AUMUND launch new calcination conveyor

The cement industry faces unprecedented pressure to decarbonise, accounting for approximately 8% of global CO₂ emissions. LC3 (limestone calcined clay cement) presents a transformative opportunity to reduce emissions and unlock economic benefits within existing industry infrastructure. LC3 is a blend of clinker, calcined clay, limestone, and gypsum, which reduces carbon emissions in the cement production process by up to 40% compared to ordinary portland cement.

LC3 technology represents a paradigm shift in cement composition, utilizing approximately 50% clinker (compared to 95% in ordinary Portland cement), 30% calcined clay, 15% limestone, and 5% gypsum. The synergy between calcined clay and limestone creates complex pozzolanic reactions, with calcined clay providing additional alumina that reacts with limestone to form carboaluminate phases, contributing significantly to strength and durability while maintaining comparable or superior performance characteristics to conventional cement.

Building on more than two decades of expertise in conveying hot materials – including proven solutions like the KZB-S (up to 1000°C), BZB-H-I (up to 850°C), and FPB-K (up to 850°C) – AUMUND has developed the eLCC specifically for efficient clay calcination. The development project, initiated nearly four years ago in collaboration with HOLCIM, culminated in the construction of a pilot demonstration unit at AUMUND's headquarters in Rheinberg, Germany, where initial calcination tests produced encouraging results.

The technology addresses the critical challenge of clay calcination, which requires precise temperature control at 750 – 800°C – significantly lower than traditional clinker production temperatures. This temperature reduction, combined with the eLCC's energy-efficient design, contributes substantially to the overall carbon footprint reduction achieved by LC3 cement.

Advanced technical features:

The eLCC incorporates the following advanced design elements and features:

• Triple heat barrier system: advanced engineering limits chain and roller temperatures while maintaining optimal calcination conditions.
• Heat deflector technology: strategically positioned plates at discharge and return points minimise heat losses and create distinct calcination zones.
• Inert gas purging capability: controls colour variations from iron oxidation, ensuring consistent product quality.
• Complete enclosure and insulation: maximises thermal efficiency and minimises environmental heat loss.

Superior energy efficiency and proven durability

The eLCC's specific energy requirement is significantly lower compared to alternative solutions due to its completely enclosed and insulated design. The compact heating chamber volume reduces heat losses substantially and enables rapid system startup, providing unprecedented operational flexibility for plant operators. This design philosophy aligns with the cement industry's need for responsive, efficient production systems.

Based on AUMUND's robust pan conveyor technology, the eLCC benefits from decades of field-proven reliability. The modular design architecture allows production capacities to be expanded seamlessly by adding additional modules, providing long-term scalability as market demand for LC3 cement grows.

Carbon-neutral operation capability

While the eLCC can accommodate various heating systems including ceramic gas burners, its electric heating elements can be powered entirely by renewable energy sources such as wind or solar power. This capability enables completely carbon-neutral calcination processes with zero direct CO₂ emissions, thus representing a fully sustainable cement production technology approach.

Global market presence

With the support of HOLCIM, a global cement industry leader, in the development and testing process, the eLCC technology is now ready to be globally marketed. AUMUND's established presence in the cement sector, supported by decades of successful global partnerships and technological expertise, positions the company to drive the widespread adoption of the eLCC as a sustainable calcination technology.

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Read the article online at: https://www.worldcement.com/product-news/22102025/aumund-launch-new-calcination-conveyor/