Use more clay, less clinker

Reduce the clinker factor down to 50 percent, save money, emit less CO2.

Using activated clay instead of clinker has a triple effect on the cost and sustainability of your cement production. First, less clinker means you emit less CO2. Second, clay reduces energy requirements by up to 40 percent – because activation is achieved at below 900 degrees instead of 1,450 degrees Celsius. This significantly reduces energy costs, especially when using regenerative energy and fuel sources. Third, the substitute makes the cement more carbon neutral and improves its quality. All of which makes activated clay worthy of your attention. Explore further benefits.

polysius
activated
clay

Benefits

01 Reduce the clinker factor
02 Emit 70% less CO2 per ton with clay in comparison to clinker
03 Substitute increasingly scarce or expensive SCMs like slag, by a low-cost environmentally-friendly product
04 Become more self-sufficient on raw materials
05 Increase product quality and output
06 Be ready for future low-carbon cement types
07 Increase production efficiency and cut fuel expenses
08 Spend less on CO2 emission certificates
Components of CO2 emissions with an activated clay plant
Cost breakdown: production cost per ton of cement
Formulation of cement: mortar test of sample according to ISO norm
Flash Dryer, Calciner & Cooler: Both options have their pros & cons – the decision depends on the individual weighing of the relevant criteria.
General flow sheet of a flash process AC and cement grinding plant: Example for processing of a typical sedimentary kaolinitic clay

Lead the industry in sustainability

Where limestone is scarce, clinker limestone and clinker imports are expensive. By relying on clay, you can increase your margins and your independence from supply markets
For example, Bangladesh, parts of India and West Africa benefit from local, low-cost clay materials
Activated clay reduces transport cost for clinker imports, and enables local value creation
Make your contribution to sustainability and deliver an even better product at the same time
The refinement of residual materials opens up new business opportunities and income streams
Even with some difficult raw material components (e.g. iron oxide), we can deliver a gray product, if desired
We at thyssenkrupp have done R&D trials in our flash process plant on over 50 different clays
Together with our clients, we optimize the final product towards the best solution in quality, sustainability, and cost.
All types of fuel, from conventional to coarse, low-quality alternative fuels are possible to use.
Bet on a partner who supports everything from initial geological and raw material analysis, to plant operation

Contact

Dr. Gunnar Markert
thyssenkrupp Industrial Solutions AG
Senior Manager
Business Development & Sales

+49 2525 99 3369
Send email
Connect on LinkedIn

References

Navoi Mining and Metallurgical Combinat (Phosphate rock POLCAL calcination) Kaniambo Nickel S.A.S, New Caledonia (Nickel ore drying and calcination)
Explore further
solutions: