6.1 1 UNFCCC – NAI SOFTWARE Sector: Industrial Processes Practical Aspects and Exercises CGE...

1 6.1

UNFCCC – NAI SOFTWARE Sector: Industrial Processes

Practical Aspects and Exercises

CGE

Greenhouse Gas Inventory Hands-on Training Workshop

2 6.2

CONTENT

Details on use of the UNFCCC – NAI Software to calculate and report GHG emissions in the Industrial Processes sector.

Practical exercises (to be solved by the participants after the presentation).

3 6.3

BACKGROUND

The decision trees in the IPCC good practice guidance are used to choose a good practice method that suits national circumstances.

The UNFCCC-NAI Software contains, basically, the methods of lesser complexity that countries can use to prepare their inventories.

However, in principle, the software can be used to report the estimated emissions independently of the complexity of method used (Tier 2, 3, etc).

4 6.4

SECTOR: INDUSTRIAL PROCESSES Sector 2: Industrial Processes Source Categories and Subcategories Worksheets Cement Production (CO2 and SO2) 2-1s1 (A or B) to 2-1s2 (3) (*) Lime Production (CO2) 2-2s1 (1) Limestone and Dolomite Use (CO2) 2-3s1 (1) Soda Ash Production and Use (CO2) 2-4s1 to 2-4s2 (2) Asphalt Roofing (NMVOC, CO) 2-5s1 to 2-5s2 (2) Road Paving with Asphalt (NMVOC) 2-5s3 (1) Glass Production (NMVOC) 2-5s4 (1) Concrete Pumice Stone (SO2) 2-5s5 (1) Ammonia Production (CO2, NMVOC, CO, SO2) 2-6s1 to 2-6s2 (2) Nitric Acid Production (N2O, NOx) 2-7s1 (1) Adipic Acid Production (N2O, NOx, NMVOC and CO) 2-8s1 (1) Carbide Production (CO2 and CH4) 2-9s1 to 2-9s4 (4) Production of Other Chemicals (CH4, NOx, NMVOC, CO and SO2) 2-10s1 to 2-10s5 (5) Iron and Steel (CO2, NOx, NMVOCs, CO and SO2 2-11s1 and 2-11s3 (3) Ferroalloys (CO2) 2-11s4 (1) Aluminium (CO2, PFC) 2-11s5 to 2-11s7 (2) Other Metal Production (all non-ferrous metals except Aluminium) (CO2) 2-11s1 (1) SF6 used in Aluminium and Magnesium Foundries (SF6) 2-11s1 (1) Pulp and paper Industries (NOx, NMVOC, CO, SO2) 2-12s1 to 2-12s2 (2) Food and Drink Industries (NMVOC) 2-13s1 to 2-13s2 (2) Emissions Related to Production of HFCs, PFCs and SF6 2-14s1 to 2-14s2 (2) Emissions Related to Consumption of HFCs, PFCs and SF6 2-15s1 to 2-15s3 (13) (#) Quantity of sheets

Changes in the worksheets with respect to the IPCC Software * In the current software the CO2 emissions from cement production are calculated in two separate sheets, Table 2-1s1A for

emissions from cement production proper, and Table 2-1s1B for emissions from clinker production, which take into account the CKD factor. Please only fill in EITHER sheet 2-1s1A OR Sheet 2-1s1B.

5 6.5

SECTOR: INDUSTRIAL PROCESSESCement and Lime Production

SECTOR: INDUSTRIAL PROCESSES (1) UNFCCC - NAI

SOFTWARE MAIN

CATEGORIES Tier 1:

Worksheets

Tier 2 Methods

Remarks

Cement Production (CO2 and SO2)

2-1s1A for CO2 and 2-1s2 for SO2

2-1s1B (for CO2) New worksheet in the software

- In the current software the CO2 emissions from cement production are now calculated in two separate sheets, Table 2-1s1A for emissions from cement production proper, and Table 2-1s1B for emissions from clinker production, which take into account the CKD factor (Tier 2). Please only fill EITHER sheet 2-1s1A OR Sheet 2-1s1B. - The emissions of SO2 are calculated from cement production (Tier 1 only).

