CEMENT ADDITIVES

Green materials can be considered

as materials that use less

natural resources and energy

and generate less CO2

1. Despite using

optimised and sophisticated processes,

green cements still emit large amounts of

CO2. To improve the ecological balance

of cement, every possible initiative to

make cement ‘greener’ needs to be

considered.

Reducing CO2 emissions

during clinker production

Cement accounts for approximately five

per cent of the world's carbon dioxide

emissions. The estimated average carbon

footprint is 0.83t CO2/t of traditional

Portland cement clinker (ranging from

0.7 to 1.4t). About 60 per cent of this

is released in unavoidable chemical

reactions as the limestone decomposes

(calcination process)2. The remaining

40 per cent is generated from the vast

amounts of energy needed to heat the

clinker to about 1450°C.

The main focus for the cement plants

is the optimisation of clinker production.

As a result, the share of alternative fuels

is strongly increasing and the generated

heat is used more efficiently. Today,

most cement plants operate dry-process

kiln systems with multi-stage cyclone

preheaters and precalciners, consuming

approximately 3000MJ thermal energy

per tonne of clinker. However, a

significant amount of cement plants still

operate long wet-process kiln systems

with a thermal energy consumption of

up to 6000MJ/t of clinker. CO2 is saved

when the wet ground raw material

slurry contains less water. Sika offers

special wet-system grinding aids allowing

moisture content reduction of the kiln

feed while maintaining the viscosity of

the slurry.

Reduced CO2 emissions

derived from electric energy

Cement production consumes a high

amount of electric energy, typically in

the range of 90-130kWh/t of cement,

Cement is a major part of today’s construction industry which demands

solutions that consider both economical and ecological aspects. Cement

manufacturers are continuously striving to achieve more efficient and

environmentally-friendly production methods. Sika offers cost-effective

concepts for a more ecologically-friendly production of so-called

‘green’ cement.

by Jorg M Schrabback,

Sika Sevices AG,

Switzerland/Germany

IConcepts for ‘green’ cement

Cement is a major part of construction solutions that

consider both economical and ecological aspects

APRIL 2010 ICR

“绿色”水泥的概念

作者：JORG M. SCHRABBACK，西卡瑞士公司

2 “绿色”水泥的概念 创造性水泥研磨解决方案

您的挑战：兼顾能源消耗以及成本最优

化的优质水泥生产

我们的方案：创新的高效能西卡水泥添

加剂

更多关于西卡助磨剂，西卡聚羧酸技术以及其它信息，

请访问 www.sika.com/hardfacts

“绿色”水泥的概念 3

CEMENT ADDITIVES

Green materials can be considered

as materials that use less

natural resources and energy

and generate less CO2

1. Despite using

optimised and sophisticated processes,

green cements still emit large amounts of

CO2. To improve the ecological balance

of cement, every possible initiative to

make cement ‘greener’ needs to be

considered.

Reducing CO2 emissions

during clinker production

Cement accounts for approximately five

per cent of the world's carbon dioxide

emissions. The estimated average carbon

footprint is 0.83t CO2/t of traditional

Portland cement clinker (ranging from

0.7 to 1.4t). About 60 per cent of this

is released in unavoidable chemical

reactions as the limestone decomposes

(calcination process)2. The remaining

40 per cent is generated from the vast

amounts of energy needed to heat the

clinker to about 1450°C.

The main focus for the cement plants

is the optimisation of clinker production.

As a result, the share of alternative fuels

is strongly increasing and the generated

heat is used more efficiently. Today,

most cement plants operate dry-process

kiln systems with multi-stage cyclone

preheaters and precalciners, consuming

approximately 3000MJ thermal energy

per tonne of clinker. However, a

significant amount of cement plants still

operate long wet-process kiln systems

with a thermal energy consumption of

up to 6000MJ/t of clinker. CO2 is saved

when the wet ground raw material

slurry contains less water. Sika offers

special wet-system grinding aids allowing

moisture content reduction of the kiln

feed while maintaining the viscosity of

the slurry.

