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Technical and cost assessment of energy efficiency improvement and greenhouse gas emission reduction potentials in Thai cement industry

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Abstract

The cement industry is one of the most energy-consuming industries in Thailand, with high associated carbon dioxide (CO2) emissions. The cement sector accounted for about 20.6 million tonnes of CO2 emissions in 2005. The fuel intensity of the Thai cement industry was about 3.11 gigajoules (GJ)/tonne cement; the electricity intensity was about 94.3 kWh/tonne cement, and the total primary energy intensity was about 4.09 GJ/tonne cement in 2005 with the clinker to cement ratio of around 82%. In this study, the potential application of 47 energy-efficiency measures is assessed for the Thai cement industry. Using a bottom-up electricity conservation supply curve model, the cost-effective electricity efficiency improvement potential for the Thai cement industry is estimated to be about 265 gigawatt hours (GWh), which accounts for 8% of total electricity use in the cement industry in 2005. Total technical electricity-saving potential is 1,697 GWh, which accounts for 51% of total electricity use in the cement industry in 2005. The CO2 emission reduction potential associated with the cost-effective electricity savings is 159 kilotonne (kt) CO2, while the total technical potential for CO2 emission reductions is 902 ktonne CO2. The fuel conservation supply curve model shows a cost-effective fuel-efficiency improvement potential of 17,214 terajoules (TJ) and a total technical fuel efficiency improvement potential equal to 21,202 TJ, accounting for 16% and 19% of the total fuel use in the cement industry in 2005, respectively. CO2 emission reduction potentials associated with cost-effective and technical fuel-saving measures are 2,229 ktonne and 2,603 ktonne, respectively. Sensitivity analyses were conducted for discount rate, electricity and fuel prices, and exchange rate that showed the significant influence of these parameters on the results. Hence, the results of the study should be interpreted with caution.

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Notes

  1. It is the average annual growth of energy consumption divided by average annual growth of gross domestic product (GDP).

  2. At the beginning of this study, we chose 2005 as the base year. However, since some of the companies decommissioned some kilns in their plants between 2005 and 2008, we decided to update the base year to 2008. Since the clinker and cement production capacity are the data involved in assessment of the potential application of each energy efficiency technology, we can use 2008 as the base year, although the actual production of each company in 2008 is not known yet.

  3. However, it should be noted that preventative maintenance is not a general measure that is applicable all over the plant, and its application could be specified in the heat-using parts of the process such as the preheater and kiln or the electricity-using parts of the process such as motors and fans.

  4. Specific data for consumption of each type of fuel in the Thai cement industry was not available.

  5. Additional electricity is used for the grinding of blended materials such as blast furnace slag.

  6. It should be noted that the base year for the analysis is 2008 for which we have the clinker and cement production capacity and technology information from plants which we need for the construction of CSC. However, to compare the energy saving to the total energy use of the industry, we could find the more reliable data for 2005. We did not need the total energy use of the industry to construct CSC though.

  7. Exchange rate in 2005 = 40.27 THB/US$, Exchange rate in 2008 (up to Nov. 27) = 33.02.

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Acknowledgment

Authors are grateful to managers and engineers in the cement companies that participated in this study and provided us the required information and data. We also would like to thank Ms. Somthida Piyapana, the director of the Thai Cement Manufacturing Association for her kind assistance. We are grateful to Prof./Dr. Surapong Chirarattananon and Dr. Peter du Pont for their comments on this study. Special thanks to Mr. Warut Chivamavin from ENCON Lab in Thailand for his cooperation. Finally, we would like to thank Lynn Price of Lawrence Berkeley National Laboratory and Dr. Ernst Worrell of Ecofys for their valuable comments and input on this study.

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Authors and Affiliations

  1. The Joint Graduate School of Energy and Environment, King Mongkut’ s University of Technology Thonburi, 126 Pracha-uthit Rd, Bangmod, Tungkru, Bangkok, Thailand, 10140

    Ali Hasanbeigi

  2. Department of Building Engineering Services, Energy Technology Division, University of Applied Sciences, Schneidershof, 54293, Trier, Germany

    Christoph Menke

  3. The School of Energy, Environment, and Material, King Mongkut’s University of Technology Thonburi, Bangkok, Thailand

    Apichit Therdyothin

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  1. Ali Hasanbeigi
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Correspondence to Ali Hasanbeigi.

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Hasanbeigi, A., Menke, C. & Therdyothin, A. Technical and cost assessment of energy efficiency improvement and greenhouse gas emission reduction potentials in Thai cement industry. Energy Efficiency 4, 93–113 (2011). https://doi.org/10.1007/s12053-010-9079-1

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