on Life Cycle Assessment of Portland Cement Manufacturing...
Transcript of on Life Cycle Assessment of Portland Cement Manufacturing...
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.
Date: 22/12/2010
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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
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• 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.
Objectives
• To assess the life cycle of Portland cement manufacturing process to minimize the environmental impact.
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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
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
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Other raw material
EnergyOther
environmental interactions
Airborne emissions
Water effluents
Solid waste
Crushing
Clinker cooling
Raw material grinding
Lime Stone Mining
Raw meal storage and blending
Stacking and reclaiming
Clinker storage
Preheating and burning
Clinker grinding
Cement storage in silos
Packing and dispatch
Use
Disposal
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Prehetar section
K -string
Rotary kiln
grate cooler
Riser duct
Coal burner
clinkerCool air by fan
Raw
mate
rial fe
ed
Perhetar fan
200deg tem.
1100 deg tem.
• Cement is an inorganic, non-metallic substance with hydraulic binding properties, and is used as a bonding agent in building materials.
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Cement Compound
Weight Percentage
Chemical Formula Abbreviated Notation
Tricalcium silicate
50 Ca3SiO5 or 3CaO•SiO2 C3S
Dicalcium silicate 25 Ca2SiO4 or 2CaO•SiO2 C2S
Tricalciumaluminate
10 Ca3Al2O6 or 3CaO •Al2O3 C3A
Tetracalcium aluminoferrite
10 Ca4Al2Fe2O10 or CaO•Al2O3•Fe2O3 C4AF
Gypsum 5 CaSO4•2H2O
Cement Manufacturing Process
Overview of Life Cycle Assessment
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Life Cycle of product, process, service
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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
Goaland scopedefinition
Inventoryanalysis
Impactassessment
Interpretation
Product development,improvement
Strategic planning
Public policy
Marketing
Methods
LCA framework and applications (Phases)
Study area
Goal:
• To assess the potential environmental impactdue to cement manufacturing process
• Purpose of this study is for academic programonly but the outcomes and conclusions will bebeneficial for Indian cement industry so as totackle with environmental impacts, energyefficiency and cost effectiveness.
Definition of goal and scope
Scope of the study
• The scope of the project focuses on the raw materialacquisition, processing, and product manufacturingstages i.e. lime stone mining to Cement.
Definition of goal and scope
• 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
Energy
Infrastructure
Other raw materials
Waste heat
Fugitive dust
Dispatch
UseDisposal
(1) (2) (3) (4)
(5) (6) (7) (8)
(9) (10) (11) (12) (13) 14)
(15) (16) (17) (18)
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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
Inventory analysis
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Involves data collection and calculationprocedures to quantify relevant inputs andoutputs 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
Sr.no.
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
Inventory analysis
Lime stone mines
Sr.No.
Raw material Consumption of rawmaterial per unit of outputTones/ Tone of Cement
Name of product
1 Lime stone 0.8757
Cement
2 Shale 0.1
3 Iron ore/ Red ochre 0.0181/0.0111
4 Coal 0.0926
5 Gypsum 0.0706
6 Fly ash 0.2931
Inventory analysis
Process plant :
Stack attached to Min. Particulatematter (mg/Nm3)
Max. Particulatematter (mg/Nm3)
Avg. Particulatematter (mg/Nm3)
Raw mill and KilnExhaust
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
Particulate matter analysis of different stacks
• 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
SO2
NO
NO2
NOx
CO
HCL
NH3
PM
TOC
CO2
O2
H2O
HF
C6H6
Hg
Hydrocarbon
Cobalt
Copper
Lead
Manganese
Nickel
Thalium
Vanadium
Zink
Unit
kg/ ton
0.0146744
0.9254828
0.0167089
1.432698
0.6726382
0.0005658
0.0264336
0.0263513
0.011914
514.67345
220.48723
167.53291
ND
ND
1.436E-05
ND
1.41E-05
2.48E-05
2.825E-05
0.0001199
9.616E-06
2.179E-06
ND
4.016E-06
Inventory analysis
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Emissions ( e.g. CFCs )
Chemical reaction releases Cl, Br
Cl, Br destroy ozoneMidpoint ( 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
Approach:
Impact assessment of environmental loading
