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Energy ProcediaProcedia 12000000 919 Energy 00 (2011) (2011) 915

Energy Procedia
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ICSGCE 2011: 2730 September 2011, Chengdu, China

Use of Wastes in Construction Industries as an Energy Saving Approach

Md. R. Karima*, Muhammad F. M. Zaina, M. Jamila, Fook C. Laib, Md. N. Islamc
Faculty of Engineering and Built Environment, Universiti Kebangsaan Malaysia. b Regional Technology Support Centre, Sika Kimia Sdn Bhd, Malaysia c Department of Civil Engineering, Dhaka University of Engineering and Technology, Gazipur, Bangladesh
a

Abstract In the modern society, demands and consumption of energy in different modes (electrical, thermal, fuel, etc.) are rising gradually for growing population, technological advancement, industrialization, transportation, construction and so on. Besides, natural resources are reducing and cost of energies is increasing day by day. Consequently, our awareness is concentrated to the sustainable development by: saving energy, using renewable energy, using alternative sources of fossil fuels, utilizing more waste materials etc. In this paper, a critical review and energy saving strategy by consumption of waste materials (slag, fly ash, rice husk ash, palm oil fuel ash, ash from timber) as a supplement of cement and/or ingredient of concrete have been presented. The technical and financial benefits of supplementary use of waste materials in cement and concrete have also been cited here. Based on the published documents, it can be concluded that effective utilization of these wastes as a supplement of cement or constituent of concrete will be a constructive and valuable way of saving energy as well as sustainable construction.

2011 Published by Elsevier Ltd. Selection and/or peer-review under responsibility of University of Electronic 2011 Published by Elsevier Ltd. Selection Science and Technology of China (UESTC). and/or peer-review under responsibility of ICSGCE 2011
Keywords: Cement; concrete; waste materials; energy saving

1. Introduction Nowadays, for the survival of human being, all the basic needs including accommodation, transportation, education, health/medical, communications, etc. are mostly depended/related on the energy and electricity. In this civilized world, due to growing inhabitants and living requirements the demands of every substances (consuming and using) are continuously rising and natural resources are reducing gradually. Construction of buildings and infrastructures are one of the most important elements for the modern development in the planet, and for this, concrete is used worldwide and consumption of
* Corresponding author. Tel.: +603-89216451. E-mail address: reza_civil128@yahoo.com.

1876-6102 2011 Published by Elsevier Ltd. Selection and/or peer-review under responsibility of University of Electronic Science and Technology of China (UESTC). doi:10.1016/j.egypro.2011.10.120

