Cement Sustainability Initiative - World Business Council For .

2.2.2Particulate matter/dustThe terms ‘dust’ or ‘particulate matter’ includeemissions of coarse dust, fine dust, soot, particlesand aerosols.Dust emissions from cement kilns have been reduceddramatically over the last two to three decades dueto regular improvements in design and operation,including increased use of modern de-dustingequipment. Nevertheless dust emissions from poorlyequipped or poorly operated kilns can be high.In most countries, the cement industry is not amajor source of dust and particulates, though onsome sites these particulate emissions may still beof significance. The data on particulate emissionsshown in Table 1 from the European BREF aresimilar to those from Australian and US cementplant inventories (NPI 1999; EPA AP-42 1995).2.2.3 Oxides of nitrogen (NOx)and sulfur (SO2)NOx is formed by the reaction of nitrogen in airand fuel with oxygen at the high temperaturesreached during the clinker production process. SOxemissions are predominantly (99%) in the form ofsulfur dioxide (SO2). SO2 is primarily formed fromoxidation of volatile sulfur present in raw materials,but in some specific process configurations it mayresult from fuel sulfur oxidation.In some countries, the industry is a relativelysmall contributor to national emissions ofthese pollutants. For example, the UK NationalAtmospheric Emissions Inventory (NAEI 2009)showed that the cement industry contributed about2.5% of the total NOx and 1.0% of the total SO2emissions in the UK in the year 2008.2.2.4Oxides of carbon (CO2andCO)Cement production is a source of emissions of thegreenhouse gas carbon dioxide (CO2). As much as6%2 of global man-made carbon dioxide emissionsoriginate from cement production.Reducing CO2 emissions is a key focus of the CSI’swork. In 2001 the CSI companies agreed on amethodology for calculating and reporting CO2emissions, the Cement CO2 and Energy Protocol.It is aligned with the WBCSD / WRI GreenhouseGas Protocol and was revised in 2005 and in 2011.To date, all CSI companies follow this protocol todetermine and report their CO2 emissions.4The emission of carbon monoxide (CO) during theclinker production process is caused by incompletecombustion of small quantities of organicconstituents present in some raw materials. Formost kilns the CO content is well below 2000 mg/Nm3 (BREF 2010).2.2.5Cement production is not a significant source ofVOCs but small quantities of organic constituentscan be released from the natural raw materialsduring the clinker production process. Undernormal circumstances the VOC content of theexhaust gas from cement kilns ranges between1 and 60mg/Nm3 (BREF 2010). In viewingnational inventories of pollutants, major sourcesof VOC emissions are typically road and air traffic,together with organic solvent use, oil and chemicalindustry processes, and industrial and residentialcombustion.2.2.6“Reference Document on Best Available Techniques in theCement, Lime and Magnesium Oxide Manufacturing, May2010”, European Commission. http://eippcb.jrc.ec.europa.euAcid gasesCement production is a minor source of hydrogenchloride (HCl) and hydrogen fluoride (HF) arisingfrom trace amounts of chlorine and fluorine presentin raw materials and fuels.21Volatile Organic Compounds (VOCs)34IPCC Special Report on Carbon Dioxide Capture and Storage,UNEP Intergovernmental Panel on Climate Change, files-images/SRCCS-WholeReport.pdf, p. 113.See www.wbcsdcement.org/co2dataDirectly accessible via: www.cement-co2-protocol.org/v3Cement Sustainability Initiative 52 Emissions from cement productionThe cement industry has significantly improvedits performance over the last 30 years but it is stilla source of NOx and SO2 emissions. The data onNOx and SO2 emissions shown in Table 1 fromthe European BREF are again similar to those forAustralian and US cement plants (NPI 1999; EPAAP-42 1995).Approximately 50% of carbon dioxide emissionsfrom cement production originate from thechemical reaction that converts limestone (CaCO3)to calcium oxide (CaO), the primary precursor tocement. About 40% of the industry’s CO2 emissionscome from fossil fuel combustion during cementproduction. The remaining emissions come fromthe transport of raw materials (about 5%) and thecombustion of fossil fuels required to produce theelectricity consumed by cement production (about5%) (Battelle 2002). According to the CSI’s Gettingthe Numbers Right database (GNR), which coversclose to one third of global cement production,the average specific CO2 emissions amounted to652 kg/ton cementitious product in 2010.3

