https://www.zkg.de/en/artikel/zkg_Latest_trends_in_clay_activation-3683572.

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https://fctcombustion.com/clay-calcining-technologies

Table 1
OPC (95% clinker / 5%
gypsum) 
LC3 (50% clinker/  
15% limestone /  
OPC (95% clinker / 5% 30% activated clay / 5%
  gypsum)  gypsum)  Impact
Fuel consumption kcal/ kg 30% decrease in
684 525*
cement  fuel
Power consumption 40% decrease in
85 51.1
kWh/t cement  power
CO₂ kg/kg cement
Raw materials 0.53 0.27 50%
Fuel** 0.26 0.21 20%
Power 0.06 0.04 30%
Total CO₂ emission 40% decrease in
0.85 0.51
kg/kg  CO₂
* Based on calcined clay fuel consumption of 496 kcal/kg
** excludes "neutral" CO2 fuels
 

You’ll note that Table 1 also references the fact that by halving clinker content, you could double
cement production. This would certainly be a driver for cement manufacturers seeking to
increase productivity. However, even where extra capacity is not required, the benefits are
incredibly valuable. A more efficient, more environmentally friendly process – working smarter,
not harder.  
Reasons to use calcined clay to reduce your clinker factor 

 Up to 40% CO₂ emissions reduction per tonne of cement

 30% reduction in power consumption per tonne of cement
 40% reduction in fuel consumption per tonne of cement
 Increase productivity without increasing emissions
  Worldwide availability
 Maintain cement quality with much-reduced environmental
impact
 Technology is proven and available now, with high ROI and
low OPEX 

Managing the risks of a new investment

With any new technology, there will always be some hesitation. Being an early adopter carries
risks as well as benefits. But having dedicated ourselves to Mission Zero – equipping the cement
industry with the means to achieve net zero emissions by 2030 – we want to give cement
manufacturers the confidence that they are investing in solutions that will work for them. That’s
why we set up a pilot plant in our test facility in Denmark, specifically dedicated to calcined
clay.
 
Here, we can carry out full chemistry and mineralogical testing of your clay source, as well as a
clay reactivity analysis. We can also put your clay through our pilot test system, including
crushing/drying, calcining, colour control, strength testing, etc. to show that the clay will meet
the strength and colour requirements of a blended cement for ultimate peace of mind before
making an investment.
 
This facility was instrumental in the decision by French cement manufacturer Ciment Vicat to
invest in a 525 tpd clay calcination plant, which will be built in France. Citing increasing demand
for sustainable cements as one of their main drivers, Ciment Vicat approached us with the project
knowing we had the ability to confirm the suitability of their locally available clay source. We
tested 5 tonnes of clay and were able to give them the reassurance they needed to proceed with
the investment. 
“We are excited and proud to be setting a new standard for green cement in Europe”

RENAUD CLAIE, PROJECT DIRECTORVicat Group

“With the results from the pilot studies at FLSmidth’s test facilities, we are confident that this
technology will provide a truly environmentally-friendly alternative, enabling us to reduce CO₂
emissions by 16 per cent compared to our existing cement products as soon as the site is
commissioned in 2023, and perhaps even more than that in the future,” says Renaud Claie,
project director at Vicat Group. Leadership like this is so important to moving the industry
forward. Where one global leader moves, others will follow. We congratulate Ciment Vicat on
their initiative and commitment to their sustainability goals. 
The Ciment Vicat project 

Ciment Vicat has ordered Europe’s first full-scale clay calcination plant. It will have a design
capacity of up to 525 tpd and be located at their site in Xeuilley. The scope of the contract with
FLSmidth includes a clay feeder, dryer crusher, calcination tower and gas emissions abatement
equipment. In addition, the project also includes the facilities needed for alternative fuels
handling. Altogether, the company expects both a financial and environmental return-on-
investment from lower CO₂ emissions, fuel savings and reduced clinker ratio. 
One decade to make a difference
Calcined clay is a stable, widely available resource that slots in easily to the existing cement
manufacturing process. It requires new but familiar technologies. It produces a different but
equally high-quality cement product, at a lower cost, using less energy and less fuel. It has the
potential to dramatically reduce the cement industry’s environmental impact.
 
What are we waiting for? FLSmidth is ready to assist with your clay calcination plans and to
help answer any questions or concerns you might have. This is our decade to make a difference.
We can reduce the pressure on our industry and on our planet by moving the cement industry
over to a more environmentally friendly cement product as standard.