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Limestone Calcined Clay Cement

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 Outline
• Concrete products with LC3
• Economics of LC3 production

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 Concrete products with LC3
• Building materials
• Small scale production
• Industrial scale production
• Pre-fabricated elements
• Industrial scale
• Construction
• Houses
• Roads
• Pavements

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 Building materials with LC3 – small scale production

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 Building materials with LC3 – small scale production

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 Building materials with LC3 – properties

Development of strength in Paving block from various

cement types
350
Compressive strength (kg/cm2)

300

250

200

150

100

50

0
7 Days 14 Days 28 Days
Curing days

OPC(LC3) OPC LC3 PPC

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Building materials with LC3 – industrial scale production

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Building materials with LC3 – industrial scale production

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 Pre-fabricated elements - industrial scale

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 Pre-fabricated elements – deemed application

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 Pre-fabricated elements – trial lab results
(M-50 Grade: Pre-Stressed Hollow Core slabs)

Raw materials Base composition Katni + Birla OPC JKL + Birla OPC JKL + Wonder OPC
OPC 400
LC3 450 450 450
Aggregate (10mm) 1076 1067 1067 1085
Stone dust 780 685 685 695
Water 150 160 160 150
Water: cement 0.375 0.36 0.36 0.33
Compressive strength results
(Target 22MPa in 22 hours, 50 MPa in 28 days, 0 slump)
22 hrs 22.0 14.0 19.0 22.5
3 days 31.5 - - -
7 days 46.0 32.0 39.0 44.6
28 days 55.2 51.0 52.6 57.3
 Construction - Houses

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 Construction - Houses

• Use of industrial wastes in the building construction - 17.27 kg/sq.ft.

• Saving of CO2 from the use of LC3 - 5.15 kg/sq.ft.

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 Construction - Roads
Stretch 1: RCC pavement Stretch 2: Steel fibre reinforced Stretch 3: Polymeric fibre
concrete pavement reinforced concrete pavement

Grade of M35 Grade of M35 Grade of M35

Concrete concrete concrete
Thickness of 200 mm Thickness of 200 mm Thickness of 200 mm
slab slab slab
Cover depth 40 mm Fibre type and 25 kg/m3 of Fibre type and Hybrid mix of
dosage steel hooked dosage 3 kg/m3 of
ended glued Durus S 400 &
fibres (DRAMIX 0.91 kg/m3 of
RC 80/60) Fibrin XT fibres
(BONAR fibres)
Steel mesh 10 mm f @150 Expected Expected
reinforcement mm c/c at the material material
bottom of the properties properties
slab • Flexural 3.8 MPa • Flexural 4.2 MPa
strength strength
• Equivalent 2.5 MPa • Equivalent 1.0 MPa
flexural flexural
strength strength

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 Construction - Roads

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 Construction - Roads

Type of Grade Compressive Strength (MPa) Compressive Strength (MPa) Flexural

Concrete Strength
(MPa)
7 Days 28 Days 28 days
Strength Std Avg Strength Std Avg Avg. Strength
Deviation Strength Deviation Strength

PP fiber 30.9 37.7

based
concrete M35 30.3 1.36 31.4 38.8 2.01 39.36 Sample not
32.9 41.6 casted
Reinforced 30.7 38.2
cement M35 27.9 1.93 30.1 41.7 2.17 39.20 5.31
concrete
31.6 37.7
Steel fiber 29.8 39.1
reinforced M35 31.9 1.50 31.5 42.5 2.19 41.60 7.57
concrete
32.7 43.2

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 Economics of LC3 production

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 Process Map for a Typical Cement Plant in India – Ordinary Portland Cement

Major raw materials: Limestone, Clay (Additive), Gypsum

Other significant inputs: Electricity (from the grid), Pet coke

Important sub-processes: Limestone extraction, Raw meal preparation, Clinkerization,

Blending, Packing and dispatch, Power generation

Products: Cement
 Process Map for a Typical Cement Plant in India – Fly Ash Based Portland
Pozzolana Cement (PPC)

Major raw materials: Limestone, Clay (Additive), Gypsum, Fly ash

Other significant inputs: Electricity (from the grid), Pet coke

Important sub-processes: Limestone extraction, Raw meal preparation, Clinkerization,