Lime Production

2-2s1 Obtain/estimate lime production data by type of lime. Calculate EF and CO2 emissions for type of lime

- The default emission factors in the IPCC Guidelines correspond to 100% of CaO (or CaO.MgO) in lime and can lead to an overestimation of emissions because the CaO and MgO content may be less than 100%. Suggestion: Calculate EF outside the software using stoichiometric ratios and CaO (CaO.MgO) content by lime type (or use default values for calculating EF). After having obtained the EF, emissions can be calculated directly in the software.

6 6.6

SECTOR: INDUSTRIAL PROCESSESExercise 2.1: Cement Production (I)

Country A: Year: 2000

Data Three Portland cement plants operate in the country.

Information could not be obtained directly from the plants. The country’s national statistics report only the data included in the following table.

Country Year Cement Production

(tonne)

Clinker

Exported

(tonne)

Clinker

Imported

(tonne)

A 2000 1 052 600 199 994 0

7 6.7

SECTOR: INDUSTRIAL PROCESSESExercise 2.1: Cement Production (II)

Tasks

Using the UNFCCC–NAI Software:

1. Calculate CO2 and SO2 emissions.

2. Verify the emissions reported in the Sectoral and Summary Tables.

3. Fill Table 8A (Overview Table) for the self evaluation of quality and completeness.

8 6.8

SECTOR: INDUSTRIAL PROCESSESExercise 2.1: Cement Production (III)

Steps 1. Open the software and select in the Industrial Processes sector

Worksheet 2-1s1B CO2 from Cement Production (Tier 2).2. Enter the amount of clinker produced in the year. Estimate clinker

production from cement production (because the clinker fraction is not known use the default value of 95% for Portland cement). Subtract for clinker imports and add for exports (999,970 tonne + 199,994 tonne = 1,199,964 tonne clinker produced).

3. Add a note in the documentation box clarifying how the quantity of clinker produced in the year was estimated.

9 6.9

SECTOR: INDUSTRIAL PROCESSESExercise 2.1: Cement Production (IV)

Steps

4. Enter the CO2 EF selected. In absence of data for the clinker lime percentage consider default value of 65% and use default EF (clinker) = 0.5071 tonne CO2/tonne clinker).

5. Calculate CO2 emissions from clinker production. In absence of data on CKD, apply default correction factor for lost CKD (i.e. add 2% to the CO2 calculated for clinker). CKD correction factor = 1.02

6. Open the software and select in the Industrial Processes sector Worksheet 2-1s2 SO2 from Cement Production (Tier 1).

7. Enter the amount of cement produced in the year.

8. Enter the SO2 default EF for cement production.9. Go to the Sectoral and Summary Tables and verify the emission report.

10 6.10

CO2 EMISSIONS FROM CEMENT PRODUCTION (TIER 2 METHOD)

ADD NOTE IN THE DOCUMENTATION BOX CLARIFYING HOW THE QUANTITY OF CLINKER PRODUCED WAS ESTIMATED

11 6.11

SO2 EMISSIONS FROM CEMENT PRODUCTION (TIER 1 METHOD)

12 6.12

CO2 AND SO2 EMISSIONS REPORT FROM THE CEMENT PRODUCTION IN THE SECTORAL TABLE

13 6.13

CO2 AND SO2 EMISSIONS REPORT FROM CEMENT PRODUCTION IN

THE SUMMARY REPORT TABLE

OBSERVE THAT THE SOFTWARE CALCULATES AUTOMATICALLY THE TOTAL NATIONAL EMISSIONS

14 6.14

CO2 AND SO2 EMISIONS FROM CEMENT PRODUCTION REPORT IN THE SHORT SUMMARY TABLE

15 6.15

SECTOR: INDUSTRIAL PROCESSESExercise 2.2: Cement Production (I)

Country A: Year: 2000Data Three Portland cement plants operate in the country. The

production data were collected directly from the plants. The data included information on CaO content of the clinker (67% average clinker lime percentage).

Each plant exported 20% of its annual production of clinker. All of the CaO was from a carbonate source.