Reduced CO2 emissions

derived from electric energy

Cement production consumes a high

amount of electric energy, typically in

the range of 90-130kWh/t of cement,

Cement is a major part of today’s construction industry which demands

solutions that consider both economical and ecological aspects. Cement

manufacturers are continuously striving to achieve more efficient and

environmentally-friendly production methods. Sika offers cost-effective

concepts for a more ecologically-friendly production of so-called

‘green’ cement.

by Jorg M Schrabback,

Sika Sevices AG,

Switzerland/Germany

IConcepts for ‘green’ cement

Cement is a major part of construction solutions that

consider both economical and ecological aspects

APRIL2010ICR作为当今建筑行业的一种主要材料,水泥的生产需要统

筹考虑经济发展以及生态保护两方面

作者：Jorg M. Schrabback，西卡瑞士公司 2010年4月 ICR

水泥是当今建筑行业的一个主要构成部分，由于需

要在生产过程中同时兼顾到经济与生态效益，对解

决方案有着很高要求。水泥生产商一直致力于不断

改进生产技术，使其更为高效、环保。针对这种有

利于生态系统维护的水泥生产技术，西卡提出了一

个成本最优化理念，即俗称的“绿色水泥”。

绿色材料可泛指那些对自然资源和能

源的消耗较小，CO2排放量较少的材

料。尽管已投入使用了优化、先进的

生产工艺，绿色水泥的生产过程仍然

会造成大量CO2的排放。为提高水泥生

产的生态平衡度，任何能使水泥生产

变得更为“绿色”的创新都值得被考

虑。

从水泥熟料生产中减排

水泥生产过程中的CO2排放量占全世

界碳排放量的5%，每吨传统波特兰

水泥熟料产生约0.83吨CO2（范围在

0.7~1.4间），其中大约60%源自在石灰

石分解（煅烧）过程中产生的不可避

免的化学反应，其余的40%则来自于

水泥熟料的加热过程，在该过程中，

熟料被加热至1450ºC，并因此产生大

量的能源消耗。目前，大部分水泥厂

商使用的回转窑干法煅烧系统，都配

有多级旋风预热器和分解炉，每吨熟

料会产生大约3000MJ的热能消耗。然

而，绝大多数的水泥厂仍在使用湿法

长窑系统，其熟料的热能消耗量高达

60,00MJ/t,而当湿磨生料浆含水量较少

时，便会产生CO2。西卡提供的特殊湿

法研磨系统可在保持泥浆流动性的同

时允许降低入窑料的湿度。

减少电能消耗过程中的碳排放

水泥生产过程中会消耗大量的电能，

通常每吨水泥的电能消耗量为90~130

千瓦时，如果使用煤电，每百万吨水

泥就会产生90,000~130,000吨CO2。实

际上，CO2的排放量取决于电能来源。

而超过50%的电能消耗产自于生料以

及成品水泥的研磨过程。

诸如助磨剂这样的化学处理剂可提高

生产率并降低单位能耗。西卡在传统

技术的基础上对助磨剂进行了技术创

新，通过应用聚羧酸聚合物将磨机产

量提至最高。在保持恒定细度的前提

下，同传统助磨剂生产相比，带来了

产能的显著提高（见图表1），而在这

种技术的支持下，每百万吨水泥生产

中会减少多达10,000吨的CO2排放。

“绿色”水泥的概念

4 “绿色”水泥的概念 通过调整水泥配方减排

在水泥的生产过程中，会产生CO2排放

的环节主要是水泥熟料的生产，这使得

行业不得不加强优化水泥配方。新型水

泥将发展重点落实在增加用于替代水泥

熟料的混合材使用上，比如石灰石、火

山灰、粉煤灰和矿渣。每降低一个百分

比的水泥熟料，可减少每百万吨混合水

泥中产生的8300吨CO2排放，但与此同

时，也会对强度的发展产生-0.5N/mm2

的影响。而化学改进剂可以在提高水泥

强度方面为厂商提供更多的选择性。

通过调整选粉机并使用助磨剂提高水

泥细度

在水泥技术方面，水泥细度、熟料含

量及强度之间相互关联紧密，其互相

之间的作用效果会因地域不同而发生

变化。以初步近似值统计来看，每增

加100cm2

/g的布莱恩比表面积，强度

即可在2天及28天后分别提高+1N/mm2

和+1.5 N/mm2

。

在粒径分布方面，3~32µm粒径范围内

的颗粒越多，强度就会越高。在一个

恒定的比表面，粒径在3~32µm之间

的颗粒含量每增加5%就能提高约+1N/

mm2

的后强。

然而细度越高，意味着生产率越低，

布莱恩比表面积每增加100cm2

/g，会

导致生产率降低约3~4%。如上所述，

助磨剂可以补偿生产损失，从而通过

最经济的方式达到预定细度。相比不

添加助磨剂的情况，这种方法可以使

产量提高10~20%，也可在产量恒定的

情况下增大约300cm2

/g的比表面积。

通过改进外加剂质量加速水泥水化

化学物质可以加速熟料的水化，从而

提高不同龄期的强度（见图表2）。在

细度恒定的情况下，视当地条件，如

熟料的成分及活性而定，2天后强度

可提高2~5N/mm2

，后强可提高约7N/

mm2

（EN196要求下的标准砂浆）。

上述早强的提高可抵消强度在水泥熟料

掺量下降4~10%时受到的影响，由此，

在每百万吨混合水泥的生产过程中可减

少33,000~83,000吨的CO2排放。另一种

增加强度的方法是在生产过程中使用一

部分活性较低的熟料，如贝利特熟料。

综合化学改进剂以及细度两者的影响

力，可以实现58N/mm2

的强度提高。通

过这种优势，可取代约10~16%的水泥熟

料，从而在每百万吨水泥生产的过程中

减少80,000~130,000吨的CO2排放。优化

粒径分布可以使这种效果得到进一步增

强。西卡为客户提供的标准及定制型高

效助磨剂、质量改进剂，可最大程度地

降低二氧化碳排放量。

通过减少原料波动保证生产的稳定性

水泥生产是一个会持续受到自然环境

变化影响的过程，水泥生产商在生产

链中的均化设备上投资很多，从不同

原材料到生料及熟料的储存，再到水

泥成品库。在每道工序中控制质量的

稳定性，可以确保变化被控制在尽可

能小的范围内。变化越小，需要的安

全限度也越低，因而为保证水泥性能

