One of the major environmental, social, and governance (ESG) goals of the cement industry is to reduce CO2 emissions. And it has become a challenging task for them as most the cement manufacturers are now using fossil fuels, like coal, to generate energy. As per a report, around 5 billions tonnes of cement, a major building or construction material across the world, are produced every year in Thailand.
But every tonne of cement generates around 600 kg of CO2 or Carbon Dioxide. In fact, the global cement industry is now contributing around 8 percent of the total anthropogenic CO2 emissions. This major depends on the materials the cement manufacturers are using in production, the fuel being used, and the type of cement kiln they use.
There is no doubt that CO2 is a major greenhouse gas and can greatly influence climate change. This gas is released by different aspects of cement manufacturing. If you are a cement manufacturer and worried about this, then you will have to come up with some best solutions to lower CO2 emissions.
Yes, now the cement industry can reduce CO2 emission using different methods. In fact, some researchers have come up with the potentially most effective ways to effectively decarbonize the industry. As per the experts, with the solutions, CO2 emission could range from around 70 percent to minus 30 percent of the current emission levels where CO2 can be removed from the environment.
The experts have suggested that this can be done using a perfect combination of CCS- Carbon Capture and Storage, fuel, and some intermediate product substitutes. But talking about the most effective and sensible method to lower CO2, the experts have suggested combining Refuse Derived Fuel (RDF) generated from MSW- Municipal Solid Waste with CCS. This can cut emissions by around 20 percent.
Fuel and process-related emissions account for a great portion of cement’s CO2 emissions. So, both these processes can be changed to witness a reduction in carbon emissions. By coming up with some workable intervention and identifying the sources along with a better fuel substitute, it is possible to decarbonize the global cement industry.
So, let’s talk about some of the major decarbonization options along with their interplay in terms of direct emissions during the cement manufacturing process. These solutions have proved to create the most potential impact.
The chemistry behind the manufacturing process of cement is accountable for around 60 percent of carbon emissions from cement. So, it is quite challenging to lower the production of carbon during the manufacturing process. To produce cement, powdered limestones are heated at a high temperature and then properly combined with different components to create an intermediary product. That is called Clinker.
Around 40 percent of the total weight of limestone is CO2 that is emitted during the process. Well, as per the experts, well-designed and well-equipped CCS plants located near a cement production unit or kilns would be able to capture the carbon released during the production and then store it by not allowing it to enter the atmosphere. Some experts have suggested that CCS plants have impressive potential, with multiple large-scale as well as pilot tests planned.
There is no doubt that cement manufacturing is an energy-intensive process. For per ton of clinker, around 3.5 Gigajoules of thermal energy is used. That means another major source of CO2 in the cement industry is the way cement factories are powered. Well, instead of utilizing fossil fuels that are carbon-intensive, cement producers can go for carbon-neutral biomasses or fuels. But it may be noted that biomasses are a limited resource, and using them alone can cost you more. That’s why it can be combined with MSW- Municipal Solid Waste.
Most of the cement plants in Thailand are now using RDF fuel, a fuel created by processing MSW and nonrecyclables. This has become an ideal coal substitute. When burnt, RDF produces a sufficient amount of heat, but it emits a lower amount of CO2 compared to coal. This can be a costly way to reduce fossil fuel use. Besides, this is an environmentally friendly method of waste management. So, you should give this a try if you want to lower your CO2 emission.
As discussed above, manufacturing clinkers is a carbon-intensive process due to the carbon released by limestone, as well as the amount of energy needed during the process. So, another effective way to lower carbon emissions is by lowering the demand for clinkers in ement plants. Instead of using clinkers, plants can go for different waste materials like coal ash or blast furnace slag. Some studies have proved that around 40 percent of clinkers in cement production units can be easily substituted in this method, and it will not affect the core strength of cement.
Well, this simple analysis can offer insights into the things that are and are not important for zero-emission; a comprehensive analysis is required to fully cut down emissions.
Even though all the methods mentioned here can help a cement plant to cut carbon emissions, the most effective way is using a coal substitute, i.e., RDF along with CCS. Made of MSW, RDF has proved to be a game-changer in this process. This can be used as a supplementary fuel or standalone fuel in different sectors. RDF’s energy content is around 50 percent off industrial coals.
It has become so popular that coal gasification plants, coal-fired power plant boilers, fluidized beds, or cement kilns, all these things are now powered up using RDF. On the other hand, due to the reduction in non-combustible materials and fuel particle size, RDF is more homogenous and much easier to burn. With this, you can help your plant to work towards its sustainable development goals. So, what are you waiting for? Partner with a reliable and professional RDF manufacturer and get ready to make your cement more efficient.