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    Cement plant environmental handbook

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    Cement Plant - Environmental Handbook

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    JK
    Cement plant environmental handbook

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    © All Rights Reserved
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    lovato ae Environmental Handbook Second Edition IF YOU WANT TO GROW IN THE FUTURE YOU SHOULD MAKE SURE THAT YOU HAVE STRONG ROOTS | | Second Edition Contact Managlng Eton Thomas Armstrong, Senior Editor Phil Kerton Fesistant Editor Suzanne Starbuck Production iter: Muriel Design: JMF Associates ‘Advertsing David Hargreaves, Elodie Compos, “radeship Publications Lts Old King’s Head Court, 15 High tres, Docking, Surrey, RH AR, UK. “el: +44 (0} 1306 740383 Fax: 44 (9 1306 T4n6c0 mall inio@cerNet.com Website: ww CernNat.comn Copyright© Tradeship Publications Lid All ights reserved No part ofthis publication may be reproducee, stored ina retrieval system, o transite nary formor by any means electronic, mechanical or ‘otherwise, without prior writan eansent from Tadoship Pubicatons Lid. This publication is intended solely foruseby professional personnel who are competent to evaluate the significance and limitations ofthe information proved erein, and who will accept total responstbilty forthe application ofthe information, Printed in the UK by Warners (Midlands) ple, Acknowledgments The publishers would ike to acknowledge, with grateful thanks, ll individuals, companies and associations who have contributed articles to this handbook. Front cover Photograph supped courtesy of Siemens AG, Germany (owewsiemens.comn) laimer Altnough every effort hasbeen madeto ensure the ‘accuracy and completeness ofthis publication, the publishers de not accept any responsiblity for any erors ‘oromissions ny views expressed are those of the publishers ane ther correspondents Tradeship Publications Lt Introduction 1, Environmental context and sustainability challenges 8 The way forward: extended co-processingto produce altemative binders with a zero environmental aotprint. 3. ‘ean-PlerraDegre, Cements, Suitzeland '@ Sustainability and cement ~adéressing evolving challenges, Pipe Fonta, Cement Sustanabilty Initiative {CH}, Switzerland ' CO, reduction: principles ofthe EUEmissions Trading Systern Tino Vian, Lafarge erent Wéssingen GmbH, Germany Sustainability inthe cement sector, arco Gols, kaleement, tly ' Proposed industrial coal reduction regulation for Ontario, Canada ‘re Helge Kerstansen, foundation fer Scientific and Industrial Research SINTEP) Norway ‘8 Ourcontribution tothesocietal challenges ofthe futur. ‘1 Tighter regulations for emissions. Keto, CPX Constancy, Uk Quarry operations and ecosystems 38 The Quarry Lie Award research and dialogue to promote biodversity conservation Heidebergcement aG Germany 'B Quarryrestoration leader in Medley, Florida. ‘Audey Beene and suhamnnad Khan, Titan oride US & Wieternetworkimprovementsat Tora delos Vados, ‘Ana Gonzalez de Aledo and Mara Luisa @ueno, Cementos mos Notorariim Group, Spain Conserving nature's foundations: biodiversity management plan guidance. Philippe Fonta, Cement Sustainability Inatve (CSI, Switzerland CO, emissions and energy efficiency ( Achieving the best energy consumption: the key drivers and some practical case studies. asce Evens, Emam Lid, UK 5ACK’s waste heat recovery power generation system for cement plants, CChongren Zhang, Anhui Conch Kawasal Engineering Cots (ACK, China | Waste heat recovery inindla’s cement industry toned Kumar, ACE Led, na '& Energy conservationin the cement plants of Japan, Jopan Cement Association, japan Maintaining the EU ETSin practice Arthur Harisson, arthur Masson 36, UK 1H Reduction of CO, omissions: a winning strategy. Cementos argos A, Colombia, 1 CO} mitigation from the use of alternative fuels Eniique De Hoyos Guajardo, Cemex Méxien, Moxco | The potential for energy savings from electrical power audits Lawrie Evans, EmCemsttd, UK Energy conservation: E-C? Starys Cement Inc, Canada Strategies and systems for using AFRs 3 Developing an AF road map. . ‘rian Herat Resouceé Aa 1 The creation and use of alternative fuels around the world David Hooper, Global AF Ltd Hong Kang 2 2 32 40 2 44 46 54 62 6s 68 n 78 2 6. 7 1 Success in growing a waste uel business, : as ‘Geocyel France and Belgium ‘Alternative fuels and raw materials:a win-vinsolution fr the indian cementindustry. 88 ‘Sormath Bhattacharjee and Rit Bharadwaj, institute forIndustial Productivity, India 1 Key considerations inthe introduction of alternative fuels and raw materials so ech, Laeige Asia Se Bhd, Malaysia ig requirements for co-processing of wastesin China and india 2 XéreHelgeKarstensen, Foundation fr Scientic and Industrial Research SATE Harway and Yan Dural Chinese Research Academy ofEnvicnmental Scences, Chia i Secondary fuel preparation. 