An overview of energy savings measures for cement industries

Madlool, N.A.; Saidur, R.; Rahim, N.A.; Kamalisarvestani, M.

doi:10.1016/j.rser.2012.10.046

Cited by 153 publications

(74 citation statements)

References 42 publications

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“…Regarding the waste produced, it should ideally be recycled to reduce the consumption of natural resources. The effectiveness of these measures has been demonstrated in the literature (Brunke and Blesl, 2014;Habert et al, 2010;Ishak and Hashim, 2014;Madlool et al, 2013;Mikulcic et al, 2015;Schneider et al, 2011;Woodward and Duffy, 2011). These studies comprehensively discussed various energy saving measures and their potential for reducing CO 2 emissions from the manufacture of cement.…”

Section: Materials Efficiency Of Unit or Stagementioning

confidence: 99%

Analysis of material flow and consumption in cement production process

Tianming

Shen

et al. 2016

Journal of Cleaner Production

115

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a b s t r a c tCement production, which is highly dependent on the availability of natural resources, will face severe resource constraints in the future. This is especially true for the cement industry in China. Thus, the industry is focusing on reducing the consumption of natural resources at both the manufacturing and operational stages. The aim of this article is to improve the management of resources used in the cement production process and mitigate their environmental effects. First, material flow routes for the cement manufacturing process are established, after which three mass balances are built during the three production stages using actual plant data received from an existing cement manufacturing facility. Finally, the material efficiency of the units and stages as well as the waste recycle rates during these stages is calculated. The results show that approximately 2.48 t, 4.69 t, and 3.41 t of materials are required to produce a ton of the product in raw material preparation, clinker production, and cement grinding stages, and their waste rates are 63.31%, 74.12%, and 78.89%, respectively. The recycling rate of wastes during clinker production is remarkably higher than those during other manufacturing stages, wherein waste gases are directly discharged into the atmosphere. The material efficiency values for a raw mill, pyro-processing tower, rotary kiln, clink cooler, and cement mill are determined to be 36.69%, 34.24%, 39.24%, 29.76%, and 25.88%, respectively, whereas the waste recycling rates for these units are found to be 16.33%, 81.98%, 100.00%, 99.53%, and 0.00% respectively. These results will provide researchers with knowledge regarding the effectiveness and efficient use of natural resources in the cement sector. These important findings can also be used to influence the development of national and industrial policies in relation to the goal of achieving sustainable development in the cement industry.Crown

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Section: Materials Efficiency Of Unit or Stagementioning

confidence: 99%

Analysis of material flow and consumption in cement production process

Tianming

Shen

et al. 2016

Journal of Cleaner Production

115

View full text Add to dashboard Cite

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“…(8), the power (P) is equal to 58.7 KW. Therefore, it was proposed to replace the fans with suitable variable speed ones to reduce the electrical energy consumption [7,8]. The relation between flow (Q), speed (N) and power (P) for fans and pumps are shown in Eqs.…”

Section: Quality Parametersmentioning

confidence: 99%

“…Then they proposed several saving methods related to different energy sources based on energy assessment and economical studies. The results showed 25% reduction of total energy consumption.In this paper, implementation of proper energy saving actions in an Iranian cement production plant was studied and several useful methods were suggested to improve energy consumption, since cement industry is considered to be one of the most energy intensive industries [7,8]. Establishment of proper saving actions is necessary to facilitate energy performance along with execution of national standard, ISIRI 7873 [9].…”

mentioning

confidence: 99%

Energy consumption assessment in a cement production plant

Afkhami

Akbarian

Beheshti³

et al. 2015

Sustainable Energy Technologies and Assessments

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“…About 40% of the total input energy is lost in hot flue gases, cooling the stack and kiln shell ( Figure 1) (Trezza and Scian 2005). Hence, heat recovery and utilization is essential to improve the whole process (Madlool et al 2013).…”

Section: Energy Conservationmentioning

confidence: 99%

Energy conservation and waste utilization in the cement industry serve the green technology and environment

Najjar

Waite

2014

International Journal of Sustainable Engineering

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The cement industry is one of the most energy-intensive industries consuming 4 GJ/ton of cement, i.e. 12 -15% of the energy use in total industry. Energy cost accounts for 30% of the total cost of cement production. Seventy-five per cent of this energy is due to the thermal energy for clinker production. It is also found that 35% of this supplied thermal energy is lost in flue gas streams. Most modern kilns use pet coke or coal as their primary fuel. Instead, the municipal waste in landfills offer a cheap source of energy and reduce the environmental effects of dumping solid waste. The calcination and drying processes and the kiln need large quantities of thermal energy. About 40% of the total energy input is lost in the hot flue gases and cooling the stack plus the kiln shell. Hence, it is suitable to use an organic Rankine cycle (ORC) to recover the exhaust energy from the kiln. Alternatively, a 15 MW gas turbine engine combined with a steam turbine could be utilized. It was found that ORC produces 5 MW with a capital cost recovery period of 1.26 years. However, the gas turbine combined system produces 21.45 MW with a maximum recovery period of 2.66 years.

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An overview of energy savings measures for cement industries

Cited by 153 publications

References 42 publications

Analysis of material flow and consumption in cement production process

Analysis of material flow and consumption in cement production process

Energy consumption assessment in a cement production plant

Energy conservation and waste utilization in the cement industry serve the green technology and environment

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