Presentation on Life Cycle Assessment of Portland Cement Manufacturing Process

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

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

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

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

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

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

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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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

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

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

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

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

Study area

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.

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.

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

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

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

Sr. no. Inventory analysis Lime stone mines Name of raw material Name of product Consumption of raw material 1 Explosive,( Ammonium Nitrate Fuel Oil @ 100gm/ ton of Lime stone) Lime stone 89.95 gm/ton 2 Saw dust/ rice husk Lime stone 10.65 gm/ton 3 Diesel Lime stone 0.42 lit/ton > 3 lit/ ton

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 0.8757 2 Shale 0.1 3 Iron ore/ Red ochre 0.0181/0.0111 4 Coal 0.0926 Cement 5 Gypsum 0.0706 6 Fly ash 0.2931

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 32.4 50.8 41.6 Cooler 46.5 54.9 50.7 Cement mill 38.0 55.6 46.8 Coal mill 46.0 55.6 50.8 LM Crusher 46.1 54.8 50.45

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: 0.036 Lit/ ton F.O. sludge : 0.015Lit/ ton

Inventory analysis Water consumption (Process plant) Industrial: 7.96 lakh lits/ day Domestic: 4.18 lakh lits/day Total : 1296213 lit/ day Water consumption (Limestone mine) Industrial: 77,213 lits/ day Domestic: 5000 lits/day i.e. 185.18 lit/ ton

Inventory analysis Inventory analysis of Kiln and raw mill exhaust Parameter Unit H2O 167.53291 kg/ ton HF ND C6H6 ND SO2 0.0146744 Hg 1.436E-05 NO 0.9254828 Hydrocarbon ND NO2 0.0167089 Cobalt 1.41E-05 NOx 1.432698 Copper 2.48E-05 CO HCL NH3 PM TOC CO2 O2 0.6726382 0.0005658 0.0264336 0.0263513 0.011914 514.67345 220.48723 Lead Manganese Nickel Thalium Vanadium Zink 2.825E-05 0.0001199 9.616E-06 2.179E-06 ND 4.016E-06

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

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

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

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

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

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: 514.6734 kg CO2/ ton of cement 1 x 514.6734 = 514.6734 kg CO2 eq characterisation factor category indicator GWP = 1 category indicator result

kg Sb eq/ kg Naptha 0.0201 LPG 0.0187 NGL 0.0187 Coal 0.0067 Natural Gas 0.0187 Petrolium 0.0201 Crude oil 0.0201 LNG 0.0187 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 SF4 23900 Nox 0.7 0.028 0.13 1.2 Sox 1 0.048 0.096 Dust 0.82 HCL 0.088 0.5 CO 0.027 COD 0.022 T-P 3.06 T-N 750 Phenol 0.00008 Source: Handbook of LCA 2002

Evaluation of impact assessment Parameter GWP AP POCP EP HTP SO2 0.014674 0.000704 0.001409 NO NO2 NOx 1.0028886 0.040116 0.186251 1.719238 CO 0.018161 HCL 4.97904E- 0.000283 05 NH3 PM 0.021608 TOC CO2 514.6735

Evaluation of impact assessment PM kg/ ton of cement 0.07 0.06 0.05 0.04 0.03 0.02 Graphical presentation of emitted particulate mater based on functional unit. R & K exhaust Cooler Cement mill Coal mill LM crusher 0.01 0 PM 34

Evaluation of impact assessment 0.06 Human toxicity potential (kg eq. 1,4 DCB) 0.05 0.04 0.03 0.02 0.01 R & K exhaust Cooler Cement mill Coal mill LM Crusher 0 PM

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

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

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

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

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

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).

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).

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 IS0 14040, First edition 1997-06- 15, 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 www.lcacenter.org http://www.epa.gov/nrmrl/lcaccess/index.html http://www.scienceinthebox.com/en_uk/sustainability/lifecycleassessment _en. html