Session: 11-01: Process Heat for Desalination and Industrial Decarbonization

Paper Number: 131253

131253 - Assessing the Environmental Impacts of Electrified Cement Production 

Abstract: 

The production of ordinary Portland cement (OPC) is responsible for approximately 5-7% of global anthropogenic carbon dioxide (CO₂) emissions. As demand for cement is expected to rise due to increased urban and energy infrastructure projects, it is crucial to transform this sector sustainably to meet these needs while minimizing its significant contribution to environmental impacts. This has prompted a growing interest in sustainable practices by developing low carbon technologies while meeting surging demand for building materials. Electrification of heat supply is one of interesting options for mitigating the generation of CO₂ emissions resulting from the combustion of fossil fuels.

 

This study assesses cradle-to-gate environmental impacts of two electrified cement plants: (a) employing an electrified pre-calciner utilizing resistive elements or magnetic induction, along with plasma gas to provide high-temperature heat within the rotary kiln, and (b) utilizing an electrified pre-calciner in conjunction with the indirect electrification of the rotary kiln, achieved by combusting hydrogen generated through water or steam electrolysis. This assessment is performed using a life cycle assessment (LCA) framework and is compared against a reference cement plant. The study integrates data from existing literature, including information on best available technology, process modeling and expert consultation, to establish life cycle inventory data. Aspen Plus simulation model is developed that provides estimated mass and energy balances for an industrial cement production. Furthermore, the LCA of the electrified cement production process is conducted using Sphera’s LCA for Experts software (GaBi), with a focus on a geographical location in Saudi Arabia. Different scenarios, including process configurations and the effect of using future decarbonization scenarios for the electricity mix in Saudi Arabia, are evaluated

 

The finding shows that electrified processes could lead to substantial reductions in global warming potential (GWP), with the carbon emission intensity of the electricity grid playing a pivotal role in determining the environmental performance of these technologies. Beyond GWP, the study also evaluates other non-climate impact indicators, such as acidification, eutrophication, human toxicity potential, fossil and mineral resource depletion, to identify potential environmental trade-offs associated with climate change mitigation efforts. To achieve near zero carbon emissions, CO₂ emissions from cement production could be further reduced by combining electrification measures with carbon capture and storage (CCS). While electrification has the potential for reducing carbon emissions, the actual uptake of this technology in the industrial sector remains uncertain and will depend on the future technology improvement and cost competitiveness of electric solutions compared to other low-carbon alternatives. Overall, we aim to contribute to the environmental impact assessment of such new process concepts, enabling informed decisions about the value of further research and development.

Presenting Author: Glenda Teran-Cuadrado King Abdullah University of Science and Technology (KAUST)

Presenting Author Biography: Glenda Teran Cuadrado holds a Bachelor of Science in Chemical Engineering and is currently pursuing a Ph.D. in Chemical Engineering at Sustainable Built Environment research group, Department of Biological and Environmental of Science and Engineering (BESE) at KAUST. She is affiliated with Climate and Livability Initiative, KAUST. She focuses on analyzing the life cycle of building materials, with a particular emphasis on massive construction activities, including those in Saudi Arabia. One of her research aims is to develop local databases to accurately quantify emissions from the construction sector while exploring scientific methods to reduce carbon emissions in the cement industry.

Authors:

Anissa Nurdiawati King Abdullah University of Science and Technology (KAUST)
Glenda Terán-Cuadrado King Abdullah University of Science and Technology (KAUST)
Sami Al-Ghamdi King Abdullah University of Science and Technology (KAUST)