Energy Consumption and Greenhouse Gas Emission from Ceramic Tableware Production: A Case Study in Lampang, Thailand 1876-6102 © 2015 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/). Peer-review under responsibility of the Organizing Committee of 2015 AEDCEE doi: 10.1016/j.egypro.2015.11.483 Energy Procedia 79 ( 2015 ) 98 – 102 ScienceDirect 2015 International Conference on Alternative Energy in Developing Countries and Emerging Economies Energy Consumption and Greenhouse Gas Emission from Ceramic Tableware Production: A Case Study in Lampang, Thailand Panatda Riyakada, Siriluk Chiarakorna* aDivision of Environmental Technology School of Energy, Environment and Materials King Mongkut’s University of Technology Thonburi, Bangkok 10140, Thailand Abstract This paper presents energy consumption and greenhouse gas (GHG) emission from ceramic tableware production in Lampang, Thailand. All data of energy consumption in ceramic production were collected from a small enterprise manufacturing plant and the unit of analysis was 1 kg of product. A scope of study was gate to gate. The amount of GHG emission in a unit kgCO2e/kg of product was calculated by 2006 IPCC Guidelines for National Greenhouse Gas Inventories method and the emission factors were referred from Thailand Greenhouse Gas Management Organization (TGO) and IPCC databases. The results showed that the total energy consumption from ceramic tableware production was 24.28 MJ/kg of product and almost 98% of total energy consumption was from liquefied petroleum gas (LPG) consumption during firing. The amount of GHG emission was 0.237 kgCO2e/kg of product. The glost firing was found to be a hotspot of energy consumption and GHG emission. © 2015 The Authors. Published by Elsevier Ltd. Peer-review under responsibility of the Organizing Committee of 2015 AEDCEE. Keywords: energy consumption, greenhouse gas emission, ceramic tableware,ceramic production, Lampang * Corresponding author. Tel.: +66 2 470 8654; fax: +66 2 470 8660. E-mail address: Siriluk.chi@kmutt.ac.th (S.Chiarakorn). Available online at www.sciencedirect.com © 2015 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/). Peer-review under responsibility of the Organizing Committee of 2015 AEDCEE http://crossmark.crossref.org/dialog/?doi=10.1016/j.egypro.2015.11.483&domain=pdf http://crossmark.crossref.org/dialog/?doi=10.1016/j.egypro.2015.11.483&domain=pdf Panatda Riyakad and Siriluk Chiarakorn / Energy Procedia 79 ( 2015 ) 98 – 102 99 1. Introduction Ceramic industry is one of the important industries of Thailand. The revenues from ceramic industry has been increasing up to 20,000 million baht per year [1]. Main ceramic products consists of ceramic tiles, sanitary wares, gift and decorations, tablewares and insulators. Among all products, tablewares ranked the most exported ceramic product, contributed for 36.74% of total exported ceramic products in Thailand, followed by sanitary ware (27.06%) and ceramic tiles (24.03%) [2]. In Thailand, there are approximately 100 ceramic tableware producers but more than 50% are located in Lampang, Northern Thailand [3]. It is widely known that the most famous product, “Cham tra kai” a ceramic tableware with a hen design, is the signature of Lampang. But nowadays, Lampang ceramic industry has suffered from energy crisis because the cost of energy has been continuously increasing. As a result, many small plants have been shut down. Ceramic production are energy intensive because firing process requires the temperature ranged from 800 – 2000 °C [4]. Ceramic production is not only one of industry that consumes high energy but also emits large amount of greenhouse gases (GHG) which cause global warming [5]. However, the database of energy consumption as well as GHG emissions from ceramic tableware production have not been available. Therefore, this research aimed to evaluate the energy consumption and GHG emission of ceramic tableware production from a small enterprise manufacturing plant in Lampang, Thailand. The hotspots of energy consumption and GHG emission were identified. The output results could be useful information for energy conservation and GHG management in ceramic tableware production. Fig. 1. A stoneware plate (7-inch diameter) selected in this study 2. Methodology The activities data were collected from a small enterprise manufacturing plant in Lampang, Thailand. The 7-inch stoneware (Fig.1) was selected as an example in this study. The average weight of the plate was 0.41 kg/piece. The forming process was jiggering method. A jiggering machine was shown in Fig 2. A scope of this study was gate to gate. The energy consumption and GHG emission in each manufacturing process were analysed, based on the functional unit of 1 kg product. The amount of GHG emission was calculated by IPCC 2006 method. The emission factors were from TGO and IPCC databases as presented in Table 1. The GHG emission in a unit of kgCO2e/kg of product was calculated by Eq. (1) [6] and Eq. (2) [7]. The Eq. (1) was used to calculate amount of GHG emission from energy consumption (electricity and LPG). The Eq. (2) was used to calculate amount of carbon dioxide emission from decomposition of CaCO3. In this study, the calcination fraction (f) was unknown and the method from IPCC(2006) recommended using f value as 1.00 for the calculation. 