2.2.7Trace metalsTrace metals are present in raw materials andfuels, at widely variable but usually very lowconcentrations5. The behavior of the trace metalsin a cement kiln depends on their volatility. Nonvolatile metals and metal compounds leave the kilnas part of the clinker. Volatile metals condense inthe preheater and raw mill system and return to thekiln with the raw meal. This concentrating effectcan lead to an increase of emissions, for instance,when the raw mill system is not running or in theevent of kiln upsets. Volatile metals which do notcondense in the raw mill system leave with thecombustion gases in low concentrations.2.2.8Organic micro-pollutantsThe following substances are sometimes collectivelyreferred to as ‘micro pollutants’ as the absolutemass of their releases from a given process isnormally orders of magnitude lower than thereleases of NOx or other air pollutants:Formation of dioxins and furans occurs at relativelylow temperatures – most typically in exhaust gasesfrom a variety of combustion processes (includingforest fires and domestic cooking) as the gases coolthrough a temperature range of 450 C to 200 C.To minimize the possibility of dioxin formation it isimportant that the kiln gases are cooled as quicklyas possible through this critical temperature range.Based on detailed analysis of existing data andnew samples collected by CSI members, in welloperated, modern cement kilns dioxin emissionsare not related to the type of fuels used (SINTEF 2ndedition January 2006).A number of countries have conducted nationaldioxin inventories. In some countries, these showthat the cement industry is generally a minorcontributor to dioxin emissions (less than 3%of the total). Major sources include municipalwaste incinerators, residential wood combustion,agricultural burning, and steel mills among others.62 Emissions from cement production Polychlorinated dibenzodioxins andpolychlorinated dibenzofurans – collectivelyknown as “dioxins and furans” or “PCDD/PCDFs” Polychlorinated biphenyls – usually known as“PCBs” Polycyclic aromatic hydrocarbons – known as“PAHs”.656See, for example, typical concentrations as identified by theCSI’s work on fuels and materials use: www.wbcsdcement.orgFor example, Canada’s 1999 dioxin emissions inventory showedmunicipal waste incineration as responsible for 58% of totaldioxin releases. Emissions from the cement sector accountedfor less than 1%: “Dioxins and Furans and Hexachlorobenzene,Inventory of Releases,” Environment Canada, January 1999. Canbe downloaded from the CEPA website

3 Selection of the mainemissions source andpollutantsThis protocol aims to ensure that CSI companiesfocus on monitoring, measuring and reporting ofthe most important emission sources and pollutantsfrom the cement industry. This section identifies thekey sources and pollutants for this protocol.Selection of the main emissionsource3.1Near-ground fugitive releases of dust originatein most cases from quarrying and preparation ofraw materials, handling and storage of fuels, andtransport (sometimes worsened by wind action andother natural sources), but not from the combustionprocess. Fugitive emissions of this sort are difficultto measure and impact mainly on the localenvironment (and are therefore the responsibility ofthe local plant management), whereas releases fromhigh stacks may have an impact on air quality overa much larger area.This protocol therefore considers emissions from themain kiln stack only, but it encourages individualcompanies to measure on a wider scope of emissionreleases than those outlined in this referencedocument.Selection of the main pollutantsThe following emissions from the main kiln stackhave been identified as the main focus for thisprotocol, and therefore for reporting within the CSI,due to their volume and/or significance: Dust / particulate matter Oxides of nitrogen (NOx) Sulfur dioxide (SO2).3.3 Selection of other pollutantsOther pollutants of concern to stakeholders(including local communities and regulatoryauthorities) and which should be measured are: Trace metals and their compounds such as:Mercury (Hg), Cadmium (Cd), Thallium (Tl),Antimony (Sb), Arsenic (As), Lead (Pb), Chromium(Cr), Cobalt (Co), Copper (Cu), Manganese (Mn),Nickel (Ni) and Vanadium (V). Volatile organic compounds (VOCs) or TotalHydrocarbons (THC); they include methane andethane with other hydrocarbons and are reportedas carbon. Polychlorinated dibenzodioxins and dibenzofurans(PCDD/PCDFs); they include the 17 congeners ofthe NATO scheme adopted internationally and arereported as International Toxic Equivalent (I-TEQ)7.This selection is largely in keeping with otherimportant international guidelines, e.g. ReferenceDocuments on Best Available Technique (BREF) andthe Industrial Emissions Directive (IED) in Europe,and the National Emission Standard for HazardousAir Pollutants (NESHAP) in the USA. Others are alsoconsidered, such as the US EPA documentationAP-42 and the Australian NPI Guideline.Other pollutants such as acid gases can beconsidered as minor and not material consideringthe trace amounts of Chlorine and Fluor present inraw materials and fuels.7Refer to Technical Annex, Table A6Cement Sustainability Initiative 73 Selection of the main emissionssource and pollutantsSome regulatory systems designate specificmeasurement points for specific processes. Based oncomparisons of plants with different kiln systems,de-dusting installations and geographical locations,the main stack of the clinker production processhas been shown to be the most important sourceof emissions to air by the cement industry. Thisis due to the volumetric flows as well as emissionconcentrations which are comparatively high at thispoint in the process.3.2

