Low-Carbon Cement in China

Transcription

1 CSI Forum --Learning-by-Sharing Open Forum Low-Carbon Cement in China China Building Materials Academy

2 China Building Materials Academy Founded in 1950, owned by the central government. The largest comprehensive R&D organization in the fields of building materials and inorganic non-metal materials in China. Over 3000 scientific researchers out of 5000 staff. Among the first group of institutes authorized by the Academic Degree Committee of the State Council to award Master s degree and Doctorate. About 500 ministerial and higher level awards granted by government, including over 100 national prizes 9 technical standardization committees, including National cement technical standardization committee Post doctoral station has also been established in the Academy. Completed more than 2600 national and ministerial level key research projects 2

3 China Building Materials Academy State Key Laboratory of Green Building Materials Energy Conservation and Emission Reduction Research Center Study BAT and BP of the whole world for cement industry Analyze the situation of cement industry in China Evaluate the potential of energy conservation and emission reduction Research on the technologies and methods to achieve the goal Establish a low carbon development models for cement industry Supply policies suggestion for central governments 3

4 The Situation of Cement Industry in China Cement Production Growth GDP Growth 亿吨 亿元 亿吨 1980 年 1990 年 2000 年 2009 年 亿元 1980 年 1990 年 2000 年 2009 年 亿吨 0.87 亿吨 1980 年 1990 年 2000 年 2009 年 亿元 亿元 1980 年 1990 年 2000 年 2009 年 Requirements based on social development Cement is hugely used as building material China experiences quick economic growth Much investments are put into infrastructure construction Urbanization is speeding up Residential structures increase significantly 4

5 The Situation of Cement Industry in China Global energy consumption:41.2 billion tons of standard coal % China energy consumption:2.8 billion tons The first state pollution source survey : Exhaust gas emission quantity ranks third after power and metallurgy sectors Emit SO million tons, NO X 1.7 million tons, dust 3 million tons in China energy consumption: 2.8 billion tons of standard coal % China cement industry:0.19 billion tons Heat consumption is 120 kg standard coal/ ton of clinker, power consumption is 120 kwh/ton of cement. Based on calculation: the production of a ton of clinker releases 815 kg direct CO 2 emission, with 390 kg from combustion, 425 kg from decomposing; the production of a ton of cement with power consumption releases 70 kg indirect CO 2 emission. 5

6 Energy policy for Chinese industry Energy shortage Consumption increase Reservation decrease Structure worse More needed Economic growth GDP grow Urbanization PCI increase Potential threat Chinese central government also set up a mandatory target to reduce GHG emission by 40% - 45% for unit GDP during next 10 years ( ). 6

7 Energy policy for Chinese cement industry To guarantee the energy saving and emission reduction with cement industry in China: to execute relative laws, policies and regulations to speed up the structure reform for cement industry to enact energy saving and emission reduction codes (standards) for cement industry to promote the use of alternative fuel to develop and use BAT and BP to strengthen international cooperation and information distribution For energy saving and emission reduction, we are taking action! 7

8 Series standards for cement industry Establish three standard systems for energy saving and emission reduction, including scientific and accurate statistics system, monitoring system and assessment system, in order to achieve the settled target. Cement plant design code for energy saving The limitation of energy consumption for unit cement product Energy consumption auditing for cement production Power consumption auditing for cement production The calculation method for the CO 2 emission from cement industry Technical requirement for environmental labeling products: lowcarbon cement 8

9 Cement plant design code for energy saving (1)For limestone crushing, limited to 2 kwh/t. (2)For raw material grinding, limited to kwh/t. (3)For clinker burning, Limited to kwh/t. (4)For coal grinding, limited to kwh/t. (5)For cement grinding, limited to kwh/t. (6)For packing, limited to 1.2 kwh/t. 9

10 The limitation of energy consumption for unit cement product For existed cement plant Classification Coal consumption for clinker kg/t Power consumption for clinker kwh/t Power consumption for cement kwh/f Energy consumption for clinker kg/t Energy consumption For cement kg/t 4000t/d or more ~4000t/d 1000~2000t/d t/d or less Grinding plant For newly established cement plant Classification Coal consumption for clinker kg/t Power consumption for clinker kwh/t Power consumption for cement kwh/f Energy consumption for clinker kg/t Energy consumption For cement kg/t 4000t/d or more 2000~4000t/d 1000~2000t/d t/d or less