Country Year Cement Production

(tonne)

Clinker

Production

(tonne)

Clinker

Exported

(tonne)

A 2000 1 052 600 1 199 964 199 994

16 6.16

SECTOR: INDUSTRIAL PROCESSESExercise 2.2: Cement Production (II)

Tasks


1. Calculate CO2 emissions using the Tier 2 method.

2. Verify the emissions report in the Sectoral and Summary Tables.


4. Print the used worksheets, the Sectoral Summary Tables and the Overview Table (8A).

17 6.17

SECTOR: INDUSTRIAL PROCESSESLimestone and Dolomite; Soda Ash

SECTOR: INDUSTRIAL PROCESSES (2)

UNFCCC - NAI

SOFTWARE

MAIN CATEGORIES

Tier 1: Worksheets

Remarks

Limestone and Dolomite Use

2-3s1 Estimate quantity of limestone or dolomite used. Adjust the default EF using the fractional purity (f) of limestone in CaCO3

- Good practice guidance has not yet been developed. After having obtained the EF, emissions can be calculated directly in the software. - Consumption is assumed to equal material mined plus material imported minus material exported. Alert: Exclude of calculation limestone or dolomite used for producing cement, lime and magnesium, agricultural activities and processes where CO2 is not generated.

Soda Ash Production and Use

2-4s1 (production) 2-4s2 (use)

- Good practice guidance has not yet been developed. If activity data are available then there is no difficulty in using the software to obtain the emissions. Alert: CO2 emissions associated with the use of coke in soda ash production should be accounted for separately and subtracted from the totals in the combustion section. - For most of the major uses it is assumed that for each mole of soda ash used, one mole of CO2 is emitted.

18 6.18

SECTOR: INDUSTRIAL PROCESSESProduction and Use of Mineral Products


UNFCCC - NAI SOFTWARE

MAIN CATEGORIES

Tier 1: Worksheets

Remarks

Asphalt Roofing

2-5s1(NMVOC) 2-5s2 (CO)

- Good practice guidance has not yet been developed. If activity data are available then there is no difficulty in using the software to obtain the emissions. The spreading of asphalt leads to NMVOC emissions.

Road Paving with Asphalt

2-5s3 (NMVOC) - Good practice guidance has not yet been developed. If activity data are available then there is no difficulty in using the software to obtain the NMVOC emissions (a conversion factor of 100 kg/asphalt/m2 road surface may be used). - There are not worksheets to estimate SO2, NOx and CO emissions from asphalt plants (EFs are provided in the Reference Manual). Suggestions: 1) For those gases make calculations outside of the software, 2) incorporate the results manually in the Sectoral Table and the Summary Tables of the Inventory, 3) add a note in the information box of Worksheet 2-5s3 clarifying the method used and results obtained.

19 6.19

SECTOR: INDUSTRIAL PROCESSESOther Mineral Products

SECTOR: INDUSTRIAL PROCESSES (4) UNFCCC -

NAI SOFTWARE

MAIN CATEGORIES

Tier 1: Worksheets

Remarks

Glass Production

2-5s4 NMVOC

Good practice guidance has not yet been developed. If activity data are available then there is no difficulty in using the software to obtain NMVOC emissions.

Concrete pumice stone

2-5s5 SO2 Good practice guidance has not yet been developed. If activity data are available then there are no difficulties in using the software to obtain SO2 emissions.

20 6.20

SECTOR: INDUSTRIAL PROCESSESAmmonia Production


UNFCCC -NAI SOFTWARE

MAIN CATEGORIES

Tier 1: Worksheets

Remarks

Ammonia Production

2-6s1 (Tier 1a CO2) 2-6s2 (Tier 1b CO2) 2-6s2 (Tier 1 NMVOC, CO, SO2)

Good practice guidance has not yet been developed. - The most accurate method (Tier 1a) is based on the consumption of gas (or oil). It is recommended to determine the carbon content of natural gas for each plant. - As an alternative, the emissions may be estimated based on ammonia production (Tier 1b; Tier 1). - If activity data are available then there is no difficulty in using the software to obtain emissions.

