Examining the use of Fluorspar in the Cement industry

Transcription

1 Examining the use of Fluorspar in the Cement industry Nestor Quintero, CEMEX Research Group Fluorspar 2013, London, October

2 DISCLAIMER This presentation contains certain forward-looking statements and information relating to CEMEX, S.A.B. de C.V. and its subsidiaries (collectively, CEMEX ) that are based on the beliefs of its management, as well as assumptions made by and information currently available to CEMEX. Such statements reflect the current views of CEMEX with respect to future events and are subject to certain risks, uncertainties, and assumptions. Many factors could cause the actual results, performance or achievements of CEMEX to be materially different from any future results, performance or achievements that may be expressed or implied by such forwardlooking statements, including, among others, changes in general economic, political, governmental, and business conditions globally and in the countries in which CEMEX does business, changes in interest rates, changes in inflation rates, changes in exchange rates, the level of construction generally, changes in cement demand and prices, changes in raw material and energy prices, changes in business strategy, and various other factors. Should one or more of these risks or uncertainties materialize, or should underlying assumptions prove incorrect, actual results may vary materially from those described herein as anticipated, believed, estimated, expected or targeted. CEMEX does not intend, and does not assume any obligation, to update these forward-looking statements. Unless otherwise noted, all figures are presented under Mexican GAAP Copyright CEMEX, S.A.B. de C.V. and its subsidiaries. 2 2

3 CEMEX: Global Building Materials Company Annual sales of US$15 billion Presence in more than 50 countries worldwide, with more than 46,000 employees Production capacity of 96 million metric tons/year of cement Production of approximately 51 million cubic meters of readymix concrete and more than 158 million metric tons of aggregates in cement plants and a minority participation in 12 cement plants Close to 2,000 ready-mix concrete facilities and 376 aggregate quarries 223 land-distribution centers, and 71 marine terminals 3 3

4 GLOBAL LEADER IN OUR CORE BUSINESS (1) Weighted for consolidation and ownership (operations 100% owned or <100% owned but fully consolidated are counted at full capacity; operations <50% are weighted by % owned). 4 4

5 PEOPLE, THE MAIN DRIVER FOR SUCCESS Our values are: Collaboration. Work with others in a collective pursuit of excellence Integrity. Act with honesty, responsibility, and respect at all times Leadership. Envision the future and focus our efforts on service, excellence, and competitiveness We work passionately in order to: Attract and retain the best pool of talent in the industry Strive for excellence in our performance Foster a collaborative, inclusive, and innovative work environment 5 5

6 A VERTICALLY INTEGRATED COMPANY We supply cement, ready-mix concrete, and aggregates, as well as a range of other construction products and services. 6 6

7 SUSTAINABILITY IN OUR DNA Our Sustainability Model is based in 3 objectives and focuses on 7 action oriented priorities: Sustainability Model at CEMEX Enhance Our Value Creation Lead in Sustainable Construction Low Income Housing & Infrastructure Manage Our Footprint Enhance our Carbon Strategy Excellence in Environmental & Biodiversity Management Engage Our Stakeholders High Priority to Health & Safety Strengthen local communities Partnership with Key Stakeholders Sustainability at CEMEX is embedded in our business strategy 7 7

8 CEMEX RESEARCH GROUP CEMEX Research Group AG (CRG) was established in 2001 in Switzerland. Mission Ensure CEMEX s industry leadership and strong market position by enabling CEMEX operations to deliver the best-in-industry value to their customers through deployment of CEMEX global Research & Development and Intellectual Property management worldwide Currently, CRG employs close to 100 people from 26 nationalities with multidisciplinary backgrounds from research scientists to engineers, business professionals and commercialization experts. CRG develops innovative business and engineering solutions working closely with the operations for the continuous growth of CEMEX as a global leader in the construction materials industry. Geneva Brügg b. Biel Basel Bern Zurich 8 8

9 GLOBAL RESEARCH & INNOVATION LAB The CEMEX Global Research Laboratory plays a key role in the success of our company by generating innovative construction solutions and business practices for the construction industry. A multidisciplinary group of researchers collaborate and make use of cutting-edge technology as well as unique investigation tools to develop new products. Develop economically viable and innovative solutions to match the needs of our customers, according to a well planned Technological Agenda. 9 9

10 WHAT IS CEMENT? A cement is a binder, a material that sets and hardens independently when in contact with water. Portland cements are made using clinker a precursor of cement, produced in a calcium, silica and alumina oxides system at 1450 C The four main components being: Alite(3CaO SiO 2 ) Belite(2CaO SiO 2 ) C3A (3CaO Al 2 O 3 ); C4AF (4CaO Al 2 O 3 Fe 2 O 3 ) Clinker phase formation 10 10

