Environment
Saving Electrical Energy
Published
4 years agoon
By
admin
The major cost factor in a cement factory is no longer the primary fuel but electric energy, due to the increasing use of secondary fuels, Although many energy-saving measures have already been considered and implemented, the search for further solutions continues to counter increasing power costs. Siemens suggests some areas to consider.
New and upcoming solutions, which were developed in other industries such as paper, chemical and steel, can be easily adapted to the cement sector. There are low-cost solutions which can be financed from the opex budget, while the larger investments will require a capex evaluation. Siemens is continually searching for new ways to save energy and advises cement producers to consider several areas in the plant which offer potential to further reduce electricity consumption. Figure 1 shows the typical investment costs and the expected ROI period for variable-speed drives (VSD), IE2- IE3 motors instead of IE1-motors (IE), optimising auxiliary equipment (AUX), continuous vibration monitoring (VIB), total harmonic distortion check (THD), management information system (MIS), secondary fuel management (FM), mill control optimisation system (MCO) and waste heat recovery and power generation (WHR).
Variable speed control If flow of processed air is presently being controlled using a damper, a variable speed drive can save energy because at lower speeds, less energy is drawn from the grid (see Figure 2). This energy-saving method is already typically used for larger drives. However, since small frequency inverters are more affordable today, every attempt should be made to save energy in this power range. Furthermore, many of the belt conveyors in a cement plant can run at lower speeds and still transport material. Low motor speeds will also reduce wear on the mechanical system. It is important to ensure that the drive motor is suitable for frequency inverter operation. Normally, an insulated bearing in the motor is sufficient potential by reducing operation speed.
International efficiency motors
Extensive legislation on energy efficiency has been passed in the EU with the objective of reducing energy usage in the private and industrial sectors, and therefore reducing overall CO2 emissions. The new IE2_IE3 motors have higher efficiencies than IE1 motors (see Figure 3). Since electric power costs are much higher than capital investment costs for motors, a typical ROI period is within two years. The EU directive for the new IE motors has been in place since June 2011, and the high quantities of small motors in a cement plant represent an ideal potential for slashing energy consumption as motor efficiencies can be increased drastically in this area. As a result, it is more cost effective to replace a number of small motors than one big motor (see Figure 4). If an existing motor is to be replaced, the higher efficiency class motor will have a payback time of between 1.5 and three years.
Optimising auxiliary equipment
A complex cement plant often means that extensive auxiliary equipment is required, eg pressurised air supply, cooling water and process water, which could be linked together to increase availability. The capacity of these sections is normally oversized since they are calculated for worst-case conditions. However, this equipment frequently operates in idling mode. Therefore, speed can be controlled to match actual consumption. This reduces power consumption, and therefore reduces energy consumption for these high numbers of auxiliary units with a low power rating. If necessary, the next step is to evaluate reducing the total number of auxiliary units. When it comes to lighting process areas, LED floodlights can slash power consumption by 80 per cent. In addition, all lighting systems should be intelligently controlled to reduce energy consumption even more. A detailed on-site review of an entire cement plant will bring to light potential opportunities for saving energy.
Continuous vibration monitoring
Energy can also be saved by keeping the plant operational, because ultimately, the most important value to be considered is the kW/t of cement produced. Therefore, all measures should be taken to guarantee continuous operation. Unplanned downtimes negatively affect plant efficiency as start-up procedures are unproductive and costly. Continuously monitoring the vibration of all units especially the bearings of all machines is extremely important (see Figure 5). It is essential to ensure that all parts are replaced before equipment fails, and, therefore, that spare parts are available on-site in the required time. If part of the production facility is down due to damaged equipment, all efforts must be made to resume operation as soon as possible. This is why it makes sense to invest in advance, and avoid unscheduled downtimes.
Total Harmonic Distortion (THD)
The increased use of variable speed drives in a cement plant will save energy but can also result in a higher harmonics in the electrical network. These increase losses in other connected loads and more power is consumed.
