Cement Industry BRAZILIAN CEMENT INDUSTRY A FOUNDATION FOR CONSTRUCTING DEVELOPMENT INDUSTRY MEETING FOR SUSTAINABILITY NATIONAL FEDERATION OF INDUSTRIES – CNI Robson Braga de Andrade Chairman BOARD OF EDUCATION AND TECHNOLOGY – DIRET Rafael Esmeraldo Lucchesi Ramacciotti Director of Education and Technology ASSOCIAÇÃO BRASILEIRA DE CIMENTO PORTLAND – ABCP Renato José Giusti President SINDICATO NACIONAL DA INDÚSTRIA DE CIMENTO – SNIC José Otávio Carneiro de Carvalho President ASSOCIAÇÃO BRASILEIRA DE CIMENTO PORTLAND – ABCP Mário William Esper Institutional Relations Manager BRASÍLIA 2012 © 2012. CNI – CNI – National Federation of Industries Any part of this publication may be reproduced provided the source is mentioned. C748i National Confederation of Industry. Brazilian Associaton of Portland Cement / Brazilian cement industry. A foundation for the construction of development / National Confederation of Industry. Brazilian Associaton of Portland Cement. – Brasília: CNI, 2012. 58 p. (Rio+20 Sectorial fascicle) 1. Sustainability 2. United Nations Conference on Sustainable Development I. Title II. Series CDU: 502.14 (063) CNI ABCP SNIC National Federation Brazilian Associaton Sindicato Nacional da of Industries of Portland Cement Indústria do Cimento Headquarters Headquarters Headquarters Setor Bancário Norte Jaguaré Rua da Assembléia, 10 Quadra 1 – Bloco C Av. Torres de Oliveira, 76 20011-901 – Rio de Janeiro – RJ Edifício Roberto Simonsen 05347-902 – São Paulo – SP Phone: (21) 2531-1314 70040-903 – Brasília – DF Phone/Fax: (11) 3760-5300 Fax: (21) 2531-1526 Phone: (61) 3317-9000 www.abcp.org.br www.snic.org.br Fax: (61) 3317-9994 www.cni.org.br LIST OF FIGURES Figure 1. Economic feature of the sector ............................................................... 15 Figure 2. Cement production chain ....................................................................... 16 Figure 3. Cement production process scheme ..................................................... 17 Figure 4. Clinker volume by type of kiln (%) ........................................................... 19 Figure 5. Energy savings potential based on best available technology in 2006 .......................................................... 20 Figure 6. PCH St. John in Itaú de Minas – MG ...................................................... 20 Figure 7. Valente Mine – Cantagalo RJ ................................................................. 23 Figure 8. Deposit of clay – Itapeva SP ................................................................... 23 Figure 9. Felicissimo Mine – Ipanema National Forest .......................................... 24 Figure 10. Chico Pernambuco cavern – BA ............................................................. 25 Figure 11. Riparian Forest-Stream Mariano – Cajati SP .......................................... 26 Figure 12. Graça farm – João Pessoa PB ................................................................ 27 Figure 13. Timber park – João Pessoa PB .............................................................. 27 Figure 14. Private Reserve of Natural Heritage (PRNP) – Matozinhos MG ............. 28 Figure 15. Ballet Cave – Matozinhos MG ................................................................. 28 Figure 16. Private Reserve of Natural Heritage (PRNP) – Arcos MG ....................... 29 Figure 17. Ephraim hole – Arcos MG ....................................................................... 29 Figure 18. Evolution of clinker and cement production and use of mineral additions .................................................................. 30 Figure 19. Coprocessing waste scheme ................................................................. 31 Figure 20. Types of waste for coprocessing ............................................................ 31 Figure 21. Evolution of coprocessing regulation ..................................................... 32 Figure 22. Coprocessing evolution .......................................................................... 32 Figure 23. Waste after homogenization ................................................................... 33 Figure 25. Hot disc ................................................................................................... 34 Figure 24. Representation in kilometers of the amount of tires coprocessed in 2010 .............................................................................. 34 Figure 26. Urban Solid Waste – Municipal Treatment Plant – Cantagalo RJ ........... 36 Figure 27. Urban Solid Waste – Waste Shed – Cantagalo RJ ................................. 36 Figure 28. Sources of CO2 emissions in the cement industry ................................. 37 Figure 29. Clinker/cement ratio ................................................................................ 38 Figure 30. Co-processing and greenhouse gases reduction .................................. 39 Figure 31. Cement production x CO2 emissions ..................................................... 40 Figure 32. Specific CO2 emissions ........................................................................... 40 Figure 33. Variation of CO2 emissions by sector ..................................................... 41 Figure 34. Share of the cement industry in total brazilian CO2 emissions in 2005 ............................................................. 41 Figure 35. Average CO2 emissions per ton of cement ............................................ 41 Figure 36. CO2 emissions saving potential in the Brazilian cement industry ........... 42 Figure 37. Sustainability Reports ............................................................................. 44 Figure 38. Sustainable development fair – Cantagalo RJ ....................................... 45 Figure 39. Houses in São Luiz do Paraitinga – SP .................................................. 46 Figure 40. Social programs – Votorantim Cement ................................................... 48 Figure 41. Restoration of the Graça chapel – João Pessoa PB .............................. 49 Figure 42. Environmental education center – Holcim MG ....................................... 50 Figure 43. Educating Green – Holcim RJ ................................................................ 51 Figure 44. Environmental education – Lafarge RJ ................................................... 52 Figure 45. Per capita consumption of cement ......................................................... 56 Figure 46. Thermal energy substitution rates: International comparison ............... 57 Figura 47. Thermal energy substitution in Germany ................................................ 57 SUMMARY CNI presentation Sectorial presentation 1 Introduction ........................................................................................................... 13 2 Cement production process ................................................................................. 17 3 Use of resources ................................................................................................... 19 3.1 Energy ......................................................................................................... 19 3.2 Water ........................................................................................................... 22 Recycling of Water – The Votorantin Cement Case .................................... 22 3.3 Raw Materials: Limestone and Clay ............................................................ 22 3.4 Preservation of Biodiversity ........................................................................ 26 3.5 Raw materials : Mineral Additions ............................................................... 30 3.6 Co processing of scrap tires ....................................................................... 33 3.7 Co processing of treated urban solid waste ............................................... 35 4 Climate .................................................................................................................. 37 4.1 Cement Industry’s main contribution to the fight against Climate change ................................................................ 38 5 Social and environmental resposibility .................................................................. 45 5.1 Initiatives coordinated by the Brazilian Cement Portland Association ........ 45 5.2 Industry Initiatives ........................................................................................ 47 5.3 Votorantim Cimentos ................................................................................... 48 5.4 Cimpor Cements of Brazil ........................................................................... 49 5.5 Holcim Company ........................................................................................ 50 5.6 Holcim Awards ............................................................................................ 51 5.7 Lafarge ........................................................................................................ 51 5.8 InterCement ................................................................................................. 53 6 Challenges and opportunities for the sector in its path to sustainability .............. 55 6.1 Expanding its installed capacity .................................................................. 55 6.2 Co-processing: Enhancing energy substitution ......................................... 56 6.3 Co processing of treated urban solid waste ..............................................