4 Emissions monitoring(measurements)The emissions can be monitored by using eithercontinuous or discontinuous measurements. Themeasurements will be taken according to therecognized rules of metrology and according tothe methods recognized in corresponding nationalenvironmental regulations.The technical annex to this protocol gives insightson various technologies suitable for continuousmeasurements: “in-situ” and “extractive” measuringdevices, “cold” and “hot” extractive devices, andthe different physical methods of analyses.The technical annex gives the standards whichare recommended for the measurements –sampling and analyses – of the pollutants andparameters. Those standards are InternationalISO Standards (see: www.iso.org), US-EPAmethods (see: www.epa.gov) and EN standards(see: www.cen.eu). Methods defined by nationalstandards or methods recognized equivalent tothe recommended standards may be used as well.Methods used have to be identified.4 Emissions monitoring(measurements)The technical annex recommends that theselection criteria for continuous emission monitors(CEMs) should include – among others – the rightidentification of the pollutants to be measuredaccording to the requirements set in the regulationsand operating permits and according to thecommitments taken in these guidelines; parameterssuch as oxygen, moisture and the gas flow shouldalso be included. The emission levels and valuesshould be assessed for the various scenarios ofoperation of the kiln system. The analyzers shouldbe certified by a recognized certification body orsuitability demonstrated with performance tests.Attention should be paid to the supplier’s ability toprovide local technical support.The technical annex recommends that contractorsor bodies carrying out the discontinuousmeasurements and the analyses have implementeda quality management system that follows asexample the international standards ISO 9001: 2008and ISO 17025: 2005 “General requirements for thecompetence of testing and calibration laboratories”.The experience of contractors or bodies should bechecked for the components analyzed.4.1 Recommended frequency ofmeasurementsThe frequency of the measurements should bebased on the nature of the pollutants releasedand on the concerns of stakeholders. A companyadhering to these guidelines will measure the mainpollutants (dust, NOx and SO2) continuously withcontinuous emission monitors (CEMs). Before theCEMs are in operation on a site, these pollutantsshould be measured at least once a year.The volatile organic compounds or totalhydrocarbons (VOC/THC) should preferably bemeasured continuously or at least once a year.Other pollutants should be measured periodically,according to the frequency reported in Table 2. Themeasurements should be made under conditionswhich reflect the normal operating conditions of thecement production process.The measurement made periodically will berenewed within a period of six months followingany significant change8 in the process: nature offuels, raw materials, or air pollution control device.88Refer to Technical Annex, Section 7

