This project is funded by
the European Union
Cement industry in Poland
Andrzej Werkowski, Expert
GHG Inventory and MRV of Industrial Emissions
Workshop, Tbilisi, 27-28 March 2017
Cement industry in Poland
Cement Industry in Poland 2016
Cement Plants 13
Cement Groups 9
Production Capacity 15 mln t
Clinker
Production Capacity 22 mln t
Cement
Clinker Production 12 mln t
Cement Production 16 mln t
Dry technology 14 kilns
(3 reserve)
Wet technology 2 kilns
(4 reserve)
Kiln Capacity 500 – 8.500
t /24 h
Cement industry – Market share
9,2%
21,9%
11,9% Lafarge
Heidelberg
CRH
0,1% CEMEX
Nowa Huta
5,9%
Miebach
1,4% Mapei
Polen Cement
20,5%
Dyckerhoff
12,3%
16,8%
Cement Plants in Poland
• Górażdże
• Ekocem
Cement Plants in Poland
• Małogoszcz
• Kujawy
Cement Plants in Poland
• Ożarów
• Rejowiec
Cement Plants in Poland
Polen Cement • Odra
• Warta
Cement Plants in Poland
• Nowiny
Cement Plants in Poland
• Chełm
• Rudniki
Cement Plants in Poland
Cement Plant Kraków – Nowa Huta
Cement Plants in Poland
• Górka (Aluminous cement)
Technology
• Over 98% of cement production in Poland is
produced using dry method and modern
technology meeting BAT requirements
• Most of production lines are equipped with novel
cyclon heat exchangers and calciners
Cement Production Process
Cement industry in Poland
Energy efficiency related factors
Consumption of: 2009 2010 2011 2012 2013
Coal 864 962 1 203 920 726
[th Mg]
Alternative fuels 752 952 1 227 1 180 1 131
[th Mg]
Electric energy 98 100 102 104 104
kWh/Mg cement
Heat 3 692 3 712 3 828 3 766 3 722
kJ/kg clinker
Cement industry in Poland
Cement Production
Cement industry in Poland
Cement and Clinker production
Cement industry in Poland
CO2 emissions
Cement Production
Energy consump[tion
Depending on raw materials and technology used cost of energy
represents 20% ÷ 40% of total variable cost of cement production
Cement industry – Alternative fuel
Heat from Alternative Fuel Alternative Fuel Mix
1,8%1,3% 1,7%
3,1%
6,4%
50 0,6%
45
40
35
30
% 25
85,1%
20
15
10
5 RDF Sewage waste
0 Used tires Waste from Power Plants
1990 2000 2005 2009 2010 2011 2012 2013 Coal processing waste Rubber waste
Other
World EU Poland
Cement industry
Primary Raw Materials
Primary Raw Materials - Mix
249 117 Limestone
Sand
Ferrous additives
Anhydrite
Ferrous sulphate
Other
5 636
Marl/Chalk
10 307 Gypsum
Clay
154 16,5 mln tonnes / annum
Cement industry
Alternative Raw Materials
Secondary Raw Materials - Mix
89
124 Fly ash
Slag
483 Reagypsum
Ferrous dust
Fluidal ash
Bypass dust
Shale burned
Sand from fluidal bed
Other
1 602
1 264
3,6 mln tonnes / annum
Cement industry in Poland
Important facts
• Waste treatment benefits
• In 2012 1,1 Mtonnes of waste were co-processed
in Poland (46% subsitution rate)
• The cement industry reached 60% substitution
level in 2016 (unofficial information yet)
• CO2 reduction
• Use of waste-derived alternative fuels abated
emission of 1,8 Mtonne of CO2 in 2012
• At 60% substitution rate, the savings increase by
35% to 2,5 Mtonne of CO2 annually
Cement industry in Poland
Important facts
• Energy production and coal savings
• Polish cement industry replaced over 700
ktonnes of coal in 2012
• With substitution level 60% in 2016 1mln tonnes
of coal were replaced
• The 1,2 Mtonnes RDF processed in 2012 by the
cement industry is equivalent to between 660 M
EUR and 1,2 bln EUR in Waste to Energy plant
expenditure
• In 2016 additional 500 ktonnes of RDF
processed led to further savings of 275 M EUR to
500 M EUR in WtE plants
Cement industry in Poland
Important facts
• 2,5 bln € invested in cement industry over past
20 years
• 1 € invested in cement industry creates 2,8 € in
other sectors
• 25.000 jobs (directly and indirectly)
• 400 mln €/annum – taxes paid to central and
local budgets
• 6 mln tonnes/annum – use of alternative fuels
and secondary raw materials
Cement industry in Poland
Achievements & Threats
Polish Cement Industry:
Implemented privatization, restructuring and complex
modernisation programs in 1990 – 2015
Invested in highly efficient, low energy consuming production
technologies becoming one of the most modern and
environmentally friendly industries in the EU
Successfully compete on the EU and global markets
Ready to further invest to maintain competitiveness and
growing environmental requirements
Exposed to indirect CO2 emission negative effect due to
coal-based fuel mix in Poland and growing energy prices
(Polish energy sector will be coal-based still for long time)
Vulnerable to Carbon Leakage
How to contact
The project team can be contacted at personal e-mail addresses
[email protected] and:
[email protected] Clima East Office, c/o Milieu Ltd
Chaussée de Charleroi No. 112
1060 Brussels (Belgium)
Tel: +32 2506 1000
Website:
English: www.climaeast.eu - Russian: http://russian.climaeast.eu/
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