GNR

Getting the Numbers Right.A Database for the Cement

Industry Eamon Geraghty

GNR

Objective

CSI CEO’s decision October 2006“Develop representative statistical

information on the energy and CO2 performance of clinker and cement production, worldwide and regionally, to serve the need of internal and external stakeholders”

GNR

PWC

• PWC appointed as contractor in 2007– PWC Paris

• 2 Data collection cycles complete• Information available for

– 1990– 2000– 2005– 2006

• Anti-trust concerns preclude collection of data less than 1 year old.

GNR

Structure

• Project Agreement– WBCSD and PWC– Confidentiality– Code of Conduct– Project Management Charter

• Individual Service Agreement– Participant and PWC– Participants may be CSI members, non-CSI

members or Federations• Non-CSI members foreseen by the Project

Agreement

GNR

Intellectual Property Rights

• Database software: PWC • Database content: PWC• Database inputs: Participants• Database outputs:

– Participant Specific: Participant– Federation Specific: Federation– Broader than one participant or federation:

WBCSD/CSI

GNR

Queries

• The GNR will answer queries from interested stakeholders.

• 15 queries have been answered in 2008 to date.

• Queries are channeled through the PMC• PWC are obligated to anti-trust and

confidentiality commitments • Payment may be requested to cover

costs

GNR

Queries

• Direct to gnrpmc@wbcsd.org• Request should indicate:

– Name and function of requesting organisation– Description of the proposed use of the data– Contact details for response or clarification– Details of the requested information– Geographic coverage required– Specific variables requested– Time frame for data

GNR

Basic Data

• Basic document: “The Cement CO2 Protocol”

– A methodology for calculation and reporting CO2 emissions

– Available at www.wbcsdcement.org– Features

• An Excel tool• Explanation manual

• Aligned with the WRI/WBCSD protocol

Example of Protocol.xls

GNR

Assurance of Data

• Assurance at plant and company level is required for all CSI companies.

• “Limited Assurance” * is the standard.– At least every 3 years– Practioner to assess need for site visits– National & regional trading system verifications

accepted. – 1990 is not verifiable

• Assurance necessary, for example,for CDM benchmark setting.

• Collection tool requests the assurance status of all data *As per ISAE 3000

GNR

The Collection Tool

• Downloaded from PWC, the tool filters the information in the “protocol”

• Simple checks for completion• Filtered information uploaded to portal

and taken into database by PWC• Both company and plant level information

is collected

CRH_Filtering Tool_V2.8.xls

GNR

The data base

• PWC execute a number of “business”checks on incoming data including:– Compatability with industry norms– Compatability with historical data

• Clarifications of inputs regularly required.• PWC consolidates to:

– Specific company reports– Regional and world reports

GNR

Coverage : 794 million tons

0%10%20%30%40%50%60%70%80%90%

100%

Europe NorthAmerica

JapanAus NZ

CIS Africa +ME

Asia ex.China,

India, CISand

Japan

China andIndia

LatinAmerica

GNR

Coverage

0%

10%

20%

30%

40%

50%

60%

70%

80%

World Kyoto Annex1 Kyoto non Annex1

The representivity of the data base varies from region to region. Care is required in interpretation.

GNR

GNR Outputs 2006

GNR

CO2 Emissions Per Tonne ClinkerAverage gross CO2 emissions per tonne clinker

(All GNR Participants)

914 880 868 866

0

200

400

600

800

1000

1200

World

kg C

O2

/ ton

ne c

linke

r

1990200020052006

Average net CO2 emissions per tonne clinker(All GNR Participants)

907 864 847 844

0

200

400

600

800

1000

1200

World

kg C

O2

/ ton

ne c

linke

r

1990200020052006

GNR

CO2 Emissions Per Tonne CementitiousAverage gross CO2 emissions per tonne cementitious

(All GNR Participants)

759 729 692 679

0

200

400

600

800

1000

1200

World

kg C

O2

/ ton

ne c

emen

t

1990200020052006

Average net CO2 emissions per tonne cementitious(All GNR Participants)

752 715 675 661

0

200

400

600

800

1000

1200

World

kg C

O2

/ ton

ne c

emen

t

1990200020052006

GNR

CO2 Emissions for Kiln TypeWeighted average gros CO2 emission per tonne clinker per kiln type

(All GNR Participants)

842

861 95

5

896 1,

043

0

200

400

600

800

1000

1200

DRY WITH PREHEATERAND PRECALCINER

DRY WITH PREHEATERWITHOUT PRECALCINER

DRY WITHOUTPREHEATER (LONG DRY

KILN)

SEMI-WET/SEMI DRY WET

kg C

O2

/ ton

ne c

linke

r

1990200020052006

GNR

Clinker Volume by TechnologyClinker volumes by technology

(All GNR Participants)

0

100

200

300

400

500

600

700

1990 2000 2005 2006

Mill

ion

tonn

es o

f clin

ker

WETSHAFT KILNSEMI-WET/SEMI DRYMIXED KILN TYPEDRY WITHOUT PREHEATER (LONG DRY KILN)DRY WITH PREHEATER WITHOUT PRECALCINERDRY WITH PREHEATER AND PRECALCINER

Clinker Production(All GNR Participants)