Table 2: Frequency of measurements of coveredpollutantsThe continuous measurements with CEMs followingcommissioning need routine checks, propermaintenance and periodical calibration.PollutantFrequency ofmeasurements ��Continuously”VOC/THC”Continuously or at leastonce a year The technical assessment of data: Data are inusual range for the cement production process,data are coherent. The comparison of emissions monitored for thesame kiln and pollutant in different months andyears. A data validation process which should beimplemented by the companies.”PCDD/F”Once every two yearsMore indications are given in the Technical Annex.”Hg”Once every year“other heavy metals”Once every two yearsThe quality assurance process for both continuousand discontinuous measurements should include:The frequency of measurements could be reducedfor mercury when the measured emissions arebelow the threshold set in Table 3. The frequencyof measurements would return to the normalfrequency as per Table 2 when measurements goabove that threshold.When PCDD/F or mercury is measuredcontinuously, they do not have to also be measuredperiodically.pollutantThreshold ”Hg”25µg/Nm34 Emissions monitoring(measurements)Table 3: Threshold for mercuryMeasurementsare Once every twoyears4.2 Quality assuranceThe quality of measurement and reporting relies onthe successful implementation of successive workingsteps: sampling, analysis and reporting. Companiesshould assign resources and clear responsibilitiesfor the monitoring, validating and recording ofemissions. People should be trained for bothoperational and maintenance checks.Cement Sustainability Initiative 9

5 Key Performance IndicatorsThe CSI companies are aware of the need to trackthe progress of improvements, and to make thisprogress clear to all their stakeholders. This protocoltherefore includes a number of simple, reliable andrepresentative Key Performance Indicators (KPIs).KPI 1: Overall coverage rate5 Key Performance IndicatorsThis KPI is designed to show the percentage ofclinker produced by kilns covered by a monitoringsystem (continuous or discontinuous measurements)meaning dust, NOx, SO2, VOC/THC, heavy metals(Hg, Cd, Tl, Sb, As, Pb, Cr, Co, Cu, Mn, Ni and V),PCDD/F. The full production from a kiln is includedin the KPI only when emissions of all pollutants (all17 listed pollutants) are monitored, otherwise theproduction contribution from the kiln should beconsidered zero.KPI 3”X”: Emission data pollutant “X”9This KPI is designed to show the releases of emissionsof dust, NOx, SO2, VOC/THC, Hg, heavy metals 1(sum of Cd and Tl), heavy metals 2 (sum of Sb, As,Pb, Cr, Co, Cu, Mn, Ni and V), and PCDD/F(pollutant previously identified) from the kiln tothe air. There are separate KPIs for each of thesepollutants or group of pollutants as indicated in Table4. Both specific and absolute values are reported.Table 4: Definition of KPI 3”X” for each pollutantIndicatorCommentsKPI 3”dust”KPI 3”NOx”Sum of nitrogen monoxide plusnitrogen dioxide expressed asnitrogen dioxideCalculation example for KPI 1:Company A operates 50 kilns producing 50 milliontons of clinker per year. In the reported time frame,all emissions of pollutants (previously identified)were monitored at 35 kilns producing 40 milliontons of clinker.KPI 3”SO2”KPI 3”VOC/THC”Total hydrocarbons includingmethane and ethane expressedas carbon (C)In this case we get: KPI 1 (40,000,000 tons /50,000,000 tons) x 100 80%KPI3”PCDD/F”Sum of 17 congeners of NATOscheme expressed as I-TEQThe KPI 1 of company A is therefore 80%, meaningthat 80% of its clinker is produced in kilns coveredby monitoring systems which meet this protocol.KPI 3”Hg”Mercury and its compoundsexpressed as mercury (Hg)KPI 3”HM1”Sum of Cadmium and Thalliumand their compounds expressedas cadmium (Cd) and thallium(Tl)KPI 3”HM2”Sum of Antimony, Arsenic,Lead, Chromium, Cobalt,Copper, Manganese, Nickel andVanadium and their compoundsexpressed as antimony (Sb),arsenic (As), lead (Pb), chromium(Cr), cobalt (Co), copper (Cu),manganese (Mn), nickel (Ni) andvanadium (V)KPI 2: C overage rate continuousmeasurementThis KPI indicates the percentage of clinkerproduced by kilns which have installed continuousmeasurements for dust, NOx and SO2. The fullproduction from a kiln is included in the KPI onlywhen all emissions of the pollutants (dust, NOxand SO2) are monitored, otherwise the productioncontribution from the kiln should be consideredzero.910“X” is a generic reference to any of the pollutants