Fly ash transport, Blending, Packing and dispatch, Power generation

Products: Cement
Potential Process Map for LC3 Production in a Typical Indian Cement Plant

Major raw materials: Limestone, Clay (Additive), Gypsum, Kaolinitic clay

Other significant inputs: Electricity (from the grid), Pet coke

Important sub-processes: Limestone extraction, Raw meal preparation, Clinkerization,

Clay calcination, Blending, Packing and despatch, Power generation

Products: Cement
Methodology of Economic Analysis

Comparative
analysis using
different scenarios

Cement
Cost estimation
production cost Cement plant
using data from
estimation tool visits
cement plants
(Excel) developed

Cement production
cost estimation tool
(based on Raw
• Secondary sources • Data collection • Cost of cement material cost and fuels)
(in consultation • Excel tool based on Raw
with Dr. A K modification material costs and
Chatterjee) Fuel costs
Inputs

Raw Fuels Electricity

Materials
Limestone Pet Coke Electricity from Grid

Fire Clay

Gypsum • There is onsite

generation of electricity
but for our calculation
Fly Ash we have assumed
electricity from grid
Raw China Clay

Calcined Clay

Clinker
 Scenarios
Thermal Grinding
150 100 50 Power 50 100 150 200 350 400
Plant Unit
200

400
300 400

300
400

200
Cement Plant China Clay
(Raw materials 400 300 200 150 100 50 mines 50 100 150 300
from own mine) (Raw Clay)

400

300
200

200
China Clay
150 100 50 mines 50 100 150
(Calcined Clay)

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Cost of Materials

S.No Material Cost (Rs/Tonne)

1 Gypsum 1,083
2 Limestone 351
3 Clay (Additive) 486
4 Petcoke 6,977
Calcined Clay
5 1,000
(Calcined at site)
6 Clinker 2,135
Calcined Clay
7 3,000
(Calcined at source)
8 Fly Ash 200
Case 1
Comparison between OPC, PPC, and LC3 costs when Fly-Ash and China clay are transported over
varying distances and clay is Calcined on site
2,500
Cost of production (Rs./Tonne)

2,000

1,500

OPC
1,000
PPC
LC3
500

0
0 50 100 150 200 300 400 500 600
OPC 1,932
PPC 1,540 1,548 1,557 1,565 1,582 1,598 1,615 1,632
LC3 1,568 1,577 1,585 1,593 1,610 1,627 1,643 1,660
Distance (Kms)
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Case 2
Comparison between OPC, PPC, and LC3 costs when Fly-Ash and Calcined clay are transported
to site

2,500
Cost of Production (Rs./Tonne)

2,000

1,500

1,000 OPC
PPC
500 LC3

0
0 50 100 150 200 300 400 500 600
OPC 1,932
PPC 1,540 1,548 1,557 1,565 1,582 1,598 1,615 1,632
LC3 2,168 2,177 2,185 2,193 2,210 2,227 2,243 2,260
Distance (Kms)

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 Case 3
Comparison between PPC, and LC3 when Fly-Ash and Raw China Clay are transported to a
grinding unit and China clay is Calcined on site
2,500
Cost of cement production (Rs./Tonne)

2,000

1,500

1,000 OPC
PPC

500 LC3

0
0 50 100 150 200 300 400 500 600
OPC 2,081
PPC 1,648 1,657 1,665 1,673 1,690 1,706 1,723 1,740
LC3 1,652 1,660 1,668 1,677 1,693 1,710 1,726 1,743
Distance (Kms)

Assumptions
27 Clinker is transported 300 Kms to grinding unit
 Case 4
Comparison between PPC, and LC3 when Fly-Ash and Calcined Clay are transported to a
grinding unit

2,500
Cost of Production (Rs./Tonne)

2,000

1,500

1,000 OPC
PPC
500
LC3
0
0 50 100 150 200 300 400 500 600
OPC 2,081
PPC 1,648 1,657 1,665 1,673 1,690 1,706 1,723 1,740
LC3 2,252 2,260 2,268 2,277 2,293 2,310 2,326 2,343
Distance(Kms)

Assumptions
28 Clinker is transported 300 Kms to grinding unit