Carbon Management in an Emissions-Intensive Industry in a Developing Economy: Cement Manufacturing in Indonesia

2018 ◽  
Vol 2 (1) ◽  
pp. 1-9 ◽  
Author(s):  
Togar W. S. Panjaitan ◽  
Paul Dargusch ◽  
Ammar A. Aziz ◽  
David Wadley
Keyword(s):  
Alternative Fuels ◽  
Cement Industry ◽  
Cement Production ◽  
Carbon Management ◽  
Production And Consumption ◽  
Carbon Dioxide Equivalents ◽  
Strategic Position ◽  
Reduce Emissions ◽  
Cement Manufacturing ◽  
Capital Intensive

Around 600 Mt carbon dioxide equivalents (CO2e) of anthropogenic greenhouse gases (GHG) emission originates from energy production and consumption in Indonesia annually. Of this output, 40 Mt CO2e comes from cement production. This makes the cement industry a key sector to target in Indonesia’s quest to reduce its emissions by 26% by 2020. Substantial opportunities exist for the industry to reduce emissions, mainly through clinker substitution, alternative fuels, and the modernization of kiln technologies. However, most of these abatement options are capital intensive and considered as noncore business. Due to this, the private sector is unlikely to voluntarily invest in emission reduction unless it saves money, improves revenue, enhances the strategic position of the firm, or unless governments provide incentives or force adoption through regulatory and policy controls. In this study, we review the profile of the Indonesian cement industry and assess the carbon management and climate policy actions available to reduce emissions. The case highlights opportunities for improved carbon management in emission-intensive industries in developing countries.

scholarly journals Recent Progress in Green Cement Technology Utilizing Low-Carbon Emission Fuels and Raw Materials: A Review

2019 ◽  
Vol 11 (2) ◽  
pp. 537 ◽  
Author(s):  
Ali Naqi ◽  
Jeong Jang
Keyword(s):  
Carbon Dioxide ◽  
Carbon Dioxide Emissions ◽  
Alternative Fuels ◽  
Raw Materials ◽  
Low Cost ◽  
Cement Industry ◽  
Industrial Wastes ◽  
Low Carbon ◽  
Cement Production ◽  
Cement Manufacturing

The cement industry is facing numerous challenges in the 21st century due to depleting natural fuel resources, shortage of raw materials, exponentially increasing cement demand and climate linked environmental concerns. Every tonne of ordinary Portland cement (OPC) produced releases an equivalent amount of carbon dioxide to the atmosphere. In this regard, cement manufactured from locally available minerals and industrial wastes that can be blended with OPC as substitute, or full replacement with novel clinkers to reduce the energy requirements is strongly desirable. Reduction in energy consumption and carbon emissions during cement manufacturing can be achieved by introducing alternative cements. The potential of alternative cements as a replacement of conventional OPC can only be fully realized through detailed investigation of binder properties with modern technologies. Seven prominent alternative cement types are considered in this study and their current position compared to OPC has been discussed. The study provides a comprehensive analysis of options for future cements, and an up-to-date summary of the different alternative fuels and binders that can be used in cement production to mitigate carbon dioxide emissions. In addition, the practicalities and benefits of producing the low-cost materials to meet the increasing cement demand are discussed.

scholarly journals Theoretical Study on the Production of Environment-Friendly Recycled Cement Using Inorganic Construction Wastes as Secondary Materials in South Korea

2018 ◽  
Vol 10 (12) ◽  
pp. 4449 ◽  
Author(s):  
Jihoon Kim ◽  
Sungho Tae ◽  
Rakhyun Kim
Keyword(s):  
Alternative Fuels ◽  
Cement Industry ◽  
Firing Process ◽  
Gypsum Board ◽  
Environment Friendly ◽  
X Ray ◽  
Mineral Components ◽  
Waste Gypsum ◽  
Cement Manufacturing ◽  
By Products