21 6.21

SECTOR: INDUSTRIAL PROCESSESNitric Acid, Adipic Acid Production


SOFTWARE MAIN

CATEGORIES Tier 1:

Worksheets

Remarks

Nitric Acid Production Adipic Acid Production

2-7s1 2-8s1

- To achieve the highest accuracy, estimate N2O emissions at the plant level using N2O generation and destruction factors (if abatement technologies are implemented). Nationally compiled production data may be used when plant-specific data are not available. - The worksheet of the software does not facilitate subtraction of the N2O destruction. Suggestions: 1) Make the calculation outside of the software, 2) incorporate the results manually in the Sectoral Table and the Summary Tables of the Inventory, 3) add a note in the documentation box of Tables 2-7s1 and 2-8s1 clarifying the method used and results obtained. - If no abatement technologies are implemented, use the software directly to estimate the emissions of N2O, NOx, NMVOC and CO. Alert: The N2O destruction factor for NSCR in Table 3.8 should not be applied to an emission estimate using the NSCR default generation factor.

22 6.22

SECTOR: INDUSTRIAL PROCESSESCarbide, Other Chemicals


SOFTWARE MAIN

CATEGORIES Tier 1: Worksheets

Remarks

Carbide Production Silicon Carbide 2-9s1, 2-9s2 (CO2 and CH4). Tier 1a based on consumption of petrol coke, carbon content in coke and carbon input sequestered in product. 2-9s3 Tier 1b based on Carbide production (CH4) Calcium Carbide 2-9s4 based on Carbide production

Good practice guidance has not yet been developed. If activity data are available then there is no difficulty in using the software to obtain emissions. Calcium Carbide Alert: In the case that lime is not produced in the plant, the emissions from the CaO step should be reported in the section “lime production”.

Production of Other Chemicals

2-10s1 to 2-10s5 (CH4, NOx, NMVOC, CO and SO2) A simple methodology is provided

Good practice guidance has not yet been developed. If activity data are available then there is no difficulty in using the software to obtain emissions. If necessary, add more lines to the worksheet.

23 6.23

SECTOR: INDUSTRIAL PROCESSESIron and Steel

SECTOR: INDUSTRIAL PROCESSES (7) Metal Production (2-11s1 to 2-11s11) UNFCCC - NAI

SOFTWARE MAIN


Tier 2 Methods Remarks

Iron and Steel 2-11s1 (CO2). The Tier 1 calculates emissions from the consumption of the reducing agent and using EF similar to those used to estimate combustion emissions.

2-11s3 (NOx, NMVOCs, CO and SO2

The Tier 2 method includes a correction for the carbon stored in the metals produced. With this method, emissions from iron production and steel production are calculated separately.

CO2 - If activity data are available then there are few difficulties encountered in using the software to obtain CO2 emissions (both using Tier 1 and Tier 2 method). Suggestions: - To estimate the emissions from iron and steel separately and obtain the total of emissions; do the calculations outside the software and incorporate the results manually into the Sectoral and Summary Tables. For steel produced in electric arc furnaces also add the carbon released from consumed electrodes. - Lime added to electric arc furnaces and its CO2 emissions should be accounted for in the lime use section. - When biomass carbon is used the emissions should be reported in the land-use change and forestry sector. Alert: The estimation of CO2 emissions based on production data and production base EF (Worksheet 2-11s2) is not considered to be good practice. Non-CO2 gases If activity data are available then there is no difficulty in using the software to obtain emissions.

24 6.24

SECTOR: INDUSTRIAL PROCESSESExercise 2.3: Iron and Steel Production (I)

Country A: Year: 2000

Data A plant producing iron and steel operates in the country. The data,

submitted directly by the plant, included only the iron/steel production and the amount of coke used as reducing agent (80,000 tonne). It was impossible to obtain more details about the chemical composition of the reducing agent and mineral used.

Country Year Iron/steel production (tonne)

A 2000 200 000

25 6.25

SECTOR: INDUSTRIAL PROCESSESExercise 2.3: Iron and Steel Production (II)

Tasks


1. Calculate CO2 emissions.

2. Verify the emissions reported in the Sectoral and Summary Tables.


26 6.26

SECTOR: INDUSTRIAL PROCESSESExercise 2.3: Iron and Steel Production (III)

Steps

1. Open the software and select in the Industrial Processes sector Worksheet 2-11-1 for Metal Production (because detailed data for reducing agents are not available use the Tier 1 Method. This method slightly overestimates emissions; 1–10%)

2. Enter the mass of reducing agent used (80,000 tonne).

3. Because country-specific data at the plant level are not available use the default EF for reducing agents in pig iron production (3.1 tonne CO2/tonne reducing agent).