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cement and concrete are increasing day by day. It is reported that over 25 billion tons of concrete are produced annually worldwide; as a result, global cement consumption is 2.9 billion tons per year and is expected to rise to 4 billion tons by year 2020 [1]. On the other hand, huge waste materials are produced worldwide as industrial by products (slag, fly ash); for example, 450 million ton of fly ash are produced per year, but just a few quantities (35 million ton, less than 8%) are used [2]. Only a small fraction of the 100 million tons slag produced worldwide is used [3]. The similar fashion is happened in the agricultural wastes - palm oil fuel ash (POFA), rice husk ash (RHA), sawdust ash/ash from timber (AFT). A small amount of these are used but most of them are simply disposed as garbage. All of these waste materials contain a high amount of silicon dioxide in amorphous form and accordingly, several researchers suggested using these as pozzolanic materials in concrete production. Consequently, today, utilization of waste materials as a potential alternative in the construction industry is a great research interest and it could play an important role for minimizing/solving the above mentioned problems. As an energy saving policy, we can therefore reduce/solve the challenge following a simple formula: use as much concrete as needed, but with as little Portland cement as possible. This means to replace as much Portland cement as possible by supplementary cementitious materials, especially those are industrial by-products, and agricultural wastes (POFA, RHA, AFT). This study summarizes the role of waste materials in construction industries and also presents a possible way to save energy using industrial by-products and agricultural wastes as a part of the energy challenge for the twenty first century in the globe. 2. Cement, Concrete and Energy Cement and concrete industry is one of largest consumer of natural resources -aggregates, sand, clinker and fuel [2]. For these reasons price of these raw materials are increasing everyday. It is relevant to mention that cement is the most energy intensive substance after aluminium and steel [3]. Total energy requirement in cement manufacturing depends on the production process (either wet or dry). About 850 to 900 kcal/kg heat energy is required with new dry precalciner kiln systems which is approximately 56 to 66% of the energy requirement of old wet process kilns (1300-1600 kcal/kg) [4]. The electricity use in cement production varies between 90 and 150 kWh per ton [5]. The global average electricity consumption was 111 kWh per ton of cement according to the GNR database [6], in the year 2006. Energy consumption varies significantly between countries and regions [6], [7]. According to the International Energy Agency report, 2007, electricity consumption ranges from 90 to 120 kWh/t of cement while different statistics are observed in the United States, Mexico and Canada where typical figures are all above 120 kWh/t of cement [7]. Apart from the CO2 capture and storage technology, it is not expected advanced technologies to cause a significant change of electricity and thermal energy consumption in cement production. However, electricity demand could be declined from the current average value of 110 kWh/t of cement (2006) to some 105 kWh/t cement in 2030. Thermal energy demand could also be decreased from the current 3.38 GJ/t (2006) to 3.3 GJ/t clinker in 2030 [8]. It can be noted that cement and concrete production not only put negative impact on environment in terms of carbon dioxide emissions but also responsible for the depletion of the worlds most valuable fossil energy resources; hence that has necessitated the exploitation of sustainable construction materials [9]. It is well known that, for solving the energy demand of the planet, sustainable development is a vital issue in every sector including construction industry all over the world and its development could meet the following important goals: reduction of the amount of polluting and CO2 gases emitted during the manufacture of concrete; more efficient use of waste materials; development of low-energy, long-lasting, flexible buildings and structures; exploiting the thermal mass of concrete in a structure to reduce energy demand. To fulfill these objectives, replacement materials can be added separately to the concrete or used to replace the clinker in composite cements. The latter case is more commonly used in Europe, while

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replacement materials are more commonly added to the concrete in US. The incorporation of waste material in cement production could be a valuable step in terms of energy saving that is revealed from the following examples: Waste materials from other industries are increasingly being used to replace the traditional raw materials used in the production of Portland cement clinker. These include foundry sands, fly ash and bottom ash from coal fired power plants, spent catalysts and filter clays, mill scales, etc. Blast furnace slag (BFS) contains high amount of calcium oxide, hence, the maximum level of limestone replacement by BFS is between 20 and 30%. In practice, about 10% replacements are more commonly reported in different literatures. The energy requirement for the cement manufacturing is reported by Ehrenberg and Geiseler [10] that is shown in Table 1. It is seen from this table, 5.72 GJ/ton energy is required for CEM I (without slag), whereas 4.34 GJ/ton, 3.38 GJ/ton and 2.17 GJ/ton energies are required for the addition of 30%, 50% and 75% slag respectively. Therefore, by 50% slag replacement, energy requirement is reduced to 59.1% as compared to CEM I (100%), so, 40.9% energy can be saved using 50% slag. For the 75% slag replacement, only 37.9% energy is required as compared to CEM I (that means 62.1% energy could be saved). Thus, it is expected to use RHA, POFA, AFT directly in manufacturing of cement because these wastes also contain high percentage of silica similar to slag.
Table 1. Energy consumption in cement production [10]. Sl No. 1 2 3 4 Type of cement CEM I (without slag) CEM II/B-S with 30% slag CEM III/A with 50% slag CEM III/B with 75% slag Total Energy requirements GJ/ton (kWh/ton) (%) 5.72 (1587) 100.0 4.34 (1206) 76.0 3.38 (938) 59.1 2.17 (602) 37.9

