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Article history: A hybrid life-cycle assessment method was performed on national and provincial statistics to study
Received 13 January 2014 pollutants generated by the cement industry in China, the impacts of these pollutants, and the potential
Received in revised form for environmental improvement. Results showed that the key factors that contribute to overall envi-
21 March 2014
ronmental burden are the direct emissions of nitrogen oxides (NOx), particulates, and carbon dioxide
Accepted 20 April 2014
Available online xxx
(CO2) into the atmosphere, as well as the use of coal during cement production. The amounts of CO2,
sulfur dioxide (SO2), NOx, and particulates generated by the cement industry in China in 2009 were
approximately 1.11 billion, 0.53 million, 2.10 million, and 3.60 million tons respectively, which accounted
Keywords:
Hybrid life-cycle assessment
for approximately 14.8%, 2.4%, 12.3%, and 26.2% of the national CO2, SO2, NOx, and particulate emissions,
National and provincial statistics respectively. Effective approaches to reduce the environmental impacts of the cement industry include
Cement optimizing the industrial structure in cement production, improving consumption efficiency of energy
Transport and raw materials in cement production, using industrial waste and by-products instead of limestone,
Energy recovery decreasing cement export, and promoting electricity recovery technologies in the cement industry.
Ó 2014 Elsevier Ltd. All rights reserved.
http://dx.doi.org/10.1016/j.jclepro.2014.04.048
0959-6526/Ó 2014 Elsevier Ltd. All rights reserved.
Please cite this article in press as: Chen, W., et al., Pollutants generated by cement production in China, their impacts, and the potential for
environmental improvement, Journal of Cleaner Production (2014), http://dx.doi.org/10.1016/j.jclepro.2014.04.048
2 W. Chen et al. / Journal of Cleaner Production xxx (2014) 1e9
Wang, 2010; Cui and Li, 2011; Piao et al., 2012; Xu et al., 2013). 2.2.2. System boundaries
However, only two studies (Hong and Li, 2012a,b) conducted via System boundaries were set by applying a cradle-to-gate
LCA on cement production in China have been published in English- approach. Four cement production scenarios, namely, large (dry
language peer-reviewed journals. In addition, most works on rotary kiln with a production capacity higher than 4000 tons
cement production in China have focused on on-site case studies clinker/day), moderate (dry rotary kiln with a production capacity
with relatively low representation. To evaluate the environmental between 2000 tons and 4000 tons clinker/day), small (dry rotary
impacts generated by the cement industry at the national level, kiln with a production capacity between 1000 tons and 2000 tons
hybrid LCA was performed on national statistics to study pollutants clinker/day), and shaft kiln were included in this study. For each
generated by the cement industry in China, the impacts of these scenario, 100% cement dust was recycled. For the scenarios with dry
pollutants, and the potential for environmental improvement. rotary kilns, 100% wastewater was reused on site, whereas the
wastewater generated from the shaft kiln was treated in a civilian
2. Materials and methods wastewater treatment plant. Fig. 2 presents the system boundaries
of the dry rotary kilns and the shaft kiln. Three stages, namely, raw
2.1. Estimating the national environmental impacts of cement material crushing, clinker generation, and cement grinding, were
production generally considered. The clinker generation stage of the scenarios
that employ dry rotary kilns included homogenization, preheating
Specific on-site data hardly represent regional inventories and precalcining, and incineration in the kiln. Meanwhile, the
because of numerous factors (e.g., cement strength, plant size, corresponding stage in the shaft kiln scenario included mixing with
applied processes and technologies, management attention, energy water, ball-making, and incineration in the kiln. Raw materials,
structure, energy efficiency, mix ratio of clinker and additive ma- energy consumption, road transport, direct emissions (i.e., carbon
terials). In the present study, hybrid LCA was conducted on national dioxide, sulfur dioxide, nitrogen oxides, and particulates), and
and provincial statistics to study pollutants generated by the infrastructure were considered in each process.
