Life Cycle Assessment of Portland Cement Manufacturing Process

Date: 22/12/2010PresentationonLife Cycle AssessmentofPortland Cement ManufacturingProcessPresentationbyNikhil KulkarniPurpose: 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• References2

Problem formation• Concrete is second only to water as the mostconsumed substance on Earth, with almost oneton of it being used for each human every year onthe planet earth. (Lafarge Coppee SA. Globe and Mail, October 20, 2000).• one of the largest greenhouse gas emitting, highlyenergy and natural resource consumingindustries.3

Objectives• To assess the life cycle of Portland cementmanufacturing process to minimize theenvironmental 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• References5

Cement Manufacturing ProcessTypes :1) Hydro process (Wet process)2) Pyro process (Dry process)Considering life cycle of cement, it undergoesvarious chemical and physical transformations.Considering product system:Inputs:Raw materials and energy (Electricity andfuel sources)Outputs: Principal product, Emissions to air, solidwaste, other environmental interactions6

Lime Stone MiningCrushingStacking and reclaimingAirborneemissionsOther raw materialRaw material grindingRaw meal storage and blendingWatereffluentsPreheating and burningClinker coolingClinker storageSolid wasteClinker grindingCement storage in silosEnergyPacking and dispatchUseDisposalOtherenvironmentalinteractions7

200deg tem.Prehetar sectionRaw material feedK -stringRiser ductRotary kiln1100 deg tem.Coal burnergratecoolerPerhetar fanclinkerCool air byfan9

Cement Manufacturing Process• Cement is an inorganic, non-metallic substancewith hydraulic binding properties, and is used as abonding agent in building materials.CementCompoundWeightPercentageChemical FormulaAbbreviatedNotationTricalcium50 Ca3SiO5 or 3CaO•SiO2 C3SsilicateDicalcium silicate 25 Ca2SiO4 or 2CaO•SiO2 C2STricalciumaluminateTetracalciumaluminoferriteGypsum10 Ca3Al2O6 or 3CaO•Al2O310 Ca4Al2Fe2O10 orCaO•Al2O3•Fe2O35 CaSO4•2H2OC3AC4AF10

Overview of Life Cycle AssessmentLife Cycle ofproduct, process,service11

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• References12

MethodsGoaland scopedefinitionInventoryanalysisImpactassessmentInterpretationProductdevelopment,improvementStrategic planningPublic policyMarketingLCA framework and applications (Phases)

Study area

Definition of goal and scopeGoal:• 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 scopeScope of the study• The scope of the project focuses on the raw materialacquisition, processing, and product manufacturingstages i.e. lime stone mining to Cement.• Functions of the product system• Primary function of cement: Used as a bonding agentin building material.• Functional unit• As cement industry is a bulk manufacturerindustry all the data collection and calculationsin this study have been done for per ton basis.

Definition of goal and scope –System boundariesFuel(1) (2) (3) (4)Fugitive dustInfrastructureEnergy(5) (6) (7) (8)(9) (10) (11) (12) (13) 14)Waste heatOther raw materials(15) (16) (17) (18)DispatchDisposalUse

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• References18

Inventory analysisInvolves 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 emissions19

Sr.no.Inventory analysisLime stone minesName of raw material Name of product Consumption ofraw material1 Explosive,( AmmoniumNitrate Fuel Oil @ 100gm/ tonof Lime stone)Lime stone89.95 gm/ton2 Saw dust/ rice husk Lime stone 10.65 gm/ton3 Diesel Lime stone 0.42 lit/ton> 3 lit/ ton

Process plant :Inventory analysisSr.No.Raw materialConsumption of rawmaterial per unit of outputTones/ Tone of CementName of product1 Lime stone 0.87572 Shale 0.13 Iron ore/ Red ochre 0.0181/0.01114 Coal 0.0926Cement5 Gypsum 0.07066 Fly ash 0.2931

Inventory analysisParticulate matter analysis of different stacksStack attached toMin. Particulatematter (mg/Nm3)Max. Particulatematter (mg/Nm3)Avg. Particulatematter (mg/Nm3)Raw mill and KilnExhaust32.4 50.8 41.6Cooler 46.5 54.9 50.7Cement mill 38.0 55.6 46.8Coal mill 46.0 55.6 50.8LM 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 analysisWater consumption(Process plant)• Industrial: 7.96 lakh lits/ day• Domestic: 4.18 lakh lits/dayTotal : 1296213 lit/ dayWater consumption(Limestone mine)• Industrial: 77,213 lits/ day• Domestic: 5000 lits/dayi.e. 185.18 lit/ ton

Inventory analysisInventory analysis of Kiln and raw mill exhaustParameterUnitH2O167.53291kg/ tonHFNDC6H6NDSO20.0146744Hg1.436E-05NO0.9254828HydrocarbonNDNO20.0167089Cobalt1.41E-05NOx1.432698Copper2.48E-05COHCLNH3PMTOCCO2O20.67263820.00056580.02643360.02635130.011914514.67345220.48723LeadManganeseNickelThaliumVanadiumZink2.825E-050.00011999.616E-062.179E-06ND4.016E-06