7 Boris Sassenrath and Tim Heme, vecoplan AS, Germany Alternative fuels case studies 8 Nakingagreen commitment Lucky Cement 14, Pakistan 1B Experiences with wastes as alternative fuels and materials, 104 Tinovillane, Lafarge Zement mb, Germany ‘Using FIRSU as an alternative uel 7 107 Enrique De Hoyas Guajardo, Cernox Maxie, Meee 4 Environmentalimplications of introducing solid felsinto the energy mix ofthe Egyptian cementindustry..... 110 Formas t-Halim aablan Cement Company, Eayot |B Theuse of biomass at Votorantim Cimentos’ Nobres plant, Braz a2 Livia Blo: de cand and Naiare Kaveles cle Souza, Yetoratin Centos, ran '® Hon Chong cement plantin Vietnam ~The “Best Sustainable Performers 2009-2013", na ‘wong Thi Phuong Lar, Holm Vietnam, Vet Emission monitoring and abatement 116 @ Using advanced modelling tools to reduce NO, and CO emissions from cement kilns. 118 Tah Abas and ichalsAetopets, rl UK ‘The ilterbag asa key component for reducing emissions and costs. 12 ‘rere atwoties Eon hres Gn Aa 1 Mereuryaderessing evertghtning regulations ur Totnes Cates ine le Contig UA 1 No,reducton-nen SHCRisnot enough bt “pn ine Kine Consulting US 1 xperences withthe ner regenerative thera ovation TO) system atthe opting coment plat ba ‘Gerhard Philipp, Woplinger Bausofindustia GmbH, Austria NO,emission reduction atthe Vidal Ramos plant. .37 ‘aro Henrique rterlenghi and Caias Roberto Morera da Cun, Votovantin Cimentos, Braz $3. Using high-sulphur raw materials and fuels in acement plant —a case study, 140 Prakash Singh, ® Chandrasokharand Rajasekar, UlyaTech Cement Lg, Inia |B Formation and control of dioxins in modern preheaterjprecalciner dry: process kilns 1a ‘re Helge Karsenson, Foundation for Scientific andindustial Research (SNTEF), Norway 1 More than meets the eye: emissions (bio monitoring, dispersion and isk analysis as innovative tools, NMG aia Jose Botelho, Sci and José Manuel Palma-Olveira, University of isbon/Secl, Portugal Cement milling and products 150 '@ Reducing CO; emissions through cement grinding optimisation, 152 ike Sumner, Keith Marsay Ricardo Stoppa and Josephine Cheung, Grace Construction Products, UX |B Production and use of cements with artificial pozzolan 156 ‘bia Regina Soares SViera and José EustSquie Machada, Vatorantim Cimento, Sra ‘Mi Limestonecalcined clay cement. ene, JerbreDLaffalyond A ale Polytecbn que Federale de Lausanne, Snitzeland The first edition of The Cement Plant Environmental Handbook was published in 2003, This second edition comes after a significant gap and the times have changed somewhat. n 2003 the Cement Sustainability Initiative (CSI) was only a year old, and had yet to achieve the respect and influence thatit novr attracts. Also, ‘he first edition ofthe influential European Union reference document on best applicable technologies for environmental protection in the cement and lime sector was only two years old, ‘Tofind out more about today’s environmental concerns, @ search was made for relevant journal articles, indexed by the British Library, covering period of 18 months from January 2013. This tured up 215 results, of which almost 80 per cent are concerned with four broad topics. ‘Thirty-four per cent are concerned with the use of alternative fuels, a clear winner over the topic of emission abatement, which tooka 21 per cent share including a mere seven per cent for dust control. The nextclasses were aspects of concrete technology and novel clinkers (12 per cent}, and plant design and performance (11 per cent]. Incontrast, a similar (but not identical) survey in 2003 identified a 20 per cent share for dust abatement, tying for top place with waste fuels. Many changes since 2003 result from pledges made under the CSI, Combining data from Holcim, Lafarge, HeidelbergCement and Cemex, the following percentage reductions in emissions per tonne of cement had been achieved by 2013:NO, - 25 per cent, dust -55 per cent and SO, ~60 percent, In addition, reductions in net CO; emissions since 1990 had reached 25 per cent. Other figures for 2013 are: clinker factor ~73 per cent, and alternative fuel proportion ~ 19 per cent [including a seven per cent contribution from biomass). This ew edition of the Handbook has successfully attracted articles from leading experts, principally among cement producers, and their industrial associations and consultants. The aim has been to provide an up-to- date understanding of how the best standards of environmental performance and sustainability aré achieved, and to consider the different challenges encountered in various countries. One nation's alternative fuel may actually be the conventional energy