Furthermore, harmonics in the network also reduce the service life of many consumers. Power utility companies stipulate stringent limits on the harmonics generated by the electrical equipment in a cement plant. As a consequence, periodic checking of the THD level in a cement plant will show whether the equipment is still working within its limits. If the value is too high, a harmonic filter (ie a tuned power-factor-compensation unit) should be installed to reduce the THD value in the power supply. A periodic check will also show if measures should be taken to keep the THD within its limits. Siemens recommends a check every four years.
Combining MIS reports with EMS
The Energy Management System (EMS) archives energy data from each department. It evaluates data to identify energy trends, time overlay trends and key performance indicators. A plant can reduce energy consumption based on analysis of historical data.
Furthermore, the data allows forecasts to be made about future energy consumption. At the same time, demand can be tracked and, when necessary, controlled.
For instance, typically, a mill section of a cement factory should not consume any energy when the mill is switched off. This can easily be checked using a Management Information System (MIS) report.
MIS continuously monitors on cement kiln line power consumption, and if consumption is higher than normal, this could mean that a component has failed. The report helps identify a pending failure, and allows time for the necessary corrective measures to be implemented. In short, continuous evaluation of MIS reports can help save energy and detect potential equipment failures.
Secondary fuel management
Due to decreasing resources and increasing market prices for primary fuels such as oil, gas or coal, cement manufacturers must search for alternative energy sources. Currently, available secondary fuels include tyres, plastics, waste paper, waste oil, industrial waste, Tetrapak, old carpets, foam plastics, animal waste, wood shred, etc. All these secondary energy sources have different heat capacities. A kiln that has a high percentage of secondary fuels will operate at higher temperatures. Energy management to handle up to ten different fuels is becoming increasingly important, as secondary fuel costs have risen tremendously (these were previously free). Many secondary fuels result in changes in exhaust gas, clinker characteristics and kiln temperatures. A secondary fuel control management system to plan steady and continuous kiln operation can be implemented, based on Siemens standard CEMAT/PCS7 function blocks in the DCS or as a stand-alone system (see Figure 6).
Mill control system
Mill Control Optimisation (MCO) provides additional possibilities to improve grinding and mill efficiency. The system shortens the start-up phase and allows the mill to operate stably at maximum production levels. To operate the plant with a low electrical energy tariff, mills must be started and stopped. This means it is necessary to ensure a smooth and efficient start-up, as it will reduce the energy consumption per tonne of ground material. The MCO can operate as a standalone system or fully integrated CEMAT/PCS7 application in PLCs (see Figure 7). The system especially helps night shift operators, when there is only a few personnel staffing the central control room.
Waste heat recovery
Hot process gases produced from a kiln contain thermal energy, which is normally used for other process areas such as the raw or coal mill. Although this allows energy to be saved, the use of excess thermal energy can still be optimised. The excess energy can be converted into electrical energy (see Figure 8). The gases from the pre-heater tower and from the cooling area are used to generate high- pressure steam in boilers. A steam turbine drives a synchronous generator, which in turn feeds electrical energy back into the medium-voltage system of a cement plant. Optimum results can only be achieved based on a tailor-made system, which also takes into consideration any future cement plant modifications. Siemens provides cement manufacturers with continuous and ongoing assistance to identify a plant’s energy-saving requirements. Only through continuous energy-saving solutions can cement plants be optimised on a sustainable basis.
If flow of processed air is presently being controlled usinga damper, a variable speed drive can save energy.
The increased use of variable speed drives in a cement plant will save energy but can also result in a higher harmonics in the electrical network.
Maarten Holland & Karen Chong, Siemens, Germany
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Reclamation of Used Oil for a Greener Future
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6 days agoon
June 16, 2025By
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In this insightful article, KB Mathur, Founder and Director, Global Technical Services, explores how reclaiming used lubricants through advanced filtration and on-site testing can drive cost savings, enhance productivity, and support a greener industrial future. Read on to discover how oil regeneration is revolutionising sustainability in cement and core industries.
