Presentation on Life Cycle Assessment of Portland Cement Manufacturing Process

Transcription

1 Date: 22/12/2010 Presentation on Life Cycle Assessment of Portland Cement Manufacturing Process Presentation by Nikhil Kulkarni Purpose: Internet Based Environmental Management Course, CCE, Indian Institute of Science, Bangalore, India. 1

2 Flow of presentation Problem formation Objectives Cement manufacturing process Overview of Life Cycle Assessment Methods Definition of goal and scope Inventory analysis Impact assessment of environmental loading Evaluation of impact assessment Scope for further work Conclusions/ Recommendations References 2

3 Problem formation Concrete is second only to water as the most consumed substance on Earth, with almost one ton of it being used for each human every year on the planet earth. (Lafarge Coppee SA. Globe and Mail, October 20, 2000). one of the largest greenhouse gas emitting, highly energy and natural resource consuming industries. 3

4 Objectives To assess the life cycle of Portland cement manufacturing process to minimize the environmental impact. 4

5 Flow of presentation Problem formation Objectives Cement manufacturing process Overview of Life Cycle Assessment Methods Definition of goal and scope Inventory analysis Impact assessment of environmental loading Evaluation of impact assessment Scope for further work Conclusions/ Recommendations References 5

6 Cement Manufacturing Process Types : 1) Hydro process (Wet process) 2) Pyro process (Dry process) Considering life cycle of cement, it undergoes various chemical and physical transformations. Considering product system: Inputs: Raw materials and energy (Electricity and fuel sources) Outputs: Principal product, Emissions to air, solid waste, other environmental interactions 6

7 Lime Stone Mining Crushing Stacking and reclaiming Airborne emissions Other raw material Raw material grinding Raw meal storage and blending Water effluents Preheating and burning Clinker cooling Clinker storage Solid waste Clinker grinding Cement storage in silos Energy Packing and dispatch Use Disposal Other environmental interactions 7

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9 200deg tem. Prehetar section Raw material feed K -string Riser duct Rotary kiln 1100 deg tem. Coal burner grate cooler Perhetar fan clinker Cool air by fan 9

10 Cement Manufacturing Process Cement is an inorganic, non-metallic substance with hydraulic binding properties, and is used as a bonding agent in building materials. Cement Compound Weight Percentage Chemical Formula Abbreviat ed Notation Tricalcium 50 Ca3SiO5 or 3CaO SiO2 C3S silicate Dicalcium silicate 25 Ca2SiO4 or 2CaO SiO2 C2S Tricalcium aluminate Tetracalcium aluminoferrite Gypsum 10 Ca3Al2O6 or 3CaO Al2O3 10 Ca4Al2Fe2O10 or CaO Al2O3 Fe2O3 5 CaSO4 2H2O C3A C4AF 10

11 Overview of Life Cycle Assessment Life Cycle of product, process, service 11

12 Flow of presentation Problem formation Objectives Cement manufacturing process Overview of Life Cycle Assessment Methods Definition of goal and scope Inventory analysis Impact assessment of environmental loading Evaluation of impact assessment Scope for further work Conclusions/ Recommendations References 12

13 Methods Goal and scope definition Inventory analysis Impact assessment Interpretation Product development, improvement Strategic planning Public policy Marketing LCA framework and applications (Phases)

14 Study area

15 Definition of goal and scope Goal: To assess the potential environmental impact due to cement manufacturing process Purpose of this study is for academic program only but the outcomes and conclusions will be beneficial for Indian cement industry so as to tackle with environmental impacts, energy efficiency and cost effectiveness.

16 Definition of goal and scope Scope of the study The scope of the project focuses on the raw material acquisition, processing, and product manufacturing stages i.e. lime stone mining to Cement. Functions of the product system Primary function of cement: Used as a bonding agent in building material. Functional unit As cement industry is a bulk manufacturer industry all the data collection and calculations in this study have been done for per ton basis.