• The categories of the environmental problems
a) Resource depletion/Abiotic depletion ADPADPb) Global warming , GWPGWPc) Acidification, APAPd) Photo-oxidant formation, POCPe) Eutrophication, EPEPf) Human toxicity, HTPHTP
Impact assessment of environmental loading
Sr. No
Impact name Classification CommonPossibleCharacterizationfactor
Description ofCharacterizationfactor
1 Resource depletion Global RegionalLocal
Resource depletion potential
Kg Sb- eq
2 Acidification RegionalLocal
Acidification potential
kg SO2-eq
3 Eutrophication Local Eutrophicationpotential
kg PO4-eq
4 Greenhouse effect Global Global warming potential
kg CO2-eq
5 Ecotoxicity (no unit) Local----
Multimediamodeling
6 Human toxicity via water,soil, air, and plants
Global RegionalLocal
Human toxicity potential
Multimedia ModelingKg of 1,4,DCBeq
Impact assessment of environmental loading
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
• Simple conversion and aggregation:
∑ ×=subs
subssubscatcat esultInventoryRCharFactesultIndicatorR ,
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
Sample calculation:
• 514.6734 kg CO2/ ton of cement
• 1 x 514.6734 = 514.6734 kg CO2 eq
GWP = 1
impact categor
y
category indicator
characterisation factor
category indicator result
Evaluation of impact assessment
ADP GWP AP POCP EP HTP
kg Sb eq/ kgkg CO2 eq/
kgkg SO2 eq/
kgkg C2H4 eq /
kgkg PO4 eq/
kgkg 1,4 DCB
eq/ kgNaptha 0.0201
LPG 0.0187NGL 0.0187Coal 0.0067
Natural Gas 0.0187Petrolium 0.0201Crude oil 0.0201
LNG 0.0187
CO2 1CH4 21
HCF 2800N2O 310SF4 23900Nox 0.7 0.028 0.13 1.2Sox 1 0.048 0.096Dust 0.82HCL 0.088 0.5CO 0.027
COD 0.022
T-P 3.06T-N 750
Phenol 0.00008
Source: Handbook of LCA 2002
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-05
0.000283
NH3
PM 0.021608
TOC
CO2 514.6735
Evaluation of impact assessment
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• Graphical presentation of emitted particulate mater based on functional unit.
0
0.01
0.02
0.03
0.04
0.05
0.06
0.07
PM
R & K exhaust
Cooler
Cement mill
Coal mill
LM crusherPM
kg
/ to
n o
f cem
en
t
Evaluation of impact assessment
0
0.01
0.02
0.03
0.04
0.05
0.06
PM
R & K exhaust
Cooler
Cement mill
Coal mill
LM Crusher
Hu
man
to
xic
ity p
ote
nti
al
(kg
eq
. 1,4
DC
B)
Evaluation of impact assessment
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
Valuing / Weighting
Evaluation of impact assessment
Scope of further work
• Indian cement industry is one of the most growingindustrial sector.
• India’s per capita cement consumption is belowthan the world average per capita cementconsumption.
• There are many new cement manufacturing unitsand cement grinding units are in progress in India.
• Still the reliable and acceptable LCA are notavailable for specifically Indian conditions.
• The LCAs should be carried out for different typesof cement. The LCA of cement will help to betteruse of natural resources with minimizedenvironmental impact. 37
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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
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.
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• 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.
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 operationsto lower lifecycle emission profiles.
Conclusions/ Recommendations
3. Process
• Encouraging cement plants to take up LCA studies voluntarily for continual improvement.
• Waste heat recovery system
4. Use of Alternate Fuel
• National policy to systemize supply on long termbasis for consistent quality waste derived fuel.
Conclusions/ Recommendations
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).
7. Packaging• Policy initiatives to discourage the usage of
packed cement bags for large infrastructureprojects and bulk consumers.
• Encouraging the investments in bulk materialhandling and transport facilities to bring downseepage loss
Conclusions/ Recommendations
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).
• Vijay Kulakarni and Ramachandra, T.V. 2009, EnvironmentalManagement,
• RalphHome, Tim Grant and KarliVerghese, Published by CSIROPublishing, 2009, Life Cycle Assessment – Principles, practices andprospects
• 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, FinalReport - Life cycle assessment of example - packaging systems for milk
• Jan R. Prusinski, Medgar L. Marceau and Martha G. VanGeem, LIFECYCLE 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 DifferentTreatment Options for Plastic Wastes
• UNEP LCA Training Kit, Module e – Impact assessment, Life CycleAssessment - 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
References