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Use of alternative fuels and environmentalactions in cement industry

TITAN Group, Greece

Photo: Cement plant, TITAN group ( www.titan.gr )

“TITAN Group is an independent multi-regional producer of cement and other related building materials.Headquartered in Greece, with a track record of continuous growth since its establishment in Greece,106 years ago, it has expanded its production and distribution operations into 12 countries, directly employing more than 6,300 people, with a consolidated turnover of € 1,496,915,000 in 2007.” (TITANgroup, 2007, URL: www.titan.gr ).

Table 1. Financial results in 2007, TITAN Group

Source: TITAN Group, TITAN annual report & annual butellin 2007, www.titan.gr



Figure 1. Environmental performance and consequences of the cement production chain, TITAN Group Source: TITAN Group, Corporate Social Responsibility & Sustainability Report 2007, Commitment to the Environment

“Reducing carbon dioxide emissions with blended cements Blended cements are made by co-grinding clinker, gypsum, and various natural and other substances such as pozzolana, limestone, blast furnace slag, fly ash and others. The use of blended cements, in addition to whatever superior technical characteristics they have, such as a lower requirement for water and more durability over time, is the most appropriate, technically-sound solution to help conserve natural resources and to lower CO2 emissions. This is a significant incentive to expand the use of blended cements in markets in which legislation permits it. Over the past years, the Group has followed

a strategy aimed at increasing the production of blended cements and, at the same time, reducing the use of clinker in Greece and Southeastern Europe. The percentage of clinker used in grey cement was reduced from 76.6% during 2003-2006 to 74.9% in 2007 while for the Group as a whole it was 80%.Reduction of 106,000 tons of clinker resulted in emission savings of 92,000 tonnes CO2.” (TITANGroup, 2007, URL: www.titan.gr)TITAN Group produced 15 million tonnes of cement for the year 2007.



Table 2. Cement process data for the year 2007, TITAN Group

Source: TITAN Group, Corporate Social Responsibility & Sustainability Report 2007, Commitment to the Environment

Investments and expenses for the environment

For the year of 2007 total expenses for the implementation of environmental plans and policy raised upto 30.8 million Euros. The amount of 19.7 million Euros of new investments for environmental actions isincluded in previous expenses, which represents the 65% of the total cost. The aim of these investmentsis the integrated exploitation of new and environmental friendly technologies.

The results of the environmental policy of the TITAN group are counted through specific targets andindicators. Figure 2 shows the results of specific environmental actions in specific years, thedevelopment of these actions and future projections.

Figure 2. Current state of the environmental performance and future projections, TITAN Group Source: TITAN Group, Corporate Social Responsibility & Sustainability Report 2007, Commitment to the Environment

Climate change

Climate change is an important problem and challenge faced by humanity. The GHG emissionsincrement, caused by the use of fossil fuels (used by cement industry), is joined with the global warmingand the challenge for the cement industry is the development of processes and practices in order toreduce the CO2 emissions (measured in tonnes per product unit), securing the production and supply ofcement in years where the demand for new houses and infrastructures is globally increased.The strategy of the Group for reduction of CO2 emissions is based on the following areas:

Measurement of CO2 emissionsCement plant operation contributes to CO2 emissions, affecting the greenhouse



Direct CO2 emissions from the cement production process, are the result of:

• Conversion of raw material (mainly limestone) into clinker which is the main component of cement.

• Fuels consumption, based on fact that most of fuels burned into cement kilns (coal, oil and pet coke)produce CO2 as result of chemical reaction of carbon with oxygen.

Indirect CO2 emissions are produced during the power production which is required for the production ofclinker and cement, as well as, during the transportation of raw material, fuels and products.For the year 2007 in TITAN group plants, total direct CO2 emissions raised up to 9.3 million tonnes

which was equal to the respective one of the former year (2006). This is explained by the fact that therewas not any change on the production process of the clinker.Specific CO2 emissions were measured on 689 kilograms per tonne of products which is on the samelevel with the respective of the year 2006.So, concerning CO2 emissions no important change was identified between years 2007 and 2006.Figure 3 shows the production of CO2 emissions (total and specific) in TITAN cement plants for the

period 2003 to 2007.

Figure 3. CO2 emissions (total and specific)in TITAN cement plants, TITAN Group.Source: TITAN Group, Corporate Social Responsibility & Sustainability Report 2007,Commitment to the Environment

Efficient use of thermal energy and

power

During the cement production process,raw material is consumed, as well as,thermal and electrical energy. Thesystematic monitoring and recording isrequired to ensure environmentaleffects are completely evaluated. Thesystematic application of mechanisms

for monitoring and its improvements is in high priority for the TITAN group.

Figure 4. Thermal energy consumption (total and specific) in TITAN cement plants, TITAN Group. Source: TITAN Group, Corporate Social Responsibility & Sustainability Report 2007, Commitment to the Environment

Thermal energyIn 2007, 39088 TJ of energy wereconsumed during the cement andclinker production process in TITANgroup cement plants. The meanconsumption was measured on 3583MJ per tonne of clinker, a little higher(2.3%) than the consumption of 2006.The biggest amount of required thermalenergy (98.6% on calorific basis) wasproduced by using conventional energy resources (fuels), like, coal, petcoke, oil and natural gas. Therest of energy was produced by using alternative fuels.

