Sectoral Approachin the Cement Industry

Japan Cement Association

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Sectoral Approach in the Cement Industry
Outline of Cement Working Group of the Global Superior Energy Performance Partnership

October 2012
Japan Cement Association
1. Background
The Global Superior Energy Performance Partnership(GSEP) is an initiative of the Clean Energy Ministerial(CEM) and the International Partnership for Energy
Efficiency Cooperation (IPEEC). It is the successor of
the APP (Asia Pacific Partnership on Clean
Development and Climate) indicated in APPENDIX.
The GSEP cement working group (Cement WG) aims to
reduce global energy use in industrial facilities andcommercial buildings in order to improve energy
security and to reduce global greenhouse gas emissions(GHG) by:

Encouraging industrial facilities and commercial
buildings to pursue continuous improvements inenergy efficiency, andPromotingpublic‐private
partnerships
forcooperation on specific technologies or inindividual energy‐intensive sectors.

On September 12th and 13th, 2011, in Washington D.C.,
the governments of the United States, Japan and Finland
organized the GSEP workshop to bring together for the
first time the participants of the sectoral working groups
including Power, Steel and Cement and the other threegroups under the GSEP.
This report describes outcomes of the GSEP workshop
including the breakout session, and the proposed
framework and work plans of the Cement WG.

2. GSEP workshop
Approximately 140 public and private sector
representatives from 14 countries came together todefine collective strategic objectives and discuss work
plans for each working group. Plenary sessions allowed
participants to better understand the activities of theother working groups and to identify possible
opportunities for collaboration.
In order to establish the Cement WG under GSEP,
government officials from the United States and Japan,
and private representatives such as national tradeassociations and cement companies, participated in a
breakout session of the cement sector. In the breakout
session participants shared the view that APP left
significant outcomes and discussed how to make further
progress under the GSEP framework.
It was decided the 1st Cement WG meeting should beheld to confirm goals, member countries and an
operational guideline. The chair of the session alsosuggested to adopt the roadmap illustrated below, basedon the APP Roadmap, for the GSEP WG.
All participants agreed the concept that the Cement WG
creates a voluntary framework for international
cooperation on the basis of public and private
partnership. The following goals were then proposed:Collaboration on policies, programs and projects
geared toward further enhancing the energy
efficiency and reducing the GHG emissions of thecement manufacturing process.
Promotion of sustainable applications of cement
and concrete products as tools to enhance energy
efficiency and avoid GHG footprints across thebuilt environment.

The participants identified that securing participation of
the governments of major economies, especially China
and India, is indispensable for the continuation of GSEP.

Roadmap of the GSEP
Cement Working Group(image)YEAR 2011
Outcomes of APP/CTF
2008 May. (5th)Agreed on the “Status
Report” and to continue
efforts to come up with anaggregated seven-country
reduction potential.

2006 Apr.(1st )Start of APP/CTF

YEAR 20052011 Apr.
APP Final PIC
The Partnershiphad formallyconclude its jointwork.

1.Capacity Building Programs
Centre of ExcellencePerformance Diagnosis
2.Innovative R & D
3.Best Available Technologies

23

GSEP/CWG

 Share of information
including technology
 Establishment of technology
transfer mechanism
 Development of MRV
Methodology
 Capacity building for skills
and expertise Regional Low Carbon
Technology roadmap
Establishment of financemechanism Collaboration with existingorganizations

To be discussed

2010 Dec. (9th Final )Final Review anddiscussions of all Projects
2008 Oct. (6th)Invite IEA to discusstechnology roadmap

Establishment of Public /Private Partnership

3. Proposed Structures of the Cement WG
The Japan Cement Association (JCA) proposed thefollowing structures of the Cement WG to thegovernment through experiences of APP activities andalso outcomes of the workshop:
3.1.

Public private partnership as the significant
framework
In order for the private sector to develop and transfer
technologies based on a bottom-up approach, it isrequested to share updated information on the status ofclimate initiatives, policies, technology, materials
availability etc in member countries and have continuing
dialogue with governments taking into consideration
supporting policy measures. The JCA considerably
expects the opportunity to discuss relevant policies withdecision makers at the Cement WG as the succeeding
initiative of APP.
3.2.

