Comparative Analysis Of Coal, Fuel Oil And Natural Gas For Cement Production
A comparative analysis of coal, fuel oil, and natural gas for cement production involves evaluating the efficiency, cost-effectiveness, environmental impact, and availability of each energy source within the cement manufacturing process. Coal, a traditional fuel, is renowned for its abundance and affordability but faces scrutiny due to its high carbon emissions. Fuel oil, although versatile, suffers from price volatility and environmental concerns, notably pollution and greenhouse gas emissions. Conversely, natural gas emerges as a cleaner alternative, offering lower emissions and operational efficiency, albeit with fluctuations in pricing and availability. The assessment entails examining factors such as energy intensity, production output, technological advancements, and regulatory compliance to determine the optimal energy source for cement manufacturing, balancing economic viability with environmental sustainability while meeting production demands.
This study is a comparative analysis of the use of coal, fuel oil and natural gas for
cement production noting their physical and chemical properties, cost and
availability, impact on the environment and human health. Out of the seven cement
manufacturing industries in Nigeria, three industries use these fuels were selected
for the study. The industries are NigerCem –Ebonyi state, Dangote cement –Benue
state and UniCem -Cross river state. Questionnaires were used to gather information
on the three fuels. The likert 3- scale model was adopted, using 2.0 as the cut off
mark. Based on the analysis of the study, it was observed out that amongst these
three (3) fuels, fuel oil is presently expensive though available, while coal and
natural gas are cheap but coal is not available due to the closure of Nigeria‟s coal
mine. In terms of environment and health, coal and fuel oil emit much harmful
gases to the environment and cause more health problems to cement worker but
natural gas emits less of these harmful gases to the environment and cause less
health problems to workers. The study therefore shows that natural gas is the best
fuel because it is cheap, readily available and creates fewer problems to the
environment.
Title page
Certification
Approval
Dedication
Acknowledgement
Abstract
Table of contents
CHAPTER ONE
INTRODUCTION
1.1 Background of study 1
1.2 Statement of problem 2
1.3 Aims and objectives 2
1.4 Significance of study 3
1.5 Scope of study 3
CHAPTER TWO
LITERATURE REVIEW
2.1 Energy source 5
2.1.0 Coal 5
2.1.1 Fuel oil 15
2.1.2 Natural gas 15
2.2 Cement 17
2.2.0 Cement manufacturing processes 18
2.2.1 Major characteristics of cement industry 22
2.2.2 Energy challenge in the industry 23
2.2.3 Demand for cement 25
2.2.4 Emission from cement industry 26
2.3 Conceptual framework 30
CHAPTER THREE
RESEARCH METHODOLOGY
3.1 Research methods 31
3.2 Sample procedure/sample size determination 31
3.3 Data collection 33
3.4 Operational measures of the variable 33
3.5 Research analysis 34
CHAPTER FOUR
PRESENTATION AND ANALYSIS OF DATA
4.1 Data presentation 35
CHAPTER FIVE
SUMMARY, CONCLUSION AND RECOMMENDATION5.1 Summary 50
5.2 Conclusion 51
5.3 Recommendation 51
REFERENCE 53
APPENDIX 56
INTRODUCTION
1.1 BACKGROUND OF STUDY
Energy is commonly defined as the ability to do work or to produce heat.
Normally heat could be derived by burning a fuel (i.e. a substance that contains
internal energy which upon burning generates heat). (IEA, 2004).
The energy system today is highly dependent on fossil fuel with coal, fuel oil and
natural gas accounting for about 80% of world primary energy demand. (Kul,
2001).
Fuels are the major source of energy for industries and cement industry is not an
exception. However, the energy source to be adopted will have to meet the varying
needs of different countries and at the same time enhance the security of each
against the energy crisis that have taken place in the past. The selection/ choice of
fuel type depend on various factors such as environmental pollution, ease in
processing, storage and handling, availability and cost of the fuel.
Coal, fuel oil and natural gas are the most commonly used energy carrier in cement
industries. The energy use for cement production is distributed as follows:-
92.7% for pyro-processing
5.4% for finishing grinding and
1.9% for raw grinding (Choate, 2003).
The choice of fuel use entails the level at which green house gases (GHG) are
emitted, the cost of cement and the quality of the cement produced.
This research work will help in selecting the best fuel and techniques to be use in
order to attain a high quality product at a lower cost with lesser green house gas
emission to the environment.
1.2 STATEMENT OF PROBLEM
The choice of fuel is attained by comparative analysis of coal, fuel oil and natural
gas in cement production. In comparing these fuels, the following problem arises:-
Knowledge of the physio- chemical properties of coal, fuel oil and natural
gas.