Figure 5. Sharing of fuels used in TITAN cement plants in 2007, TITAN Group.Source: TITAN Group, Corporate Social Responsibility & Sustainability Report 2007, Commitment to the Environment

During the year 2007 theconsumption of alternative fuelswas increased comingapproximately on 1.4%, onthermal basis, following thetrends of previous years.

Although, the total quantities ofused alternative fuels remain low,the sharing of such fuels was



increased 40% on calorific basis, comparing to respective quantities for the year 2006.

Electrical energyIn 2007, TITAN group cement plants consumed 1509 GWh (5431 Tj) of electrical energy, which isalmost equal to the respective energy consumption of the previous year. The mean energy consumptionraised up to 117 KWh per tonne of produced cement, which is 3.8% increased comparing to theconsumption for the year 2006, due to the small increment of clinker production and the significant

production of cement production.

Figure 6. Power consumption in TITAN cement plants for the period 2003 to 2007, TITAN Group.Source: TITAN Group, Corporate Social Responsibility & Sustainability Report 2007, Commitment to the Environment

The reduction of electrical energyconsumption was ranged from 10%to 40%, regarding the type ofproduced cement. The result is

explained by investments in newtechnologies and replacement ofconventional hummer mils withvertical cement kilns in the cement

process chain.

Alternative fuels

Municipal, agricultural and industrial residues and wastes, as well as, by-products of the process ofwastes could be used as alternative fuels in order to replace the use of conventional fuels like coal, oiland pet coke. The use of alternative fuels is accounted as an environmentally friendly solution for thehandling of wastes and residues targeting the reduction of indirect environmental effects, related tomining, use and transportation of conventional fuels. In 2007, the use of 25500 tonnes of alternativefuels drove to the reduction of 18200 tonnes of conventional fuels in clinker production process. In the

period 2003 to 2007 the use of alternative fuels was increased tree times.

Alternative fuels 2006 2007

Energy efficiency, kcal/kg clinker 836 855% fuel substitution of virgin fuels Appr. 1% 1.37%% biomass in kiln fuel 0.6% 0.6%% alternative materials 7.3% 7.1%Clinker: cement ratio 0.81 0.80

In two cement plants of the TITAN group in Greece (Kamari plant and Thessaloniki plant), wherealternative fuels are already used, the protocol WBCSD/ CSI is implemented, in combination withactions based on the current legal frame work for fuels.

Figure 7. Consumption of alternative fuels used in TITAN cement plants for the period 2003 to 2007, TITAN Group.Source: TITAN Group, Corporate Social Responsibility & Sustainability Report 2007,Commitment to the Environment

Emissions

Dust

Main resources of dust emissions incement plants of TITAN Group areplants’ chimneys and open surfaces. Allcement plants are equipped withsystems for monitoring and recording of



emissions (measuring according to current legislative framework and WBCSD/ CSI protocol).The system secures the health of employees in the plants and the reductions of effects in neighboringcommunities and areas.In 2007, specific dust emissions raised up to 85 grams per tonne of produced clinker (at the same levelwith year 2006) which is equal to 928 tonnes in total (Figure ??).

Figure 8. Dust emissions in TITAN cement plants for

the period 2003 to 2007, TITAN Group.Source: TITAN Group, Corporate Social Responsibility & Sustainability Report 2007, Commitment to the Environment

SOx

The sulphur content in raw materials is the mainreason for SOx emissions during the cementproduction process. The contribution of suchemissions is significant for the creation of acidrain and the reduction of SOx emissionsremains in high priority.In 2007, specific SOx emissions raised up to 299 grams per tonne of produced clinker (or 3263 tonnesin total), due to targeted actions. Figure 9 shows the distribution of SOx emissions for the period 2003 to

2007.

Figure 9. SOx emissions in TITAN cement plants for the period 2003 to 2007, TITAN Group.Source: TITAN Group, Corporate Social Responsibility & Sustainability Report 2007, Commitment to the Environment

NOx

NOx emissions are one of results of fuelscombustion in high temperatures. Scientificstudies prove that these emissions contribute inthe creation of acid rain and urban haze.In 2007, the total NOx emissions raised up to

19016 tonnes or 1752 grams per tonne ofproduced clinker, which is in lower level that the respective of the year 2006. Specific emissions werereduced, respectively. This was the result of continuing and systematic actions in order to secure theoptimum operation of combustion units. Figure 10 shows the specific NOx emissions for the period 2003to 2007

Figure 10. NOx emissions in TITAN cement plants for the period 2003 to 2007, TITAN Group Source: TITAN Group, Corporate Social Responsibility & Sustainability Report 2007,Commitment to the Environment

ReferencesTITAN Group , Corporate Social Responsibility & Sustainability Report 2007, Commitment to theEnvironment, http://www.titan.gr/UserFiles/File/csr2008/Commitment_to_the_Environment_En.pdf

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