所需要的熟料含量也可以变得更低。

在水泥的研磨过程中，变量小的稳定

生产可以带来更高的生产率及更好的

强度效果。通过分析粒径分布结果，

对水泥细度进行常规控制，并以诸如

西卡助磨剂这样的化学改进剂加以辅

助，便可实现水泥生产商的预设质量。

案例分析：减排的潜力

案例分析是用以阐明减排潜力的最佳

方法。在本案例中，厂家年产CEM III/A

32.5N矿渣水泥770,000吨，熟料掺量为

0.46。这个项目的目标是将水泥配方进

equivalent to 90,000-130,000t CO2

per 1Mt of cement if the electricity is

coal-generated. Indeed, the related CO2

emission depends on the source of the

electric energy. More than 50 per cent of

the consumed electrical energy is related

to the grinding of raw materials and the

finish cement grinding process.

Chemical processing agents like

grinding aids increase production rates

and reduce specific energy consumption.

Sika offers products based on traditional

technologies for grinding aids but also a

unique new grinding aid technology which

uses polycarboxylate polymers to generate

the highest mill output3. Significant

production increase versus blank grinding

at constant fineness is achievable (Figure

1). As a consequence, CO2 emissions can

be reduced by up to 10,000t CO2 per

1Mt of cement.

Reduced CO2 emissions with

cement formulation

The fact that clinker causes the main

CO2 emissions during cement production

leads the industry to a stronger cement

formulation optimisation. The focus

of new cement developments is to

increasingly replace clinker with secondary

cementitious materials like limestone,

natural pozzolanes, fly ash and slag. Each

percentage of reduced clinker content

lowers the carbon dioxide emission by

8300t CO2 per 1Mt blended cement,

but also adversely affects the strength

development in the magnitude of -0.5N/

mm². Chemical processing agents offer

different opportunities to enhance the

4Improved cement fineness

with adjusted separator

settings and grinding aids

In cement technology, fineness, clinker

content and strength are in close

connection. Exact relations can be

determined for different local conditions.

As a first approximation, increasing

specific surface according to Blaine by

additional 100cm²/g leads to enhanced

strength development in the scale of

+1N/mm² after two days and +1.5N/mm²

after 28 days respectively.

Significant enhancements can be

achieved when targeting an optimised

particle size distribution towards a greater

proportion of the particle size fraction

3-32µm, which is the most important for

strength development5. At a constant

specific surface, an additional five per

cent content of particles 3-32µm result

in approximately 1N/mm² more final

strength.

Higher fineness also implicates a

lower production rate. Each 100cm²/g

more specific surface according to Blaine

reduces the cement production rate by

approximately 3-4 per cent6. As already

described, grinding aids can compensate a

loss of production and thus contribute to

achieving the desired fineness in the most

economical way. A typical production

increase of 10-12 per cent with a grinding

aid versus blank grinding could in this

way generate an approximately 300cm²/

g higher specific surface at constant

production rate.