11 Energy consumption auditing for cement production According basic requirement of energy assessment, work can be done as following: General information of energy consumption; Energy flow chart; Data collection; Energy consumption analysis; Efficiency analysis of each equipment; Consumption/Product analysis; Energy cost analysis; Retrofitting assessment; Energy saving amount calculation. 11

12 Energy consumption auditing for cement production Energy flow chart for kiln system (kj/kg-cl) 12

13 Power consumption auditing for cement production Power equilibrium auditing the translations loss assessing power consumption of offices and others auditing power consumption for raw meal preparation, including mining, crushing, drying, homogenization and grinding, etc Power from co-generation kWh Power from national grid kWh auditing power consumption for clinker burning, including kiln motor, high temperature fan, cooler, etc auditing power consumption for cement making, including grinding, packing, etc Effective power used by equipments kWh Transmitting loss kWh Wire loss kWh Translation loss kWh Motor loss kWh Lighting kWh auditing high power consumption units with 20 kw, such as crusher, mill, big fan, big motor, etc 13

14 Calculation Method of CO 2 Emissions with Cement Production The standard standardizes the basis, scope, conversion and reporting of CO 2 emissions from cement production enterprises and provides a unified CO 2 emissions accounting method for the cement industry. This standard is based on " IPCC Guidelines for National Greenhouse Gas Inventories " and ISO14064 "Greenhouse Gas Emission Inventories and Verification" and the basic principles of "The Cement CO 2 Protocol: CO 2 Accounting and Reporting Standard for the Cement Industry" widely used internationally. In combination with the technical characteristics of the Chinese cement industry, the CO 2 calculation method here can reflect the actual situation of Chinese cement production enterprises more accurately. The standard provides the calculation method of CO 2 emissions for cement production enterprises. The standard can be applied to calculate the direct and indirect CO 2 emissions in every production process of the cement industry. 14

15 Calculation Method of CO 2 Emissions with Cement Production Terms and definition Carbon dioxide Source --The physical unit or process that produces and releases CO 2 into the atmosphere Emission Factor--CO 2 emissions per unit of energy and/or raw material consumed, which is determined by statistical analysis and calculations. Direct carbon dioxide emissions--emissions from CO 2 sources that are owned or controlled by the company. For example, CO 2 emissions from carbonate materials decomposition and fuel combustion in a cement kiln. Biomass fuels--organic biomass(animal or plant) that can be used as fuel or used as fuel after processing, such as biodiesel, which does not include fossil fuels. Indirect carbon dioxide emissions--co 2 emissions resulting from the consumption of purchased electricity and clinker etc. For example, CO 2 emissions associated with purchased electricity released during its generation in the power plant are considered indirect CO 2 emissions. Combustible Carbon not Including in Fuel Combustible carbon in raw materials or other non-energy materials, such as unburned carbon in fly ash. Alternative raw materials--wastes with appropriate chemical ingredients that can fully or partly replace natural mineral raw materials in cement production, e.g., carbide slag, furnace blast slag etc. Operational boundaries--boundaries of production and scope of calculation set by the enterprises when calculating the carbon dioxide emissions. Alternative Fuels--Wastes with a certain calorific value( 21000kJ/kg)that can fully or partly replace coal and other fossil fuels in the cement production process. Absolute quantity of CO 2 emission--total CO 2 emissions from CO 2 sources that are owned and controlled by the company and emissions resulted from the consumption of input energy in a statistical period. Co-processing Waste Materials --Activities that transferring wastes original or pretreated to kiln systems of cement production to incinerate, for the purpose of hazard-free and comprehensive utilization. Total Quantity of CO2 Emission Total CO2 emissions of direct carbon dioxide emissions, indirect carbon dioxide emissions and other indirect CO2 emission from cement production enterprises in a statistical period, which do not conclude CO 2 emissions of biomass fuels, waste co-processing, waste heat utilization of cement kiln exhaust. 15