cement industry in China, the impacts of these pollutants, and the
potential for environmental improvement (Fig. 1). To identify and 2.2.3. Life-cycle impact assessment methodology
quantify the key factors (i.e., substances and processes) that The life-cycle impact assessment results (LCIA) were evaluated
contribute to the national environmental impact of the Chinese at midpoint and damage levels by the IMPACT 2002þ method
cement industry, LCA was performed on on-site data from various (Jolliet et al., 2003), one of the most widely used LCA approach. To
technologies used in cement production. In addition, national sta- check the reliability of the results obtained via IMPACT 2002þ,
tistics on the key factors were used for the assessment. LCA was also Recipe E (Goedkoop et al., 2009; Schryver et al., 2009), TRACI (Bare
repeated by using hybrid national statistics and on-site data to et al., 2003), and CML (Guinée et al., 2001) method were used.
determine whether new key factors have been generated. The IMPACT 2002 þ method was an update method based on the re-
aforementioned three steps were repeated until no new factor was sults of the IMPACT 2002 model for human health (Pennington
found. Provincial statistics on cement production were then used to et al., 2005), Centrum voor Milieukunde Leiden (CML, Guinée
determine the national and provincial environmental impacts of et al., 2001), and Eco-indicator 99 (Goedkoop and Spriensma,
the cement industry. 2000). It defined 15 midpoint categories (i.e., carcinogens, non-
carcinogens, respiratory inorganics, ionizing radiation, ozone
2.2. The LCA of cement layer depletion, respiratory organics, aquatic ecotoxicity, terrestrial
ecotoxicity, terrestrial acidification/nutrification, land occupation,
2.2.1. Functional unit aquatic acidification, aquatic eutrophication, global warming, non-
A functional unit provides a reference for the related inputs renewable energy and mineral extraction) and 4 endpoint cate-
and outputs of a product (ISO 14040, 2006). In this study, the gories (i.e., human health, ecosystem quality, resources depletion,
production of 1 ton common Portland cement, which accounts and climate change), all of which were related to the inventory
for approximately 98% of the total cement production in China results. In addition, normalization was applied in this study, in or-
(Xu, 2013), was selected as the functional unit. All materials, der to analyze the respective share of each midpoint impact to the
emissions, and energy consumption were based on this func-
tional unit.
Please cite this article in press as: Chen, W., et al., Pollutants generated by cement production in China, their impacts, and the potential for
environmental improvement, Journal of Cleaner Production (2014), http://dx.doi.org/10.1016/j.jclepro.2014.04.048
W. Chen et al. / Journal of Cleaner Production xxx (2014) 1e9 3
total impact as well as to compare the midpoint impact with each background data, including those on infrastructure and wastewater
other. All categories were normalized to better identify the key treatment from Europe (Frischknecht et al., 2007), were used
factors except aquatic eutrophication and aquatic acidification, due because Chinese data were unavailable.
to no detail information was available to support the damage level Statistics on the energy consumption (i.e., coal and electricity)
on aquatic eutrophication and aquatic acidification (Jolliet et al., and direct emissions (i.e., SO2, NOx, and particulates) of each sce-
2003). The complete characterization factors and detailed meth- nario, which were used instead of the on-site data on key factors,
odology for IMPACT 2002þ (http://www.sph.umich.edu/ were taken from references (Zeng et al., 2009; Jiang et al., 2010;
riskcenter/jolliet/impact2002þ.htm) and TRACI (http://www.epa. Ministry of Environmental Protection, 2008). Statistics on provin-
gov/nrmrl/std/traci/traci.html) are available on the website of the cial cement production in 2009 were taken from (China Report
University of Michigan Risk Science Center website and the United Network, 2010), and the percentages of cement output for various
States Environmental Protection Agency website, respectively. cement technologies were obtained from Ze (2010).
Similarly, those for ReCiPe (http://www.cml.leiden.edu/research/
industrialecology/researchprojects/finished/recipe.html) and CML 2.3. Life-cycle inventory (LCI) of cement
(http://cml.leiden.edu/software/data-cmlia.html) are available at
the Institute of Environmental Science of Leiden University website. The life-cycle inventory results of each cement production sce-
nario are presented in Table 1. Raw materials and energy con-
sumption, direct emissions are based on the functional unit.