184 181 184 191

54 66 76 7632 29 27 2723 7 13 1448 65 64 7034 42

54 5621

5983

94

38

83

9898

0

100

200

300

400

500

600

700

1990 2000 2005 2006

Mill

ion

tonn

es o

f clin

ker Asia ex. China, India, CIS and Japan

China and IndiaAfrica + MELatin AmericaCISJapan Aus NZNorth AmericaEurope

GNR

Alternative Fuel UsageAbsolute volumes of alternative fossil fuels

(All GNR Participants)

0

1000

2000

3000

4000

5000

6000

7000

8000

9000

10000

1990 2000 2005 2006

Thou

sand

tonn

es o

f alte

rnat

ive

foss

il fu

els

Asia ex. China, India, CIS and Japan

China and India

Africa + ME

Latin America

CIS

Japan Aus NZ

North America

Europe

GNR

Biomass UsageAbsolute volumes of biomass

(All GNR Participants)

0

500

1000

1500

2000

2500

3000

3500

4000

4500

1990 2000 2005 2006

Thou

sand

tonn

es o

f bio

mas

s

Asia ex. China, India, CIS and Japan

China and IndiaAfrica + MELatin America

CISJapan Aus NZ

North AmericaEurope

GNR

Thermal Energy Per Tonne ClinkerThermal energy per tonne clinker

2000

2500

3000

3500

4000

4500

5000

5500

6000

6500

7000

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

% clinker production

MJ/

t

2006 2005 2000 1990

GNR

Energy Consumption Per Tonne Clinker Per Kiln Type

Weighted average thermal energy consumption per tonne clinker per kiln type(All GNR Participants)

3,38

2

3,69

9 4,48

9

3,84

4

6,34

3

0

1000

2000

3000

4000

5000

6000

7000

8000

DRY WITH PREHEATERAND PRECALCINER

DRY WITH PREHEATERWITHOUT PRECALCINER

DRY WITHOUTPREHEATER (LONG DRY

KILN)

SEMI-WET/SEMI DRY WET

MJ

/ ton

ne c

linke

r

1990200020052006

GNR

Energy Consumption Per Tonne CementAverage electric energy consumption

(All GNR Participants)

0

20

40

60

80

100

120

140

160

180

World

kWh

/ ton

ne c

emen

t

1990200020052006

GNR

Clinker Cement RatioClinker to cement ratio(All GNR Participants)

83 82 79 78

0

10

20

30

40

50

60

70

80

90

100

World

%

1990200020052006

GNR

Regional average emissionsAverage gross CO2 emissions per tonne cementitious

(All GNR Participants)

813

797

807

773

718

708

705

915

742

771

742

771

693

690

663

849

686 73

9

667 723

666

673

632

793

669 72

9

638 72

4

651

684

634 79

0

0

200

400

600

800

1000

1200

Africa + ME Asia ex. China,India, CIS and

Japan

China and India CIS Europe Japan Aus NZ Latin America North America

kg C

O2

/ ton

ne c

emen

t

1990200020052006

Average net CO2 emissions per tonne cementitious(All GNR Participants)

813

797

807

773

711

699

705

890

742

768

742

771

671

671

659 81

7

684 732

667 72

3

636

650

620 76

4

667 72

2

638 72

4

619 662

621 76

0

0

200

400

600

800

1000

1200

Africa + ME Asia ex. China,India, CIS and

Japan

China and India CIS Europe Japan Aus NZ Latin America North America

kg C

O2

/ ton

ne c

emen

t

1990200020052006

GNR

2006 Net CO2 per tonne clinker

Year: 2006Region: World-wide

Company: All GNR participants

Weighted average 844 kg CO2/t clinkerCorresponding percentageStandard deviation 97.6 kg CO2/t clinker

620 Mt clinkerNumber of plantsTotal production volume in the graph

Formula of the linear regression between 10% and 90%Regression coefficient (r2) between 10% and 90%

615

y= 1,49 x + 766

0.98

52%

CSI - "Getting the Numbers Right"

Net CO2 emission per tonne clinker

200

300

400

500

600

700

800

900

1000

1100

1200

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

% clinker production

kg C

O2/

t

Net CO2 emission per tonne clinker (1% - 99%) Linear regression (10% - 90%) Weighted average

GNR

2006 Net CO2 per tonne cementYear: 2006

Region: World-wideCompany: All GNR participants

Weighted average 661 kg CO2/t cementCorresponding percentageStandard deviation 222 kg CO2/t cement

800 Mt cement

** Graph generated with data at company and country level **

231

y= 2,68 x + 530

0.99

49%

Number of companiesTotal production volume in the graph

Formula of the linear regression between 10% and 90%Regression coefficient (r2) between 10% and 90%

CSI - "Getting the Numbers Right"

Net CO2 emission per tonne cement (Company level)

200

300

400

500

600

700

800

900

1000

1100

1200

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

% cement production

kg C

O2/

t

Net CO2 emission per tonne cement (Company level) (1% - 99%) Linear regression (10% - 90%) Weighted average

GNR

Objective and ConclusionObjective“Develop representative statistical information on the energy and CO2

performance of clinker and cement production, worldwide and regionally, to serve the need of internal and external stakeholders”

Conclusion: GNR:A wealth of data to develop knowledgeto manage and improve the cement industry’s CO2 and energy performanceCSI invites further participation especially PCA, Latin American Federations, China, Russia & Japan.