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Feasibility Study on Effective Use of Energy in the Cement Manufacturing

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Feasibility Study on Effective Use of Energy in the Cement Manufacturing NEDO-IC-OOER33 Feasibi ity Study on Effective Use of Energy i n the Cement Manufacturing Process March, 2001 New Energy and Industrial Technologies Development Organization (NEDO) Entrusted to International Center for Environmental Technology Transfer Feasibility Study on Effective Use of Energy in the Cement Manufacturing Process International Center for Environmental Technology Transfer March, 2001 Study purpose This survey was conducted in order to study the potential of COM as to reduce green house gas and cost by transferring Japanese energy conservation technologies to Thailand’s cement industry, which is one of Thai industry’s largest energy consumers. Specifical Iy, in cooperation with the Siam Cement Industry Company Limited (SCI), we investigated the use and consumption of energy in SCI’s white cement production plant, which needs much energy consumption comparing gray cement production. Introduction In December 1997, the Third Session of the Conference of the Parties to the United Nations Framework convention on Climate Change (COP3) was held in Kyoto. The conference adopted the Kyoto Protocol, which targets a 5 percent minimum average reduction in greenhouse-effect gas emissions in developed nations from 1990 levels. This goal, scheduled for achievement between 2008 and 2012, seeks to prevent global warming caused by carbon dioxide and other greenhouse-effect gasses. Japan's reduction target is 6 percent. The Kyoto Protocol specified measures for flexibly achieving these goals, including Joint Implementation (JI), in which developed nations can share the amounts of gasses to be reduced through international projects, and the Clean Development Mechanism (CDM) for joint implementation by developed and developing nations. Considering the current circumstances in which development of nuclear energy and alternative energies faces rigorous restrictions, Japan must try to conserve energy jointly with developing nations through CDM and the like. We must reach our target by making good use of these systems. On the other hand, in developing nations, particularly those of Asia, energy conservation technologies have not been deployed well due to a shortage of engineers and funds as well as delays in plant modernization, although in recent years industrialization has been making rapid progress through industrial promotion policies. If Japan contributes to sustainable development in developing nations through the transfer of its energy conservation technologies, both Japan and developing nations will benefit. Under these conditions, this survey aimed at the following three by transferring our energy-saving technology to the cement industry in Thailand, which consumes much, more energy. - Reducing the emission of greenhouse effect gases - Reducing the cost - Possibility of Clean Development Mechanism (CDM) To be concrete, we made a survey in cooperation with the Siam Cement Industry Corporation (SCI), which has the longest history in Thailand and produces the largest quantity now. Firstly, we surveyed the existing situation of energy application and consumption at Siam White Cement Corporation (SWCC), subsidiary of SCI, production equipment; and secondly proposed to introduce the gas turbine generator from the viewpoint of highly efficient utilization of energy to verify the estimated effect. We discussed the verification result with the SCI engineers and estimated the effect after improvement. These were included in our report to be reflected in the equipment improvement-working plan. At the end of the joint survey, we hope not only the gas turbine generating technology is helpful for the white cement plants but also that the good effect will extend to the gray cement plants and other manufacturers. SCI is in no condition to carry forward the project immediately judging from the gas supply infrastructure and .the demand for white cement. However, we will continuously contact with SCI, 1) to get SCI plan working information, 2) to provide SCI with information on CDM activities including COP6, and 3) to continue contacting with OEPP (Office of Environmental Policy and Planning) or Thai Government official agency of CDM. We will continue to discuss to realize the project with fixing our eyes on SCI's preparations to receive CDM. Finally, we were deeply impressed during this investigation that SCI engineers and other members actively exchanged opinions based on various technical data. We are deeply grateful to many people in Thailand and Japan who gave us valuable information and honest opinions during the investigation. March, 2001 Gosin Kura, Managing Director International Center for Environmental Technology Transfer Report on Result of " Feasibility Study on Effective Use of Energy in the Cement Manufacturing Process" Contents [Introduction] Summary................................................................................................................................................ 1 Chapter 1. Basic data of the Project.............................................................................................4 Section 1. Existing conditions in Thailand ............................................................................4 1.1.1 Political, economical, and social conditions ...................................................... 4 1.1.2 Energy conditions .................................................................................................. 19 1.1.3 Needs for CDM project ......................................................................................... 36 Section 2. Necessity to introduce energy saving technology into cement production process ................................................................................ 38 Section 3. Meaning, need, and effect of this project and influence on and spreading to the similar industries ................................................................. 39 Chapter 2. Implementation of the project ......................................................................... 40 Section 1. Project planning ................................................................................................... 41 2.1.1 Outline of the province of Saraburi .................................................................. 41 2.1.2 Details of the project ............................................................................................ 42 2.1.3 Reduction in greenhouse gas emissions ...........................................................42 Section 2. Outline of Siam Cement Industry (SCI).......................................................... 46 2.2.1 Issues and plans of Siam Cement Industry ....................................................48 2.2.2 Related facilities at Siam Cement Industry ....................................................49 2.2.3 SCI's Capability to fulfill the project ................................................................73 2.2.4 Details of the project and specifications of related equipment after the modification ....................................................................................................81 2.2.5 Funding, equipment, service and other elements of the project provided by the two parties ............... 107 2.2.6 Preconditions and problems related to project implementation ..............108 2.2.7 Project schedule ...................................................................................................108 Section 3. Development of the funding plan .................................................................. 110 2.3.1 Funding plan for the project implementation ...............................................110 2.3.2 Prospects for funding ......................................................................................... 113 Section 4. Things related to CDM conditions .................................................................114 2.4.1 Arrangement and adjustment with the partner for the purpose of realizing CDM: Setting project conditions and work responsibility by taking into account the actual situation of the project cite..................... 114 2.4.2 Possibility to agree that the project is regarded as CDM............................115 Chapter 3. Effects of the project ................................................................................................116 Section 1. Energy-saving effects..........................................................................................116 3.1.1 Technical grounds for energy-saving effects................................................. 116 3.1.2 Baseline for calculating the effects..................................................................116 3.1.3 Concrete energy-saving effect...........................................................................118 3.1.4 How to confirm concrete effects........................................................................ 121 Section 2. Effect of reducing greenhouse gas.................................................................122 3.2.1 Technical background to the reduction in greenhouse gas........................ 122 3.2.2 Baseline for calculating the effect....................................................................122 3.2.3 Concrete CO2 reduction effects......................................................................... 126 3.2.4 Method of confirming the effect........................................................................ 129 Section 3. Effects on Productivity ...............................................................
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