L B / o o t i / 2 7 / o 3 
ANALYSIS OF 
ENERGY EMBODIED IN CEMENT 
PRODUCED IN SRI LANKA 
A 
B y 
Dampege Don Ananda Namal 
Thi s thes i s w a s submi t t ed to the D e p a r t m e n t o f M e c h a n i c a l E n g i n e e r i n g o f the 
U n i v e r s i t y of M o r a t u w a in par t ia l fulf i l lment of the r e q u i r e m e n t for t he D e g r e e o f 
M a s t e r o f E n g i n e e r i n g in E n e r g y T e c h n o l o g y . 
D e p a r t m e n t o f M e c h a n i c a l E n g i n e e r i n g 
T h e Facu l ty o f E n g i n e e r i n g 
Unive r s i ty o f M o r a t u w a 
Sri L a n k a . 
F e b r u a r y 2 0 0 3 
WW TheSis Coll 
1 7 7 1 3 
University of Moratuwa 
77713 
7 7 7 1 3 
t 
DECLARATION 
•A 
I hereby declare that this submission is my own work and that, to the best of my 
knowledge and behalf, it contains no material previously published or written by 
another person nor material, which to substantial extent, has been accepted for the 
award of any other acedemic qualification of a university or other institute of higher 
learning except where acknowledgment is made in the text. 
D D Ananda Namal 
Abstract 
Analysis of the embodied energy in cement produced in Sri Lanka was carried out 
considering national boundaries. National energy input to the cement manufacturing was the 
main focus of this study and therefore any energy involvement outside Sri Lanka was not 
taken in to consideration in this analysis. The total embodied energy content was analyzed in 
three levels. In level 1, direct energy consumption in manufacturing of cement at Puttalam 
cement factory was analyzed and energy consumption for ancillary inputs was considered in 
the level 2. Energy consumption for raw material extraction and transportation within the 
country was analyzed in level 3. 
The direct delivered energy consumption was assessed by carrying out an energy survey at 
Puttalam cement factory. Then this direct energy was referred to primary energy by 
considering the national energy mix in electricity generation together with transmission and 
distribution losses in electricity distribution, power plant efficiencies, and energy 
consumption in refining petroleum fuels. 
The total national energy requirement to produce one ton of cement in Sri Lanka was found to 
be 4896 MJ based on the present energy mix of electricity generation. This varies between 
4982 MJ/MT and 4732 MJ/MT according to the future energy mix of the electricity 
generation and the transmission loss reduction plan of Sri Lanka. 
The outcome of this study can be used to select the best material for building construction 
from cement based products and in the formulation of energy conservation policies like the 
Building Code. In addition the outcome of the study can be used as inputs for further research 
relevant to energy content of materials. 
I 
CONTENTS 
Item Page No. 
Declaration i 
Abstract ii 
Contents iii 
List of Tables vii 
List of Figures x 
Acknowledgement xii 
1. Chapter 1: Research Problem Being Analyzed 1 
1.1 Background of the Energy Scenario of Sri Lanka 1 
1.1.1 Energy Resources 2 
1.1.2 Electrical Energy 3 
1.1.3 Petroleum Energy 3 
1.2: Research Problem at the Scene 4 
1.3 Objectives of the Study 5 
1.4 Rationale and Justification 5 
2. Chapter 2: Literature Survey 7 
2.1 Introduction 7 
2.2 Energy Analysis 8 
2.1.1 End Use Energy Analysis 8 
2.1.2 Primary Energy Analysis 9 
2.1.3 Embodied Energy Analysis 9 
2.1.4 Life Cycle Energy Analysis 9 
2.3 Theory of Embodied Energy Analysis 10 
2.4 Factors Affecting the Embodied Energy 12 
2.4.1 Recycling and Reuse 12 
2.4.2 Energy Source 13 
2.4.3 Production Process 14 
2.4.4 Transport 15 
2.4.5 Raw Material 17 
2.4.6 System Boundary 18 
s 
2.5 Embodied Energy in Fuel & Energy 20 
2.6 Practical Problems and Issues 22 
2.7 Embodied Energy and Global Warming 24 
2.8 Benefits of Embodied Energy Analysis 27 
