sustainability of cement industryevolution of fuel efficiency in cement sector (mj/t cement) 0 0,5 1...

SUSTAINABILITY OF CEMENT SUSTAINABILITY OF CEMENT INDUSTRYINDUSTRY

Pedro Mora PerisTechnical Director of OFICEMEN

FOUR CORNERSTONES FOUR CORNERSTONES FOR THE CEMENT FOR THE CEMENT

INDUSTRY OF THE 21INDUSTRY OF THE 21stst

CENTURYCENTURY

21st CENTURY CEMENT INDUSTRY

BATs

BEPsSOCIAL COMMINTENT

BIODIVERSITY

Sustainability is multidisciplinary

1. NEW CHALLENGES1. NEW CHALLENGES

2.1. 2.1. WhatWhat isis BTAsBTAs??

2.2. 2.2. Bat: primary measuresBat: primary measures

2.3. 2.3. ThermicThermic energyenergy

2.4. Electric 2.4. Electric energyenergy

2.5. 2.5. EmissionsEmissions

2.6. 2.6. SpanishSpanish voluntaryvoluntary agreementagreement

2. BEST AVAILABLE TECHNIQUES (2. BEST AVAILABLE TECHNIQUES (BATsBATs))


BATs

DEFINED IN ART 2 (12) OF IPPC DIRECTIVE

• “Most effective and advanced stage in the development of activities and their methods of operation..”

• ..“indicate the practical suitability of the techniques for providing basis for Emission Limit Values”.

• …”to prevent/reduce the impact on the environment as a whole”.

• TECHNIQUES: technology+ plant design, building, maintenance, operation, decomission.

• AVAILABLE: developed in economical and technical viable conditions.

• BEST: Most effective in level of protection of environmet as a whole.

2. BEST AVAILABLE TECHNIQUES (2. BEST AVAILABLE TECHNIQUES (BATsBATs))2.1. WHAT IS 2.1. WHAT IS BATsBATs??

2.2. BAT: PRIMARY MEASURES2.2. BAT: PRIMARY MEASURES

5

• Environmental Management System (ISO 14.000)• Process control and optimisation• Selection and control of substances entering the kiln

• Monitoring:

• Process parameters• Continous monitoring: Dust, NOx, SOx, CO• Continous or periodic monitoring: HCl, HF, TOC• Periodic monitoring: D/F, metals


DRY PROCESS

HEAT EXCHANGER

PRECALCINER

2900 – 3200 MJ/clinker tonne

THERMAL ENERGY IN CEMENT PRODUCTION

36993489

0

500

1000

1500

2000

2500

3000

3500

4000

4500

5000

EU AVERAGE SPAIN AVERAGE

MJ/

tonn

e cl

inke

r

KILN FUEL EFFICIENCYKILN FUEL EFFICIENCY

SITUATION WORLD WIDESITUATION WORLD WIDE SITUATION IN SPAIN AND EUROPESITUATION IN SPAIN AND EUROPE

2. BEST AVAILABLE TECHNIQUES (2. BEST AVAILABLE TECHNIQUES (BATsBATs))2.3. THERMIC ENERGY2.3. THERMIC ENERGY

SPANISH KILN FUEL EFFICENCYSPANISH KILN FUEL EFFICENCY

0

500

1000

1500

2000

2500

3000

3500

4000

4500

5000

1975 1980 1985 1990 1995 2000 2005

EVOLUTION OF FUEL EFFICIENCY IN CEMENT SECTOR (MJ/t cement)

0

0,5

1

1,5

2

2,5

3

3,5

4

4,5

5

SouthKorea

Japan Spain EU Italy India USA China

GJ/t CLINKER

40 % 40 % ofof fuel fuel reductionreduction sincesince 19751975

4% more 4% more efficientefficient thanthan European averageEuropean average

OnlyOnly SouthSouth KoreaKorea andand JapanJapan are more are more efficientefficient

