Life Cycle Assessment of Ethiopian Cement Manufacturing: A Potential Improvement on the Use of Fossil Fuel in Mugher Cement Factory

Abstract

The use of imported fuel in the Ethiopian cement industry increased the cost of production and the environmental burden, necessitating intervention. The greenhouse gas (GHG) emission, energy usage intensity, and resource exploitation of Ethiopian cement production were evaluated using the life cycle impact assessment (LCA) tool, aiming to recommend improvements. The LCA study used cumulative energy demand (CED) and Intergovernmental Panel on Climate Change (IPCC) 2006 life cycle impact assessment (LCIA) methods. For the case study of Mugher cement factory (MCF), the results on energy use intensities showed 3.74, 3.67, and 2.64 GJ/ton of clinker, Ordinary Portland cement (OPC), Pozzolana Portland cement (PPC), respectively. The result revealed MCF's energy use intensity was within the global range of 3.32 to 5.11 GJ/ton of cement production using similar kiln technology. The results on the GHG emissions were 0.87, 0.84, and 0.59 tons of CO₂-equivalent/ton of clinker, OPC, and PPC, respectively. Process emissions accounted for 60% of overall CO₂ emissions, with energy-related emissions accounting for the remaining 40%. CO₂ emissions of MCF are below the global limit of 0.9 tons/ton of clinker, where all energy sources are fossil fuels. However, it is higher than the 0.65 ton/ton of clinker from a moderate rotary kiln in China. MCF used 70% of its total energy sources from imported fossil fuels, and transportation of the imported fuel added 1.2% CO₂ to total emissions. A suggested fossil fuel use improvement scenario for MCF, where coffee husk replaces 50% of the imported coal improved the energy intensity, GHG emissions, and total cost of coal in clinker production by 1.2%, 14%, 36%, respectively.