16 Calculation Method of CO 2 Emissions with Cement Production Operational boundaries Operational boundaries set by cement enterprises when calculating the CO2 emission, i.e. production boundaries and scope calculation, as the figure showed. 16

17 Calculation Method of CO 2 Emissions with Cement Production Calculation Items of CO2 emissions in cement production enterprises Calculation units Production process Calculation items CO 2 emissions Formulas 1 Mining Fuel consumption from self-owned vehicles transportation Power consumption in production processes Poi(Psi) Pei (14) (15) 2 Preparation of raw meal, clinker calcination, cogeneration, waste disposal, office building and others Decomposition of carbonates in raw meal Combustion of non-fuel carbon in raw meal Consumption of material coal in the production process Consumption of alternative fuels in the production process Combustion of non-fuel carbon in waste co-processing Fuel Combustion from vehicles transportation Power consumption in production processes Waste heat utilization of cement kiln exhaust Purchased or sold cement clinker Prc Pro Psc Pbc Pα Pβ Pγ Pδ Poi (Psi) Pei Pg Pc Pk (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) (18) 3 Cement manufacturing Consumption of material coal in the production process Fuel consumption from vehicles transportation Power consumption in production processes Purchased or sold slag powder Psc Pbc Poi (Psi) Pei Ps (8) (9) (14) (15) (19) 4 Production and management Fuel consumption from vehicles transportation Power consumption in production processes Poi (Psi) Pei (14) (15) 17

18 Calculation Method of CO 2 Emissions with Cement Production Calculation Basis of CO2 emissions in cement production enterprises actual statistical data of cement production enterprises basis Calculation of CO2 emissions in cement production actual detecting data of cement production enterprises 18

19 Calculation Method of CO 2 Emissions with Cement Production Calculation Basis of CO2 emissions in cement production enterprises Cement and Clinker production Average 28 d compressive strength of cement and clinker actual statistical data of cement production enterprises Raw-clinker ratio Dust amount of kiln bypass The consumption of material coal alternative fuels and electricity The amount of waste co-processing and waste heat power generation The amount of purchased clinker and slag powder

20 Calculation Method of CO 2 Emissions with Cement Production Methods, Frequency and Requirements of actual detecting data No. Detecting data Detecting methods Detecting frequency Detecting requirements 01 CaO and MgO content in clinker GB/T176 Methods for chemical analysis of cement Once per day Daily data is for monthly average and annual average calculation 02 CO 2 content and loss of raw meal GB/T12960 Quantitative determination of constituents of cement GB/T176 Methods for chemical analysis of cement Once per month Monthly data is for weighted average calculation. It should be immediately detected and increase the detection frequency when the ratio of raw materials or raw materials have changed. Then calculate the weighted average. 03 Flu gas and dust content of kiln exhaust stack GB/T4915 Emission Standard of Air Pollutants for Cement Industry Detect by once per half year or the default value adopted Test data of every six months is for average calculation. It should be immediately detected and increased testing frequency if the process conditions have changed. Then calculate average. 04 Dust loss-on-ignition loss of kiln bypass GB/T176 Methods for chemical analysis of cement Once per half year Test data of every six months should be for the annual average calculation. It should be immediately detected and increased testing frequency if the process conditions have changed. Then calculate annual average. 05 Non-fuel carbon content of raw meal GB/T 476 Ultimate Analysis of Coal Detect by once per half year or the default value adopted Test data of every six months should be for the annual average calculation. It should be immediately detected and increased testing frequency if the process conditions have changed. Then calculate annual average. 06 Carbon content and lower heating value of coal GB/T 476 Ultimate Analysis of Coal GB/T212 Proximate Analysis of Coal GB/T213 Determination of calorific value of coal Once per batch when into factory Or for the ultimate Analysis of Coal, or foe the proximate analysis of coal and determination of calorific value of coal. 07 Lower heating value of alternative fuels GB/T213 Determination of calorific value of coal Detect by once per half year or the default value adopted The alternative fuels should first be classified. It should be immediately detected if added new species. Then calculate annual average. 08 Lower heating value and moisture content of waste co-disposal GB/T212 Proximate Analysis of Coal GB/T213 Determination of calorific value of coal Detect by once per half year or the default value adopted The disposal waste should first be classified. It should be immediately detected if added new species. Then calculate annual average. 09 Exhaust utilization amount and temperature of waste heat outside the operational boundaries GB/T Heat balance, Thermal efficiency, overall energy consumption test and calculation methods of Cement rotary kiln Once per half year Test data of every six mouths is for weighted average calculation. It should be immediately detected and increase the detection frequency condition has been changed. Then calculate the weighted average. 20