2. BEST AVAILABLE TECHNIQUES (2. BEST AVAILABLE TECHNIQUES (BATsBATs))2.3. THERMIC ENERGY2.3. THERMIC ENERGY

ELECTRICITY CONSUMPTION WORLDWIDEELECTRICITY CONSUMPTION WORLDWIDE

1.1. 7% 7% reductionreduction sincesince 19901990

2.2. IndirectIndirect emissionemission ofof COCO22

3.3. KeyKey issueissue: : priceprice ofofelectricityelectricity

2. BEST AVAILABLE TECHNIQUES (2. BEST AVAILABLE TECHNIQUES (BATsBATs))2.4. ELECTRIC ENERGY2.4. ELECTRIC ENERGY

LESS EMISSIONSLESS EMISSIONSLOW LOW NOxNOx BURNERBURNER

++COMBUSTION WITH COMBUSTION WITH DIFFERENT STAGESDIFFERENT STAGES

++SELECTIVE NONSELECTIVE NON--CATALYTIC CATALYTIC

REDUCTIONREDUCTION

PRIMARY MEASURESPRIMARY MEASURES++

ABSORBENTS IN DRY ABSORBENTS IN DRY PROCESSESPROCESSES

ELECTROSTATIC FILTERSELECTROSTATIC FILTERS++

SLEEVE FILTERSSLEEVE FILTERS

NOx

500 - 800 mg/Nm3

SOx

200 - 400 mg/Nm3

Particles30-50 mg/Nm3 (Kilns

and coolers)

10-30 mg/Nm3

(subsidiary process)

2. BEST AVAILABLE TECHNIQUES (2. BEST AVAILABLE TECHNIQUES (BATsBATs))2.5. EMISSIONS2.5. EMISSIONS

BAT & BATAEL

10

BREF 2001 BREF

2009

30

2020

10


200

450

200

500400

800InitialLevel<1000

InitialLevel>1000

Lepol & long

-NOTE: “Existing kiln system design, fuel mix properties including waste, raw material burnability can influence the ability to be in the range…”


BATAEL: NOx

BAT & BATAEL: SOxSO2 emissions 2004 - Continuous

(Reduced Scale)

0100200300400500600700800900

1,000

mg/

Nm

3

0 % (None)0 - 10 %10 - 40 %Above 40 %

Thermal substitution:

Measurem.: 253 Average: 218.9Min: 0Max: 4,837StDev: 452.7

400

50


2.6. SPANISH CEMENT SECTOR VOLUNTARY AGREEMENT2.6. SPANISH CEMENT SECTOR VOLUNTARY AGREEMENT

MINISTERY OF MINISTERY OF ENVIROMENTENVIROMENT

++OFICEMENOFICEMEN

++AUTONOMOUS AUTONOMOUS COMMUNITIESCOMMUNITIES

++CEMENT COMPANIESCEMENT COMPANIES

InvestmentInvestment ofof 600 600 MM€€ ininenviromentalenviromental measuresmeasures

(2000(2000--2007)2007)

InvestmentInvestment ofof 1000 1000 MM€€in in BATsBATs technologiestechnologies

SUSTAINABLE SUSTAINABLE PRODUCTIONPRODUCTION

++ECONOMIC ECONOMIC

FEASIBILITYFEASIBILITY


3.1. 3.1. SustainableSustainable use use ofof resourcesresources

RecyclingRecycling: : ReductionReduction ofof clinkerclinker--cementcement ratio ratio

ValorisationValorisation

3.2. Sectorial 3.2. Sectorial agreementsagreements

3.3. 3.3. EnviromentalEnviromental managementmanagement systemssystems

3. BEST ENVIRONMENTAL PRACTICES (3. BEST ENVIRONMENTAL PRACTICES (BEPsBEPs))

21st CENTURY CEMENT

INDUSTRY

BATs

BEPs

3.1. SUSTAINABLE USE OF RESOURCES3.1. SUSTAINABLE USE OF RESOURCES

DIRECTIVE 2008/98/CE

REDUCTION

REUTILIZATION

RECYCLING

VALORISATION

ELIMINATION

Vertedero

0 10 20 30 40 50 60 70

EU15

EU27

Bélgica

Alemania

España

Francia

Holanda

Austria

Reciclado

0 10 20 30 40 50

EU15

EU27

Bélgica

Alemania

España

Francia

Holanda

Austria

LANDFIELD OF WASTES (%)

RECYCLING OF WASTES (%)