2.2.4. Data sources
Four frequently used cement production technologies were
3. Results
studied in the present study. For the large-production scenario,
annual statistics and monitoring data from the Shenfeng Cement
3.1. LCIA results
Co., Ltd. (Shandong, China) were used. For the moderate-
production and shaft kiln scenarios, data were taken from Wang
Comparisons of the LCIA midpoint results for each scenario are
(2007) and Li (2009), respectively. For the small-production sce-
shown in Table 2. The large-production scenario presented the
nario, annual statistics and monitoring data from the Jinchang
lowest environmental burden in all categories except in global
Cement Group Co., Ltd. (Gansu, China) were used. However, direct
warming, in which the small-production scenario presented the
air emission data were obtained from the Hongda Cement Plant
lowest value. Compared with large- and small-production sce-
(Yunnan, China) because of lack of information from the former. In
narios, a relatively high environmental burden was observed in the
addition, the Chinese standard for cleaner production in the
moderate-production and shaft kiln scenarios in most categories
cement industry (HJ 467-2009) was used to determine water
except for respiratory organics, aquatic ecotoxicity, and aquatic
consumption in the moderate-production scenario, as well as direct
eutrophication categories. Such finding was attributed to the rela-
air SO2 and NOx emissions in the shaft kiln scenario because of lack
tively high resource consumption and direct air emission. To
of information in the previously mentioned references.
identify and describe the most significant process for each
CO2 emission was calculated according to Eq. (1) (Wu et al.,
midpoint, the contribution of the dominant process to each
2006):
midpoint is also presented in Table 2. For each scenario, the energy
E ¼ 3:67a k Mcoal Q þ 0:38 Mlimestone (1)
Table 1
where E, a, k, Mcoal, Q, and Mlimestone represent the amount of CO2 Life cycle inventories of each cement production scenario. Values are presented per
emission per ton of cement production, carbon oxygenation effi- functional unit.
ciency of coal (0.93, National Development and Reform
Dry rotary kiln Shaft kiln
Commission, 2011), carbon emission factor of coal (26.1 103,
National Development and Reform Commission, 2011), mass of coal Large Moderate Small
consumption per ton of cement production, caloric value of coal, Resource Limestone (ton) 1.05 0.93 0.84 1.18
and mass of limestone consumption per ton of cement production, consumption Gypsum (kg) 50.51 33.24 71.00 42.90
Water (ton) 0.36 0.75 3.73 0.85
respectively. The caloric value of coal considered in the present
Sandstone (kg) 54.81 151.20 76.00 e
study was 24.48 MJ/kg. Mudstone (kg) e 68.72 e e
Road transport (16 t, lorry) was estimated by using Eq. (2), as Shale (kg) e e 28.00 e
follows: Dolomite (kg) e e e 53.68
Red clay (kg) e e e 33.66
E ¼ ðEFv þ M EFD Þ=W (2) Pyrite cinder (kg) 14.64 e e e
Iron powder (kg) e 41.15 e 18.32
Nickle slag (kg) e e 18.00
where E, EFv, W, M, and EFD represents the amount of air pollutants Magnesium e e e 71.01
during transport, the emission factors of motor vehicles, the load of slag (kg)
vehicles, the mass of diesel consumption per kilometer, and the Slag (kg) e 74.09 32.17
emission factor of per kilogram diesel generation, respectively. The Blast furnace e e 41.00 e
slag (kg)
emission factors of motor vehicles and the mass of diesel con- Fly ash (kg) 241.39 e 208.00 e