2.9 State of the Art of Embodied Energy Studies in the World 28 
2.9.1 Life Cycle Embodied Energy in Office Furniture 29 
2.9.2 Life Cycle Analysis of Heavy Vehicles 30 
2.9.2 Energy Payback Time of Photovoltaic Vehicles 31 
2.9.3 The Energy Intensity of Photovoltaic Systems 3 1 
2.9.4 Energy Payback ratio and CO2 Emission Associated with 
Electricity Generation from a Natural Gas Power System 31 
2.9.5 Which is Better? Steel, Concrete or Wood 31 
2.9.6 Energy use from Cradle to Grave for Three Single Family Houses 32 
2.9.7 Using Monte-Carlo simulating in Life Cycle Assessment for 
Electric & Internal Combustion Vehicles 32 
2.9.9 Embodied Energy and Life Cycle Energy Analysis in Built 
Environment 32 
2.9.10 Data for Life Cycle Energy Calculation 36 
3. Chapter 3: Methodology and Scope of the Study 
3.1 Scope of the Study 
3.2 Energy and Material Consumption at Puttalam Cement Factory 
3.2.1 Energy for Raw Material 
3.3 Referring Delivered Electrical Energy to Primary Energy 
3.4 National Energy Embodied in the Petroleum Fuels 
3.5 Energy Requirement in Transport 
3.6 Referring Delivered Thermal Energy to Primary Energy 
43 
43 
43 
44 
44 
44 
45 
4. Chapter 4: Assessment of Cement Manufacturing Process at Puttlam Cement 
Factory 46 
4.1 Raw Material 46 
4.2 Energy 48 
4.3 Production Process 51 
4.4 Human Resources 54 
4.5 Ancillary Inputs 
4.6 Extraction of Limestone 
4.6.1 Fuel Consumption in Heavy Vehicle and Other Machinery 
4.6.2 Electrical Energy Consumption 
4.6.3 Water Consumption 
4.6.4 Production 
4.6.5 Oil Consumption 
4.6.6 Human Resources 
55 
57 
57 
58 
59 
59 
59 
61 
5. Chapter 5: Analysis of National Energy Supply 
5.1 Electricity Mix - Past, Present and Future 
5.2 Efficiency of Power Generation 
5.3 Transmission and Distribution Losses 
5.4 Lakdhanavi Power Project 
5.5 Petroleum Energy 
5.5.1 Refinery 
62 
62 
74 
75 
75 
76 
77 
6. Chapter 6: Analysis of Embodied Energy in Cement 80 
6.1 Embodied Energy in Delivered Energy 80 
6.1.1 Petroleum Fuel 80 
6.1.2 Calculation of Transport Energy 83 
6.1.2.1 Energy Consumption to Produce Lubricant Oil 83 
6.1.2.2 Energy Consumption for Servicing Vehicle 84 
6.1.2.3 Energy Consumption for Fuel Pumping 85 
6.1.2.4 Total Energy Consumption for Vehicle Operation 86 
6.1.3 Electricity 87 
' 6.2 Embodied Energy in Cement 92 
6.2.1 Level 1 Analysis 92 
6.2.2 Level 2 Analysis 93 
6.2.2.1 Energy Consumption for Employee Transport 93 
6.2.2.2 Energy Consumption for Employees Uniform 94 
6.2.2.3 Energy Consumption for safety Shoes 94 
6.2.2.4 Energy Consumption for Lubricating Oil 94 
6.2.3 Level 3 Analysis 95 
7. Chapter 7: Discussion and Conclusion 101 
7.1 Embodied Energy in Cement 101 
7.1.1 Level 1 Energy 102 
7.1.2 Level 3 Energy 103 
7.2 Sensitivity Analysis 103 
7.2.1 Sensitivity to National Electrical Energy Mix 103 
7.2.2 Sensitivity to Reduction of Transmission and Distribution Losses 105 
7.3 Self Generation of Electricity 106 
7.4 Comparison of Embodied Energy of Cement Found in Literature 107 
7.5 Use of the Result 107 
Reference 109 
Annex 1: Energy Requirement in Producing Lubricating Oil 112 
Annex 2: Energy Consumption for Shoe Manufacturing 113 
Annex 3: Energy Consumption at Kabool Lanka Ltd. 114 
Annex 4: Energy Consumption for Petroleum Fuel Filling Stations 116 
Annex 5: Properties of Fuel 117 
List of Tables 
Chapter 2 
2.1 Energy Breakdown of a Loaf of Bread in the UK 
2.2 Effect of Recycling in Embodied Energy 
2.3 Efficiency of Thermal Power Plants 
2.4 Comparison of Transport Energy of Steel 
2.5 CO2 Emission - kg/passenger km 
2.6 CO2 Produced from Varying Raw Material in Steel Production 
2.7 Embodied Energy of Some Building Material 
2.8 The Main Green House Gases 
2.9 Embodied Energy of Building Materials 
2.10 Embodied Energy of Fuel Oil 
2.1 1 Comparison of Embodied Energy Data Available for Steel 