The cement industry endeavors to reduce CO2 emissions from cement manufacturing by utilizing industrial by-products as alternative fuels and developing secondary concrete products from construction wastes. With these efforts, the cement industry is attempting to become more eco-friendly and reduce environmental load. This study analyzed the possibility of using inorganic construction wastes to produce environmentally friendly recycled cement using the process of proportioning. To this end, the types and production trends of recyclable construction wastes and previous studies on the development of recycled cement using such construction wastes were analyzed. Based on this analysis, recyclable inorganic construction wastes were selected, and real waste was collected. The chemical composition of each inorganic construction waste was analyzed using X-ray fluorescence, and the composition of ordinary commercial cement was used as the baseline. After the collected inorganic construction wastes were mixed, they were fired using the Bogue formula. The mineral components of clinker, which was generated from the firing process, were predicted and analyzed. Waste gypsum board and ceiling materials were shown to contain large amounts of CaO, which could substitute limestone—a key component of cement. These results suggested that if the limestone content was greater than 85 wt %, mixing inorganic construction wastes in appropriate proportions could be used to develop various types of Portland cement.

Co-Processing Hazardous Waste in the Chinese Cement Industry - Status 2014

2015 ◽  
Vol 768 ◽  
pp. 679-686 ◽  
Author(s):  
Juan Xu ◽  
Shao Feng Sun ◽  
Kårehelge Karstensen ◽  
Da Hai Yan ◽  
Zheng Peng
Keyword(s):  
Waste Management ◽  
Hazardous Waste ◽  
Alternative Fuels ◽  
Raw Materials ◽  
Cement Industry ◽  
Waste Generation ◽  
Cement Production ◽  
Management Capacity ◽  
The World

As China develops its economy, hazardous waste generation is expected to increase rapidly. Recovery and recycling, i.e. co-processing of Alternative Fuels and Raw materials (AFRs) and treatment of hazardous waste in energy-and resource-intensive industries such as the cement industry seems to be an supplementary option to conventional technologies which can increase the overall waste management capacity in China significantly. With the largest cement production in the world, the industry can save significant amounts of non-renewable coal and raw materials by substitution with wastes which needs treatment. However, co-processing requires appropriate regulations and policies to support its development and safe and sound implementation.

scholarly journals Metode Menentukan Klor dalam Sludge Oil: Perbandingan Metode Wet dan Metode Jena

2021 ◽  
Vol 10 (1) ◽  
pp. 1-7
Author(s):  
Herliati Rahman ◽  
Akhirudin Salasa
Keyword(s):  
Environmental Sustainability ◽  
Alternative Fuels ◽  
Negative Impact ◽  
Raw Materials ◽  
Cement Industry ◽  
Raw Material ◽  
Chlorine Content ◽  
Cement Production ◽  
Average Accuracy ◽  
The Difference

Currently, the use of alternative fuels and raw materials (AFR) in the cement industry is very attractive. This is driven by demands for environmental sustainability and the efficiency of fuel and raw material costs. One of the materials that can be used as AFR is sludge oil. However, it needs to be ensured that the chlorine content in the sludge oil does not exceed the threshold so that it does not have a negative impact during the cement production process. It is known that if the chlorine content is more than the threshold, it can cause blocking or clogging of the separator and the kiln. This study aims to determine the performance of the Jena Multi EA 4000 instrument in determining the chlorine content in sludge oil quickly and accurately. Analytic Jena Multi EA 4000 is an Atomic Absorption Spectrometers (AAS) instrument that can be used for analysis of samples in the form of solids or slurries containing chlorine. As validation of the resulting analysis, the wet method is used, which as usual, to determine chlorine levels. From the statistic analysis, namely the F-test and T-test, We found that F-count equal to 0.0080 and F-table equal to 4.2839. it shows that F-count < F-table, indicating the difference in the variance of the two methods H0: s12 = s22 is accepted because there is no difference to the variability of these two tests and the value of T-count = -3.9717 and T-table = 2.1788 so that T-count <T-table is accepted because there is no difference in the average accuracy of the two methods H0: M1 = M2.  