Acceleration of cement

hydration with quality

improving additives

Chemical substances can accelerate the

hydration of the clinker phases, leading

to higher strength at different ages

(see Figure 2). At constant fineness and

depending on the local conditions like

the amount of clinker and reactivity,

strength after two days can be improved

in the range of 2-5N/mm² while the

final strength can be enhanced up to

approximately 7N/mm² (standard mortar

according to EN 196).

The indicated early strength

development allows reducing clinker

content by 4-10 per cent. Consequently,

the carbon footprint is diminished in the

range of 33,000-83,000t CO2 per 1Mt of

blended cement. Another opportunity to

take advantage of the strength increase

would be to partially use less reactive

clinker, eg belite clinker.

CEMENT ADDITIVES

Figure 1: increasing mill output reduces the specific energy consumption per tonne of cement and

The cement production

process offers multiple

possibilities to reduce

the CO2 emissions

水泥生产过程的许多

环节都有降低CO2排

放的可能

equivalent to 90,000-130,000t CO2

per 1Mt of cement if the electricity is

coal-generated. Indeed, the related CO2

emission depends on the source of the

electric energy. More than 50 per cent of

the consumed electrical energy is related

to the grinding of raw materials and the

finish cement grinding process.

Chemical processing agents like

grinding aids increase production rates

and reduce specific energy consumption.

Sika offers products based on traditional

technologies for grinding aids but also a

unique new grinding aid technology which

uses polycarboxylate polymers to generate

the highest mill output3. Significant

production increase versus blank grinding

at constant fineness is achievable (Figure

1). As a consequence, CO2 emissions can

be reduced by up to 10,000t CO2 per

1Mt of cement.

Reduced CO2 emissions with

cement formulation

The fact that clinker causes the main

CO2 emissions during cement production

leads the industry to a stronger cement

formulation optimisation. The focus

of new cement developments is to

increasingly replace clinker with secondary

cementitious materials like limestone,

natural pozzolanes, fly ash and slag. Each

percentage of reduced clinker content

lowers the carbon dioxide emission by

8300t CO2 per 1Mt blended cement,

but also adversely affects the strength

development in the magnitude of -0.5N/

mm². Chemical processing agents offer

different opportunities to enhance the

strength development of cement4.

Improved cement fineness

with adjusted separator

settings and grinding aids

In cement technology, fineness, clinker

content and strength are in close

connection. Exact relations can be

determined for different local conditions.

As a first approximation, increasing

specific surface according to Blaine by

additional 100cm²/g leads to enhanced

strength development in the scale of

+1N/mm² after two days and +1.5N/mm²

after 28 days respectively.

Significant enhancements can be

achieved when targeting an optimised

particle size distribution towards a greater

proportion of the particle size fraction

3-32µm, which is the most important for

strength development5. At a constant

specific surface, an additional five per

cent content of particles 3-32µm result

in approximately 1N/mm² more final

strength.

Higher fineness also implicates a

lower production rate. Each 100cm²/g

more specific surface according to Blaine

reduces the cement production rate by

approximately 3-4 per cent6. As already

described, grinding aids can compensate a

loss of production and thus contribute to

achieving the desired fineness in the most

economical way. A typical production

increase of 10-12 per cent with a grinding

aid versus blank grinding could in this

way generate an approximately 300cm²/

g higher specific surface at constant

production rate.

Acceleration of cement

hydration with quality

improving additives

Chemical substances can accelerate the

hydration of the clinker phases, leading

to higher strength at different ages

(see Figure 2). At constant fineness and

depending on the local conditions like

the amount of clinker and reactivity,

strength after two days can be improved

in the range of 2-5N/mm² while the

final strength can be enhanced up to

approximately 7N/mm² (standard mortar

according to EN 196).

The indicated early strength

development allows reducing clinker

content by 4-10 per cent. Consequently,

the carbon footprint is diminished in the

range of 33,000-83,000t CO2 per 1Mt of

blended cement. Another opportunity to

take advantage of the strength increase

would be to partially use less reactive

clinker, eg belite clinker.