2.12 Comparison of Embodied Energy Data Available for Wood 
2.13 Comparison of Embodied Energy Data Available for Concrete 
2.14 Global Warming Potential (20 year time horizon) 
2.15 Specific CO2 equivalent Emissions for Fuels 
2.16 Potential Production Energy Saving of Recycle Material 
2.17 Average Fuel Consumption of Vehicle 
2.18 Energy used by Mode of Transport (MJ/passenger km) 
2.19 Embodied Energy Coefficients 
Chapter 4 
4.1 Details of Raw Material Supply 
4.2 Annual Consumption of Raw Material 
4.3 Consumption of Limestone 
4.4 Quantity of Limestone - Year 2001 
4.5 Consumption of the Laterite 
4.6 Monthly Electricity Consumption of the Factory - 2001 
4.7 Furnace oil Consumption - 2001 
4.8 Diesel Consumption in Shunting Train Engine - 2001 
4.9 Fuel Consumption in Heavy Equipment - 2001 
4.10 Heavy Vehicle Running Hours 
4.11 Crusher Output-2001 
4.12 Raw Mill Output-2001 
4.13 Clinker Production & Energy Consumption - 2001 
4.14 Cement Production - 2001 
4.15 Details of the Employees at Cement Factory - 2001 
4.16 Employees Transport Details 
4.17 Details of Uniform 
4.18 Annual Consumption of Explosives 
4.19 Details of Heavy Vehicles & Machinery - 2001 
4.20 Monthly Diesel Consumption - 2001 
4.21 Monthly Electricity Consumption - 2001 
4.22 Monthly Production - 2001 
4.23 Details of Oil Consumption - 2001 
4.24 Annual Oil Consumption - 2001 
Chapter 5 
5.1 Existing Hydro Power Plants - 2000 
5.2 Details of Existing Thermal Plants - 2001 
5.3 Committed and Candidate Power Plants 
5.4 Forecasted Annual Electrical Energy Demand - GWh 
5.5 Annual Generation - Base Case Plan 
5.6 Efficiency of Thermal Power Plants 
5.7 Planed T&D Loss Reduction 
5.8 Operating Energy Data 
5.9 Employee Data 
5.10 Employee Transport Details 
5.11 Petroleum Imports 
5.12 Refined Petroleum Product Mix - 1999 
5.13 Petroleum Production - 2001 
5.14 Monthly Fuel Consumption - 2001 
Chapter 6 
6.1 Energy Content of Petroleum Fuel at Delivery 
6.2 Sequence of Engine Oil Changes 
6.3 Energy Consumption of Vehicle Service 
6.4 Energy Consumption of Vehicles 
6.5 Energy Consumption per passenger km 
6.6 Employee Transport Energy Consumption 
6.7 Fuel Transport Energy Factors 
6.8 i Factors of the Power Plants 
6.9 Embodied Energy of Cement 
Annexes 
A-1 -1 Energy Consumption: Year 2001 - Caltex Lubrication Lanka Ltd. 
A-2-1 Electrical Energy Consumption & Production 
A-3-1 Energy Consumption & Production 
A-4-1 Monthly Fuel Sold & Energy Consumption 
A-4-2 Monthly Energy Consumption & Vehicle Serviced 
j j . A-5-1 Properties of Fuel 
IX 
List of Figures 
Chapter 1 
> 
1.1 Energy Supply by Source - 2000 
1.2 Energy Consumption by Sectors 
1.3 Petroleum Demand Growth 
1.4 Fossil Fuel Requirement for Power Generation 
Chapter 2 
2.1 Different Levels of Embodied Energy Analysis 
2.2 Embodied Energy in Reuse & Reprocessing 
2.3 Energy Profit Ratio 
2.4 Extent of Up Stream Process 
2.5 Energy Loss Chain in Coal Based Power Generation 
2.6 Global Temperature Change 
2.7 Sea Level Rise 
2.8 Green House Effect 
2.9 GHG Emission in Sri Lanka - 1994 
2.10 Global CO2 Emission 
2.11 Embodied Energy of Office Furniture 
Chapter 3 
3.1 Referring Delivered Energy to Primary Energy 
Chapter 4 
4.1 Share of Energy by Source 
4.2 Process Flow Diagram - Puttalm Cement Factory 
Chapter 5 
5.1 Historical Electricity Generation 
5.2 Future Energy Generation 
5.3 Thermal Hydro Mix 
Chapter 7 
7.1 Breakdown of Embodied Energy of Cement 
7.2 Breakdown of Level One Energy 
7.3 Breakdown of Heat Energy 
4 
X 
V 
7.4 Breakdown of Level 3 Energy 
7.5 Variation of Electrical Energy Mix 
7.6 Variation of Primary Energy Required to Deliver One kWh of Electricity from the 
National Grid 
7.7 Variation of Embodied Energy of Cement with Energy Mix in Electricity Generation 
7.8 Variation of Embodied Energy of Cement with Energy Mix in Electricity Generation 
and Planed T&D Loss Reduction 
V