source for another. ‘The response from authors has been pleasing, as shown by the scope and depth of topics covered. However, there are a number of topics and geographical regions that we have been unabletto include and will hopefully appear in the next edition of the Handbook. Sincere thanks are due to all the authors for their ime and commitment to sharing their knowledge and experience. Phil Kerton, Senior Editor November 2014 sustainability challenges Westart with a collection of articles that explain just why various performance standards and reports are required from cement plants, accompanied by an overview of the technical methods that are available ‘tomeet them. Regulations are becoming more strict and corporate policies firmer and more extensive. Those involved in negotiating details ‘and communicating their outcomes need to appreciate the practical implications that may result from poorly-drafted or inappropriate regulations. Likewise, staff living with new systems and demands. Tere eae ut cc cag ‘contributions are essential to the sustained livelihood of their places of a Pa Most ofthe articles address the current sustainability agenda and the ‘demands of current regulations. However, we start with acontribution Cee eee ett ete ce ad customers need to adapt to new conditions. Products must evolve away ee eeu cee eee standards and reduce dependency upon virgin raw materials, taking See eee Cee eae tas Wevertoeeeeeeeaebes The way forward: extended co-processing to produce alternative binders with a zero environmental footprint by Jean-Pierre Degré, Cementis, Switzerland Embra ing the circular economy concept and encouraging the replacement of “commodity” cementsbyalterative cementitious binders -zero clinker cements ~ produce Global cement production is expected to increase significantly above Sont by 2020, with corresponding increases in energy anc ‘aw material demands and environmental impacts, Clinker i responsible for about 5-6 Der cent of the worldwide emissions of CO, adsl from human activity. its process from lime. and silica-bearing rw material, suchas limestone al clay, which are ground and fed into a rotary kin for pyroprocesing. From the clinker production paint of view, ret CO, emissions are not changed by using alterativefuelsorret. ‘The clinker content of cement can be reduced significantly by using other major ‘constituents, having ether “hydraulic or pozlanic actly. Due to exsting leget framenoris and standards, but many due ‘0 current practices inthe Bulleing industry, nly a fovs minerals are used, such as ground limestone, blast furace slag, coal fy ash and natural pozzolarie materials, based on regional availabilty Figure 1: e>processingin waste management hierarchy | Avoidance and rection Co-processing Incineratinjcoicnertion with energy recovery Landing 2m waste, byproducts and low-grade minerals via re-processing, is the only genuinely sustainable way forward, according to san Pierre Degré, To continue covering. the future growing céemand for cement, and consiering. the limits of natural resourcas and accessible fossl fuels, there i @ need for @ much more drastic reduction of clinker Tacos. tis now fproven that the production of altematve Binders with zero clinker can be attained, So, the development of altemative binder technologies not requiring nigh temperature firing of timestone and sikca materials absolutely mandatory. Today, lange number of researchers are engaged wortdwide, but stueles remain atan eal stage, If tocay’s coment industry wants to survive this century, a comolete remodelling of endproducts ig necessary, via resource diversification and new process evelooments. India represents one of tre mest signfcont examples. Here, curert cement production Is around 350Mte and i forecast to reach approximately Lont within the next 1015 years, Due to the sational Scarcity of reserves of highrgrade limestone ‘and traditional fuels, the production of alternative binders from a set of managed mineral wast or low-grade rasources isthe only sustainable opportunity for the Indian cement sector to flfl the country’s future dernand and growth, Integrated co-processing concept ‘co-pracessng invohes the use of wastes oF low-quality materials in resource intense industios Gls) such a= cement, lime and steel manufacturing, Instead of fossil fuels. and other natural esoureos, Applied locally o-procestng brings benefits because is Upgrades waste management within the waste hierarchy (see Figure} Reduces neath and ewvironmental impacts of waste. Nainains and improves treindusral sector's eompetitvenass, Decreases the cstsoF waste management significantly Improves al human ane techrical-economne factors, Alls must be committed to maximising te use of aitematve fuels and raw materials for thet energy and mineral resource