MINBAS INNOVATION

SIA Programme

A Research and Innovation Programme for Minerals, Aggregates and Stone

MinBaS Innovation Representatives

at Vinnova meeting, May 29, 2013

• Per Murén - Chairman of the MinBaS Board, Technical Manager NCC Roads

• Jan Bida – Coordinator MinBaS Program, Research Director MinFo-Swedish Mineral Processing Research Association

• Magnus Evertsson – Professor, Chalmers University of Technology, Rock Processing Systems

• Hans-Erik Gram – PhD, Project Manager R&D Cementa, Heidelberg Group

• Björn Schouenborg – Associate Professor, SGU – Geological Survey of Sweden, Senior Researcher SP/CBI – Cement & Concrete Research Institute of Sweden

VISION

World Leading

Technology Leading position and active monitoring

of technology and expertise

Sustainable Society Climate neutral production in which

the value chain "production to use" is

optimally resource efficient

Excellent Safety A strong safety culture with machines

that are designed for minimal risk of

injury

Sustainable supply of rock materials in world class

MinBaS Innovation – SIA program Vinnova meeting 2013-05-29

MinBaS • Minerals (Industrial

minerals ) • Ballast (Aggregates) • Stone (Natural stone)

MinBaS products are used everywhere !

MinBaS products are used everywhere !

MinBaS Experience & Network

• 10 years of industrial development

between industry and academy

• 2 MinBaS RTD programs (more than 100

MSEK turnover, 70+ projects) completed

successfully

• Existing organization and experience

enable quick start

1. Production-processes •Raw materials, •Preinvestigation •Production •Logistics

2. Usage, Products •Prototyping •Application technology •Market •Standards •Reuse and recycling,

3. Society and industry •Legal framework •Employment •Internationalisation •CO2 and energy •LCA, SDI •Environmental load •Restauration

Project type – ”TRL” 1. Technology development 2. Demonstration 3. Implementation (of products and information)

Support for

establishment of

new enterprises,

applications and

products

MinBaS collaboration-programmes development towards Innovation system

• Products - Tailor-made products (functionality)

- cooperation with down-stream users - longlife, strong, possible for reuse and recycling - heavy products – large volumes

• Processes - Energy efficiency, low emissions, CCS, biofuels

- Recycling – zero waste - Optimal process – ex. Real Time Optimisation

- Transport solutions – logistics

• Society - Societal Acceptance - Regulations, guidelines and permits - SDI – Indicators etc. - Competence – need of personel and education

Our proposal

MinBaS Innovation

Management of the Programme

Funding Realization Advice, consulting, support

Vinnova, STEM, Formas …

Other funders ex SBUF

Industrial Organizations and

Member Companies MinBaS AB

MinBaS program

Board +

Secretariat

Expert Groups Industry Companies

Research Groups Authorities

Other specialists

Projects Projects Projects

Project Coordinators

Project Coordinators

Project Coordinators

Agreements, observers

Representatives, commitment

Quality Audit (Independent)

European context

European Institute of Innovation and Technology (EIT): KIC Raw Materials

European Innovation Partnership - Raw Materials

ERA - MIN Raw materials • Metals • REE • Aggregates • Industrial minerals • Natural stones • Recycled materials

ECTP, FA Materials. Construction sector, a major user

ETP-SMR ad hoc Raw Materials

VINNOVA Strategic Innovation Areas

MinBaS Innovation Metals/Metallurgy Mining

Swedish Mineral Strategy

The entire value chain

Research structure in Sweden

Chalmers University of Technology (CHALMERS) – Rock processing systems, yield optimisation, equipment design, aggregates

and mining, Total Production Maintenance (TPM)

Luleå University of Technology (LTU) – Underground mining, minerals processing (grinding and classification)

Lund University – Limestone technology expertise

Royal University of Technology (KTH) – Water production and purification

Umeå University (Umu) – Combustion technology for the cement and quicklime sectors

Swedish University of Agricultural Sciences (SLU) – Landscape architecture, dimensional stone

Swedish Cement and Concrete Research Institute/National Technical Research Institute of Sweden (CBI/SP)

– Dimension stone, aggregates and concrete

MEFOS – Slag formers and additives used in iron and steel production processes

Chalmers Rock Processing Systems

• Rock breakage fundamentals

• Rock processing equipment

• Plant simulation and optimization

• Rock material products & applications

0

50

100

150

200

250

300

350

Flo

w (

ton

/h)

Through crusher 11/16 Between screens Circ. Load 0/2 2/5 5/8 8/11

R&D Sweden – Aggregate & Mineral sectors

• A few large Technology & Equipment Providers

(Atlas Copco, Sandvik, Metso, Orica, Kimit, ABB)

– Consolidation of company groups

– Research in Sweden for some products

• A number of medium sized suppliers (SME)

(Jonsson, Norab, Maskinmekano, Mogensen, Tesab)