21 Classification of CO2 emission statistical calculation(1) Production process Calculate project Direct CO 2 Emissi on Indirect CO 2 Emission Other Indirect CO 2 Emission Biomass fuel CO2 Emission Absolute Quantity of CO 2 Emission Total Quantity of CO 2 Emission Unit Comparable Quantity of CO 2 Emission Decomposition of carbonate minerals in raw Non-fuel carbon burned in raw The consumption of physical coal in production process Raw material preparation, clinker, cogeneration, waste disposal The consumption of alternative fuel in production noncombustion carbon fuel in disposal waste Own vehicles transportation fuel consumption Fossil fuel carbon Biomass carbon Fossil noncombustion carbon Biomass noncombustion carbon Fossil fuel Biomass fuel Power consumption during production Power consumption during disposing waste + + Heat recovery furnace exhaust gas Used outside the boundary Cogeneration Disposal waste

22 Classification of CO2 emission statistical calculation(2) Production process Mining Own vehicles transportation fuel consumption Calculate project Direct CO 2 Emission Indirect CO 2 Emission Other Indirect CO 2 Emission Biomass fuel CO2 Emission Absolute Quantity of CO 2 Emission Total Quantity of CO 2 Emission Unit Comparable Quantity of CO 2 Emission Fossil fuel Biomass fuel Community transport vehicle fuel consumption Power consumption during production Own vehicles transportation fuel consumption Fossil fuel Biomass fuel + Cement preparation Power consumption during production physical coal consumption during production Purchased slag Purchased clinker Production management Own vehicles transportation fuel consumption Fossil fuel Biomass fuel Power consumption during production

23 Analysis and Calculation of CO 2 emission from cement industry - Visual Basic System 23

24 Low-Carbon Cement Definition of Low-carbon cement General Portland cement that has lower carbon emission in cement manufacturing. Manufacturing technology High energy-efficient technology: vertical mill, roll mill, high-efficient grate cooler, etc. Alternative raw materials technology: carbide, steel slag, high-calcium ash, pozzolanic ash, etc. Alternative fuel technology: fuel from biomass High-doped mixture technology: higher-added mixtures under the condition of ensuring the performance and the strength of cement. 24

25 Low-Carbon Cement Technical Provisions: Limits of carbon dioxide emissions per unit of Types Portland Cement product for general purpose Portland cement Symbol P I P Ⅱ Clinker + Gypsum(%) Ordinary Portland cement P O 80 且 <95 Portland blastfurnace-slag cement Portland pozzolana cement P S A P S B P P 50 且 <80 30 且 <50 60 且 <80 Portland fly ash cement P F 60 且 <80 Composite Portland cement P C 50 且 <80 Strength Grade Limits of carbon dioxide emissions per unit of product (kg CO2 / t cement) R R R R R R R R R R R R R R R R R

26 Low-Carbon Cement Low-Carbon cement--that is with 5%~10% of cement production would acquire low-carbon environmental label Environment Development Leading the future of low-carbon and green cement production Strength the CO2 emission management of cement manufacturing, and gradually reduce the CO2 emission amount of cement manufacturing 26

27 Conclusions Guaranteed by laws, policies and standards Action taken by cement manufacturers Financial support given for research and creation International cooperation strengthened with us all 27

28 Wang Lan China Building Materials Academy Beijing China Tel: , Wang Lan (Ph.D P.E.) is a full professor of China Building Materials Academy (CBMA) and a leading scientist of the State Key Laboratory of Green Building Materials, and currently directing research projects including the National Science & Technology Pillar Program, National Basic Research Program, National Natural Science Foundation of China, the Program in Formulating GB and international cooperation in the field of policies and standards enactment, AFR, newly developed technology relative to the energy saving and emission reduction of cement industry. 28