The calculation of emissions on a specific basis (g/ton clinker, mg/ton clinker, ng/ton clinker) must bedone using the mass weighted averages of the kilnsto ensure accurate data, whereas the absolute valuesof emissions (t/year, kg/year, mg/year) are calculatedby adding the total emissions of each kiln.If Company A would have operated a kiln Dproducing 0.2 million tons of clinker per yearand no specific dust emission would have beenreported, the indicator would have been:Heavy metals (Hg, Cd, Tl, Sb, As, Pb, Cr, Co, Cu,Mn, Ni and V) and PCDD/F do not need to bemeasured on installations with running factors(operational capacity or time) below 50% in a year.In these circumstances, to avoid any impact on thecoverage rates of indicators KPI 1 and KPI 4, theclinker produced from these installations will not beconsidered for the determination of these indicators.KPI 3”dust” 70.0 tons x (1,000,000 tons 500,000 tons 400,000 tons 200,000 tons) /(1,000,000 tons 500,000 tons 400,000 tons) 77.4 tons/yearThe absolute values are extrapolated to the totalquantity of clinker produced by the company.Calculation example for specific and absolutedust emissions:Company A operates 3 kilns: Kiln A produces 1 million tons of clinker per yearwith a specific dust emission of 10 g/ton clinkerand an absolute dust emission of 10.0 tons/year, Kiln B produces 0.5 million tons of clinker peryear with a specific dust emission of 40 g/tonclinker and an absolute dust emission of 20.0tons/year, Kiln C produces 0.4 million tons of clinker peryear with a specific dust emission of 100 g/tonclinker and an absolute dust emission of 40.0tons/year,KPI 3”dust” 10.0 tons 20.0 tons 40.0 tons 70.0 tons/yearWhen mercury has not been measured during oneyear because it was below the threshold the yearbefore, or other heavy metals or dioxins and furanshave not been measured in accordance with thefrequency set in these guidelines, the last availablespecific value measured will be used for reporting;the absolute value being calculated multiplying thatspecific value by the total mass of clinker producedduring the year of reporting.Calculation example for specific mercuryemissions:A specific mercury emission of 20 mg/ton clinkerhas been measured in 2009 at the stack of kiln A.In 2010, no measurement has been made, kiln Ahas produced 1.0 million tons of clinker. Mercuryemission reported in 2010 will be:KPI 3”Hg” 20.0 mg/ton clinker, andKPI 3”Hg” 20 mg x 1,000,000 tons 20.0 kg/yearThe heavy metals cover the gaseous, the vapor andthe condensed forms of the relevant heavy metalemissions as well as their compounds.KPI 4”X”: coverage rate pollutant “X”This KPI indicates the percentage of clinker producedby kilns which have monitored pollutant “X”.Cement Sustainability Initiative 115 Key Performance IndicatorsKPI 3”dust” (10 g x 1,000,000 tons 40 g x500,000 tons 100 g x 400,000 tons) / (1,000,000tons 500,000 tons 400,000 tons) 36.8 g/tonclinker, andKPI 3”dust” 36.8 g/ton clinker, and

6 ReportingThe objective of environmental reporting is toprovide the reader with a fair picture of theenvironmental footprint of the reporting entity.Reporting of emissions therefore needs to meet anumber of criteria: Data must be consistent, transparent and credible Data must be presented in a clear, standardformat Data must meet quality assurance (QA)requirements (see section 4.2) Data must allow emissions to be reported inabsolute as well as specific terms Reports must provide a flexible tool to suit theneeds of different monitoring and reportingpurposes6.1 Which installations are covered?A company can choose one of the following optionsto set the organizational boundaries on reporting ofemissions data covered by this protocol: Equity share approach Control approach (operational or financial) A combination of both6 ReportingA company should clearly state in its publicreporting which method it applies and the exactscope of what is reported.For this protocol, the definitions as outlined in theWRI/WBCSD Corporate Green

Cement is one of the most widely used man-made substances on the planet. Each year, nearly 450 kg of cement are consumed for each man, woman and child. Making cement is an energy and resource intensive process, with both local and global impacts. Recognizing this, several cement companies initiated the Cement Sustainability