3. BEST ENVIROMENTAL PRACTICES (3. BEST ENVIROMENTAL PRACTICES (BEPsBEPs))

RAW MATERIAL

EXTRACTION (QUARRIES)

RAW MATERIAL CRUSHING

MILLING PROCESS OF

RAW MATERIALS

KILN

MILLING OF CLINKER AND ADDITIONS

CEMENT

STORING

RECYCLINGPaper wastes,

Construction wastes,…

VALORISATIONSewage water,

Used tyres,Animal feeding, …

RECYCLINGFly ash,

Steel slag, …CEMENT PLANTS CEMENT PLANTS ARE AN ARE AN

ALTERNATIVE TO ALTERNATIVE TO LANDFIELDSLANDFIELDS



0

10000000

20000000

30000000

40000000

50000000

60000000

70000000

1998 1999 2000 2001 2002 2003 2004 2005 2006 2007

Alternative raw materials Natural raw materials Total raw materials

SPANISH RAW MATERIAL RECYCLING IN CEMENT PLANTSSPANISH RAW MATERIAL RECYCLING IN CEMENT PLANTS

3. BEST ENVIRONMENTAL PRACTICES (3. BEST ENVIRONMENTAL PRACTICES (BEPsBEPs))3.1. SUSTAINABLE USE OF RESOURCES3.1. SUSTAINABLE USE OF RESOURCES

ENERGY VALORISATION WORLDWIDEENERGY VALORISATION WORLDWIDE


0 10 20 30 40 50 60 70 80 90

HolandaSuiza

AustriaNoruega

FranciaBélgica

AlemaniaSuecia

Media UEReino Unido

EspañaDinamarca

Italia

CONSUMO PORCENTUAL DE COMBUSTIBLES ALTERNATIVOS EN LA INDUSTRIA CEMENTERA DE VARIOS PAÍSES EUROPEOS (2002-2005)

ENERGY VALORISATION IN EUROPEENERGY VALORISATION IN EUROPE


ENERGY VALORISATION IN EUROPEENERGY VALORISATION IN EUROPE

TREND IN GERMAN UTILIZATION OF WASTES AS ALTERNATIVE FUELSTREND IN GERMAN UTILIZATION OF WASTES AS ALTERNATIVE FUELS


ENERGY VALORISATION IN SPAINENERGY VALORISATION IN SPAIN


ALTERNATIVE CONSUMPTION IN SPAIN(Tn)

0

50.000

100.000

150.000

200.000

250.000

300.000

350.000

1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008

OILS SOLVENTS RES.HIDROCARBUROS PLASTIC NO BIOMASS NEUMÁTICOS

SERRÍN IMPREGNADO OTHERS BIOMASS BONE AND ANIMAL MEAL SEWAGE WATER WOOD PAPER AND OTHERS




DISTRIBUCIÓN PORCENTUAL DEL CONSUMO ENERGÉTICO DE COMBUSTIBLES

97,1%96,7%

95,3% 94,9%94,1%

93,5%92,6%

1,1%1,1%

1,5%1,5%

1,7%2,3%

2,3%

1,0%1,3%

1,7%1,7%

2,2% 2,3%

2,7%

0,7% 1,0%1,6% 1,9% 2,0% 2,0% 2,4%

90%

91%

92%

93%

94%

95%

96%

97%

98%

99%

100%

2003 2004 2005 2006 2007 2008 2009 (dato móvil)

TRADICIONAL ALTERNATIVO FOSIL ALTERNATIVO PARC BIOMASA ALTERNATIVO BIOMASA

SPANISH GOALSPANISH GOAL

REACHING SUBSTITUTION RATIO OF OTHER EUROPEAN COUNTRIESREACHING SUBSTITUTION RATIO OF OTHER EUROPEAN COUNTRIES


350.000 tonnes

ENERGY VALORISATION IN SPAINENERGY VALORISATION IN SPAIN

PRESENTPRESENT NEAR FUTURENEAR FUTURE LONG TERMLONG TERM

700.000 tonnes 2.000.000 tonnes


9 % 17 % 50 %

3.2. SECTORIAL AGREEMENTS3.2. SECTORIAL AGREEMENTS

Recycling of thematerials from vehicles

and domestic appliances

Replacement clinker rawmaterials normally by black slags from blast

furnaces

Plastics as fuel in cement plants

3. BEST ENVIROMENTAL PRACTICES (3. BEST ENVIROMENTAL PRACTICES (BEPsBEPs))

3.3. ENVIRONMENTAL MANAGEMENT SYSTEMS3.3. ENVIRONMENTAL MANAGEMENT SYSTEMS

“An environmental management system is a cyclical process of planning, implementation, review and improvement of the procedures and actions carried out by an organization to performits activities while ensuring achievement of its environmental targets”.

