proceedings of the 14th International Congress on the Chemistry of Cement (ICCC 2015), Beijing, China, 2015, 6 pp.
45. Pedersen, M.; Lothenbach, B.; Winnefeld, F.; and Skibsted, J., “Hydrate Phase Assemblages in Calcium Sulfoaluminate–Metakaolin–Limestone Blends,” Calcined Clays for Sustainable Concrete: Proceedings of the 2nd International Conference on Calcined Clays for Sustainable Concrete, F. Martirena, A. Favier, and K. Scrivener, eds., Springer, Dordrecht, the Netherlands, 2018, pp. 352-357.