scholarly journals ENVIRONMENTAL AND OCCUPATIONAL NOISE MANAGEMENT PROCESS IN CEMENT INDUSTRY

2019 ◽  
Vol 9 (1) ◽  
Author(s):  
MARIJA HADŽI-NIKOLOVA ◽  
DEJAN MIRAKOVSKI ◽  
NIKOLINKA DONEVA ◽  
NATAŠA BAKRESKA
Keyword(s):  
Manufacturing Process ◽  
Energy Use ◽  
Process Management ◽  
Noise Control ◽  
Raw Materials ◽  
Cement Industry ◽  
Control Measures ◽  
Cement Plant ◽  
Cement Production ◽  
Cement Manufacturing

The main environmental issues associated with cement production are the consumption of raw materials, energy use and emissions in the air. Noise emissions occur throughout the whole cement manufacturing process - from preparing and processing raw materials, from the clinker burning and cement production process, from material storage as well as from the dispatch and shipping of the final products. The heavy machinery and large fans used in the cement manufacturing process can give rise to noise emissions. Cement Plants are required to comply with standards for reduction in line with national legislation, and to conduct measurements and perform noise surveys. Having this in mind, A TITAN Group Usje Cement Plant in Skopje, following their strong commitment to high environmental performance and Corporate Social Responsibility and Sustainable Development Policy in 2013-2014 have engaged an AMBICON Lab (Faculty of Natural and Technical Sciences) from Stip, to conduct a Noise Control Study in order to identify noise sources within cement plant and marl quarry, determine their impacts on nearby residents and develop noise control/protection strategies. During the past three years, the Usje Cement plant has implemented most of the noise control measures proposed in this Study. Also, a follow-up study during 2016-2017 was conducted in order to assess the effectiveness of measures taken. This paper presents the outcomes of noise reduction measures taken. Keywords: noise, cement industry, process management, measures, environment

REDUCTION OF CO2 EMISSIONS IN CEMENT PRODUCTION BY USING PREHEATER

2019 ◽  
Vol 6 (1) ◽  
Author(s):  
Haiyan Xie ◽  
Pranshoo Solanki ◽  
Alireza Mojadam ◽  
Wenfang Liu
Keyword(s):  
Construction Industry ◽  
Cement Industry ◽  
Cement Production ◽  
Dry Process ◽  
Alternative Technologies ◽  
The Us ◽  
Potential Benefits ◽  
Potential Factors ◽  
Cement Manufacturing ◽  
Reduction Of Co2

Cement has a pivotal role in the construction industry. However, cement is one of the key contributors to global CO2 emission levels. This is due to the energy-intensive nature of cement production processes. This comparative-descriptive study focuses on the potential factors to reduce the CO2 emission level in cement production and the decision-making process of adopting new environmental-friendly technology in production. Particularly, this study compares alternative technologies in cement manufacturing to reduce CO2 emission. It collects both the industry data and the data from Texas, which is the biggest contributor to CO2 emission in the US, to analyze how a shift in production technology could affect CO2 emission and eventually improve the outcomes of environment protection and energy efficiency. This paper projects a possible improvement of implementing the method of preheater-precalciner in cement production in lieu of wet and long-dry process to upgrade kilns and reduce problematic CO2 emission. This study suggests shifting from wet and dry kilns to preheater-precalciner systems to obtain the potential benefits of CO2 emission reduction in the cement industry.

scholarly journals Process based system models for detecting opportunities and threats – the case of World Cement Production

2016 ◽  
Vol 8 (3) ◽  
pp. 246-262 ◽  
Author(s):  
Raine Isaksson
Keyword(s):  
Global Warming ◽  
Carbon Emissions ◽  
Cement Industry ◽  
System Model ◽  
Sense Making ◽  
Cement Production ◽  
Content Type ◽  
System Models ◽  
Work Related ◽  
Cement Manufacturing

