Cement Plant: The Green Revolution

Planta de Cemento:
La Revolucin Verde.

If we do not take urgent action, global temperatures could increase by 2 or more Celsius
degrees by 2050, which would have terrible consequences for all living beings. The cement
industry has an important responsibility in this climate change because it contributes with
8.5% of total emissions of CO2 (carbon dioxide), one of the main contributors to this
phenomenon. We are facing a race against time. The only solution lies in The Green
Revolution.

1. How is CO2 generated in the cement plant? Approximately 535 kg CO2 / ton
clinker due to the decarbonation of limestone and 330 for the combustion to
generate the heat required in the kiln. In total is produced 865 kg CO2 / ton clinker.
If we consider a clinker/cement ratio of 0.78, the CO2 emissions are 680 kg/ton
cement.
2. What is the goal? The IEA (International Energy Agency) and the CSI (Cement
Sustainability Initiative) generated a plan (Roadmap), in which it has aimed to
reduce 2 billion tons of CO2 emissions in 2007 to 1.55 in 2050: a 23% reduction.
The challenge is great because we do even though cement production will double by
that date. This means we must reduce our CO2 output from 680 down to 338 kg/ton
cement, 50% in 30 years.
The Cement Technology Roadmap. Source: International Energy Agency & Cement Sustainability
Initiative

3. Which countries will see increase in cement production? India will increase 3
times its current output, doubling many African countries as well as some countries
in Southeast Asia and South America. 2015 is a turning point as seen in the chart:

Global Cement Production 1990 2050. Source: International Energy Agency

4. What can we do today? Taking as a benchmark China, which from 2010 to 2013
reduced from 994 down to 425 kg CO2/ton cement.
 CO2 emissions produced by every unit cement products in China from 2000 to
2013. Source: On the future of Chinese cement industry

Reduce heat consumption. Stop the use of wet, semi dry and semi-wet
processes. Replace with 5-6 steps preheater/precalciner kiln technology (3GJ/ton
clinker). Recent reports state that China has developed a system called XDL (Xu
De Long), which reduces the heating and electricity costs by 15% compared to
suspension preheater kilns.
Reduce power consumption. Using VRM (Vertical Roller Mill) and RM
(Rolling Machine). These have a 40 and 50% (kWh / ton cement) reduction
compared to BM (Ball Mill).
Increase all equipment efficiency. Use automatic control in all areas and
processes. Increase the level of maintenance efficiency using techniques such as
RCM (Reliability Centered Maintenance). Set as Target 95% higher efficiency for
all the equipment.
Increase the use of alternative fuels. Taking as benchmark: a) Germany takes
the lead globally with 38% replacement of fossil fuels, with some plants which
reached 80% replacement. b) Cemex who retains the edge over their competitors
with 28%, and some of its plants have achieved 100% substitution. (Ferriby in
2011).
Produce cements with additives. Take India and China as benchmark, who have
the leadership substitutions Clinker 26% on average. It is feasible to increase the
 additions of fly ash and pozzolan in the future, as it has enough supply in the
market.
Use of Green Power generation. Cemex and Italcementi (Heidelberg) are
already using electricity from renewable sources (wind and hydro).
Continue research and development of CCS (Carbon Capture and Storage) .- It is
important the cooperation between universities, research centers, cement
companies, consultants and governments to achieve the goal of having five cement
plants operating before 2020 with CCS . The benchmark is Norcem Brevik
(Heidelberg) plant in Norway who leads the way as well as Taiwan Cement in
Taiwan and Saint Marys (Votorantim) in Canada.
Installation of WHR (Waste Heat Recovery).- Potentially, it is possible to recover
40% of the waste heat that passes through the preheater and the cooler, which could
generate 30% of the energy required a cement plant. In China, dozens of kilns are
working with these systems.
Research and development of Low Carbon Cements. To promote development
of cements (see article) that do not require having a decarbonation process, which,
combined with other measures allows us to have a low or zero carbon cement.

We are at the threshold of major changes in our industry that will allow us to inherit a
better planet for future generations. Cement professionals have the opportunity to be an
active part of the Green Revolution