sumption per kilometer in China were obtained from references Coal (kg) 101.94 134.60 113.00 183.63
(Cai and Xie, 2010; Jia et al., 2010). Data on transport emissions of Electricity (kWh) 81.93 130.30 102.09 121.00
polycyclic aromatic hydrocarbons (PAHs) were obtained from Emissions CO2 (ton) 0.62 0.65 0.56 0.85
2
to air SO2 (kg) 2.30 10 5.30 102 0.04 1.20
reference (Zhang, 2010) for complement. The energy consumption
NOx (kg) 0.19 2.20 0.18 2.40
of diesel generation and the emission factor of 1 kg diesel genera- Particulates (kg) 6.50 102 3.05 0.16 5.40
tion were obtained from the final life cycle inventories of fossil fuels Emission Wastewater (m3) 100% 100% 100% 0.71
in China (Yuan et al., 2006). In addition, coal-based electricity to water Reused Reused Reused
generation (Cui et al., 2012) was selected because coal has an Emission Solid waste 100% reused
to soil
important role in electricity generation in China. Relevant and
Please cite this article in press as: Chen, W., et al., Pollutants generated by cement production in China, their impacts, and the potential for
environmental improvement, Journal of Cleaner Production (2014), http://dx.doi.org/10.1016/j.jclepro.2014.04.048
4 W. Chen et al. / Journal of Cleaner Production xxx (2014) 1e9
Infrastructure (44%)
Infrastructure (54%)
renewable energy categories, whereas the transport process made
Limestone (43%)
Limestone (57%)
Limestone (62%)
Transport (47%)
Transport (63%)
Transport (60%)
the largest contribution to the carcinogens, ionizing radiation, and
Energy (55%)
Energy (70%)
Energy (88%)
Process ozone layer depletion categories. Direct emissions from cement
production made a dominant contribution to global warming,
whereas limestone production presented a dominant contribution
to terrestrial ecotoxicity and aquatic eutrophication. In the respi-
ratory inorganics, terrestrial acidification/nutrification, and aquatic
1.54 106
4.70 102
1.36 102
1.88 104
3.71 103
1.00 103
5.26 103
acidification categories, the dominant process for the large- and
Shaft kiln
598.64
20.35
0.97
2.87
1.50
1.12
3.82
1.12
whereas that for the moderate-production and shaft kiln scenarios
was direct emissions. Limestone production made the dominant
contribution to aquatic ecotoxicity in all scenarios except in the
Infrastructure (62%)
small-production scenario, in which tap water made the dominant
Limestone (55%)
Limestone (61%)
Tap water (61%)
Transport (62%)
Transport (54%)
Energy (56%)
Energy (40%)
Energy (69%)
Energy (53%)
Energy (45%)
Energy (85%) in land occupation and mineral extraction, whereas the potential
environmental impacts of wastewater treatment, iron powder, tap
Process
9.86 103
2.84 104
2.76 103
3.60 103
693.09
0.84
2.38
0.26
6.13
1.01
0.98
0.98
Infrastructure (54%)
Limestone (65%)
Transport (43%)
Transport (60%)
Transport (61%)
Energy (69%)
Energy (86%)
1.03 102
1.53 104
2.91 103
4.39 103
Moderate
except for land occupation and mineral extraction, which had mi-
603.91
801.95
Value
18.22
1.18
2.54
1.13
Infrastructure (62%)
Limestone (74%)
Transport (46%)
Transport (65%)
Transport (67%)
Energy (64%)
Energy (47%)
Energy (40%)
Energy (83%)
1.28 106
3.30 102
1.02 102
1.29 104
2.84 103
3.27 103
493.60
734.12
Value
Large
0.82
2.12
0.23
5.58
0.98
0.89
0.98
m2 org.arable
kg TEG water
kg CFC-11 eq
kg C2H3Cl eq
kg C2H3Cl eq
kg PO4 P-lim
kg PM2.5 eq
MJ primary
kg TEG soil
Bq C-14 eq
kg C2H4 eq
MJ surplus
kg CO2 eq
kg SO2 eq
kg SO2 eq
Unit
Non-renewable energy