27 6.27

SECTOR: INDUSTRIAL PROCESSESExercise 2.3: Iron and Steel Production (IV)

Steps

4. Estimate CO2 emissions.

5. Add note in the information box explaining that it was impossible to obtain more details about the chemical composition of the reducing agent and mineral used and for this reason the correction of column C is not applied.

6. Go to the Sectoral and Summary Tables and verify the reported emissions estimates.

7. Verify that the quantity of coke used as reducing agent was subtracted from the Fuel Combustion sector.

Note: Tier 2 is more accurate but also more data-intensive. Includes a correction for the carbon stored in the metals produced.

28 6.28

CO2 EMISSIONS FROM IRON AND STEEL PRODUCTION

NOTE IN THE DOCUMENTATION BOX

29 6.29

CO2 EMISSIONS FROM IRON AND STEEL PRODUCTION IN THE SECTORAL REPORT TABLE

30 6.30

CO2 EMISSIONS FROM IRON AND STEEL PRODUCTION IN THE SUMMARY REPORT TABLE

31 6.31

SECTOR: INDUSTRIAL PROCESSESFerroalloys


SOFTWARE MAIN


Remarks

- Ferroalloys 2-11s4 (for Tier 1b based on amount of ferroalloy produced). 2-11s1 (for Tier 1a if the quantity of reducing agent is known).

CO2 - The software only has the worksheet for the Tier 1b method. - It is most accurate to calculate the emissions using the Tier 1a method. Suggestion: - For the Tier 1a method make the estimation in Worksheet 2-11-1. Please only fill EITHER sheet 2-11s1 OR 2-11s4. - When biomass carbon is used the emissions should be reported in the Land-use Change and Forestry sector.

32 6.32

SECTOR: INDUSTRIAL PROCESSESAluminium, Other Metals, SF6 in Foundries


SOFTWARE MAIN


Tier 2 Methods

Remarks

Aluminium CO2 2-11-s1 for Tier 1a if quantity of reducing agent is known. 2-11s5 Tier 1b CO2 based on amount of aluminium produced PFC (CF4 and C2F6) -2-11s6 and 2-11s7 Tier 1b PFCs Calculation of Emission Data -2-11s8 and 2-11s9 Tier 1c Estimated Emission Data -2-11s10 NOx, CO, SO2

PFC If smelter- specific measurements are unavailable, default coefficients by technology type may be used.

PFCs (CF4 and C2F6) - Tier 1: The simplest method is to multiply default EF by Aluminium production. The Tier 1 c = Tier 1 (GPG200) method should be used only when no measured data exist (emissions vary significantly from one smelter to the next). - The software only has the worksheets for the Tier 1 method (2-11s8 and 2-11s9). Suggestion: For the Tier 2 method make the estimation outside the software and incorporate the results manually into the Sectoral and Summary Tables. Add a note in the documentation box of Tables 2-11s8 and 2-11s9 clarifying the method used and results obtained. NOx, CO, SO2 If the amount of aluminium produced is known then there is no difficulty in using the software to obtain the emissions.

33 6.33

SECTOR: INDUSTRIAL PROCESSESAluminium, Other Metals, SF6 in Foundries


SOFTWARE MAIN


Remarks

Other Metal Production (all non-ferrous metals except Aluminium)

Tier 1a and Tier 1b CO2 -The software does not have specific worksheets for this. Suggestion: - Use Worksheet 2-11s1 based on the consumption of reducing agents and the carbon content. Category ‘Other’. - Add more lines to this worksheet if necessary. Verify the total result (link) in the Sectoral and Summary Tables. Include any necessary explanations in the documentation box.

SF6 used in Aluminium and Magnesium Foundries

Tier 1 2-11s11

- SF6 emissions equal consumption. If the amount of SF6 consumed is known then there are is no difficulty in using the software to obtain the emissions. - Consumption is defined as the use of SF6 as a cover gas.

34 6.34

SECTOR: INDUSTRIAL PROCESSESPulp and Paper, Food and Drink


SOFTWARE MAIN

CATEGORIES Tier 1:

Worksheets

Remarks

Pulp and paper Industries

2-12s1 to 2-12s2 Good practice guidance has not yet been developed. If the annual quantity of air-dried pulp produced by pulp process type is available then there is no difficulty in using the software to obtain the NOx, NMVOC, CO and SO2 emissions.

