– Energy Benchmarking and Carbon Footprint Reduction Opportunities in Portland Cement Manufacturing Processes in Nigeria –
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ABSTRACT
Energy benchmarking and carbon footprint reduction opportunities in Portland cement manufacturing processes in Nigeria are presented.
Life Cycle Assessment (LCA) is used to estimate the environmental impact of three cement manufacturing processes in Nigeria.
The energy consumption of the cement manufacturing processes are evaluated using energy Benchmarking and Energy Savings Tool for cement (BEST-Cement).
BEST-Cement evaluates and compares the energy consumption of the cement manufacturing processes in Nigeria to China (world largest producer of cement) and International energy benchmark practices.
Energy Conservation Supply Curves (ECSC) were used to evaluate energy and emission reduction mitigations measures through the application of energy efficient measures/technological changes.
A list of 34 energy efficiency measures/technologies were applied as per the technological requirement of each cement manufacturing process technology in constructing an Energy Conservation Supply Curve (ECSC).
The carbon footprint of 1 tonne of Portland cement produced by the wet, semi-wet and dry cement manufacturing processes in Nigeria estimated using the 100 years Global Warming Potential (GWP) value are 871 kg of CO2 Eq, 694.45 kg CO2 Eq and 621 kg of CO2 Eq respectively per tonne.
The average technical potential for thermal and electrical energy savings for the three cement manufacturing processes, when compared to International cement manufacturing energy benchmarks, were 35% and 39.27%.
TABLE OF CONTENT
Cover page………………….. i
Title Page……………….. ii
Approval…………………. iii
Certification……………….. iv
Dedication………………… v
Abstract………………… vi
Acknowledgement……………. viii
Table of Content…………….. ix
List of Figures………………… xii
List of Tables…………… xiv
CHAPTER ONE: INTRODUCTION
- Introduction………………… 1
- Cement……………… 1
1.1.2 Cement Standards………….. 2
- Cement manufacturing in Nigeria……………. 4
- Cement Manufacturing Process and Technologies……….. 5
- Objectives………………… 8
- Significance of Study…………………. 8
- Scope of Study……………. 9
- Limitations………….. 10
CHAPTER TWO: LITERATURE REVIEW
- Description of cement (Portland) production processing steps…………. 11
- Raw material preparation………….. 11
- Clinker making (Pyro-processing or burning process step) 12
- Cement making (cement finish grinding process step) 14
- Cement manufacturing technologies…………. 14
- Wet cement manufacturing process…………. 15
- Semi-wet/ semi-dry cement manufacturing process……….. 15
- Dry cement manufacturing process………. 16
- Cement CO2 and GHG emission sources……………. 16
- Direct GHG emissions from calcination…………… 17
- Direct GHG emissions from fuel use………….. 19
- Direct GHG emissions from electricity………… 20
- Life Cycle Assessment……….. 20
- Carbon Footprint……………. 22
- Process Analysis………….. 24
- Environmental Extended Input Output Analysis 24
- Hybrid Analysis………… 25
- Energy Benchmarking of Cement Production Process………… 25
- Energy Conservation Supply Curve…………… 27
- Assessment of Portland cement carbon footprint………. 27
CHAPTER THREE: METHODOLOGIES
- Description of cement manufacturing plant………….. 32
- Conversion and assumptions………………….. 36
- Energy benchmarking methodology………….. 37
- Methodology for cement carbon footprint accounting………… 40
- Establish the scope…………….. 41
- Boundary setting……………. 41
- Collection of data………………… 42
- Allocation…………………. 42
- Assessing Uncertainty and Assessing data quality 42
- Calculating inventory result…………. 45
- Methodology for cement carbon footprint reduction……….. 46
- Cost of Conserved Energy……………….. 47
- Cost Carbon Reduction………………. 47
- Energy Efficient Measures and Technologies for reducing energy consumption and carbon footprint of Cement……….49
CHAPTER FOUR: RESULTS AND DISCUSSION
- Result………………. 51
- Energy Benchmarking…………………. 55
- Cement manufacturing process electrical energy consumption 56
- Cement manufacturing process thermal energy consumption 59
- Carbon footprint………………. 62
- Cement manufacturing carbon footprint process map………. 62
- Cement manufacturing process carbon footprint mitigation measures/technologies 65
- Wet cement manufacturing process Energy Conservation Supply Curve and carbon footprint reduction…….. 65
- Semi-wet cement manufacturing process Energy Conservation Supply Curve and carbon footprint reduction….. 68
- Dry cement manufacturing process Energy Conservation Supply Curve and carbon footprint reduction…… 71
CHAPTER FIVE: CONCLUSION AND RECOMMENDATION
- Conclusion…………….. 75
- Recommendation……………… 77
REFERENCE……………….. 79
APPENDIX……………. 85
INTRODUCTION
Climate change is increasingly being recognized as a major global challenge, and many organizations and individuals are actively trying to quantify their impact and also reduce Greenhouse Gas (GHG) emissions due to their activities (Doyle, 2009).
It is widely accepted that products and services that human beings utilize indirectly or directly generate GHG emissions.
The GHG emissions from anthropogenic sources are on the rise and thus warming up the planet causing adverse change in weather conditions and patterns around the world (GHG Schemes Addressing Climate Change, 2011).
The extensive use of fossil energy resources in world manufacturing industry contribute significant amount of GHG emissions to the environment (World Energy Resources, 2013).
One of such manufacturing process that contributes to the generation of GHG emission is cement manufacturing.
Cement manufacture is a major mineral commodity industry and cement production process is a highly energy intensive process (Ohunakin et al, 2012).
The energy consumed by world cement industry is estimated at about 2% of the global primary energy consumption, which is equal to 5% of the total world industrial energy consumption (Worrell et al, 2001).
REFERENCES
Intergovernmental Panel on Climate Change (IPCC) (2007). IPCC Fourth Assessment Report. Available from: www.ipcc.ch/publications_and_data/publications_and_data_reports.shtml
Ke, J., McNeil, M., Price, L., Khanna, N. Z. and Zhou, N. (2013) Estimation of CO2 Emissions from China’s Cement Production: Methodologies and Uncertainties. Energy Policy, 57(6),72–181.
Laitner, J. A, Worrell E, Galitsky C and Hanson D A(2003). Characterizing emerging industrial technologies in energy models. Environmental Energy Technologies Division Lawrence Berkeley National Laboratory Berkeley, CA. LBNL— 52774. Available online from:
Lu, H., E. Masanet and L. Price (2 009). Evaluation of Life-Cycle Assessment studies of Chinese cement production: challenges and opportunities. Proceedings of the 2009 ACEEE Summer Study on Energy Efficiency in Industry
Madlool, N. A., Saidur, R., Hossain, M. S. and Rahim, N.A. (2011).A Critical Review on Energy Use and Savings in the Cement Industries. Renewable and Sustainable Energy Reviews 15 (2011) 2042–2060.
Marceau, L. M., Nisbet. A. M. and VanGeem G M., (2006). Life cycle inventory of Portland cement manufacture. Portland cement Association. PCA R&D Serial No. 2095b
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