Aquatic eutrophication
Respiratory inorganics
Terrestrial ecotoxicity
Terrestrial acid/nutri
Respiratory organics
Aquatic acidification
Aquatic ecotoxicity
Mineral extraction
Ionizing radiation
Non-carcinogens
Land occupation
Global warming
Carcinogens
Categories
Table 2
Please cite this article in press as: Chen, W., et al., Pollutants generated by cement production in China, their impacts, and the potential for
environmental improvement, Journal of Cleaner Production (2014), http://dx.doi.org/10.1016/j.jclepro.2014.04.048
W. Chen et al. / Journal of Cleaner Production xxx (2014) 1e9 5
3.4.1. LCIA
To check the reliability of the results obtained via IMPACT
2002þ methodology, ReCiPe E, TRACI, and CML methods were used
Fig. 4. Contribution of substances to the main midpoint score. for comparison. Table 3 shows the midpoint results obtained from
various LCA methods for the large-production scenario. The LCIA
results from the ReCiPe E method were similar to those from
IMPACT 2002þ in the categories of global warming and ozone layer
identified the key factors that contribute to the overall environ-
depletion. For ozone layer depletion, the results obtained from
mental burden in all scenarios: (1) direct emissions generated by
TRACI and CML were also similar to those from IMPACT 2002þ. For
coal and limestone consumption and (2) energy (i.e., electricity and
respiratory organics, the evaluation result from IMPACT 2002þ was
coal) consumption.
similar to that from CML. For the global warming category, the LCIA
results obtained from TRACI and CML methods were slightly higher
3.2. Endpoint results than those obtained using the IMPACT 2002þ and ReCiPe E
methods because a 500-year time horizon was considered in the
The LCIA endpoint results are presented in Fig. 5. For all sce- IMPACT 2002þ and ReCiPe E. If a 100-year time horizon was
narios, energy generation (i.e., electricity and coal) had a dominant considered in IMPACT 2002þ and ReCiPe E, the potential impact on
role in the resource category. Limestone production made a global warming will be similar to those of TRACI and CML method.
dominant contribution to ecosystem quality damage, whereas For the respiratory inorganics category, the result from TRACI was
direct emission presented a dominant contribution to climate lower than those from IMPACT 2002þ and ReCiPe E because the
change damage. For the large- and small-production scenarios, equivalent values of nitrogen oxides in TRACI were significantly
limestone production, energy generation, and direct emissions had lower than in the other two methods. The result obtained from
important roles in the human health damage category. For the IMPACT 2002þ was slightly lower than that from ReCiPe E because
moderate-production and shaft kiln scenarios, direct emissions had particulate matter with a diameter larger than 2.5 mm had no effect
a dominant role. These results are similar with the LCIA midpoint under IMPACT 2002þ. For the non-renewable energy category, the
results. evaluation result from IMPACT 2002þ was 74.86 kg-oil eq (change
Please cite this article in press as: Chen, W., et al., Pollutants generated by cement production in China, their impacts, and the potential for
environmental improvement, Journal of Cleaner Production (2014), http://dx.doi.org/10.1016/j.jclepro.2014.04.048
6 W. Chen et al. / Journal of Cleaner Production xxx (2014) 1e9
Table 3
Sensitivity analysis on LCIA methods for the large-production scenario.
