Methodological issues

4.2.2.1 Cement production (2A1)

In Switzerland, there are six plants producing clinker and cement. The Swiss plants are rather small and do not exceed a capacity of 3’000 tonnes of clinker per day. All of them use modern dry process technology.

Emissions of geogenic CO2 occur during the production of clinker, which is an intermediate component in the cement manufacturing process. During the production of clinker, limestone, which is mainly calcium carbonate (CaCO3), is heated (calcined) to produce lime (CaO) and CO2 as by-product. The CaO reacts subsequently with minerals in the raw materials and yields clinker. During this reaction step no further CO2 is emitted. Clinker is then mixed with other components such as gypsum to make cement.

Blasting operations in the limestone quarries are another source of emissions for both CO2

and precursor greenhouse gases such as NOx, CO, NMVOC and SO2.

Methodology Calcination process

The geogenic CO2 emissions from the calcination process in cement production are determined by a Tier 2 method according to the decision tree Fig. 2.1. of 2006 IPCC Guidelines (vol. 3, chp. 2.1 Cement production). For cement production in Switzerland this results in the following formula:

CO2 Emissions = MClinker

•

^EFClinker

•

^CKDCorrection factor

In Switzerland, no long wet or long dry kilns are used. Only modern preheater or precalciner kilns are used and also no so-called low-alkali cement is produced. Therefore, there is no

2A Source Specification

2A1 Cement production Geogenic CO2 emissions from calcination process in cement production;

Emissions of CO2, NOx, CO, NMVOC and SO2 from blasting operations

2A2 Lime production Geogenic CO2 emissions from calcination process in lime production;

Emissions of CO2, NOx, CO, NMVOC and SO2 from blasting operations

2A3 Glass production Geogenic CO2 emissions from production of container and tableware glass, and glass wool

2A4 Other process uses of carbonates Geogenic CO2 emissions from fine ceramics, brick and tile and rock wool production as well as from use of sodium bicarbonate;

Emissions of CO2, NOx, CO, NMVOC and SO2 from blasting operations in plaster production

4 Industrial processes and product use: 4.2 Source category 2A – Mineral industry

land-filling of calcined cement dust (cement kiln dust, CKD) in Switzerland. In the cement plants all the filter dust is collected in high performance electrostatic precipitator or bag filters (having an efficiency of more than 99.999%) and being recycled to the kiln feed. In some cases small portions of the CKD are added directly to the cement as filler. Due to the kiln technology used in Switzerland the degree of decarbonization of the CKD is almost equal to that of the kiln feed, meaning, that this CKD has not been decarbonised yet. Therefore, the CKD correction factor is equal to 1.00.

Blasting operations

Emissions resulting from blasting operations during the digging of limestone are calculated by a Tier 2 method according to EMEP/EEA Guidebook 2013 (EMEP/EEA 2013, chp. 2A1, Fig. 3.1) using country-specific emission factors. The CO2 emissions from "blasting" are related only to the usage of explosives in the quarries and not to fuel consumption of e.g.

bulldozers etc.

Total emissions reported for the production of cement are the sum of emissions from calcination process and blasting operations. The share of CO2 emissions from blasting operations in limestone quarries is well below one tenth of a per cent of the geogenic CO2

emissions from the calcination process.

Emission factors Calcination process

The emission factor for CO2 for calcination is a country-specific value depending on the composition of the raw material (EMIS 2016/2A1 Zementwerke Rohmaterial). It is provided per tonne of clinker. Before 2004 a constant emission factor is assumed. Between 2005 and 2011 plant-specific data are provided by the cement industry association (Cemsuisse) and since 2011 the emission factor is assumed constant. The IPCC method neglects CO2

emissions from decomposition of MgCO3, which are taken into account in this country-specific value.

Table 4-3 CO2 emission factor for calcination in 2A1 Cement Production 1990 to 2014.

2A1 Cement production Unit 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 Calcination, CO₂ kg/t clinker 530.6 527.9 528.6 529.3 531.0 532.1 530.6 530.6 530.6 530.6

1990 - 2004 525.0

4 Industrial processes and product use: 4.2 Source category 2A – Mineral industry

Blasting operations

The emission factors are country-specific based on emission factors of civil explosives and information on the specific consumption of explosives in the quarries as documented in the Handbook on emission factors for stationary sources (SAEFL 2000) as documented in EMIS 2016/2A1 Zementwerke übriger Betrieb. They are assumed to be constant over the entire time period and are given per tonne of clinker.

