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Process Data set: Cement, at plant (en) en

Key Data Set Information
Location BR
Geographical representativeness description The data set represents the country / region specific situation, focusing on the main technologies and the region specific characteristics. All the data are based on estimatives from secondary sources.
Reference year 2005
Name
Cement, at plant
Classification
Class name : Hierarchy level
  • ILCD: Construction
General comment on data set The data set represents a generic Portland cement production and covers some relevant process steps. Post-clinker processing and raw materials preparation emissions are not considered in the dataset. The inventory is based on an adaptation of LCI cement production in Mexico, with adjusted data for raw material consumption and for the CO2 emissions due to clinker production and emissions from thermal energy used in the kiln. The dataset considers an emission factor of 0.371 kg CO2/ ton of cement for the decarbonizing process of clinker production based on Carvalho et al. (2010). The generic composition of the cement was based on estimates according to Carpio (2005) and Costa et al. (2013) for limestone, clay and silicon. For iron it was assumed the same amount from the Mexican dataset. Alternative additives (pozzolana, blast furnace slag and fly ashes) and gypsum are based on data from the WBCSD (2012). The water consumption were not considered due to lack of data. Inventory is also based on secondary data from the national inventory of greenhouse gas emissions in the cement sector. The fuel mix of thermal energy used in the cement production are based on coke petroleum (71.7%), electricity (12.2%), charcoal (2.4%), fuel oil (0.4%), steam coal (1.9%), diesel (1.2%), wood (0.9%), natural gas (0.7%) and other alternatives fuels (8.7%), such as tires, industrial waste and biomass(rice husk, bagasse, among others). However, due to lack of data on the share of these alternative fuels, the dataset only considers the fuel source from fossil fuels and electricity. Data on the fuel mix are weighted average (2009-2013) from the Brazilian Energy Balance (EPE, 2014).
Copyright No
Quantitative reference
Reference flow(s)
Time representativeness
Data set valid until 2014
Time representativeness description Annual average of the cement sector.
Technological representativeness
Technology description including background system In Brazil, 99% of the cement production is through dry kiln process. The dataset considers that clay and limestone are entirely from an onsite quarry. The preheater and precalciner uses the hot gases from the kiln to preheat the raw material prior to the kiln (SNIC 2009). The clinker is ground in mills with gypsum (3% to 6%) and depending on the type of cement and technical standard (ABNT NBR 5732) with other materials such as blast furnace slag, fly ash, pozzolan and lime fillers, to produce the Portland cement.
LCI method and allocation
Type of data set Unit process, black box
LCI Method Principle Other
Deviation from LCI method principle / explanations The LCI method chosen was the "attributional method". No allocation procedure was made. The byproduct of calcination is considered as an air emission. This process is a "gate-to-gate" dataset. Background emissions and burdens (e.g. from the raw materials mining, electricity production, etc.) are not considered in this dataset, and should be modelled specifically for LCIA purposes.
Modelling constants None
Data sources, treatment and representativeness
Data cut-off and completeness principles The product system’s boundaries encompass an estimation of the limestone, clay, gypsum, blast furnace slag, fly ash, pozzolan and lime fillers consumption involved with the cement production. No cutoff rules applied.
Deviation from data cut-off and completeness principles / explanations None.
Data selection and combination principles Data on raw materials, thermal and energy consumption, feedstock composition and CO2 emissions from calcination were based on secondary data from national reports. In the case of direct air emissions from feedstock production, these were based on secondary data. This dataset is a "gate-to-gate" dataset, without background process emissions and burdens.
Deviation from data selection and combination principles / explanations None.
Data treatment and extrapolations principles None
Data source(s) used for this data set
Sampling procedure None
Data collection period Data on CO2 emissions per ton clinker production due to calcination process are from 1990-2005 (Carvalho et al., 2010). Data on thermal and electricity consumption are from 2010 (Carvalho et al., 2010). Data on national feedstock grid is an weighted average from 2009-2013 (EPE, 2014). Data on the cement composition are estimative based on Carpio (2005); Costa et al. (2013). Alternative additives are based on Global Cement Database on CO2 and Energy Information (WBCSD, 2012). Emissions factors for feedstock grid are from 2006 (IPCC, 2006) and 2013 (EEA, 2013).
Completeness
Completeness of product model No statement
Validation
Type of review
Not reviewed
Commissioner and goal
Project IBICT "Adaptação de Inventários ao Contexto Brasileiro"
Intended applications This dataset was constructed for IBICT, with the ultimate goal to be disseminated publicly.
Data generator
Data set generator / modeller
Data entry by
Time stamp (last saved) 2016-02-12T14:26:00.309-02:00
Data set format(s)
Data entry by
Publication and ownership
UUID 7adf49b4-59bd-47a0-bf84-7dfc9e62a97f
Date of last revision 2016-02-12T14:25:32.989-02:00
Data set version 00.00.008
Copyright No
Access and use restrictions All information can be accessed by everybody.

Inputs

Type of flow Classification Flow Mean amount Resulting amount Minimum amount Maximum amount
Product flow Energy carriers and technologies / Crude oil based fuels 2.4901 MJ2.4901 MJ
Product flow Products residues in life cycle / Waste for recovery 0.0265 kg0.0265 kg
Product flow Energy carriers and technologies / Hard coal based fuels 0.0654 MJ0.0654 MJ
Product flow Valuable substances / Materials / Minerals 0.0779 kg0.0779 kg
Product flow Energy carriers and technologies / Crude oil based fuels 0.0429 MJ0.0429 MJ
Product flow Energy carriers and technologies / Natural gas based fuels 0.0243 MJ0.0243 MJ
Product flow Valuable substances / Materials / Minerals 0.0346 kg0.0346 kg
Product flow Energy carriers and technologies / Hard coal based fuels 0.0837 MJ0.0837 MJ
Product flow Products residues in life cycle / Waste for recovery 0.0329 kg0.0329 kg
Product flow Energy carriers and technologies / Electricity 0.3744 MJ0.3744 MJ
Product flow Products residues in life cycle / Waste for recovery 0.1409 kg0.1409 kg
Product flow Products residues in life cycle / Waste for recovery 0.0297 MJ0.0297 MJ
Elementary flow Elementary flows / resource / in ground 0.153 kg0.153 kg
Elementary flow Elementary flows / resource / in ground 0.0072 kg0.0072 kg
Elementary flow Elementary flows / resource / in ground 0.0048 kg0.0048 kg
Elementary flow Elementary flows / resource / in ground 0.9206 kg0.9206 kg

Outputs

Type of flow Classification Flow Mean amount Resulting amount Minimum amount Maximum amount
Product flow Materials production / Other mineralic materials 1.0 kg1.0 kg
Elementary flow Elementary flows / air / unspecified 4.19E-4 kg4.19E-4 kg
Elementary flow Elementary flows / air / unspecified 2.59E-5 kg2.59E-5 kg
Elementary flow Elementary flows / air / unspecified 8.28E-6 kg8.28E-6 kg
Elementary flow Elementary flows / air / unspecified 2.07E-6 kg2.07E-6 kg
Elementary flow Elementary flows / air / unspecified 0.637 kg0.637 kg
Elementary flow Elementary flows / air / unspecified 5.49E-5 kg5.49E-5 kg
Elementary flow Elementary flows / air / unspecified 8.18E-5 kg8.18E-5 kg
Elementary flow Elementary flows / air / unspecified 0.00129 kg0.00129 kg
Elementary flow Elementary flows / air / unspecified 1.1E-4 kg1.1E-4 kg