CEMENT ADDITIVES

ICR APRIL 2010

Figure 1: increasing mill output reduces the specific energy consumption per tonne of cement and

hence the CO2 emission

The cement production

process offers multiple

possibilities to reduce

the CO2 emissions

图表1：磨机产量提高使每吨水泥的电耗降低，因而减少CO2排放产量提高

水泥中西卡助磨剂掺量（%）

一般掺量范围

新技术

传统技术

“绿色”水泥的概念 5

行“绿色”优化，使其生产更为经济环

保，并将矿渣的含量尽量提高到CEMIII/

A标准容许的最大值。表1中，工厂使用

了传统助磨剂（醇胺类助磨剂）和两种

SikaGrind®-800系列产品（一种为纯助

磨剂，另一种为有增加强度效果的助磨

剂），并将其使用结果进行了对比。在

配方没有任何改动的情况下，两种西

卡助磨剂产品均实现了4.6%的产量增

长，并在特定能耗下降低了4.3%的CO2

排放。在这个案例中，每年产生于水泥

研磨耗电中的CO2排放占全部CO2排放量

的8.8%。因此，虽然电能消耗中CO2的

排放量有所降低，但对降低CO2的总排

放量并无显著贡献（降低0.4%）。

当把实验条件由提高产量转换为增大比表

面并维持恒定产量时（方案1），水泥熟

料掺量可被降至44%并降低3%的CO2排放

量，远大于通过节电带来的减排效应。

第二种方案是通过西卡性能改进剂增

强水泥特性，在该方案下，熟料掺量

下降到42%，且相应提高了矿渣的含

量，此时可将年CO2排放量降低6.3%。

第三种方案是将前两种方案合并，此

时，水泥熟料掺量可降至40%，并节

省8.9%的碳排放。

而本案例中，在之前方案的基础上还

同时降低了熟料成分的波动，且再次

加强了稳定生产的管控（方案4），最

终使得水泥熟料掺量达到最低值38%，

每年减少CO2排放47,400（11.9%）。

混凝土生产中的减排

迄今为止，针对水泥干、湿法生产中化

学添加剂和外加剂作用机理的研究一直

都在进行。以这些研究结果作为基础，

面对当今市场的各方面挑战，无论是为

满足大方向需求还是针对个例进行创造

性解决方案开发，都会有广阔的市场空

间。绿色水泥最关注的两点是用水量和

凝聚性，后者对于其在混凝土中发挥的

效果具有关键作用。研磨较细的混合水

泥会引发过高的用水量，从而导致混凝

土和易性变差并加大坍落度损失。基于

聚羧酸聚合物的西卡性能改进剂可以在

帮助水泥实现良好工作性的同时满足塌

落度保持的要求。

在水泥建材领域拥有的一百多年研究

技术和经验，让西卡公司的助磨剂和

混凝土外加剂成为了现代建筑行业领

域中，对高性能混凝土生产的一道有

力保障。

结论

为了使更为高效、环保的生产理念得

以实现，水泥厂商不断尝试对熟料

生产过程进行各方面优化。此外，持

续加大的减排压力也使得在水泥配方

中，熟料替换料的比重一再加大，进

而导致强度受损并降低了生产力。

西卡提供的化学添加剂可以在水泥生产

的不同阶段及应用阶段减少碳排放，并

同时提高水泥以及混凝土的性能。西卡

将助磨剂技术的重点主要落实在降低熟

料含量及每吨水泥生产的能量消耗上。

新的聚羧酸助磨剂技术SikaGrind®-800

系列可以最大限度的提高生产率，也可

配置成性能改进剂，用于提高早强和后

强。通过这种方式，西卡助磨剂便能帮

助水泥厂，在降低碳排放的同时实现利

润的最大化。

the carbon footprint is diminished in the

range of 33,000-83,000t CO2 per 1Mt of

blended cement. Another opportunity to

take advantage of the strength increase

would be to partially use less reactive

clinker, eg belite clinker.

Combining the effects of chemical

acceleration and fineness, strength

improvements in the range of 5-8N/

mm² after two days are possible. This

advantage can be used to replace clinker

by 10-16 per cent of the cement and in

that way reduce 80,000-130,000t CO2

per 1Mt of blended cement. Effects of an

optimisedparticlesizedistributioncouldSika offers standard and tailormade

quality improvers which include efficient

grinding aid technologies to minimise the

carbon footprint.

Constant production with

reduced variations

Cement production is a continuous

process subject to natural variations.

Cement manufacturers invest a lot in

homogenising equipment along the

production chain, from raw material

storage to different raw meal and clinker

storages to finished cement silos. On all

levelsconstantqualitycontrolensurespossible. The smaller the variations, the

smaller the necessary safety margins are

and hence the needed clinker content is

lower to ensure the cement properties.