Table 4-4 Emission factors for CO2, NOx, CO, NMVOC and SO2 from blasting operations in g/t clinker from source category 2A1 Cement Production in 2014

Activity data

Since 1990, data on annual clinker production are provided by the industry association (Cemsuisse as documented in the EMIS database (EMIS2016/ 2A1_Zementwerke

Rohmaterial). From 2008 onwards they are based on plant-specific annual monitoring reports from the Swiss Emissions Trading Scheme (ETS).

Table 4-5 Activity data of clinker production

4.2.2.2 Lime production (2A2)

During the production of lime calcium carbonate (CaCO3) is heated (calcined) yielding burnt lime (CaO) and CO2 as by-product. In Switzerland, there is only one plant producing lime.

There is no industry in Switzerland producing lime for its own requirements, except for sugar production. A request to both sugar producing plants confirmed that indeed they produce lime from limestone in own shaft kilns. However, the CO2 is re-captured in the sugar production process and thus no CO2 emissions occur.

Blasting operations in quarries are another source of emissions for both CO2 and precursor emissions such as NOx, CO, NMVOC and SO2.

2A1 Cement production Unit CO₂ NO_X CO NMVOC SO₂

Blasting operations g/t clinker 34.1 3.3 3.3 8.6 0.1

2A1 Cement production Unit 1990 1995 2000 Clinker production kt 4'808 3'706 3'214

2A1 Cement production Unit 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 Clinker production kt 3'442 3'452 3'512 3'461 3'443 3'642 3'587 3'368 3'415 3'502

4 Industrial processes and product use: 4.2 Source category 2A – Mineral industry

Methodology Calcination process

The geogenic CO2 emissions from the calcination process in lime production are determined by a country-specific method according to the decision tree Fig. 2.2. of 2006 IPCC guidelines (vol. 3, chp. 2.2 Lime production).

Blasting operations

Emissions resulting from blasting operations during the digging of limestone are calculated by a Tier 2 method according to EMEP/EEA Guidebook 2013 (EMEP/EEA 2013, chp. 2A2, Fig. 3.1) using country-specific emission factors. The CO2 emissions from "blasting" are related only to the usage of explosives in the quarries and not to fuel consumption of e.g.

bulldozers etc.

Total emissions reported for the production of lime are the sum of emissions from calcination process and blasting operations. CO2 emissions from blasting operations in limestone quarries account only for a small share of the total emissions.

Emission factors Calcination process

The emission factor for CO2 from calcination of limestone depends both on the purity of the limestone and the degree of calcination (i.e. amount of rest CO2 remaining in the lime

produced). A plant-specific value has been calculated based on industry declaration and it is assumed to be constant for the years 1990–2012 (EMIS 2016/2A2 Kalkproduktion,

Rohmaterial). The value is confidential and is available to reviewers on request. Since 2013, emission factors are derived from annual monitoring reports from the Swiss Emissions Trading Scheme (ETS).

Blasting operations

The emission factors are country-specific as documented in EMIS 2016/2A2 Kalkproduktion, übriger Betrieb. The values are confidential and they are available to reviewers on request.

Table 4-6 CO2 emission factor for the calcination process in lime production in kg/t lime and emission factors for CO2, NOx, CO, NMVOC and SO2 from blasting operations in g/t lime in 2014

2A2 Lime production Unit CO₂ NO_X CO NMVOC SO₂

Calcination kg/t C NA NA NA NA

Blasting operations g/t C C C C C

4 Industrial processes and product use: 4.2 Source category 2A – Mineral industry

Activity data

Activity data on annual lime production are provided by the only existing plant in Switzerland, as documented in the EMIS database (EMIS 2016/2A2 Kalkproduktion, Rohmaterial and EMIS 2016/2A1 Kalkproduktion übriger Betrieb). From 2008 onwards, they are based on plant-specific annual monitoring reports from the Swiss Emissions Trading Scheme (ETS).

Detailed activity data are not reported since they are considered confidential.

Table 4-7 In the confidential NIR, the respective table with activity data on lime production are separately reported and available to reviewers.