rate at 42.62 MJ/kg oil eq), which was similar to the result obtained statistics on energy (i.e., electricity and coal) consumption and
from the ReCiPe E method (76.63 kg-oil eq). Comparing the rest of direct air emissions during cement production were used as inputs
the LCIA results was difficult because of the significant differences to replace related on-site data. The results showed that the po-
in labeling substances and categories that resulted from the vari- tential environmental burden from dry rotary kilns in China was
ations in LCA methods. Similar results were also obtained from the lower than that from shaft kilns in the global warming and non-
rest of the scenarios (data not shown). The aforementioned infor- renewable energy categories, whereas contrary results were
mation indicated that the midpoint results obtained by the present observed in the respiratory inorganics category. These finding are
study from IMPACT 2002þ are reliable. consistent with the results of a previously reported study (Jiang
et al., 2010), which performed LCA on cement production in
3.4.2. Main contributors China based on statistics. The total environmental burden gener-
Table 4 presents the results of the sensitivity analysis of the ated by the Chinese cement industry in 2009 in the respiratory
dominant contributors. Decreasing direct emissions and coal con- inorganics, global warming, and non-renewable energy categories
sumption in all scenarios provided the highest environmental was approximately 6.80 108 kg PM2.5 eq, 1.28 1012 kg CO2 eq,
benefit in the global warming and non-renewable energy cate- and 6.26 1012 MJ primary, respectively. Fig. 6 presents the po-
gories, respectively. For respiratory inorganics, decreasing direct tential environmental impact on global warming of the cement
emissions resulted in the highest environmental benefit for the industry of each province at the national level based on a simple
moderate-production and shaft kiln scenarios, whereas decreasing geographic information system (GIS). Each impact region was
limestone and electricity consumptions presented the highest identified through impact strength (kg CO2 eq/km2). The environ-
environmental benefit for the large- and small-production sce- mental burden generated by Jiangsu Province was significantly
narios, respectively. By contrast, reducing coal processes presented higher than those generated by other provinces, with Xizang
the lowest potential environmental benefit in the global warming Province producing the lowest environmental burden. This finding
and respiratory inorganics categories, whereas that for the non- could be attributed to the relatively high cement output of Jiangsu
renewable energy category was direct air emissions. Province. Similar results were obtained for the other categories
(data not shown).
3.5. National estimated environmental impacts of cement
production 4. Discussion
To evaluate the environmental impacts generated by the cement Conclusions that dry rotary kilns exhibit better characteristics
industry at the national level, hybrid LCA was conducted on na- than shaft kilns in terms of high energy efficiency and low CO2
tional statistics based on the approach shown in Fig. 1. National emissions have been widely reported (Lu et al., 2009; Lei et al.,
Table 4
Sensitivity of dominant contributors.
Impact categories Dominant contributors Variation Dry rotary kiln Shaft kiln
Respiratory inorganics (kg PM2.5) Electricity 5% 3.47 103 5.52 103 4.32 103 5.12 103
Coal 5% 7.58 104 1.00 103 8.40 104 1.36 103
Limestone 5% 4.03 103 3.57 103 3.23 103 4.53 103
Direct emission 5% 1.82 103 3.81 102 2.56 103 6.24 102
Global warming (kg CO2 eq) Electricity 5% 3.19 5.07 3.98 4.71
Coal 5% 0.36 0.48 0.40 0.66
Limestone 5% 0.96 0.85 0.77 1.08
Direct emission 5% 31.09 32.42 28.20 42.48
Non-renewable energy (MJ primary) Electricity 5% 37.44 59.55 46.66 55.30
Coal 5% 97.56 128.82 108.14 175.74
Limestone 5% 11.43 10.12 9.14 12.85
Direct emission 5% e e e e
Please cite this article in press as: Chen, W., et al., Pollutants generated by cement production in China, their impacts, and the potential for
environmental improvement, Journal of Cleaner Production (2014), http://dx.doi.org/10.1016/j.jclepro.2014.04.048
W. Chen et al. / Journal of Cleaner Production xxx (2014) 1e9 7
Please cite this article in press as: Chen, W., et al., Pollutants generated by cement production in China, their impacts, and the potential for
environmental improvement, Journal of Cleaner Production (2014), http://dx.doi.org/10.1016/j.jclepro.2014.04.048
8 W. Chen et al. / Journal of Cleaner Production xxx (2014) 1e9
Please cite this article in press as: Chen, W., et al., Pollutants generated by cement production in China, their impacts, and the potential for
environmental improvement, Journal of Cleaner Production (2014), http://dx.doi.org/10.1016/j.jclepro.2014.04.048
W. Chen et al. / Journal of Cleaner Production xxx (2014) 1e9 9
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Please cite this article in press as: Chen, W., et al., Pollutants generated by cement production in China, their impacts, and the potential for
environmental improvement, Journal of Cleaner Production (2014), http://dx.doi.org/10.1016/j.jclepro.2014.04.048