17 Definition of goal and scope System boundaries Fuel (1) (2) (3) (4) Fugitive dust Infrastructure Energy (5) (6) (7) (8) (9) (10) (11) (12) (13) 14) Waste heat Other raw materials (15) (16) (17) (18) Dispatch Disposal Use

18 Flow of presentation Problem formation Objectives Cement manufacturing process Overview of Life Cycle Assessment Methods Definition of goal and scope Inventory analysis Impact assessment of environmental loading Evaluation of impact assessment Scope for further work Conclusions/ Recommendations References 18

19 Inventory analysis Involves data collection and calculation procedures to quantify relevant inputs and outputs of a product system. Raw material from mines water use Diesel use Saw dust/ rice husk use Explosives use Particulate matter emissions Gaseous emissions Heavy metals emissions 19

20 Sr. no. Inventory analysis Lime stone mines Name of raw material Name of product Consumption of raw material 1 Explosive,( Ammonium Nitrate Fuel 100gm/ ton of Lime stone) Lime stone gm/ton 2 Saw dust/ rice husk Lime stone gm/ton 3 Diesel Lime stone 0.42 lit/ton > 3 lit/ ton

21 Process plant : Inventory analysis Sr. No. Raw material Consumption of raw material per unit of output Tones/ Tone of Cement Name of product 1 Lime stone Shale Iron ore/ Red ochre / Coal Cement 5 Gypsum Fly ash

22 Inventory analysis Particulate matter analysis of different stacks Stack attached to Min. Particulate matter (mg/nm3) Max. Particulate matter (mg/nm3) Avg. Particulate matter (mg/nm3) Raw mill and Kiln Exhaust Cooler Cement mill Coal mill LM Crusher

23 Inventory analysis Hazardous waste : 78.8 KL in terms of used oil and grease (Lubricants) 32.9 KL F.O. sludge from D.G. sets Used oil and grease: Lit/ ton F.O. sludge : 0.015Lit/ ton

24 Inventory analysis Water consumption (Process plant) Industrial: 7.96 lakh lits/ day Domestic: 4.18 lakh lits/day Total : lit/ day Water consumption (Limestone mine) Industrial: 77,213 lits/ day Domestic: 5000 lits/day i.e lit/ ton

25 Inventory analysis Inventory analysis of Kiln and raw mill exhaust Parameter Unit H2O kg/ ton HF ND C6H6 ND SO Hg 1.436E-05 NO Hydrocarbon ND NO Cobalt 1.41E-05 NOx Copper 2.48E-05 CO HCL NH3 PM TOC CO2 O Lead Manganese Nickel Thalium Vanadium Zink 2.825E E E-06 ND 4.016E-06

26 Impact assessment of environmental loading Approach: Emissions ( e.g. CFCs ) Chemical reaction releases Cl, Br Cl, Br destroy ozone Midpoint ( Ozon depletion potential ODP ) Less ozone allows increased UVB radiation - Endpoint Skin cancer Crop damage Immune system suppression Cataracts Marine life damage Damage to materials like plastics 26

27 Impact assessment of environmental loading The categories of the environmental problems a) Resource depletion/abiotic depletion ADP b) Global warming, GWP c) Acidification, AP d) Photo-oxidant formation, POCP e) Eutrophication, EP f) Human toxicity, HTP

28 Impact assessment of environmental loading Sr. No Impact name Classification Common Possible Characterization factor 1 Resource depletion Global Regional Local 2 Acidification Regional Local Resource depletion potential Acidification potential 3 Eutrophication Local Eutrophication potential 4 Greenhouse effect Global Global warming potential 5 Ecotoxicity (no unit) Local 6 Human toxicity via water,soil, air, and plants Global Regional Local ---- Human toxicity potential Description of Characterization factor Kg Sb- eq kg SO2-eq kg PO4-eq kg CO2-eq Multimedia modeling Multimedia Modeling Kg of 1,4,DCBeq

29 Flow of presentation Problem formation Objectives Cement manufacturing process Overview of Life Cycle Assessment Methods Definition of goal and scope Inventory analysis Impact assessment of environmental loading Evaluation of impact assessment Scope for further work Conclusions/ Recommendations References

30 Evaluation of impact assessment Simple conversion and aggregation: IndicatorR esultcat = CharFactcat, subs InventoryResult subs subs

31 Evaluation of impact assessment CO2 contribute to climate change Global Warming Potential (GWP): measure for climate change in terms of radiative forcing of a mass-unit of greenhouse gas impact categor y Sample calculation: kg CO2/ ton of cement 1 x = kg CO2 eq characterisation factor category indicator GWP = 1 category indicator result

32 kg Sb eq/ kg Naptha LPG NGL Coal Natural Gas Petrolium Crude oil LNG ADP GWP AP POCP EP HTP kg CO2 eq/ kg SO2 eq/ kg C2H4 eq / kg PO4 eq/ kg kg kg kg kg 1,4 DCB eq/ kg CO2 1 CH4 21 HCF 2800 N2O 310 SF Nox Sox Dust 0.82 HCL CO COD T-P 3.06 T-N 750 Phenol Source: Handbook of LCA 2002