requirments Thereplacement offossilfuels andnatarelray materials forthe curent production of clinker ' a prerequisites proven that reaching 100 per centenergy substiutionisteasble without any compromiso to health and safety the ‘emironment,orproduct ane process vali, There is no longer any need to continue buliding more clinker production capacity. Instead, the use of cementitions mineral compounds (existing or ateial) must be actively deveicped and promoted, using low-grade resources and wastes t9 meet customer needs directly. With this approach lls can minimise their capital costs, energy demands and environmental Jimpact slong with actieving a reduction in thelr C0, footprint Furthermore, ls need drive andanticipate all egal arenorks to force the creation ard acceptance ofs mandatory circular ecoromy (see Figure 2) forte bulidinginducryby the Use oflow graderesources and wastes forthe procuction of cements, binders and al end products needed! by customs, Alternative binder for the production of zero clinker cement~ main principles Local production requies improved logistics, Use oflacairesourcasand end precuctqualty rte specticaly following local reeds. A large set of products and processes can be ‘envisaged for oroducing altemative binders with signficantyreduced energy needs, , emissions and environmental impacts compared to clinker enc traditional O>C ar’ Dor blended cements (see Figure 3), Research and evelopment are needed to develop new processes and. products that significantly Feduce dependence on natural resources Innovative. processes. such as. optimised waste management to recover ferrous and non-errous metals in parallel with proving the mineral mix needed to produce cement binders must be investigated. Extensive industial application and tals must be promoted as soon asposssl, Co-processingisnow accepted and promoted by international bodies, NGOS, academics, and intematicnal and local authorities. doesnot refer solely tothe use of alternative fuels and raw macrilsin the curren clinker procuetion mindset enone ons, Figre 3:to reduce ts environmental footpeir, the coment industry mast change ts Target inate 10 ens wots nthe caret cae nto par aver te eabihee “hate erie et Grouse | exist, pst intone Takano wat “eheonalgay pater porate Siac fn ‘Ramaboe draw apes Newtindes whan, Cer entscing Production process but also includes the evalopmant of alteratve hydraulle andor powolanic binders Thedeveloamertofthese ew tyres of cementitious binder wil require new standards and legal rameworks, specific legal structures and technical guidelines for the optimum use of wastes and lovsgrade reseutees in the sector. Alternative binder for the production of zero clinker cement main advantages Many mineral wastes and lowsgrade natural resources nave latent hydraulic and paolaric binding properties. These properties can be davelapad through simple processes. The binders can be located in an alternative, farge working area ia the C20-SidA,0, temary phase diagram (see Fgure 4, avoiding the narrow and relatively Figure location of altemative bincers in C20-S10,.AL0,temary pace dagram Ea cansat cng rrarcenng —prolocsprkesh ‘unstable phases of OPC. Altemative binders ‘eanbe used alone or as clinker replacements to produce blended cements. The quality of such blended cement products Is in mary aspactssimilaror bettertothat oF OPC andlor asia slag-and pozzlanic cements, ‘The production of alternative binders emits signicarly less 00, than tha af liner an ‘wocitional OPClcaments and also drives towards reduced dependence on traditional ‘cementadeltive(CA) sours. Thealierative, bigger working area at a lower C/S ratio results in 2 lower sensitivity tothe quabty of the input material ‘The production potential of these binders ‘could contiaute to solving the CAD/B°O. problems, extend the Ufespan of exrausted ‘quaries, and allow more flexi for new ‘quarries and the ange of usabe alternate raw material These binders can be produced at a lower cost than eller, with ‘much simpler processes (On the hardvare sk, there are a lot of pessibiltes: fer traditional roxary kilns! ‘alcnessto simple meltors, high-temperature nes, et. Pre. and post-treatment steps are the same as for clinker production, For a greenfield plent the cepital and operating ‘costs are therefore signficanay lover tha foracinkerplant, recucingthe CO, emissions and all other” environmental” potential Impacts, Those binders and blenéed cemants can be tailor-made respecting the exact customer requirements, with lower clinker factors ~ feven zero = at stable and law prlees, They can be producod closer fo thelr markets tan clinker. it wil be easy either to build small Paihia vcuiseas uu Table sources ofalkeratve anergy (AF AR CP, A, RC) Denomination aa | Re J sasthrnecesiag 7 x x CORE SIag x x | ‘Stel pares x x AF dust x Tron sulphate ee EEEEH EEE IEE wise ae i K x Feamud x x “Mumia res rom sale sag procesing x x [lumina dross (processed) x x ‘Copper siog x [> x ‘escainesiag Ht x {x | erase x x Chrome ste x x ‘coalash HE x]. x Founarysand x % Dredginastadge x x | onicpal awagesiuige x | Paporstadge x tx x “lagibottom ash hora NsWinineraon oC x Fiyash rom st ncneration x x | ‘i shale x ‘ating muccutngs rom petroleum industry x x | Spentcaabts rom pevchemialindustry x x Mine tats ee x Bovacwastes « « Phosphorous furnace tag x x Prosphormmsum x x Flvorayesum x x Flue gs esulphisoton eypsum x x ‘Construction and demelition wats x ‘Woste pass tines caen aT | clayindusry wastes x x ‘hao shredcrresiue x ‘Waste electronics and electricequpment x Waste asphalt « ‘tetas a x ‘Natural pozolanas x x | att pozotanas x x ftserrlcaco nits close to the diferent markets oF to tdrecty integrte them into esting cement plants, nereasng ther production capac. sources of alternative energy, materials, by-products and wastes ‘table 2 shows the materials that can be ‘examined with regard to their potential Usability a8 alternative fuels andor alternative raw materials (9 non-xhaustive Ts ‘altemative fuels for linker production (AF) ‘itemativeraw mataraisfor producing current cinkers AR) o-products used as addltves ‘ncement grinding (CP) alternative agaregates used in concrete mining MK) raw materalsfor alternative binder production Ch Together, these materials representa potential resource fr production of beteon 5-10ontof alternative cements ver yen Conclusions ‘Cement rocucersneestostap concentsting tn gaining acceptance of ‘one-sizefitsal products, produced to similar standards throughout the werlé. Instead they should embrace lcalsm, where local materials are ised to addvess local needs. Rather than ‘ve off profits generated from producing 2 commodity that is limited by product based Standards and codes, thereneeds tobe equal Status — oF preference ~ for perfomance based standards ‘or bulding components ‘and strcties, allowing ful vantage to be fahen of local resources. comprocessing signifies the use of waste andjor low-grade materials ia Ris such 2s the manufacture of cement, lime, steel, pass and alacric power, instead of fossil fuels and natural resources, Applied iocaly, ceovpracessing Has its place in ioday’s waste management hierarchy, reduces weste {generation and health onc. environmental impacts, maintains and improves. the indusinal sectors competitiveness, ond decreases the cots for waste management. co-processng, mainly in the cement sector Is nowinteratlanally accepted and recognise. fn October 201, the United Nations (COP 0 Basel Convention) offcialy endorsed “Techrical guidelines for hazardous wastes, copracessing in cement kilns’ A large ‘umber of national legl frameworks aieacy exist specially dedicated to co-processing fincluding Mexico, Ecuador, Costa Rice, Brazil, Chile, South Africa, Incia, China, Indonesia, Phiippines and Australia) and racy more aeuinder development. li jor {ntemational NGOs are naw on board and are ‘often promating co-socessng asa valuable solotion fr recovery of mineral and ener ‘wastes when professionally manage. (Nees ierels aaa Cemtech RMS as sie Europe/Middle East Africa /Asia /Americas Established in 1991, Comtech Conferences and ibitions have become the leading events in the cement industry calendar. Each meeting is carafully planned around a high-quality speaker programme and a ‘najor intornational equipment exhibition, all set within superb five-star hotel surroundings, to create the ultimate showease for state-of-the art technologies and their “pplication in the cement industry, rofessional development is a key focus of each meeting, schnicel programme offers work avariaty of elated themes, while infornative field sits ara organised to local produ aracting a muttinat oak cross-section of worldwide cement s, Cemtech events offer peertass networking four 1 Review key incustry trends anc new technologies rent markets and trade Analyse global @ Learn cbout sustainable manufacturing practices a Roview cac: excellence end best lormonstrating oporational ‘alable technology | Network with industry professionals and technical experts W Explores 1e-f-the art technologies in the exhibition 4 Experience Comisch’s euriorb hasitaliy 1B Visit | production facilties 1 Participate in tech sch cfc ag hemienitreview eltreview i ‘Waste tjpes potentially involved forthe production of alternative binders abies pote ad existing wastas and technsioaies Examples of some enstng technoloples Honrevhaustive sts ‘slags, ut tallags ane stulges indusity Residues rom waste cieration Dredging lade ‘Sewage aude jb Paperstudae J exting muaicatings rom petrcteurindusiy [ ine tatings | Tero waste steelwork Pyroareprocess ite a0 pres [ eiteivage trate Gastoliqulatechnalony Pyrolysis processes pomeleproess| | Phosphogypsum | Reco ust | ] Demolition wastes ‘educa ‘Waste glasstines + Tremalteaimentefaritrgmad o Clayindusty wastes | aur Shrecider Residue (ASR) Thermal esimentofelcutings ‘wate poxzotoric materials | Catena catcnrgprocess Waste asphalt [ sephats thane reatmentialiningprecess oe BEE [memes Grndngactvationo! demolition waste | Volesic ashes Under specific conditions, after 2 large set of Specific val aurns and under the umbrella Of the Stockholm convention ané UNIDO, fhe coment kin % nove offcilly reongnised find requested for the final elimination OF wastes related to persistent. organic pollutants. National cement associations nd intamational federations (CEMBURENU, Ficem, CSI, et) ave nowlargely promoting the concent Considerable effort has been made to Encourage @ greater understanding of the Concept, thanks in large part to timtations of patural resources. Knowledge development ‘onthe clinker uringprocess, environmental monitoring, wastesto-AFR and pre- processing has improved, as has cornmanity cceptance ad communication. There must Continue 2 Be ne compromise on health anc Safety, environmental impact, enceproduct andl process quality put huge davelopment potential stil exists For evamgle, the dissomination of mare Specific epa ramewors, integrating ater Alls into the co-processing concept. There is also the need to extend the portotio. leegrede energy ard mineral sources more widely. More work also still needs to be done ‘on process knawledge (pollutant balances, femissions and endsproduct environmental monitoring, ete, Further development. reajulted for RBD and new technologes ether for corprocessing ar pre-processing (waste pretreatment in space flies producing an SER meeting the specific acceptance Crieria and perm ts forcement plants). When ‘Leomestotne intogration oftusiness models ‘akthin te cement sector, extensive workand Inindset changes are needed to rove the fameworisunderpinning productstanderds, snitch ofen limit the use and numbers of Case study ect additives incurrentcement production, ‘co-processig can reach 309 pe ent thermal feneray replacement in the clinker process. Incar be also sed to develop and oxen the portolio of pozolanic andlor hydreuile binders produced at za0 oF avery low CO, footarnt, whieh can be added at tha cement indingstage oruseddlrectiyascementtious Frater by the uldingindusty Players within the cement sector without 4 2020-0 Sustainable Development vision Integrating full fossil fuel replacement bby alternative resources generated for waste and lowgrade energy sources and ‘tensive altematve cement/binderportilio produced with waste minerals or lowrrade Fatural resources wil not lst to the en of {he century. o-processingis starting to have | pas: and is moving towards a tremendous future, i Sliema wer ctmentis.com LUN Basel CoPr0 Basel Convention ~vavncbase int Portals) | easelCorention/docs/puby ‘techguidefeoment/tgcement2s ‘Alternative binder produced from dredging sludge Fora plant with a production capacity of about 0.5Mta, dredging sludge pre-treated via a setoffiter presses offers the potential to produce around 400,000tpa of pozzolanic binder. Thiscan be ether used directly by the building sector or asan additive in ‘the current cement production process. feasibility study has been conducted into the process. Estimated capex Is around €30m. be | | SIKA ADDS VALUE TO YOUR CEMENT Cement Is vital for today's construction industry. The cost aptimized production af quality cement which meets customer demands anu standards a6 well as sustainability issues challenges every cément plant individually, Sika offers innovative cement additlve correpts combined with a specialized technical support, targeting improved production rates, enhanced strength development anc adjusted workability. The reduced utiization of energy and clinker contributes to the profitability of your business, Sm senwees.ac wns CH 8048 Zh Suze 584364040 Fx 450 ms 50 wieshaco BUILDING TRUST jonmenital context and sustainability ao Sustainability and cement - addressing evolving challenges by Philippe Fonta, Cement Sustainability Initiative (csi), Switzerland The Cement Sustainability Initiative (C environmental and social challenges facing the market today. ‘The World Business Council fr Sustainable Development's (WBCSD) Cement Sustainability initiative recently announced the aunchof abroad analysis of theexteral- ties impacts and benefits) of tecement and Concrete sector, The CSI has come along Nay Since 2002, when the sector first united forts ‘agenda for Action, stating on a journey to Unerstand and adkess sustainability issues ‘The fist Agen for Action fallowed 2 £90. year extensive scoping studyandrearesented 2 major step forard forthe Industry