Purpose Visualising change needs could be complex. One way of sense-making is to use process-based system models. Global warming requires major changes in many fields and especially for cement manufacturing, which represents a growing portion of man-made carbon emissions. The industry has proposed measures for change, but it is difficult to assess how good these are and more sense-making is needed to clarify the situation. The purpose of this paper is to visualise opportunities and threats for global cement manufacturing in the context of global warming, using a process-based system model. Design/methodology/approach Available data for cement manufacturing and for carbon emissions are combined both historically and as predictions based on chosen key performance indicators. These indicators are related to a chosen process-based system model. Findings The results indicate that the global cement industry does not have a viable plan to reduce carbon emissions sufficiently to comply with the objectives of maintaining global warming below 2°C. The application of the process-based system model indicates that it has the ability to visualise important opportunities and threats at the level of global processes. Practical implications The challenges of the world cement industry with reducing carbon emissions are highlighted. This information could be useful as a driver for change. Originality/value The paper provides insights into process-based improvement work related to cement industry carbon emissions.

Use of waste derived fuels in cement industry: a review

2016 ◽  
Vol 27 (2) ◽  
pp. 178-193 ◽  
Author(s):  
Nickolaos Chatziaras ◽  
Constantinos S. Psomopoulos ◽  
Nickolas J. Themelis
Keyword(s):  
Alternative Fuels ◽  
Fossil Fuels ◽  
Fossil Fuel ◽  
Cement Industry ◽  
Wastewater Sludge ◽  
Cement Clinker ◽  
Firing Process ◽  
Cement Production ◽  
Content Type ◽  
Recycled Plastics

Purpose – Cement production has advanced greatly in the last few decades. The traditional fuels used in traditional kilns include coal, oil, petroleum coke, and natural gas. Energy costs and environmental concerns have encouraged cement companies worldwide to evaluate to what extent conventional fuels can be replaced by waste materials, such as waste oils, mixtures of non-recycled plastics and paper, used tires, biomass wastes, and even wastewater sludge. The paper aims to discuss these issues. Design/methodology/approach – The work is based on literature review. Findings – The clinker firing process is well suited for various alternative fuels (AF); the goal is to optimize process control and alternative fuel consumption while maintaining clinker product quality. The potential is enormous since the global cement industry produces about 3.5 billion tons that consume nearly 350 million tons of coal-equivalent fossil and AF. This study has shown that several cement plants have replaced part of the fossil fuel used by AF, such waste recovered fuels. Many years of industrial experience have shown that the use of wastes as AF by cement plants is both ecologically and economically justified. Originality/value – The substitution of fossil fuels by AF in the production of cement clinker is of great importance both for cement producers and for society because it conserves fossil fuel reserves and, in the case of biogenic wastes, reduces greenhouse gas emissions. In addition, the use of AF can help to reduce the costs of cement production.

scholarly journals Health Risk and Environmental Assessment of Cement Production in Nigeria

Atmosphere ◽  
2021 ◽  
Vol 12 (9) ◽  
pp. 1111 ◽  
Author(s):  
Mmemek-Abasi Etim ◽  
Kunle Babaremu ◽  
Justin Lazarus ◽  
David Omole
Keyword(s):  
World Bank ◽  
Air Pollutants ◽  
Carbon Capture ◽  
Manufacturing Industry ◽  
Crop Yields ◽  
Combined Cycle ◽  
Cement Industry ◽  
Cement Production ◽  
Cement Manufacturing ◽  
And Storage