33 Evaluation of impact assessment Parameter GWP AP POCP EP HTP SO NO NO2 NOx CO HCL E NH3 PM TOC CO

34 Evaluation of impact assessment PM kg/ ton of cement Graphical presentation of emitted particulate mater based on functional unit. R & K exhaust Cooler Cement mill Coal mill LM crusher PM 34

35 Evaluation of impact assessment 0.06 Human toxicity potential (kg eq. 1,4 DCB) R & K exhaust Cooler Cement mill Coal mill LM Crusher 0 PM

36 Evaluation of impact assessment Valuing / Weighting Sr. no. Impact Category Relative Importance Weight (%) 1 Global Warming 16 2 Acidification 5 3 Eutrophication 5 4 Fossil Fuel Depletion 5 5 Human Health 11

37 Scope of further work Indian cement industry is one of the most growing industrial sector. India s per capita cement consumption is below than the world average per capita cement consumption. There are many new cement manufacturing units and cement grinding units are in progress in India. Still the reliable and acceptable LCA are not available for specifically Indian conditions. The LCAs should be carried out for different types of cement. The LCA of cement will help to better use of natural resources with minimized environmental impact. 37

38 Flow of presentation Problem formation Objectives Cement manufacturing process Overview of Life Cycle Assessment Methods Definition of goal and scope Inventory analysis Impact assessment of environmental loading Evaluation of impact assessment Scope for further work Conclusions/ Recommendations References 38

39 Conclusions/ Recommendations Enclosing cement mill section and using rubber curtains as a barriers for dust. Control the corrosion of different transfer platforms. Provision of dust suction facility at ground level. 1. Policy Aspects A comprehensive norm for cement industry (covering all pollutants, when coal and/or alternate fuels are used.) Incentivising the use of wastes as raw materials / fuels. 39

40 Conclusions/ Recommendations 2. Mining Efforts for enrichment of low grade limestone Shifting emphasis from environment control to environment protection (using globally accepted decision making tools like LCA to operational mines.) Utilization of biodiesel for quarrying operations to lower lifecycle emission profiles. 3. Process Encouraging cement plants to take up LCA studies voluntarily for continual improvement. Waste heat recovery system

41 Conclusions/ Recommendations 4. Use of Alternate Fuel National policy to systemize supply on long term basis for consistent quality waste derived fuel. 5. Product Variation Encouraging manufacture of blended cement and incentivising the conversion of OPC grinding facilities to PPC. Optimization of supply & distribution of fly ash within a cluster. Encouraging production of low energy cement. Encouraging creation of additional grinding capacities near demand centers (Split location).

42 Conclusions/ Recommendations 7. Packaging Policy initiatives to discourage the usage of packed cement bags for large infrastructure projects and bulk consumers. Encouraging the investments in bulk material handling and transport facilities to bring down seepage loss 8. Environmental Good Practices Encouraging the cement plants to practice common / strategic sourcing across the cement sector for environmental improvement in a cluster. Encouraging creation of a Environmental Data Bank shared sourcing center, (NCB as nodal agency to share experience and technical participation).

43 References Vijay Kulakarni and Ramachandra, T.V. 2009, Environmental Management, RalphHome, Tim Grant and KarliVerghese, Published by CSIRO Publishing, 2009, Life Cycle Assessment Principles, practices and prospects INTERNATIONAL STANDARD IS , First edition , Jonna Meyhoff Fry, Bryan Hartlin, Erika Wallén, and Simon Aumônier (Environmental Resources Management Limited), January 2010, Final Report - Life cycle assessment of example - packaging systems for milk Jan R. Prusinski, Medgar L. Marceau and Martha G. VanGeem, LIFE CYCLE INVENTORY OF SLAG CEMENT CONCRETE Presentations: U.S. EPA Region X, October 15, 2009, Life Cycle Assessment: Impact Assessment & Applications, Rita Schenck, IERE G. Dodbiba, K.Takahashi, T. Furuyama, J. Sadaki, T. Kamo, and T. Fujita, Life Cycle Assessment: A Tool for Evaluating and Comparing Different Treatment Options for Plastic Wastes UNEP LCA Training Kit, Module e Impact assessment, Life Cycle Assessment - A product-oriented method for sustainability analysis Internet access _en. html