Implementation of best available techniques in cement manufacturing: a life-cycle assessment study

A cement manufacturing company located in Catalonia (Spain) has upgraded its cement production plant. The new cement production line (L6) has replaced the former lines (L3, L4 and L5) which have been operating for 30 years. The new line production L6 has been designed and constructed taking into account the best available techniques (BAT) for the cement industry. The significant improvements achieved with the new plant are related to the energy efficiency of the new kiln system which represents less amount of fossil fuel and to less emission to the atmosphere per kg of clinker produced. Life-cycle assessment (LCA) methodology has been used for the quantification and evaluation of the environmental impacts of the new production line (L6) considering the designed goals proposed and those achieved at first trimester of 2011 compared to the former production lines. To reduce uncertainty this manuscript presents a cradle-to-gate life-cycle assessment of both scenarios. Analysis using SimaPro 7.2 software shows that new production line (L6) provides a significant reduction of the environmental impact for global warming (5%), acidification (15%), eutrophication (17%) and cumulative exergy demand (13%). The damage assessment also confirmed that new production line (L6) reported a significant reduction impact for the human health (11%), ecosystem quality (11%) and resources (14%) damage compared to the former lines.

► A company upgraded its former cement production lines by the new line L6.
► New L6 was designed and constructed considering the best available techniques.
► A cradle-to-gate LCA methodology was used to evaluate and compare formers and new line.
► L6 reported a significant reduction of global warming and other mid-points impacts.
► End-point analysis reported also a damage reduction for L6 compared to former lines.