– Often considered to provide very high quality

– Development without high level research

• Small suppliers (SME)

– Locally operating

– Some on high level, major part without any R&D

R&D – Risk Analysis in general

• Consolidation of company groups

– Manufacturing moves to best available localization

– Sweden is a minor market (not an obvious choice)

• R&D often located close to manufacturing facility

– Risk for moving to low cost countries

– Decision dependent on knowledge and customers

• University research is seldom sponsored by

equipment manufacturers

– Research closely related to end users is in this case a

stronger solution

Natural stones/Dimension stones

Royal Swedish castle, 1754 –

Gotland sandstone

San Fransisco, mid 90-ies,

Vånga granite

Swedish stone

International position

World class in identifying and connecting geological characteristics of the bedrock with material and product performance

Material and structural

testing

Numerical analysis & simulation

Modelling of the construction

Geology/

Bedrock

Critical characteristics

Microstructure

MinBaS MinBaS Innovation - Objectives Mineral•Ballast•Sten

Aggregates Objectives and challenges

Secure access to raw materials and optimal location – Optimised

licensing process

Provision of skills and collaboration between industry and academia –

relevant training at all levels from operator to researcher

International collaboration through ETP SMR, ERA-MIN, Horizon 2000,

UEPG etc.

Efficient, competitive and sustainable production processes with safe

workplaces – optimal use of resources (”decoupling”)

Energy & environmental policy objectives – reduced energy

consumption & CO2 emmission in crushing, screening, loading and

haulage

Other national environmental objectives – reduction of natural sand &

gravel consumption – replaced by crushed rock aggregates (by VSI-

crushing and dry classification)

Minerals – Lime & Cement Objectives and challenges

Secure access to raw materials – focus at carbonate raw materials - optimised

licensing process

Provision of skills and collaboration between industry and academia – relevant

training at all levels

International collaboration through ETP SMR, ERA-MIN, Horizon 2020, Eula,

Cembureau etc.

Efficient, competitive and sustainable production processes and with safe

workplaces – optimal use of resources (”decoupling”)

Energy & environmental policy objectives – reduced energy consumption &

CO2 emmission in crushing, grinding and high temperature lime burning

process – improved process modelling and increased use of biofuels

Other national environmental objectives – reduction of natural sand & gravel

consumption – replaced by crushed rock aggregates and improved concret

mix design modelling

Use of slag as a component in cement – reduction of CO2 of cement

Improved properties of lime for use as lime slag additives for Steel industry

Natural Stone Objectives and challenges

• Meeting the strong competition of non European

stones: LCA, Quality, Durability and Cultural heritage

• Combining the use of stones as a carrier of historic

significance and at the same time being a modern

construction material:

• Increasing the production efficiency

• Developing a platform for innovation

• Safeguarding future competence

• Disseminating the knowledge of proper stone use in

society

Project 2013: Aggregate supply planning

• Sustainable Aggregate Supply (SAS Pilot Plant)

• Transparrent bedrock classification criteria

• Improved prediction methods for optimised use of excavated material from infrastructural projects

• Improvning the legal framework for high grade use of recycled matrials, e.g. construction & demolition waste

• Connecting geology with the potential of the material

• Exporting our know-how

• Project example: By-pass Stockholm Tunnel Project – 21 km, 5Milj. tonnes of tunnel excavation rock

Project 2013: Development of Screening

Technology for Aggregate Products.

• Increase the knowledge of the screening process and how it affects the quality of the final products

• Predict the production outcome from screening

• Investigate the possibility to compensate for wear

Project 2013: Improvement of a concrete mix design

program for sustainable and cost efficient concrete

production

Goal: A tool for finding most efficient mix. Evaluate new

constituents. Predicting effects of changed

properties of constituents.

How: Develop new ways to characterize constituents.

Develop new program based on rheological

approach.

Participants: Luleå Technical University, Cementa, Aggregate

and Concrete producers.

Organisation: Two doctoral students at LUTH, Scientific and

industrial supervisors.

The Challenge is to replace natural gravel and sand with aggregates

produced from crushed rock.

Project 2013: Improvement of a concrete mix design

program for sustainable and cost efficient concrete

production (cont.)

Gains for the society: More efficient concrete mixes will save cement natural resources and maintain the position of

concrete as the most used and cost efficient

construction material in the world.

Global challenges: Take the lead in concrete mix design – and production.

International position: Many mix design software exist without good enough knowledge of properties of a

constituent influences the fresh concrete rheology.

Involvement from governmental National environmental goals (substitution of

and industrial sector: natural aggregates with crushed rock aggregates).

Why governmental support?: Big task to replace natural aggregates with something else – many small companies

involved – need for large investments within the

concrete industry.

Project 2013: More energy efficient production

techniques

Blasting Manual wedge Wire sawing Hydraulic wedge

splitting splitting

Towards more efficient and environmentally &

labour friendly production processes