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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

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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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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Cement production


Current

Investigation and optimisation of the dynamic operating characteristics of the oxyfuel-operated cement clinker burning process for CO₂ capture

The oxyfuel technology is to be investigated qualitatively using a dynamic process simulation. This will provide a basis for the control and optimization of oxyfuel systems, resulting in a faster rollout of this crucial technology for CO₂ reduction.

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Current

Process engineering investigation of the energetic-material utilisation of wastes containing carbon fibres in cement plants - EVCAZ

In the AiF project EVCAZ, the energetic and material utilisation of wastes containing carbon fibres is to be demonstrated on an industrial scale in a cement plant. The central tasks are the evaluation of the conversion success of the CF fibres, the recording of the resulting emissions and the consideration of influences on the process and the clinker quality. The findings obtained are summarised to assess health and environmental risks and to answer questions relevant to approval as a decision-making aid for cement plant operators.

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Current

Automised Classification and Assessment of Alternative Fuels

The aim of the project is to investigate Machine Learning models for the characterisation of alternative fuels in the cement production. For this purpose, a public-accessible database (with fuel characteristics and images) is set-up and different machine learning models will be trained on that data, the algorithms will be tested on their robustness and suggestions for the classification of the fuel quality and its visualisation in the control room will be made.

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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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Current

Development of a method to improve clinker cooling and to increase energy efficiency in cement rotary kilns by using infrared cameras

In the research project, infrared cameras are used to record the surface temperature of the clinker bed in the clinker cooler. Together with calculated enthalpy flows, this allows control room personnel to identify the operating condition of the cooler. This is used in operational tests to optimise the heat transfer in the clinker cooler by controlling the drive system and adjusting the cooling air distribution.

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Current

Optimisation of clinker-efficient cements by means of multimodal particle size distributions using energy-efficient products from separate ultra-fine grinding

Separate ultra-fine grinding of cement - Energy-efficient grinding meets optimised cement and concrete properties. Today, future-oriented cements can already be produced more sustainably and efficiently by using various components of different finenesses.

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Concrete technology


Completed

New functionalities of textile-reinforced concrete through titanium dioxide modifications Subsidiary project: fine-grained concrete and cement-bound adhesive

The working plan of the Research Institute of the Cement Industry was aimed at systematic investigation of the mix formulation and workability of a nano-based cement-bound adhesive.

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Completed

ASR performance testing: extending the database to include the 60 °C concrete test with particular reference to cements with several main constituents

In the IGF (Cooperative Industrial Research) project the framework conditions for a possible performance test method for evaluating the alkali reactivity of concrete was calibrated on the basis of the requirements of the German regulations.

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Completed

Reducing the environmental impact of concrete construction through new types of cement and the concrete produced from them using starting materials that are available in adequate quantities

The aim of this research project was the laboratory and industrial production and testing of cements that contain levels of limestone above the maximum content described in DIN EN 197-1.

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Completed

Procedures for E II aggregates

VDZ and the Brandenburg Technical University Cottbus-Senftenberg (BTU) investigated whether it is possible to define an alkali sensitivity class E II-S on the basis of the 40 °C concrete test with cloud chamber storage. In addition, criteria for the rapid test procedure and the 60 °C concrete test as well as the BTU-SP rapid test were also derived.

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Completed

Determination of characteristic values based on the degree of hydration for predicting the durability of concrete

Mortar and concrete trials were used to determine characteristic parameters, such as the void filling of the cements, their hydration characteristics, the porosity of the mortars and concretes made with these cements, and the durability of the concretes.

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Completed

Boundary conditions for accurately achieving projected concrete properties in the modern 5-material system of diverse concrete constituents

Within the framework of the research project, the intention was to identify the most important influence parameters that are responsible for showing unscheduled properties such as changed consistency, signs of sedimentation, or an accelerated or decelerated strength development in certain cases of fresh concretes which are produced over prolonged periods.

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Chemistry and mineralogy


Completed

Analysis concept for the determination of trace elements in the eluate of cement-bound building materials (IGF No. 16989 N)

The aim of the AiF research project was to identify the causes of the sometimes greater scatter rates in the analysis results in the case of comparison trials for the long-term tank test.

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Completed

Interactions between siliceous fly ash or calcined clay as cement main constituent and superplasticizers based on polycarboxylate ether as well as their influences on rheological properties of fresh cement paste and fresh concrete

It was determined how the rheological properties and the consistency of fresh concrete can be improved by the adjustment of the type and proportion of fly ash or calcined clay in the cement to the clinker as well as the type and dosage of the superplasticizer.

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Completed

Suitability of various inorganic substances for use as a minor constituents in cements according to EN 197-1

The main scope of this research project was to supply evidence that selected inorganic substances are suitable for the use as minor constituents.

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Completed

Interactions between superplasticizers and cements with calcined clay in dependence of the temperature

The aim of the research project was to determine interactions between superplasticizers and cements with calcined clay.

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Completed

Development of an analysis concept for the quantification of cement, its main constituents as well as additives in hardened concrete

As part of the project, methods were developed that allow the cement content, cement type and additive content in hardened concrete to be reliably determined.

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Completed

Interactions between cements with several main constituents and methyl cellulose and their performance in dry mortar

Interactions between different structured or modified methyl hydroxyethyl celluloses and cements blended with limestone, blastfurnace slag or fly ash were determined.

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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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