Knowledge of the green houses gases (GHG) emitted by each of these fuel,
their level of emission and their effects on the environment and humans
health (esp. cement workers).
Knowledge of the cost and availability of coal, fuel oil and natural gas.
1.3 AIMS AND OBJECTIVES OF STUDY
The aims of this research work is to;
Study the physical and chemical properties of coal, fuel oil and natural gas.
Gain knowledge on the green house gases (GHG) emitted, their effect on the
environment and humans health and the level of emission from each fuel.
Study coal, fuel oil and natural gas in relation to cost and availability.
1.4 SIGNIFICANCE OF THE STUDY
With the growth in industrialization today, this study will offer numerous values both
to the cement industry and staff, the environment and society at large.
It will choose an economical and less hazardous fuel and techniques for cement
production.
Also, it will help in the selection of techniques /fuel that will reduce the emission of
green house gases (GHG) from cement industries to the environment. This gases
emitted causes acid rain, smog etc. which can cause cancer to human and destroys
plant lives.
In terms of infrastructural development, an economical fuel for production will lead
to a reduction in the cost of cement, thereby encouraging the development of
buildings and Government in development of roads, bridges, and other
construction- oriented projects.
This study will also give students of chemical engineering and other related courses
an insight of these fuels with their different environmental implications, properties
and choice of fuel when combustion of fuel is required.
1.5 SCOPE AND LIMITATION
This study would have covered all the Nigerian cement industries but due to time
and cost of analysis, it is limited to three(3) cement industries namely:- Dangote
Cement in Gboko -Benue State, United Cement Company in Calabar – Cross River
State(UniCem), and Nigerian Cement Company in Nkalagu -Ebonyi State
Analysis Of Coal, Fuel Oil And Natural Gas For Cement Production:
Analyzing the use of coal, fuel oil, and natural gas in cement production involves assessing their role in the process, their environmental impact, and their economic considerations. Let’s break down the analysis into these aspects:
1. Role in Cement Production:
Coal: Coal is a commonly used energy source in cement production. It is primarily used as a fuel in the kiln, where it provides the necessary heat to create clinker from raw materials like limestone, clay, and iron ore. The combustion of coal generates high temperatures, making it an efficient energy source for this purpose.
Fuel Oil: Fuel oil is another potential energy source in cement production. Like coal, it can be used in the kiln to provide the required heat. However, it is less commonly used than coal due to environmental concerns and cost considerations.
Natural Gas: Natural gas is increasingly being used in cement production because it burns cleaner than coal and fuel oil. It is often favored for its lower greenhouse gas emissions and ease of use in the kiln. Natural gas can also be used in other parts of the cement manufacturing process, such as drying and preheating raw materials.
2. Environmental Impact:
Coal: The use of coal in cement production is associated with high carbon dioxide (CO2) emissions, making it a significant contributor to greenhouse gas emissions in the industry. Additionally, it can release other pollutants, such as sulfur dioxide (SO2) and nitrogen oxides (NOx), which can lead to air pollution and acid rain.
Fuel Oil: Fuel oil has similar environmental concerns as coal, including high CO2 emissions and the potential for sulfur and nitrogen emissions, though it tends to produce fewer emissions per unit of energy generated.
Natural Gas: Natural gas is considered a cleaner-burning fuel compared to coal and fuel oil. It emits fewer CO2 emissions and lower levels of sulfur and nitrogen pollutants. This makes it a more environmentally friendly option for cement production.
3. Economic Considerations:
Coal: Coal has historically been a cost-effective fuel source for cement production, which has led to its widespread use. However, its economic viability can be influenced by factors such as supply availability and fluctuations in coal prices.
Fuel Oil: The cost of fuel oil can vary depending on factors like global oil prices and geopolitical stability. It may be less cost-effective than coal or natural gas, which can make it less attractive for cement manufacturers.
Natural Gas: Natural gas prices can also fluctuate, but it is often considered a more stable and economically viable option due to its cleaner and efficient burning characteristics. Government incentives and regulations may also influence the economic feasibility of using natural gas.
In summary, the choice between coal, fuel oil, and natural gas for cement production involves a trade-off between their role in the process, environmental impact, and economic considerations. Many cement manufacturers are increasingly shifting towards natural gas due to its lower environmental footprint, although the choice may vary depending on regional factors and government policies. Additionally, ongoing research and development efforts focus on improving the environmental performance of cement production regardless of the energy source used.