11 PROCESS OVERVIEW 11 11

12 BACKGROUND ON FLUORSPAR USE It is widely known that Fluospar has several uses and properties and for cement its main advantage its mineralizing effect. Welch & Gutt 1 discovered that the ion fluor can accelerate chemical reactions in the CaO-SiO2 system, allowing the Calcium and Silica ions to diffuse and combine faster. Fluorspar provides a more stable burnability (ability to be burnt) in the kilns, when properly used. Also leads to a reduction in the production temperature. 12 Clinker image by Optical Microscopy Cement Plant image (Rugby, UK) 1 Welch JH, Gutt W., Journal of the American Ceramic Society, 1959;42 12

13 BACKGROUND ON FLUORSPAR USE To better understand its action we must first differentiate between flux and mineralizer. FLUX: Compound that decreases fusion temperature without significantly altering the thermodynamic equilibrium of reactions. As example of fluxes in the cement system we have Iron and Aluminum. MINERALIZER: Compound capable of promoting the formation of an specific phase altering the thermodynamic equilibrium of reactions. Mineralizers are more efficient in the presence of a liquid phase and can contribute to the flux activity. Examples are: Zinc, Fluor, Manganese, Sulfur, among others

14 BACKGROUND IN CEMEX Development started in Mexico in the late 90 s. In 1998 initial tests were performed in grey cement at Merida Plant in the south part of Mexico. In 1999 white clinker technology was tested at Valles plant, also in Mexico. In 2000 Atotonilco plant near Mexico City adopted white clinker technology. In 2004 started full deployment of gray and white clinker technology in all Mexican operations (12 plants) In 2009 started international deployment in Panama and Colombia and a couple years later in Spain & Croatia

15 HIGHSULFUR PETCOKE PATENT In our R&D process we have found new ways to optimize alternative raw materials, whenever possible. Introduction of High Sulfur Petcoke as base fuel in the late 90 s resulted in applying the use of CaF2 to enhance the use of this type of petcoke, with patents granted to CEMEX in this regard. Further research has allowed us to better understand additional reaction mechanisms which can be introduced to our cements plants. Yet the use of Fluorspar in the cement industry remains as an alternative- not business as usualconsidering the nature and availability of CaF

16 RESULTS Inclusion of calcium fluoride into the cement systems can lead to decrease the burning temperature up to 100 C. Quality of the final product (measured by compressive strength) is maintained throughout the process. Results could be replicable in different systems under a case by case evaluation scenario

17 TECHNOLOGY DEPLOYMENT Materials Planning Execution Results YES 1 CaF2 available NO Continue local search for local options Review Options for new evaluation. Prepare tailor-made protocol Training for Plant personnel Execute Industrial Trial process Discard Project Review Process & Quality Results Review recommendations Deliver Final Trial report NO Economically feasible? Feasibility Study featuring burnability & pre-economic eval. Define implementation team Execute Industrial Implementation YES Feedback for Industrialization Search materials options for mineralization process. A feasibility evaluation shall be carried out in order to confirm benefits 17 An industrial test protocol shall be made according to each site conditions. An Implementation Group featuring Operations specialists shall be assembled Specialists Industrial trials. execute Specialists support during implementation phase. Review Process & Quality results Recommendations are reviewed by deployment team. 17

18 TECHNOLOGY DEPLOYMENT 18 18

19 CEMENT GRADE CAF2 Among the three principal types of fluorspar according to its grade of purity we can also talk about a cement grade quality. The nature of the pyro-process system in the cement industry allows the incorporation of many secondary/alternative/waste materials. Acid grade (97% or more CaF2) Ceramic grade fluorite (85 95% CaF2) Metallurgical grade(60 85% CaF2) Cement Grade These materials may not be needed to accomplish the production process but are always appreciated and may turn into benefits if properly incorporated

20 TAKEAWAYS Fluorspar could be used at almost any plant, if technically and economically feasible, the price nowadays limits its use in many locations where it could be implemented. Among the benefits for cement process is the reduction of the energy required for sintering the precursor product for cement, the clinker. Nevertheless, it requires to be handled with care and with precise dosages, since cement process and quality are very sensitive to deviations. Its inclusion in the process does not behave the same way in all cement kiln systems, so lab and industrial tests are always needed prior to industrial use. Due to the nature of cement process almost any quality of fluorspar or its subproducts(i.e. HF industry residues) can be used for cement production (as low as 40% of CaF2 content) 20 20

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