Food and Drink 2-13s1 to 2-13s2 Good practice guidance has not yet been developed. If the annual quantity of alcoholic beverage produced, by category of beverage, and the annual quantity of food produced, by category of food, are available then there is no difficulty in using the software to obtain the NMVOC emissions.

35 6.35

SECTOR: INDUSTRIAL PROCESSESProduction of HFCs, PFCs, SF6


UNFCCC -NAI

SOFTWARE

MAIN CATEGORIES

Tier 1: Worksheets

Tier 2 Methods

Remarks

Emissions Related to Production of HFCs, PFCs and SF6

2-14s1 to 2-14s2

No worksheets are provided for Tier 2.

- The software only facilitates the estimation with the simplest methods. Use Worksheet 2-14s1 for emissions of by-products and 2-14s2 for fugitive emissions. The IPCC Guidelines do not provide a default EF for inadvertent losses during production and handling of SF6. Suggestion: For the Tier 2 method make the estimation outside the software and incorporate the results manually into the Sectoral and Summary Tables. Add a note in the documentation boxes of Tables 2-12s1 and 2-14s2 clarifying the method used and results obtained.

36 6.36

SECTOR: INDUSTRIAL PROCESSESConsumption of HFCs, PFCs, SF6


UNFCCC - NAI

SOFTWARE

MAIN CATEGORIES

Tier 1: Worksheets

Tier 2 Methods

Remarks

Emissions Related to Consumption of HFCs, PFCs and SF6

2-15s1 to 2-15s3 for Tier 1a and Tier 1b (potential approach).

Tier 2. 2-15s4 to 2-15s13.

- The emissions occur as leakage from the chemicals used in different types of equipment and due to the destruction of such equipment after use. The software only facilitates the estimation with the simplest methods, both potential (Tier 1 method) and actual (Tier 2 method) - Potential bulk halocarbon emission (2-15s1) - Potential product halocarbon emission (2-15s2) - Total potential halocarbon emission (2-15s3) Tier 2. Contains actual emissions calculations for each individual chemical (bottom-up or top-down).

37 6.37

SECTOR: INDUSTRIAL PROCESSESExercise for self evaluation 1: GHG Emissions from

different industrial processes (I)

Country A: Year: 2000.

Data The National Statistics Office provided production

data of several industrial processes. Determine GHG emissions from those processes using the Tier 1 Method and the UNFCCC–NAI Software.

Verify the emissions reported in the Sectoral and Summary Tables.

38 6.38

SECTOR: INDUSTRIAL PROCESSESExercise for self evaluation 1: GHG Emissions from different

industrial processes (II)

COUNTRY A: YEAR 2000. PRODUCTION DATA OF SEVERAL INDUSTRIAL PROCESSES

PROCESS PRODUCTION EMISSION FACTOR

Quicklime 82 300 t 0.75 t CO2/t quicklime

Glass 7 173.04 t 4.5 kg NMVOC/t glass

Calcium Carbide 8 279.30 t 1.8 t CO2/t carbide

Alcoholic Beverages

Wine 155 900 hl 0.08 kg NMVOC/hl

Beer 2 136 100 hl 0.035 kg NMVOC/hl

Spirits (Rum) (*) 594 100 hl 15 kg NMVOC/hl

Foods

Bread 464 100 t 8 kg NMVOC/t

Cookies 21 400 t 1 kg NMVOC/t

Coffee roasting 20 500 0.55 kg NMVOC/t

Sugar 4 165 200 t 10 kg NMVOC/t

(*) The emission factor for the rum is based on the alcoholic content of the beverage (40% in this case). Take into account this fact and incorporate note in the documentation box in the corresponding worksheet.

39 6.39

SECTOR: INDUSTRIAL PROCESSESExercise for self evaluation 1: GHG Emissions from different

industrial processes (III)

RESULTS

PROCESS EMISSION

Quicklime 61.73 Gg CO2

Glass 0.03 Gg NMVOC

Calcium Carbide 14.9 Gg CO2

Alcoholic Beverages 3.65 Gg NMVOC

Foods 45.4 Gg NMVOC

6.40

Thank you

6.1 1 UNFCCC – NAI SOFTWARE Sector: Industrial Processes Practical Aspects and Exercises CGE...

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