The core principle of the circular economy is to redefine the life cycle of materials and products. Unlike traditional linear models where waste from industrial production is dumped/discarded into the environment causing immense harm to the environment;the circular model seeks to keep materials literally in continuous circulation. This is achievedthrough processes cycle of reduction, regeneration, validating (testing) and reuse. Product once
validated as fit, this model ensures that products and materials are reintroduced into the production system, minimising waste. The result? Cleaner and greener manufacturing that fosters a more sustainable planet for future generations.
The current landscape of lubricants
Modern lubricants, typically derived from refined hydrocarbons, made from highly refined petroleum base stocks from crude oil. These play a critical role in maintaining the performance of machinery by reducing friction, enabling smooth operation, preventing damage and wear. However, most of these lubricants; derived from finite petroleum resources pose an environmental challenge once used and disposed of. As industries become increasingly conscious of their environmental impact, the paramount importance or focus is shifting towards reducing the carbon footprint and maximising the lifespan of lubricants; not just for environmental reasons but also to optimise operational costs.
During operations, lubricants often lose their efficacy and performance due to contamination and depletion of additives. When these oils reach their rejection limits (as they will now offer poor or bad lubrication) determined through laboratory testing, they are typically discarded contributing to environmental contamination and pollution.
But here lies an opportunity: Used lubricants can be regenerated and recharged, restoring them to their original performance level. This not only mitigates environmental pollution but also supports a circular economy by reducing waste and conserving resources.
Circular economy in lubricants
In the world of industrial machinery, lubricating oils while essential; are often misunderstood in terms of their life cycle. When oils are used in machinery, they don’t simply ‘DIE’. Instead, they become contaminated with moisture (water) and solid contaminants like dust, dirt, and wear debris. These contaminants degrade the oil’s effectiveness but do not render it completely unusable. Used lubricants can be regenerated via advanced filtration processes/systems and recharged with the use of performance enhancing additives hence restoring them. These oils are brought back to ‘As-New’ levels. This new fresher lubricating oil is formulated to carry out its specific job providing heightened lubrication and reliable performance of the assets with a view of improved machine condition. Hence, contributing to not just cost savings but leading to magnified productivity, and diminished environmental stress.
Save oil, save environment
At Global Technical Services (GTS), we specialise in the regeneration of hydraulic oils and gear oils used in plant operations. While we don’t recommend the regeneration of engine oils due to the complexity of contaminants and additives, our process ensures the continued utility of oils in other applications, offering both cost-saving and environmental benefits.
Regeneration process
Our regeneration plant employs state-of-the-art advanced contamination removal systems including fine and depth filters designed to remove dirt, wear particles, sludge, varnish, and water. Once contaminants are removed, the oil undergoes comprehensive testing to assess its physico-chemical properties and contamination levels. The test results indicate the status of the regenerated oil as compared to the fresh oil.
Depending upon the status the oil is further supplemented with high performance additives to bring it back to the desired specifications, under the guidance of an experienced lubrication technologist.
Contamination Removal ? Testing ? Additive Addition
(to be determined after testing in oil test laboratory)
The steps involved in this process are as follows:
1. Contamination removal: Using advanced filtration techniques to remove contaminants.
2. Testing: Assessing the oil’s properties to determine if it meets the required performance standards.
3. Additive addition: Based on testing results, performance-enhancing additives are added to restore the oil’s original characteristics.
On-site oil testing laboratories
The used oil from the machine passes through 5th generation fine filtration to be reclaimed as ‘New Oil’ and fit to use as per stringent industry standards.
To effectively implement circular economy principles in oil reclamation from used oil, establishing an on-site oil testing laboratory is crucial at any large plants or sites. Scientific testing methods ensure that regenerated oil meets the specifications required for optimal machine performance, making it suitable for reuse as ‘New Oil’ (within specified tolerances). Hence, it can be reused safely by reintroducing it in the machines.