The cement manufacturing industry has played a fundamental role in global economic development, but its production is a major facilitator to anthropogenic CO2 release and solid waste generation. Nigeria has the largest cement industry in West Africa, with an aggregate capacity of 58.9 million metric tonnes (MMT) per year. The Ministry for Mines and Steel Development asserts that the nation possesses total limestone deposits of around 2.3 trillion MT with 568 MMT standing as established reserves and 11 MMT used. Cement industries are largely responsible for releasing air pollutants and effluents into water bodies with apparent water quality deterioration over the years. Air pollution from lime and cement-producing plants is seen as a severe instigator of occupational health hazards and work-related life threats, negatively affecting crop yields, buildings, and persons residing in the vicinity of these industries. World Bank observed in 2015 that 94% of the Nigerian populace is susceptible to air pollutants that surpass WHO guidelines. In 2017, World Bank further reported that 49,100 premature deaths emanated from atmospheric PM2.5, with children beneath age 5 having the greatest vulnerability owing to lower respiratory infections, thereby representing approximately 60% of overall PM2.5-induced deaths. Cement manufacturing involves the significant production of SO2, NOx, and CO connected to adverse health effects on humans. Sensitive populations such as infants, the aged, and persons having underlying respiratory ailments like asthmatics, emphysema, or bronchitis are seen to be most affected. Consequently, in addressing this challenge, growing interests in enacting carbon capture, usage, and storage in the cement industry is expected to alleviate the negative environmental impact of cement production. Still, no carbon capture technology is yet to achieve commercialization in the cement industry. Nonetheless, huge advancement has been made in recent years with the advent of vital research in sorption-enhanced water gas shift, underground gasification combined cycle, ammonium hydroxide solution, and the microbial-induced synthesis of calcite for CO2 capture and storage, all considered sustainable and feasible in cement production.

scholarly journals Parametric Studies of Cement Production Processes

2020 ◽  
Vol 2020 ◽  
pp. 1-17 ◽  
Author(s):  
John P. John
Keyword(s):  
Energy Consumption ◽  
Alternative Fuels ◽  
Cement Industry ◽  
Production Costs ◽  
Cement Clinker ◽  
Cement Production ◽  
Exhaust Gases ◽  
Industrial Sectors ◽  
Study Results ◽  
Parametric Studies

The cement industry is one of the most intensive energy consumers in the industrial sectors. The energy consumption represents 40% to 60% of production cost. Additionally, the cement industry contributes around 5% to 8% of all man-made CO2 emissions. Physiochemical and thermochemical reactions involved in cement kilns are still not well understood because of their complexity. The reactions have a decisive influence on energy consumption, environmental degradation, and the cost of cement production. There are technical difficulties in achieving direct measurements of critical process variables in kiln systems. Furthermore, process simulation is used for design, development, analysis, and optimization of processes, when experimental tests are difficult to conduct. Moreover, there are several models for the purpose of studying the use of alternative fuels, cement clinker burning process, phase chemistry, and physical parameters. Nonetheless, most of them do not address real inefficiency taking place in the processes, equipment, and the overall system. This paper presents parametric study results of the four-stage preheater dry Rotary Kiln System (RKS) with a planetary cooler. The RKS at the Mbeya Cement Company (MCC) in Tanzania is used as a case study. The study investigated the effects of varying the RKS parameters against system behaviour, process operation, environment, and energy consumptions. Necessary data for the modelling of the RKS at the MCC plant were obtained either by daily operational measurements or laboratory analyses. The steady-state simulation model of the RKS was carried out through the Aspen Plus software. The simulation results were successfully validated using real operating data. Predictions from parametric studies suggest that monitoring and regulating exhaust gases could improve combustion efficiency, which, in turn, leads to conserving fuels and lowering production costs. Composition of exhaust gases also depends both on the type of fuel used and the amount of combustion air. The volume of exit flue gases depends on the amount of combustion air and infiltrating air in the RKS. The results obtained from the study suggest a potential of coal saving at a minimum of about ṁcoal=1263 kg·h−1, which approximates to 76,126 tons per year at the current kiln feed of 58,000 kg·h-1. Thus, this translates to a specific energy saving of about 1849.12 kJ·kgcl-1, with relatively higher clinker throughput. In this vein, process modelling provides effective, safe, and economical ways for assessing the performance of the RKS.

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