set futon ambitious wack programme focussing fonsixspectic areas forimprovemont ‘employee health andsalety Climate protaction 2 emission monitaring and reduction responsible use of fuels and rawraterals x local imoacts on lane and communities ‘i coramurications. Recognising the importance of ‘cements fend use in constriction and Ure associated fevironmental benefits, an adltonal area = concrete reeling - as added in 2005 anc, faderessing continuausty evolving challenges, ve more areas were later added ~ water in ‘Jott and sustainable supply chal 2013), tn each area, two Kins of action wore iden tified. and promotes. Firstly, joint projects, tahere g/oupofcompaniesshare knowledge And best praciesto tackle aspecficarwiron renta, or socal issue, Secondly, individual betions, implemented by each company its ‘en operations (including target setcng and mance reporting), applying both inno: ‘Nation and best practic ‘kot has changed since 2002. Sometime ‘round 2008, the world reached point when, forthe fist time in histor, the Inajorty of people Uived in urban rather thom rua arens wth 7 per cent of these oy deli living In developing countries. ‘The need for durable, sustalnabie houses, ‘offices and public sector buildings has con- ‘nued t0 gow threughout the 21st century, tae increasingly extreme climatic events fhave emphasised the eed for resilent inastructures 'S outines its role in tackling the key sbal cement and concrete \We al Know that concrete and its main cor Stivert cement have important rles to Bay In delivering tommorrow's sustainable ‘Gees and infrastructures. Bu the industry ‘eo faces big challenges, in all three pillars of sustaiabilty thet the CS! continuousiy addresses Environmental challenges One ofthe biggestrtical sustainability issues ‘aceiby al stakeholders was the reduction of (Co, emissons and ater alroorne palltants from energy-intensive processes, TO design ‘and aply improved technologies tat reduce ‘missions it is lmpertant to have a clear an fceurate picture of te evesofemissionsand theiraigrs. “Tansparent common data reporting is one ofthe mostimportant legacies afte CI. The Carrent'Cemant CO, and snereyProtocel was Inally leased in 2008 on the basis ofthe row mostwidely-used Intemational account ing tool, calea the Greenhouse Ges (GHG) Pretaco, produce by the WECSD in partner "hi wth the World Resources institute CW {Yesion 3 Cement CO, and Energy Protocol Coy ond Energy Accounting and Reporting Stendardfor tha Cament industry, releasedin cements ky to economic and sustainable development nou apy changing and expanding Geman 0 embers eve there a tong business case fr the pura of sustainable 2001, is used by the majority of cement pro ducers dobaly, whether Si members orrot ‘ensures that al igure are reported using the same agreed methodology and can be ‘agerepated at sector (vel. t fms the basis OF cement data validation for several ager Ges, The European Union {EU} Emissions Trading System, the US Environmectal Protection” Agency {EPA} Mandatory Reporting. of Greenhouse Gases Rule, the Catfornia Climate Registry, and the Global Superior Energy Partnership {formerly AS Pacific Parineshia} have all adopted I, end the European Standardization Organization (CEN) has accapted It as a basis for develop inga cement sector standard, ‘ka important milestone in data gathering. and reporang was the launch of Getting the Numbers Right (GN) a global datzba Trough which aggregated data of cement Ca, and eneray information is accesible to Sil The database has since grovn signif tantly with the scope of data naw covering ‘A countsies and repfons where GNR system participants have clinker, cemert ane grin Frgoperations Participants cover23 percent ‘of ploba cement production, with High repre Sentalon (above 70 per cont) in Europe and the americas, andl ever 5O per cen in Indl. Irechina, the rest. of Asia and the Mie Eas, Hors are underay to increase coverage a5 ‘addtional partes Join, GNR not only dei ers the word's most comprehensive analysis Ca #60, ‘The influencing factors to reduce CO, emis sions in the manufacturing process are using, alternative raw materials ith 2 high Cad content, using alternative fuels with a low C0, emisions fatos high biomass content ‘or nigh calorific value and Increasing the cement/linker rato Economic assessment The EU Emissions Troding System is a comerstone of the EU's policy to combat climate change and a ley tacl In reducing industrial greenhouse gas emissions cost cffectivaly (see Table 2} The first, and stil Fluorinated o¥ide4.9% gases Som Table: pipe of enisions wading Plants Prelous 00, emissions 0008 an oalablecertcates 45008 1 (00; Reducton Actalemisions 400% ‘Aetual ensions Sood Trading selso0tofcenicates Buys00tofeerifientes Figure i daciang vende erent cng vain ingen reese] ins shale