The key parameters to be tested for regenerated hydraulic, gear and transmission oils (except Engine oils) include both physical and chemical characteristics of the lubricant:
- Kinematic Viscosity
- Flash Point
- Total Acid Number
- Moisture / Water Content
- Oil Cleanliness
- Elemental Analysis (Particulates, Additives and Contaminants)
- Insoluble
The presence of an on-site laboratory is essential for making quick decisions; ensuring that test reports are available within 36 to 48 hours and this prevents potential mechanical issues/ failures from arising due to poor lubrication. This symbiotic and cyclic process helps not only reduce waste and conserve oil, but also contributes in achieving cost savings and playing a big role in green economy.
Conclusion
The future of industrial operations depends on sustainability, and reclaiming used lubricating oils plays a critical role in this transformation. Through 5th Generation Filtration processes, lubricants can be regenerated and restored to their original levels, contributing to both environmental preservation and economic efficiency.
What would happen if we didn’t recycle our lubricants? Let’s review the quadruple impacts as mentioned below:
1. Oil Conservation and Environmental Impact: Used lubricating oils after usage are normally burnt or sold to a vendor which can be misused leading to pollution. Regenerating oils rather than discarding prevents unnecessary waste and reduces the environmental footprint of the industry. It helps save invaluable resources, aligning with the principles of sustainability and the circular economy. All lubricating oils (except engine oils) can be regenerated and brought to the level of ‘As New Oils’.
2. Cost Reduction Impact: By extending the life of lubricants, industries can significantly cut down on operating costs associated with frequent oil changes, leading to considerable savings over time. Lubricating oils are expensive and saving of lubricants by the process of regeneration will overall be a game changer and highly economical to the core industries.
3. Timely Decisions Impact: Having an oil testing laboratory at site is of prime importance for getting test reports within 36 to 48 hours enabling quick decisions in critical matters that may
lead to complete shutdown of the invaluable asset/equipment.
4. Green Economy Impact: Oil Regeneration is a fundamental part of the green economy. Supporting industries in their efforts to reduce waste, conserve resources, and minimise pollution is ‘The Need of Our Times’.
About the author:
KB Mathur, Founder & Director, Global Technical Services, is a seasoned mechanical engineer with 56 years of experience in India’s oil industry and industrial reliability. He pioneered ‘Total Lubrication Management’ and has been serving the mining and cement sectors since 1999.

The Indian cement industry has reached a critical juncture in its sustainability journey. In a landmark move, the Ministry of Environment, Forest and Climate Change has, for the first time, announced greenhouse gas (GHG) emission intensity reduction targets for 282 entities, including 186 cement plants, under the Carbon Credit Trading Scheme, 2023. These targets, to be enforced starting FY2025-26, are aligned with India’s overarching ambition of achieving net zero emissions by 2070.
Cement manufacturing is intrinsically carbon-intensive, contributing to around 7 per cent of global GHG emissions, or approximately 3.8 billion tonnes annually. In India, the sector is responsible for 6 per cent of total emissions, underscoring its critical role in national climate mitigation strategies. This regulatory push, though long overdue, marks a significant shift towards accountability and structured decarbonisation.
However, the path to a greener cement sector is fraught with challenges—economic viability, regulatory ambiguity, and technical limitations continue to hinder the widespread adoption of sustainable alternatives. A major gap lies in the lack of a clear, India-specific definition for ‘green cement’, which is essential to establish standards and drive industry-wide transformation.
Despite these hurdles, the industry holds immense potential to emerge as a climate champion. Studies estimate that through targeted decarbonisation strategies—ranging from clinker substitution and alternative fuels to carbon capture and innovative product development—the sector could reduce emissions by 400 to 500 million metric tonnes by 2030.
Collaborations between key stakeholders and industry-wide awareness initiatives (such as Earth Day) are already fostering momentum. The responsibility now lies with producers, regulators and technology providers to fast-track innovation and investment.
The time to act is now. A sustainable cement industry is not only possible—it is imperative.

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