Impact assessment of environmental loadingApproach:Emissions( e.g. CFCs )Chemical reaction releases Cl, BrCl, Br destroy ozoneMidpoint ( Ozon depletion potential ODP )Less ozone allows increasedUVB radiation - EndpointSkincancerCropdamageImmune systemsuppressionCataractsMarine lifedamageDamage to materialslike plastics26

Impact assessment of environmental loading• The categories of the environmental problemsa) Resource depletion/Abiotic depletion ADPb) Global warming , GWPc) Acidification, APd) Photo-oxidant formation, POCPe) Eutrophication, EPf) Human toxicity, HTP

Impact assessment of environmental loadingSr.NoImpact name Classification CommonPossibleCharacterizationfactor1 Resource depletion GlobalRegionalLocal2 Acidification RegionalLocalResourcedepletionpotentialAcidificationpotential3 Eutrophication Local Eutrophicationpotential4 Greenhouse effect Global Global warmingpotential5 Ecotoxicity (no unit) Local6 Human toxicity viawater,soil, air, and plantsGlobalRegionalLocal----Human toxicitypotentialDescription ofCharacterizationfactorKg Sb- eqkg SO2-eqkg PO4-eqkg CO2-eqMultimediamodelingMultimediaModelingKg 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 × InventoryResultsubssubs

Evaluation of impact assessment• CO2 contribute to climate change• Global Warming Potential (GWP): measure forclimate change in terms of radiative forcing of amass-unit of greenhouse gasimpactcategorySample calculation:• 514.6734 kg CO2/ ton of cement• 1 x 514.6734 = 514.6734 kg CO2 eqcharacterisationfactorcategory indicatorGWP =1category indicator result

kg Sb eq/ kgNaptha 0.0201LPG 0.0187NGL 0.0187Coal 0.0067Natural Gas 0.0187Petrolium 0.0201Crude oil 0.0201LNG 0.0187ADP GWP AP POCP EP HTPkg CO2 eq/ kg SO2 eq/ kg C2H4 eq / kg PO4 eq/kgkgkgkgkg 1,4 DCBeq/ kgCO2 1CH4 21HCF 2800N2O 310SF4 23900Nox 0.7 0.028 0.13 1.2Sox 1 0.048 0.096Dust 0.82HCL 0.088 0.5CO 0.027COD 0.022T-P 3.06T-N 750Phenol 0.00008Source: Handbook of LCA 2002

Evaluation of impact assessmentParameter GWP AP POCP EP HTPSO2 0.014674 0.000704 0.001409NONO2NOx 1.0028886 0.040116 0.186251 1.719238CO 0.018161HCL4.97904E-0.00028305NH3PM 0.021608TOCCO2 514.6735

Evaluation of impact assessmentPM kg/ ton of cement0.070.060.050.040.030.02• Graphical presentation of emitted particulatemater based on functional unit.R & K exhaustCoolerCement millCoal millLM crusher0.010PM34

Evaluation of impact assessment0.06Human toxicity potential(kg eq. 1,4 DCB)0.050.040.030.020.01R & K exhaustCoolerCement millCoal millLM Crusher0PM

Evaluation of impact assessmentValuing / WeightingSr. no. Impact Category RelativeImportanceWeight (%)1 Global Warming 162 Acidification 53 Eutrophication 54 Fossil Fuel Depletion 55 Human Health 11

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

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• References38

Conclusions/ Recommendations• Enclosing cement mill section and usingrubber curtains as a barriers for dust.• Control the corrosion of different transferplatforms.• Provision of dust suction facility at groundlevel.• 1. Policy Aspects• A comprehensive norm for cement industry(covering all pollutants, when coal and/oralternate fuels are used.)• Incentivising the use of wastes as rawmaterials / fuels.39

Conclusions/ Recommendations2. Mining• Efforts for enrichment of low grade limestone• Shifting emphasis from environment control toenvironment protection (using globally accepted decisionmaking tools like LCA to operational mines.)• Utilization of biodiesel for quarrying operationsto lower lifecycle emission profiles.3. Process• Encouraging cement plants to take up LCAstudies voluntarily for continual improvement.• Waste heat recovery system

Conclusions/ Recommendations4. Use of Alternate Fuel• National policy to systemize supply on long termbasis for consistent quality waste derived fuel.5. Product Variation• Encouraging manufacture of blended cementand incentivising the conversion of OPC grindingfacilities to PPC.• Optimization of supply & distribution of fly ashwithin a cluster.• Encouraging production of low energy cement.• Encouraging creation of additional grindingcapacities near demand centers (Split location).

Conclusions/ Recommendations7. Packaging• Policy initiatives to discourage the usage ofpacked cement bags for large infrastructureprojects and bulk consumers.• Encouraging the investments in bulk materialhandling and transport facilities to bring downseepage loss8. Environmental Good Practices• Encouraging the cement plants to practicecommon / strategic sourcing across the cementsector for environmental improvement in a cluster.• Encouraging creation of a Environmental DataBank shared sourcing center, (NCB as nodalagency to share experience and technicalparticipation).

References• Vijay KulakarniManagement,and Ramachandra, T.V. 2009, Environmental• 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: ImpactAssessment & 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