YEAR 2015

Linking with finance organizations to facilitate
effective technology diffusion.
The experience of the APP was that funding shortages
result in difficulties in the continuation of projects.
Therefore, a mechanism for financial support should beconsidered for each project of the Cement WG. At first,
in order to encourage private funding of projects, theCement WG should discuss project candidate criteriasuch as the kind of energy conservation or clean
technologies and the required level of public financial
support. This approach will link to the private sector
engagement of the Green Climate Fund under the
Durban agreement.

Technology Implementation forbased on PPP

Economic & Social
Development

3.3.

Collaboration with existing organizations andnetworks
Candidate organizations for the GSEP Cement WG tocooperate with are the Cement Sustainable Initiative(CSI), International Energy Agency (IEA) and European
Cement Research Academy (ECRA).
The CSI is one of the international sector networks under
the World Business Council for Sustainable
Development (WBCSD), a global organization working
towards
sustainable
development
with
many
international company members. The CSI, consisting of
global major and local cement companies, together withmany trade associations, including JCA, as
communication partners, has established a GHG database incorporating data from all member companies anda few cement associations. The CSI has also developed
tools and guidelines for environmental protection.
Therefore, the Cement WG proposes to invite the CSI tocollaborate and share its activities.
The IEA, having experienced the development of “TheCement Technology Roadmap 2009” and currently the
India roadmap, shall be invited since the JCA thinks thatthe development of regional/country roadmaps for
cement technologies is required in order to support the
diffusion of clean technologies to developing countries
and for the consideration of financial support.
The Cement WG should also invite ECRA to discuss
innovative technologies including CCS as one of the key
mitigation measures in the cement industry.

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4. Proposed Working Plans
After consultation with the government, the JCA
concluded the following working plans to be submitted
to the partners:
・ Enhancement and enlargement of the Center of
Excellence in order to develop a methodology fortechnology transfer and capacity building
・ Development of energy performance indicators
・ Development of a positive list of the best available
technologies in cement manufacturing
・ Facilitate breakthrough technologies in energy
conservation
・ Develop a methodology for the Measurement,
Reporting and Verification (MRV) of energy
conservation and CO2 emissions
・ Study funding methods
Main projects shall be considered as follows:
4.1.

Sharing and diffusing good practices of
production technologies
Since cement production involves a large consumptionof heat energy and power, consideration of energy
conservation is particularly important in view of energy
security as well as climate change.
Key energy conservation technologies and their diffusion
rates in Japan are shown in following table.
The JCA believes that Japanese clean technologies
should not simply be offered to developing countries, but
subject to a strategy for technology transfer and diffusion
taking into account economic criteria, weather andnational policies in the developing country. For example,
developing countries in which power prices are relatively
Technology

Diffusion
rate as of2010

low should also consider the utilization of waste heat anddrying of raw materials. Waste heat recovery facilities
are usually not applied to rainy countries since the waste
heat has to be utilized for drying of the raw materials.
When legal barriers to technology development anddiffusion are identified in developing countries, allnational institutional information on clean technology
diffusion and environmental registration should beshared among government officials from the Cement
WG members.
In addition to the installation of energy efficient facilities,
it would be necessary to provide software such as
operational know-how and energy management.
4.2. Methodology of MRVThere already exists the CSI Cement CO2 and Energy
Protocol, a “CO2 and Energy Accounting and ReportingStandard for the Cement Industry,” as the de facto global
standard for cement CO2 emissions and energy
consumption. Also, the European Committee forStandardization (CEN) is now developing a European
standard on GHG emissions for energy intensive
industries based on this protocol. Meanwhile, China hasdeveloped its national standard on CO2 emissions for the
cement industry, also aligned with the CSI’s protocol.
Therefore, the JCA deeply considers that the CSI’s
Cement CO2 and Energy Protocol should be adopted by
the Cement WG”
In future, for transparency and effectiveness, any GSEP
energy conservation project shall be assured using theprotocol. An improvement in the transparency of projects
is required for both financial and technical support.
Furthermore the JCA shall propose a new energy
performance indicator for reporting.

Energy conservation[per technical unit]

Waste heat recovery for power
generation

60%

Approximately 35～40kWh/t-cli. power conserved

High performance vertical mill to grind
blast furnace slag

73%

Maximum 40kWh/t-cem. power conserved

Roller mill system to pre-grind clinker

46%

10～20% improved of specific power consumption
during finishing process

Air beam type cooler for clinker

50%

42～167kJ/kg-cli. of energy conservation
0.5～1.5kWh/t-cli. of power saving

High performance separator

53%

10%～20% improved of specific power consumption

Vertical coal mill

90%

20～25% improved of specific power consumption

Vertical roller mill to grind raw
materials

46%

Approximately 30% improved of specific power
consumption during raw material preparation process

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4.3. Performance Diagnosis
Developing countries such as China and India requestthat a capacity building program for local experts be
implemented in order to enable performance diagnosis at
cement plants.
However, such a program should be carefully addressedsince the JCA has serious concerns about the protectionof know-how and proprietary information. Also, since
the implementation of such a program would require alarge budget, the Cement WG has to discuss amechanism for linking to financial aid.
5. Conclusions
Participating in GSEP on the basis of a public private
partnership provides a sectoral approach to technology
transfer and diffusion based on a bottom-up approachand the sharing of environmental information.
Furthermore, if discussions on climate protection are
well integrated with the establishment of recycling basedsocieties, the cement industry can make a huge
contribution towards sustainable society.

APPENDIX

6th International VDZ Congress 2009, PP.162-165

Experiences of
cement sector
action through the
Asia PacificPartnership on
Clean
Development andClimateFigure 2: APP Cement task force meeting in Tokyo

Yoshito IZUMI, Taiheiyo Cement
Corporation, Japan
Toshio HOSOYA, Japan Cement
Association, JapanThe seven countries of the AsiaPacific Partnership on Clean
Development and Climate (APP) —Australia, Canada, China, India,
Japan, the Republic of Korea andthe United States of America —have been cooperating since 2006 tomeet both their increased energy
needs and associated challenges,
including those related to air
pollution, energy security andgreenhouse gas intensities.

designed to meet Partnership goals
through international cooperation tofacilitate the development, diffusion,
deployment and transfer of existing,emerging and longer term costeffective, cleaner, more efficienttechnologies and practices among
the Partners through substantial
cooperation leading to concrete
action so as to achieve practicalresults. This paper describes cement
sector program and progress.

The Partnership established publicprivate task forces in eight key
sectors: (1) cleaner fossil energy; (2)renewable energy and distributed
generation; (3) power generationand transmission; (4) steel; (5)aluminum; (6) cement; (7) coalmining; and (8) buildings andappliances. The task forces are

1 Cement Task Force
1.1 Background of cement
sectorPartners in the sector account for 61

Figure 1: Cement Production and Energy & CO2 emissions in APP Partners

Cement production (2005)
India

Australia

Japan

China
USA

Others
Korea

60.5%

Primary energy consumption (2003)
Japan

A u s t r a lia
USA

In d ia

C h in a

O th e rs

K o re a

4 8 .2 %CO2 emissions (2003)
A u s t r a lia

Japan

In d ia

C h in aUSA

O th e rs
K orea

5 0 .5 %percent of global cement production(refer to Figure 1). The cement task
force therefore has significant
potential to reduce CO2 emissions
and conserve energy by sharing
information on clean technologies
and by cooperating further to diffuse
such technologies. In addition, thePartnership’s emphasis on publicprivate partnership will catalyze asectoral approach (see Figure 2).
Currently, Partners individuallychallenge voluntary initiatives or
national programs. For example,
the Australian cement industry was
one of the first to voluntarily
monitor, measure and manage CO2
and other emissions, resulting in a
24% reduction of CO2 per ton of
cement. The Chinese government isfunding cement projects throughnational bonds for projects thatutilize waste and other by-products,
reduce energy consumption andpromote environmental protection.
The Indian cement sector has inrecent years increased the use ofalternative fuels and raw materials(AFR) for co-processing of wastes,
which have resulted in reductions ingreenhouse gas emissions andyielded other environmental benefits.
In Japan, while the industry has
achieved one of the world’s mostefficient production systems byusing SP and NSP kilns, it is further
working
through
Keidanren
voluntary initiatives to reduce its
energy intensity per ton of cement

by 3.8% from 1990 levels by 2010.
The Korean cement industry isimplementing ways to reduce air
pollutants such as SOx and NOx,and have installed monitoring
equipment for this purpose. The U.S.
cement industry has committed toreducing its greenhouse gas
intensity and, through the Climate
Vision program, has adopted a
voluntary goal of a 10% reduction in
CO2 emissions per ton of productfrom a 1990 baseline by 2020.

