Don't Mock the Chimney... Cement Industry's Fierce Technological Competition

Operation of All Cement Company Technical Research Institutes, Korea's Cement Technology and Product Quality at World-Class Level
Outstanding in Carbon Neutral Technologies and Eco-Friendly Special Cement

Kiln and preheating chamber with an internal temperature above 1400 degrees.
Photo by Asia Economy DB

[Asia Economy Reporter Kim Jong-hwa] Cement may seem like nothing more than a dark gray powder, but it is packed with sophisticated technology. Cement companies operate their own research institutes and engage in fierce technological competition. This is why the cement industry, which is hastening its transition to an eco-friendly sector, can no longer be mocked as a "smokestack industry."

Carbon-neutral technologies for the eco-friendly industrial transition of the domestic cement industry are among the best in the world. Ssangyong C&E completed the renovation of Kiln No. 4 at its Donghae plant last June. Although this kiln was installed in 1976 and operated for 43 years as an old facility, after the renovation, it transformed into a state-of-the-art facility that increased clinker (semi-finished cement product) production, generating an additional annual profit of about 30 billion KRW. By integrating carbon-neutral technology into the old equipment, the amount of waste heat power generation and greenhouse gas reduction approximately doubled. Ssangyong C&E converted the cooling method of Kiln No. 4 from water cooling to air cooling, increasing recycled waste heat power generation from 29 MWh (megawatt-hours) to 56 MWh. Greenhouse gas reduction also rose from 21,000 tons to 55,000 tons annually. The Donghae plant operates the world's largest waste heat power generation facility for a single cement plant. This technology recovers heat sources emitted into the atmosphere by installing separate boilers in the preheater and cooler processes before and after the kiln, producing steam that drives turbines to generate electricity.

Sampyo Cement's Samcheok plant processes municipal waste generated in Samcheok City together in its self-developed municipal waste fuel pre-treatment facility. This facility separates and sorts household waste, then chops and crushes it into pieces smaller than 5 cm to be used as auxiliary fuel in the cement manufacturing process. Through this facility, the Samcheok plant recycles 70 tons of municipal waste daily as fuel. Samcheok City has reduced its annual landfill municipal waste from 10,773 tons to 2,079 tons, a reduction of over 80%, enjoying secondary benefits such as reduced waste disposal costs, decreased municipal waste disposal fees, and extended landfill usage periods.

The technological prowess of finished cement products is also recognized. Halla Cement holds a technological advantage over competitors in manufacturing special cements such as steam curing, pile filling, ground solidification, and low-heat cement. Special cement is typically made by mixing ordinary Portland cement (OPC) with other components, but Halla Cement has eco-friendly technology that lowers the OPC content to below 70%, reducing carbon dioxide emissions. In particular, the low-heat cement "CEM LOW HEAT," used in large-scale structures like dams and bridges, is highly valued as an eco-friendly cement with OPC content reduced to less than half.

Recently, cement-containing products specialized for specific uses, such as reducing inter-floor noise or for underground parking lot floors, have also been developed. Hanil Cement developed a high-density Remital for floors that reduces inter-floor noise. According to the revised Housing Act in February, from the 4th of this month, inter-floor noise tests are conducted on randomly selected sample households under stricter standards, requiring passing a noise level of 49 dB, which is more stringent than the previous 58-50 dB. The Remital developed by Hanil Cement has a 20% higher density compared to conventional floor Remital, effectively reducing heavy impact noise known as "foot hammer" sounds. In February, the floor structure using this product as a finishing material was certified as "Grade 1 heavy impact sound reduction" through the nationally accredited testing agency (KOLAS). The test results, measured at an actual apartment construction site in the metropolitan area rather than in a laboratory, enhance its reliability.

Sampyo developed a special concrete called "Bluecon Floor" to solve frequent cracking problems in apartment underground parking lot floors. This product, reflecting Sampyo's technological capabilities, significantly improves defects such as shrinkage cracks, curling (edge lifting), and coating peeling that occur as concrete ages. Even over time, it maintains the initial condition of the concrete for a long period, and apartments using Bluecon Floor have seen more than an 80% reduction in defect and repair complaints. Sampyo also demonstrates technological superiority in the special concrete market with products like Bluecon Winter, which does not freeze even at minus 10 degrees Celsius, and Bluecon Speed, which has enhanced early compressive strength. An industry insider said, "All cement companies operate research institutes and engage in fierce technological competition," adding, "The technology and product quality of Korean cement have been among the world's best for over a decade."