During cement grinding, a more constant

production with reduced variation leads to

highest production rates and best strength

results. Regular control of cement fineness

with help of particle size analysis and the

use of chemical processing agents like

SikaGrind can help to ensure that cement

plants achieve the required quality.

Case study: CO2 reduction

potential

The potential to reduce the carbon

footprint can be demonstrated best in a

case study. The chosen plant produces

770,000tpa of CEM III/A 32.5N with

a clinker factor of 0.46. The target

of the project was the ecological and

economical optimisation of the cement

formulation, bringing the slag content

close to the maximum allowed for a CEM

III/A. Table 1 shows plant results which

compare a pure traditional grinding aid

with two products of the SikaGrind-800

Series, a pure grinding aid and a strength

enhancer with incorporated grinding aid.

Without any changes of formulation, both

SikaGrind products increase production

by 4.6 per cent and consequently reduce

the CO2 emissions which are related to

the specific energy consumption by 4.3

per cent. In this example, the annual CO2

emission derived from electrical energy

used for the cement grinding process

accounts to 8.8 per cent of the total CO2

emission. Therefore, the effect of the

reduced electric energy consumption on

total CO2 emission is only very limited

(0.4 per cent saving).

Converting the production increase

into higher specific surface at a constant

production rate (Option 1) would reduce

the clinker factor to 0.44 and save three

per cent of total CO2 emissions, which is

distinctly more than with the savings of

electrical energy.

The strength-enhancing property of

the SikaGrind Quality Improver allows the

reduction in the clinker factor to 0.42 and

increasing the slag content accordingly

(Option 2). This reduces the annual CO2

emissions by 6.3 per cent.

Options 1 and 2 can be combined

(Option 3), resulting in a clinker factor

of040whichsaves89percentCOCEMENT ADDITIVES

Figure 2: enhanced strength development with SikaGrind products can be used to minimise CO2

emission of cement

Research in interactions of chemical processing additive and

possible cementitious materials

图表2：使用西卡助磨剂带来的强度增加,可减少水泥中熟料的比例,从而降低CO2排放抗压强度提高

天数

掺量纯助磨剂

掺量早强改进型助磨剂

the carbon footprint is diminished in the

range of 33,000-83,000t CO2 per 1Mt of

blended cement. Another opportunity to

take advantage of the strength increase

would be to partially use less reactive

clinker, eg belite clinker.

Combining the effects of chemical

acceleration and fineness, strength

improvements in the range of 5-8N/

mm² after two days are possible. This

advantage can be used to replace clinker

by 10-16 per cent of the cement and in

that way reduce 80,000-130,000t CO2

per 1Mt of blended cement. Effects of an

optimised particle size distribution could

furtherboostthisbenefitSika offers standard and tailormade

quality improvers which include efficient

grinding aid technologies to minimise the

carbon footprint.

Constant production with

reduced variations

Cement production is a continuous

process subject to natural variations.

Cement manufacturers invest a lot in

homogenising equipment along the

production chain, from raw material

storage to different raw meal and clinker

storages to finished cement silos. On all

levels, constant quality control ensures

thatthevariationsarekeptaslowaspossible. The smaller the variations, the

smaller the necessary safety margins are

and hence the needed clinker content is

lower to ensure the cement properties.

During cement grinding, a more constant

production with reduced variation leads to

highest production rates and best strength

results. Regular control of cement fineness

with help of particle size analysis and the

use of chemical processing agents like

SikaGrind can help to ensure that cement

plants achieve the required quality.

Case study: CO2 reduction

potential

The potential to reduce the carbon

footprint can be demonstrated best in a

case study. The chosen plant produces

770,000tpa of CEM III/A 32.5N with

a clinker factor of 0.46. The target

of the project was the ecological and

economical optimisation of the cement

formulation, bringing the slag content

close to the maximum allowed for a CEM

III/A. Table 1 shows plant results which

compare a pure traditional grinding aid

with two products of the SikaGrind-800

Series, a pure grinding aid and a strength

enhancer with incorporated grinding aid.

Without any changes of formulation, both

SikaGrind products increase production

by 4.6 per cent and consequently reduce

the CO2 emissions which are related to

the specific energy consumption by 4.3

per cent. In this example, the annual CO2

emission derived from electrical energy

used for the cement grinding process

accounts to 8.8 per cent of the total CO2

emission. Therefore, the effect of the

reduced electric energy consumption on

total CO2 emission is only very limited

(0.4 per cent saving).