ISO 14001 WORLD WIDE 100% OF SPANISH PLANTS

EMAS EUROPEAN UNION 25% OF SPANISH PLANTS


4. SOCIAL COMMITMENT4. SOCIAL COMMITMENT

4.1. Framework 4.1. Framework agreementagreement withwith TradeTrade UnionUnion

4.2. CEMA 4.2. CEMA FoundationFoundation

4.3. 4.3. HealthHealth andand safetysafety at at workwork

4.4. 4.4. ProductProduct safetysafety

4.5. Professional training4.5. Professional training

4.6. Sectorial 4.6. Sectorial studiesstudies


BATs


4.1. FRAMEWORK AGREEMENT WITH TRADE UNION4.1. FRAMEWORK AGREEMENT WITH TRADE UNION4. SOCIAL COMMITMENT4. SOCIAL COMMITMENT

November 2004: “Agreement for promotion energy in the Spanish cement industry"

CAUSE:

• Make compatible economic and social progress with respect to the environment and health and safety of workers

• New legislative framework: IPPC directive and directive envelope emission trading• Risk of industrial relocation by the requirements arising from the Kyoto Protocol• Potential the sector in terms of energy recovery as an effective measure in the fight against

climate change

RESULTS:

• Objectives of improving the environmental performance cement factories• Efficiency policy energy and replacement of fossil fuels by alternative• Contribution to compliance the Kyoto Protocol• Prevention of Labor risks

4.2. CEMA: LABOUR FOUNDATION OF CEMENT AND 4.2. CEMA: LABOUR FOUNDATION OF CEMENT AND ENVIROMENTAL FOUNDATIONENVIROMENTAL FOUNDATION

AIMSAIMS1.1. Social Social andand economiceconomic developingdeveloping, ,

friendlyfriendly withwith enviromentenviroment andand natural natural resourcesresources

2.2. DiffusionDiffusion ofof healthhealth andand safetysafetymeasuresmeasures ofof cementcement industryindustry

3.3. ResearchResearch, , developmentdevelopment andandinnovationinnovation

4.4. PromotionPromotion ofof professionalprofessional trainingtraining


ProceduresProcedures basedbased onon continuouscontinuous improvementimprovement..

SafetySafety isis anan importantimportant branchbranch ofof businessbusiness managementmanagement..

EveryEvery accidentaccident isis avoidableavoidable. . TheThe aimaim isis reachingreaching ““zerozero””accidentsaccidents..

Control Control systemssystems toto verifyverify thethe fulfillmentfulfillment ofof safetysafetyproceduresprocedures..

