Industrial strategies to help reduce energy consumption: A holistic approach for cement producers

Cement producers have faced a significant rise in energy costs with the introduction of dry-process kilns, with a record average consumption of 100-200 kwh per ton of cement (The Cement Plant Operations Handbook, 2009*). This complex challenge, coupled with rising fuel and energy costs, has prompted cement manufacturers to implement energy management programs to help reduce costs while maintaining competitiveness and increasing profits. This paper will review how many cement producers have reduced energy costs by adopting innovative sustainability programs. A holistic approach teaches a simple five-step process: audit, monitor; analyze; control and optimize. This practice helps customers to identify cost saving measures and evaluate the tools available which are best suited to their specific plant needs: power and energy management systems; variable frequency drives; model predictive control systems; energy audits; and others. Learn how other cement producers have reduced their energy costs by up to 20 percent by finding and eliminating operating inefficiencies, modifying equipment, driving energy efficiency in product design and modifying processes. Obtain the tools necessary to expand plant operations to include comprehensive energy management programs that will quickly provide measurable results and remarkable cost savings.