Converting the production increase

into higher specific surface at a constant

production rate (Option 1) would reduce

the clinker factor to 0.44 and save three

per cent of total CO2 emissions, which is

distinctly more than with the savings of

electrical energy.

The strength-enhancing property of

the SikaGrind Quality Improver allows the

reduction in the clinker factor to 0.42 and

increasing the slag content accordingly

(Option 2). This reduces the annual CO2

emissions by 6.3 per cent.

Options 1 and 2 can be combined

(Option 3), resulting in a clinker factor

of 0.40 which saves 8.9 per cent CO2

emissionsCEMENT ADDITIVES

Figure 2: enhanced strength development with SikaGrind products can be used to minimise CO2

emission of cement

Research in interactions of chemical processing additive and 对化学添加剂和各种胶凝材料之间相互作用的研究 possible cementitious materials

6 “绿色”水泥的概念 1. EDVARDSEN, C and K TOLLOSE, “Environmentally ‘Green’ Concrete Structures.” Proceedings of the FIB Symposium: Concrete and

Environment, Berlin, Oct 2001.

2. Cembureau publication “Climate Change, Cement and the EU,” www.cembureau.be, July 1998

3. SCHRABBACK, J M, “Polycarboxylate polymer-powered grinding efficiency,” Global Cement, July-Aug 2009, pp14-16

4. SCHRABBACK, J M, “Finest strength development”, International Cement Review, Sept 2009, pp75-80

5. TSIVILIS S, TSIMAS, S, BENETATOU, A and HANIOTAKIS, E, “Study on the contribution of the fineness on cement strength,”

Zement-Kalk-Gips, Jan 1990, pp26-29

6. BRUGAN, J M, “High efficiency separators – Problems and solutions,” Zement-Kalk-Gips, July 1988, pp350-355

7. SCHRABBACK, J M‚ “Additives for a challenging cement market,” World Cement, Oct 2009.

表1：SikaGrind® 800系列两种产品以及醇胺类助磨剂产品在工厂的应用比较

CEM III/A 32.5N 醇胺类助磨剂 SikaGrind®-800系列助磨剂 SikaGrind®-800系列强度改进剂

产量（吨/时） 109 114 114

掺量（%） 0.025 0.025 0.025

熟料掺量 0.46 0.46 0.46

布莱恩比表面积

（cm²/g）

目标值 3450 cm²/g 3535 3565 3550

波动 +/-200 +/-200 +/-200

筛余32µm （%） 14.5 13.4 14.1

RRSB图表：均匀性系数n 1.02 1.03 1.02

RRSB图表:特征粒径X（µm） 21.6 20.82 21.1

需水量（%） 28 28.2 27.7

2天抗压强度（N/mm²） 8.0 8.8 10.2

7天抗压强度（N/mm²） 21.9 22.9 25.6

28天抗压强度（N/mm²） 41.1 41.0 48.7

原材料带来的CO2排放（吨/年） 314300 314300 314300

工厂电能消耗带来的CO2排放（吨/年）

a）研磨过程电能消耗 35100 33600 33600

b）其它工序电能消耗 49600

CO2排放（吨/年） 排放量 399000 397500 397500

节省量 1500 1500

表2：水泥配方优化以及西卡助磨剂的添加带来的CO2排放减少

CEM III/A 32.5N

基准

醇胺类

助磨剂

方案1

使用助磨剂提高细

度，降低熟料含量

方案2

使用强度改进剂

降低熟料含量

方案3

使用强度改进剂以及提

高细度来降低熟料含量

方案4

使用选择3强度改进

剂加上更稳定的生产

产量（吨/时） 109 109 114 109 109

掺量（%） 0.025 0.025 0.025 0.025 0.025

熟料掺量 0.46 0.44 0.42 0.40 0.38

布莱恩比表面积

（cm²/g）

目标值

3450 cm²/g 3535 ≈3650 ≈3550 ≈3650 ≈3650

波动 +/-200 +/-200 +/-200 +/-200 +/-100

2天抗压强度 （N/mm²） 8.0 ≈9.0 ≈8.0 ≈8.0 ≈7.0

28天抗压强度 （N/mm²） 41.1 ≈41.0 ≈43.0 ≈43.0 ≈42.0

原材料带来的CO2排放（吨/年） 314300 302500 290600 278700 266900

工厂电能消耗带来的CO2排放（吨/年）

a）研磨过程电能消耗 35100 35100 33600 35100 35100

b）其它工序电能消耗 49600

CO2排放（吨/年） 排放量 399000 387200 373800 363400 351600

节省量 11800 25200 35600 47400

参考书目

“绿色”水泥的概念 7

Creative Grinding Solutions

by Philippe Jost and Jorg M. Schrabback

Sika Services AG, Tüffenwies 16, CH-8048 Zürich, Switzerland

Phone +41 44 436 4040, Fax +41 44 436 4150, www.sika.com

Reprint of September 2007:

performance of polycarboxylate polymer-powered

grinding aids. In this case, the innovative technology

cant production

e traditional amine-based

product reached its limit with an 8% production increase at a dosage of 0.03% (Figure 5). Moreover, these

exible the production process

can become if the mill output can be economically correlated to the grinding aid dosage.

Case study of PCE powered glycol-based

grinding aid technology

e third plant trial example demonstrates that an

ciency is also possible in the tra-

gure

c case, 0.025% of a traditional glycolbased grinding aid achieved a production increase of

9%, while the same dosage of the PCE/glycol formulation easily achieved a production increase of 16%.

Polycarboxylate polymers improve the performance

of the traditional grinding aid technologies of amino

alcohols and glycols and allow for a further increase

neness

and more favourable PSD at constant production rate.

e resulting enhanced quality allows plants to reduce

their clinker content and hence to decrease their carbon

footprints while increasing the cement manufacturer’s

tability.

Conclusions

ect on the grinding and

neness of

cement to be achieved in the most economic way. Polycarboxylate polymers improve the performance of the

traditional grinding aid technologies of amino alcohols

and glycols and allow a further increase of the production rate.

c energy consumption. It

can also be used to achieve strength enhancements with

neness and optimised particle size

e potential clinker reduction minimises the carbon footprint.

Sika’s polycarboxylate polymer-powered grinding

ers

solutions for individual challenges and also maximises

tability.

globalcement MAGAZINE July - August 2009

Figure 4 (right):PCE

powered GA increases the

p .

Figure 5 (right):PCE

powered GA allows

production

planning.

Figure 6: PCE powered GA

increase the production

s y.

Reprint of

Polycarboxylate polymer-powered

grinding efficiency

by Jorg M. Schrabback

July-August 2009:

Sika Services AG, Tüffenwies 16, CH-8048 Zürich, Switzerland

Phone +58 44 436 4040, Fax +58 44 436 4150, www.sika.com

Introduction

In today’s market of increasing competition and decreasing

volumes, cement manufacturers as well as cement users

are aiming for cost reduction with the aim to increase

profitability and stabilise or extend their own position in the

global market. Additives that offer additional benefits during

cement production and cement application in concrete can

help to differentiate oneself from the competition.

While the major quality parameters are regulated in the

different standards, additional unregulated properties can

become the decisive factor when choosing a particular cement.

Cement quality

Cement producers need to supply the cement quality

as it is defined by the standards, such as the European

standard EN 197-1, while also meeting customers

demands. Strength development is the most important

property since it is the reason why cement is used in the

construction industry.

Concrete producers look for a cement that supports

their daily work as much as possible. Key words from

this perspective are homogeneity and good concrete

workability, but also easy handling of the cement itself.

JORG M. SCHRABBACK, CORPORATE PRODUCT

ENGINEER CEMENT ADDITIVES, SIKA SERVICES AG,

SWITZERLAND/GERMANY, DESCRIBES HOW MODERN

CEMENT ADDITIVES CAN CONTRIBUTE TO AN

IMPROVED PROFITABILITY IN CEMENT BUSINESS.

Additives for

a Challenging

Cement Market

Reprinted from October 2009

[Reprinted from Oct 09] worldcement.com

Reprint of

Additives for a Challenging

Cement Market

by Jorg M. Schrabback

October 2009

since

1910

Innovation &

Consistency

SikaGrind®

西卡水泥助磨剂技术

其他文章

西卡，可靠的本地化合作伙伴

© Sika (China) Ltd. / Concrete / 05.2016

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域的领先企业。西卡的核心竞争力、主要产品和目标市场集中于：混

凝土生产，密封，粘接，防水，屋面，工业地坪，结构修补和加固，工业

化学品。

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造、汽车维修、交通运输行业提供粘接、密封、减震降噪和结构加固的

快速解决方案，为船舶制造提供可靠和持久的防水密封解决方案，为

玻璃幕墙、门窗制造、三明治板、太阳能及风力发电设备以及其它电

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