uel sobaon = = 5 «* § se > by far the biggest, Intemational system for trading greenhouse gas emission alowances, the EU ETS covers more than 13,000 power stations and industrial plants in 3 countries, aswell a atiney’,Ithas gone through several phases to Increase its effectiveness, which arguably has been uneven in itsimpact upon different sectors of industry and dificult te assess during a long period of economic donntum, ‘afarge Zement Wossngen’splant located nthe soutinwest of Germany, vas modernise in 2008 fromthe previous Lepel proces to stateottheart ‘oy-proces technélogy- Equipped with Fvestage _praneatr with calcne, the cement works hasa ‘nko capacity of 2306p Plants participating in the EU ETS must monitor their CO; emissions and to doso, they must have an approved monitoring concept. CO, monitoring Plants participating the JETS ust mon! for their CO, emissions and to do so, they ‘must have an appraved monitoring concept The concept ies upon datermning the total anual carbon input and is similar to soveral 189.8000 elements. The hey procedures are sampling and analysing fuels and ram rmatavials 2 calibration demonstrating plausibitty data storage and protection, CO, audit and reporting In the EU reported €9, emission values mus be varied. To obtain verification, an exter nal expert organisation must audit the plant te confirm the calculated CO, emission by checking for Incorsistences. in monitor ing in accordance with the approved plan and whether the values presented are cm plete and reliable. The verified data must be reported by 31 March each year an all relevant records and calculations must be tetaine for 10 years. we evident that to comply with require ments, significant dligence is needed within cach plant thatiscovered bythe ETS, Ml References ntp:/fwcllnatechange2013 orgiimages report/NGIARS_SPU_FINA.od page upy/wenps govigogaynaturscier cel images/Gresnhoumefieet 2 “tpfinwar apa gorflimaestucents/bases/ rdaylareenbouse gases html *htpshwwrecpce ehlargnizaon/organizaton shir $htpllnleccinthyote_protocoltems/2830. "raped ce/ewieb on ausstod-be emontpeodukton/av16aR4ess "hte europa cufcma/pollsfesindes. enntm Peck udcouirohsadl awratargecd ETS-htp:jecuropa.euidimay paliciesfetsfindex_en.htm ci Environmental context and sustainabi ity challenges. Sustainability in the cement sector by Marco Goisis, Halcementi,taly The cement sector is making significant inroads to becoming a low-carbon, energy-saving industry. This article looks atthe role played by technology as well as research and development n achieving this goal With cement consumption expected to roughly double from the 2208 level to sont by 2050 (IEA 2010 High Bie Scenario}, those onoatred with the sector's environmental performance need to aparece how the cement industy contributes to the expecta: {ons of society, look at how it copes withthe need to forge more sustainable incustie, and confront the issues posed by the tnee pilars of sustainably: economical, socat 2ndenvronmental, Economical The cement sector is process and capital Intensive with 30 per cent of its operating cost related to enorgy. Thre yeas of tum ver are needed to pay back the cost of anew Dlant.A cement plant's also loca businoss, towing 2 backbone for local econarries 5) Promoting 2 local industrial base and deliv ‘fing 2 stable end continuous s00rc2 of jobs andeconomic att, Social The cement sector Isa producer of cement, the ‘gue’ of concrete, the mostused man made material worwide, with a consump. ‘ton of -3/personjyear. tis also a source of key materials for the construction insist, whichis devoted to providing the homes and infrastructure needed fora global population ‘@:pected tise above ont in 2050, a]umpot ‘ver 2hntaver four decades. ‘The sector i also a pionee* in innovating Dreduets and applications that significantly improve the energy efficiency of buildings {and transport, two fel of great concam to policy mais, Environmental The cement sector i an intensive consumer of enargy and natural resources, an intense ‘emitter of CO, accounting for at least five er cent of global anthropogenic emissions (69, anda primary industia seat for using wastes trom othor industries for recycling and incineration as fuels including materials ‘hazardous to heath Coméureau, the industry's representative body in Europe has proposed a cambination Of paral strategies along, five main routes to Improve sustainabitty ‘and accress the challenges of resource efciency, energy cfficieney, carbon sequestration and reuse, Product efiiency and downstream products, Resource efficiency Altemativefiels Around 40 per cent of emissions during linker production arse from fuel combus tion. To change its carve profile ane shift from cartonvintensive fossil els to loner

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