HEALTH AND SAFETY POLICY OF SPANISH CEMENT HEALTH AND SAFETY POLICY OF SPANISH CEMENT INDUSTRYINDUSTRY

4. SOCIAL COMMITMENT4. SOCIAL COMMITMENT4.3. HEALTH AND SAFETY AT WORK4.3. HEALTH AND SAFETY AT WORK

GLOBAL CEMENT INDUSTRY ACHIEVEMENTSGLOBAL CEMENT INDUSTRY ACHIEVEMENTS


SPANISH CEMENT INDUSTRY ACHIEVEMENTSSPANISH CEMENT INDUSTRY ACHIEVEMENTSINCIDENCE INDEX

1994 - 2008

Construction

Industry

Total

Cement


CLINKER AND CEMENT SAFETY CHARACTERISTICS FILE CLINKER AND CEMENT SAFETY CHARACTERISTICS FILE

ProductProduct identificationidentification

Hazard Hazard determinationdetermination

InformationInformation ofof itsits componentscomponents

FirstFirst aidaid in case in case ofof accidentaccident

MeasuresMeasures againstagainst accidental accidental spillingsspillings

HandlingHandling andand storingstoring

ControlsControls ofof personal personal protectionprotection

PhysicalPhysical andand chemicalchemical featuresfeatures

ToxicToxic informationinformation

OtherOther informationinformation


LABELLINGLABELLING

4. SOCIAL COMMITMENT4. SOCIAL COMMITMENT4.4. PRODUCT SAFETY4.4. PRODUCT SAFETY

4.6. SECTORIAL STUDIES4.6. SECTORIAL STUDIES

DIOXINS AND FURANSDIOXINS AND FURANS RECYCLING AND VALORISATION OF RECYCLING AND VALORISATION OF INDUSTRIAL WASTES IN CEMENT PLANTSINDUSTRIAL WASTES IN CEMENT PLANTS


5.1. 5.1. HolisticHolistic systemssystems forfor biodiversitybiodiversitymanagementmanagement

5.2. 5.2. RestorationRestoration ofof quarriedquarried landland

5.3. 5.3. ProgrammesProgrammes toto promotepromote

biodiversitybiodiversity

5. BIODIVERSITY IN QUARRIED LAND5. BIODIVERSITY IN QUARRIED LAND


BATs


BIODIVERSITY

5.1. HOLISTIC SYSTEMS FOR BIODIVERSITY MANAGEMENT5.1. HOLISTIC SYSTEMS FOR BIODIVERSITY MANAGEMENT

SPECIFIC METHODOLOGY

EVALUATION TOOLS

BIODIVERSITY INDEX

PROGRAMMES TO BOOST LOCAL

SPECIES OF PLANTS AND ANIMALS

5. BIODIVERSITY IN QUARRIED LAND5. BIODIVERSITY IN QUARRIED LAND

FALCO PROJECT BY OFICEMEN: FALCON RESETTLING FALCO PROJECT BY OFICEMEN: FALCON RESETTLING IN ABANDONED QUARRIESIN ABANDONED QUARRIES

5. BIODIVERSITY IN QUARRIED LAND5. BIODIVERSITY IN QUARRIED LAND5.1. HOLISTIC SYSTEMS FOR BIODIVERSITY MANAGEMENT5.1. HOLISTIC SYSTEMS FOR BIODIVERSITY MANAGEMENT

5. BIODIVERSITY IN QUARRIED LAND5. BIODIVERSITY IN QUARRIED LAND5.2. 5.2. RestorationRestoration ofof quarriedquarried landland Cantera de Los Arenales

Mijas

• Recovery natural environment: – Treatment of slopes. – Landscape integration. – Transplantation of cork oaks.

Espiel

Córdoba

5. BIODIVERSITY IN QUARRIED LAND5. BIODIVERSITY IN QUARRIED LAND5.3. 5.3. ProgrammesProgrammes toto promotepromote biodiversitybiodiversity

• Recreation of Humedal – Recovery of ecosystems in

regression. – Refuge for Bird migratory. – Observatories of birds.


• Rocky slopes: – Natural revegetation. – Original copses attract birds

which disperse seeds. – High biodiversity of flora and

fauna.

Necessary for the conservation of raptors and rupícolaflora..

BOOSTING BIODIVERSITY BY MEANS OF BEES

CementCement plantplant ofof Lafarge in Villaluenga Lafarge in Villaluenga de la de la SagraSagra (Toledo) (Toledo)


Native species recovery

QUARRIES RESTORATION TO PROMOTE BIODIVERSITYQUARRIES RESTORATION TO PROMOTE BIODIVERSITYOrange Orange treestrees in Alicante in Alicante


QUARRIES RESTORATION TO PROMOTE BIODIVERSITYQUARRIES RESTORATION TO PROMOTE BIODIVERSITYLocal Local flowersflowers in in YepesYepes


6. CONCLUSIONS6. CONCLUSIONS

Enable cement producer tomanufacture a competitiveproduct in a cost effectiveand sustainable manner

Optimise the value of theproduct for cement customer


BATs


BIODIVERSITY

THANKS FOR YOUR ATTENTION!Pedro Mora Peris

sustainability of cement industryevolution of fuel efficiency in cement sector (mj/t cement) 0 0,5 1...

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