3. Technical and Financial Benefits of Wastes Waste materials could be used successfully in construction industries and it would meet the design specifications and requirements provided that materials are processed properly that is suggested by several researchers. These by products (slag, fly ash) and agricultural wastes (RHA, POFA, AFT) act as pozzolans and could be used as supplement of cement in concrete production as documented in different literatures. Slag is usually used in concrete because it has following advantages: improves durability and reduces porosity; improves the interface with the aggregate; shows lower cement requirement; saves energy; and shows good performance as well as better engineering properties [11]. Strength of concrete increases with addition of fly ash [12], [13]. The POFA, RHA could be used as supplement of cement in concrete production that are argued by many researchers. The presence of RHA in concrete, improves compressive strength [14] and resistance against sulfate attack [15]. In some cases, contributions of waste materials in concrete production not only save cement but also make better performance in the concrete properties such as strength, durability. For example, POFA can be used in concrete production as a cement replacement material to make good resistance against sulfate attack [16], [17]. Thus, more utilization of waste in cement or concrete has the following multiple advantages: less use of cement and hence saving fuel, clinker as well as reduction of CO2 emission; waste disposal problem could be solved; production cost of cement and concrete will be reduced; hence financial benefits will also be achieved. Furthermore, it can easily be understood from above discussion that incorporation of wastes (fly ash, POFA, slag, RHA, AFT) in cement or concrete will be a great achievement in terms of energy saving, sustainable construction and CO2 reduction without sacrificing the strength of concrete. 4. Possible Way of Energy Saving Utilization of waste materials is one of the best ways to achieve the goal of sustainable construction, the lower energy consumption and less CO2 emission. This policy has already been observed in a study of

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Ehrenberg and Geiseler [10] for slag replacement in cement production and found lower energy requirement that is shown in Table 1. They concluded that energy consumption could be reduced by accumulation of wastes (slag) in cement manufacturing. Their findings are valuable and forthcoming step for saving energy as well as production of sustainable construction. Accordingly, the authors would like to propose a possible direction to save energy using various wastes (slag, fly ash, POFA, RHA, AFT) in cement and concrete production that is summarized in Fig. 1. As shown in the figure, energy saving and sustainable construction could be possible because of the following reasons: Effective utilization of waste in cement and concrete production Less use of cement, thus lower energy consumption Declination of CO2 emission due to less cement consumption Solution of waste disposal problem Searching a way of sustainable development
Collection of different wastes (Slag*, Fly ash*, Palm oil fiber, shell, etc., Rice husk, and Timber Processing and removal of contaminant, if any Burning by kiln or furnace in cement industry Burning in boiler/ furnace to produce ash Grinding of ash with measuring energy

Use as supplement of clinker

Measurement of required energy/fuel for blended cement/OPC production Properties of blended cement and OPC

Utilization of ash and OPC in concrete

Properties of concretes (blended cement/OPC)

Recommendation regarding energy consumption, saving and production cost

Fig. 1. Utilization of wastes in cement and concrete as an energy saving approach. *Burning is not required, could be put
into clinker or mixed in grinding.

It is well known that, for burning clinker, required temperature is about 14000C but the POFA, RHA, AFT are produced at a temperature about 6000C-7000C. Thus, from the preliminary investigation, one can therefore easily estimate that fuel energy could be saved for more utilization of wastes provided that properties of final product are kept unchanged. The amount of saving energy could be obtained after performing experiments. In addition, findings of Ehrenberg and Geiseler [10] also support this offer regarding energy saving as well as sustainable construction. 5. Conclusion It is already observed that about 25% to 60% energy could be saved with incorporation of slag in cement manufacturing without sacrificing the properties of cement. Thus, involving large amount of

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agricultural wastes (RHA, POFA, AFT) and industrial by-products (slag, fly ash) in cement and concrete production will be promising consideration in construction industry for saving fuel energy and sustainable construction. This waste consumption method could save energy; put contribution in sustainable development and reduction of CO2 emission. Moreover, for saving energy, utilization of these wastes in cement and concrete manufacturing is logical, practical, valuable and applicable topic for comfortable and continued existence of present and future population in the planet. Acknowledgements Finance of this research is supported by Ministry of Science, Technology and Innovation; Fundamental Research Grant Scheme (FRGS); and Department of Civil and Structural Engineering, Universiti Kebangsaan Malaysia (UKM). References
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ETSAP - Technology brief I03 June 2010 - www.etsap.org manufacturing industries, May 2010,[online] available: ftp://ftp.jrc.es/pub/eipccb/doc/clm_brief_0510.pdf. (CSI)/European cement research academy (ECRA), 2009. the next industrial revolution, IEA, 2009.