Energy management and efficiency — A systems approach

Today´s economic and environmental climate calls for efficient energy consumption and management. Cement manufacturing is an energy intensive process requiring significant thermal and electrical energy components; these components account for 35% of US manufacturing costs. Energy management should be a core activity in a company´s business plans. Implementation, in a systems approach, is required to achieve energy efficiency, environmental improvement, and sustainable development. Assessing plant performance and identifying efficiency opportunities are paramount. Electrical energy costs are about 50% of the total energy cost of cement manufacturing, motivating companies to employ various strategies to combat these rising costs. Often, management programs consist of simple motor replacement plans aimed at increasing the overall efficiency of a plant´s installed motor base. These programs can take years to implement and are often scrutinized during economic downturns. To show immediate progress, a systems based approach is required. This paper will describe the common traits displayed in successful, systems based energy management. A cement specific application, the belt driven clinker cooler fan, will be used as an example of how this approach can improve efficiency, maximize the use of limited resources and enhance project success.