Figure 4: CSI CO2 Protocol training seminar in China

1.2 Objectives
The task force’s objectives are to
conduct surveys on the current
situation, develop performanceindicators, share information andexperiences on clean technologies inorder to conserve energy, manage
emissions of greenhouse gases andair pollutions, promote use of AFR,
and thereby diffuse and deploy suchclean technologies in the cement
industry of each Partner. Ways todiffuseanddeployclean
technologies are explored at task
force meetings.

1.3 Key Actions
The task force meetings havealready been held in 7 locations asshown in Table 1.
One of the key components of thecement task force’s effort is tocollect reliable data.
Another
important element of this group’s
work is to share information on
good/best practices so that these

may be replicated where appropriate
in this very de-centralized sector(Figure3).

2 Major Projects andOutcomes

Addressing barriers to the utilizationof clean technologies could assist
Partners to more effectively address
their greenhouse gas emissions
whilst recognizing that differing
national
circumstancesmayinfluence the potential for energy
conservation in domestic cement
industries. In addition, concerted
efforts to reduce SOx, NOx and dust
are essential to the global efforts to
reduce air pollutants.

2.1 Survey of the industry’s
current situation

Figure 3 : Key Major Streams of Cement Sector Activity

Clean T echnologies

Benchmarking

Diffusion of Best Practices& New Clean Technologies

Set National Benchmark

C enter of
Excellence(B eijin g)
Be st
P ractices

D emon stration
P rojects

Ca pa city Ne w C lea nTechno lo gies
Building

Estimate Em issions
Reduction Potentials
Identify Barriers

Furthermore, adoption of the CSI
CO2 Protocol, developed by the
WBCSD CSI, was agreed as thefirst calculation tool for thecollection of plant data. Japan has
improved the calculation sheet toprovide additional data such asenergy-efficiency indicators and air
pollutants. Since China has not yet
used the CSI CO2 Protocol for the

Table 1: The task force meetings

1st April 18-21,

2006 Berkley, California, USA

2nd September 20-21, 2006, XIAN, China
3rd April 18-19,

2007, Delhi, India

4th September 12-13, 2007, Melbourne, Australia

CO 2
Cement factories
in AP6 countries

A questionnaire survey of thecurrent cement industry of eachPartner was carried out to collectuseful basic information. The results,
published as an interim report in
October 2007, can be viewed on the
APP website. With the addition of
new data from Canada the report
was updated in the fall of 2008. [1]Review theBenchmark
Periodically

5th May 13–14,

2008, Charleston, SC, USA

6th Oct 24,

2008, Tokyo, Japan

7th July 15–16,

2009, Seoul, Korea (plan)calculation of CO2 emissions,
Australia, Japan and the USA
provided support to China throughtraining seminars held jointly with
the WBCSD CSI in Beijing andZhuhai during 2008. Further
seminars will be held in China
during 2009 as part of the capacity
building program that helps trainees
from every region of China
understand
the
needs
for
implementing climate protection
measures. During the training
seminars (Figure 4), actual reference
data is input into the calculation
sheets of the Protocol.
A further survey was carried out by
each Partner to identify barriers toachieving the maximum potential
energy efficiency improvements andto the implementation of thegood/best practices. The following
are some examples. In Australia,
permitting requirements necessitatedby multiple-levels of government
createchallenges
tothedevelopment,
expansion
andmovementofcement-related
products. China’s large size and thediversity of local circumstances
havecreatedchallenges
ingenerating meaningful benchmarks
and other measurement tools. In
India, further increased use of AFR
ishinderedbyinsufficientregulatory measures and a lack ofavailability of the relevant foreign
good/best practices. In Japan,
existing high rates of efficiency inthe cement sector mean that further
increases are extremely challenging.

Table 2: Example of Best Practices

Raw materials

Vertical roller mill for raw materials

Preheater /Kiln

SP/NSP kiln system
5-stage suspension preheater
Vertical coal mill
Air beam type clinker coolers

Finish Grinding

Improved separator
Pre-grinding using roller mill system
Vertical roller mill for blast-furnace slag grinding

Use of waste heat

Power generation utilizing waste heat

For Korea, the use of alternative
fuels for reducing net CO2
emissions is very limited because
the current regulatory structure does
not permit it and the supply of
appropriate alternative fuels are
inadequate to meet demand. In the
United States stringent permitting
requirements,
limitedmarketacceptance of blended cements andresistance to AFR use hinder
advances in the sector.
A collection of the clean
technologies used by each Partner
was compiled into a booklet andpublished on the APP website in
March 2009[2]. The APP booklet is
not only shared with the Partners but
also utilized for external referencesuch as for cement technology
papers and the technology roadmaps
developed by the IEA and CSI.

2.2 Benchmarking
For this project, the development of
performance indicators and an
estimation of reduction potentials
were discussed in April 2007 andPartners agreed to select a cementbased emissions intensity of CO2(net) [kg-CO2/ t-cement] as acommon indicator and total energy
intensity for clinker production (net)[MJ/ t-clinker] as a voluntary
indicator.
Each Partner has been estimating
the CO2 reduction potential using
the common indicator. Japanestimated the reduction potential bya bottom-up calculation of bestpractices at each plant as shown in
Table 2. Aggregated results of all
Partners will be reported.

Figure 7: Locations of Cement Plant performance diagnosis
in IndiaFigure 6: Locations of Cement Plant performance diagnosis
in China

Cement Plant.
Cement Plant
Cement Plant

Cement Plant

Cement Plant

Cement plant
Cement Plant

Cement Plant

2.3 Performance Diagnosis
Experts in energy conservation,
environmental management andement production in the Japanese
cement industry have visited cement
plants in China (Figure 6) and India(Figure ７) for certain periods since
2008.
The experts carried out performance
diagnosis, primarily for energy
conservation and environmental
management, and provided shortterm and medium-to-long term
recommendations on how, whereappropriate, plants can optimize
technologies
andoperational
approaches. Japan will follow-up
their actions after receiving therecommendations from the experts
in 2009.

3 Findings
3.1 Enhancing Private Public
Partnership
Each government and cement
industry of the seven APP members
play their own roles in thePartnership. Together they also
represent
public-private
sectoractions that are based on the transfer
and deployment of existing clean
technologies
throughmutualunderstanding of differentiatedviewpoints
andeconomic
backgrounds of individual Partners.
3.2 Defining a Sectoral
ApproachThrough the Partnership the JCA
andPCA,
togetherwith
CEMBUREAU,
developedaposition paper on a sectoral
approach to greenhouse gas
management in March 2009. This
position paper can be viewed oneach association’s website[3]. The
next task force meeting in July will
invite non-Partnership members,
including
CEMBUREAU,
todiscuss technology transfer anddevelopment
of
new
clean
technologies.

3.3 Removing Regulatory
Barriers
Through the Partnership the JCA
and PCA, together with respect toregulatory
barriers
preventing
deploymentof
co-processing
technologies for the utilization ofwastes which will lead to CO2emissions
reduction,
thecircumstances of each Partner havebeen identified and best/goodpractices will be further shared withthe governments to remove suchbarriers through the APP activities.
3.4 Developing Incentivized
Mechanism

the transfer of clean technologies
would be established among thecement associations of participant
countries.

References[1]
http://www.asiapacificpartnership.or
g/pdf/Projects/Cement/PSU/CMT0601%28Interim%20Report%2907100
4.pdf
[2]
http://www.asiapacificpartnership.or
g/pdf/Projects/Cement/APP_Bookle
t_of_Cement_Technology.pdf[3]

It is necessary to create incentive
mechanisms to drive investment
and adoption of new technologies
and to help overcome policy andfinancial barriers that today preventthe adoption of many cost-effective
efficiency measures in developing
countries.

4 Next Steps
Since 2006, through participation in
the APP, Japan has presented its
numerous activities on clean
development and climate both
domestically and internationally so
as to introduce Japanese advancedenergy conservation technologies.
Japan has been collating national
environment data from each Partner,
and working eagerly to share theinformation so as to increase theunderstanding of project activities
and the environment in Partnercountries. In order to collect further
reliable data and encourage thetransfer of clean technologies, Japan
will continue efforts to support
monitoring, reporting and theimplementation of verifiable actions
in developing countries.
A future framework on climatechange, which is currently underdiscussion, should require theparticipation of "all major emitting
countries". Therefore, if the cementtask force of the APP, which is oneof the most practical sector actions
in a sectoral approach, further
cooperates with non-APP members,
an international framework based on

http://www.jcassoc.or.jp/cement/3p
df/ja1_08_16.pdf