4.2.2.3 Glass production (2A3)

Source category 2A3 Glass production comprises geogenic CO2 emissions from the carbonate containing raw materials, i.e. soda ash, limestone and dolomite. In Switzerland, the following three glass types are produced: container glass, tableware glass and glass wool. Today, there is only one production plant remaining for container glass and tableware glass after the other plants closed in 2002 and 2006, respectively. Glass wool is produced in two plants.

Methodology

For determination of geogenic CO2 emissions from glass production, a Tier 2 method according to the decision tree Fig. 2.3 of 2006 IPCC guidelines (vol. 3, chp. 2.4 Glass production) is used. For glass production in Switzerland this results in the following formula:

CO2 Emissions = MGlasstype

•

^EFGlasstype

•

(1 – cullet ratio)

The cullet ratio describes the share of recycled glass material which is used in the production. The melting of cullet causes no geogenic CO2 emissions.

From 2005 onwards, the geogenic CO2 emissions from 2A3 Container glass production is determined according to a Tier 3 method based on the amount of carbonate containing raw materials used, i.e. soda, dolomite and limestone and their effective carbonate content.

Emission factors

The emission factors for glass production in Switzerland are taken from IPCC 2006 (vol.3, chp. 2.4 Glass production, Table 2.6). For the production of container glass (1990–2004), tableware glass and glass wool the values for glass type container, tableware and fibreglass are taken, respectively. As the emission factors are material properties, they remain constant over time.

From 2005 onwards, effective amounts of carbonate containing raw materials (soda ash, dolomite and limestone) are available for the container glass production and thus the

4 Industrial processes and product use: 4.2 Source category 2A – Mineral industry

corresponding CO2 emission factors are taken from IPCC 2006 (vol. 3, chp. 2.1, Table 2.1).

As these emission factors are material properties, they remain constant over time.

Table 4-8 Geogenic CO2 emission factor for glass production in g/t glass and g/t carbonate containing raw material (IPCC 2006).

Activity data and cullet ratios

Activity data of tableware and container glass production are based on data from Swiss glass producers. For glass wool production, activity data are based on data from the two glass wool production plants in Switzerland. Since 2008, activity data are based on plant-specific annual monitoring reports.

Source category 2A3 Glass production is dominated by the emissions from the production of container glass and glass wool.

Detailed information on activity data for container glass production and tableware production is confidential as there is only one production plant for container glass and tableware glass, respectively. Data are available to the reviewers on request (EMIS 2016/2A3 Hohlglas Produktion, EMIS 2016/2A3 Glas übrige Produktion and EMIS 2016/2A3 Glaswolle Produktion Rohprodukt).

2A3 Glass production Unit CO₂ geogenic

Glass wool (fibre glass insulation) g/t 250'000

Glass (speciality tableware) g/t 100'000

1990–2004 2005–2014

Container glass g/t 210'000

Soda use g/t soda 414'920

Dolomite use g/t dolomite 477'320

Limestone use g/t limestone 439'710

4 Industrial processes and product use: 4.2 Source category 2A – Mineral industry

Table 4-9 Activity data of glass production in Switzerland and cullet ratio in % as well as consumption of carbonate containing raw materials in container glass production

4.2.2.4 Other process uses of carbonates (2A4)

Source category 2A4 Other process uses of carbonates comprises geogenic CO2 emissions from the carbonate containing raw materials used in the production of ceramics (2A4a) and rock wool (2A4d) as well as from the use of sodium bicarbonate (2A4d). In addition, also emissions from blasting operations in plaster production (2A4d) are reported.

Ceramics (2A4a)

Source category 2A4a Ceramics consists of the production of fine ceramics and brick and tile.

Fine ceramics (2A4a)

In Switzerland, the main production of fine ceramics is sanitary ware. The carbonate containing raw materials limestone and dolomite as well as small amounts of soda ash are

2A3 Glass production Unit 1990 1995 2000 Container glass

Production kt C C C

Cullet ratio % C C C

Soda use kt NA NA NA

Dolomite use kt NA NA NA

Limestone use kt NA NA NA

Glass (speciality tableware)

2A3 Glass production Unit 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 Container glass

Production kt 37.5 38.1 44.5 44.4 33.5 35.7 41.4 38.7 33.4 32.3

Cullet ratio % 65 73 71 69 69 71 72 61 67 67

Im Dokument Switzerland’s Greenhouse Gas Inventory 1990–2014 (Seite 194-200)