100 Panatda Riyakad and Siriluk Chiarakorn / Energy Procedia 79 ( 2015 ) 98 – 102 (1) EF (unit) dataActivity Emission GHG where EF = emission factor, kgCO2e/unit (2) FEFM CaCO ofion decomposit from Emissions CO 3CaCO32 where EFCaCO3 = emissions factor for the particular carbonate, tonnes CO2/tonne carbonate M = weight or mass of the carbonate, tonnes F = fraction calcination achieved for the carbonate, fraction Fig. 2. A jiggering machine used in this study Table 1. The emission factors used in this study Activity data Unit Emission factor References Liquefied petroleum gas (LPG) kg 0.4122 kgCO2e/unit [8] Electricity kWh 0.6093 kgCO2e/unit [8] Calcium carbonate (CaCO3) tonne carbonate 0.43971 tonnes CO2/ unit [7] * 1 tonne = 1000 kg 3. Ceramic tableware production The production processes of stoneware plate was presented in Fig.3. The clay was purchased from clay manufacturer. Then, the products were formed by jiggering method and dried at room temperature. After drying, the products were loaded on shuttle kiln for a first firing at 800 °C for 5 h, called biscuit firing. The next step was glazing, the products were covered with thin glaze layer. After that, the glazed plates were loaded into shuttle kiln for glost firing at 1,220°C for 8 h. Both firing processes used LPG. Finally, the final products were conveyed to the quality checking and classified the quality level as either Grade A, Grade B or another Grades. Panatda Riyakad and Siriluk Chiarakorn / Energy Procedia 79 ( 2015 ) 98 – 102 101 Fig. 3. Production process of a stoneware plate 4. Results and Discussion The total energy consumption of ceramic tableware production was 24.28 MJ/kg of product, contributed by electricity only 1.11% and LPG 98.89%. The energy consumption and GHG emission from each process are shown in Table 2. Major energy sources consumed in ceramic tableware production were from electricity and LPG. The electricity consumption was only from forming process (0.27 MJ/kg of product) and LPG consumption was used for combustion in biscuit firing process (7.44 MJ/kg of product) and glost firing process (16.57 MJ/kg of product). Thus, glost firing process was determined as a hotspot of energy consumption, accounted for 68.25% of total energy consumption. The GHG emissions from ceramic tableware production were from the consumption of energy (electricity and LPG) and the decomposition of calcium carbonate (CaCO3) during glost firing, CaCO3 was one of glaze materials composition. Total GHG emission was 0.237 kgCO2e/kg of product. From Fig.4, the largest GHG emission was from LPG during biscuit and glost firing (80.97%), followed by electricity consumption (18.62%) and decomposition of calcium carbonate (0.41%). Similar to the energy hotspot, glost firing process was also found to be the hotspot of GHG emission with the largest share of 56.28% of total GHG emissions. Thus, the energy conservation and GHG mitigation options for ceramic tableware production should be focused in glost firing process. Table 2. Energy consumption and GHG emission (per 1 kg of product) Unit Process Energy Consumption GHG Emission Electricity (MJ/ kg of product) LPG (MJ/ kg of product) Total (MJ/ kg of product) % kgCO2e/kg of product % Forming 0.27 0 0.27 1.11 0.046 18.62 Drying 0 0 0 0 0 0 Biscuit firing 0 7.44 7.44 30.64 0.062 25.10 Glazing 0 0 0 0 0 0 Glost firing 0 16.57 16.57 68.25 0.138a+0.0009b 55.87a+0.41b QC/packing 0 0 0 0 0 0 Total 0.27 24.01 24.28 100 0.237 100 aFrom LPG consumption bFrom decomposition of calcium carbonate 102 Panatda Riyakad and Siriluk Chiarakorn / Energy Procedia 79 ( 2015 ) 98 – 102 Fig. 4. Percentages of GHG emissions divided by sources from a stoneware plate production (gate to gate) 5. Conclusion The total energy consumption from a 7-inch stoneware plate production was 24.28 MJ/kg of product and almost 98% of total energy consumption was from LPG consumption during firing. The amount of GHG emission was 0.237 kgCO2e/kg of product. The shares of GHG emissions were from LPG (80.97%), electricity consumption (18.62%) and decomposition of calcium carbonate (0.41%). Glost firing was found to be a hotspot of energy consumption and GHG emission. Acknowledgements The authors would like to express to their gratitude to the National Research Council of Thailand (NRCT) for financial support. The authors would like to thank Chupra Co., Ltd. for their kind collaboration in data collection and field survey. The authors also thank Lampang Ceramic Association (LCA) for their kind collaboration and supports. References [1] Lathulee T, Thongprasert S, Thongprasert M. Energy efficiency study in ceramic industry. IE Network 2007; 345-350. [2] The Office of Industrial Economics. Industrial economic reports; 2013. available online: http://www.oie.go.th. [3] Department of Industrial Works. Standard industrial classification (Thailand) Tsic 2014. available online: http://www.diw.go.th. [4] Quinteiro P, Araújo A, Dias AC, Oliveira B, Arroja L. Allocation of energy consumption and greenhouse gas emissions in the production of earthenware ceramic pieces. Journal of Cleaner Production 2012; 31: 14-21. [5] Peng J, Zhao Y, Jiao L, Zheng W, Zeng L. CO2 emission calculation and reduction options in ceramic tile manufacture: the Foshan case. Energy Procedia 2012; 16: 281-304. [6] Intergovernmental Panel on Climate Change (IPCC). IPCC Guidelines for National Greenhouse Gas Inventories 2006. available online: http://www.ipcc-nggip.iges.or.jp/public/2006gl. [7] Hanle L, Maldonado P, Onuma E, Tichy M, Oss HG. Chapter 2: Mineral industry emissions. 2006 IPCC Guidelines for National Greenhouse Gas Inventories, 3, 2006, pp.2.35. [8] Thailand Greenhouse Gas Management Organization (TGO). Emission factor CFP 2014. available online: http://thaicarbonlabel.tgo.or.th/carbonfootprint/index.php?page=9.