Connect with us

Concrete

How Upgrades Can Deliver Energy Savings Across the Cement Process

Published

on

Shares

Jacob Brinch-Nielsen, Vice President of Professional Services, FLSmidth Cement, brings together recommendations from experts across the flow sheet to demonstrate the role of upgrades in optimising the cement manufacturing process.

The Energy Challenge in Cement Manufacturing
Reducing energy consumption is a core goal for all cement producers, sitting alongside alternative fuels, reduced clinker content and carbon capture as one of the four pillars of decarbonisation. As we look to the future, when new emissions abatement technologies will skyrocket energy use once more, that goal becomes ever more important.
While automation and digitalisation have a critical role to play in optimising energy use, advances in mechanical equipment are often focused on reducing energy consumption – meaning there are many equipment upgrades that could help lower your energy bills, providing a relatively swift ROI in exchange for minimal disruption to your process. By optimising key process areas—grinding, dosing, preheating, and more—plants can reduce energy costs while improving operational performance. But where should they start?

Easy Upgrades to Optimise the Grinding Process
“One of the biggest sources of inefficiency in cement grinding is overgrinding,” explains Nick Litzenberger, Design Engineer. “Every extra pass through the mill consumes energy but does not necessarily improve product quality. This is especially critical in Type 1L cement, where fine limestone particles can lead to excessive power consumption and reduced throughput. Many cement plants still operate second- generation separators, which lack the precision of modern designs. Upgrading to a third-generation separator can optimise particle size distribution, lower energy use, and boost mill output.”
Third-generation separators for ball mills like the O-SEPA® or SEPAX™ utilise more hard-wearing materials, improving seal performance and separating more efficiently. These types of upgrades require just a 2 – 3-week shutdown, as much of the work can be done while the mill remains operational and deliver a 5 per cent to 10 per cent reduction in power consumption.
Among third-generation separators for VRMs, options like the ROKS-H separator specifically address overgrinding in Type 1L cement, delivering energy savings of about 2 – 3 per cent while improving product quality. Even an upgrade from an early 3rd generation separator, like a ROKS, to one of the latest separator designs, like a ROKS-H, can reduce power consumption and improve cement quality in a grinding circuit.

Reducing Energy Use in Feeding and Dosing
Even small inefficiencies in feeding and dosing can result in wasted energy and increased operational costs. If your dosing system struggles to maintain consistent feed rates, the inevitable result is instability in pyroprocessing and impacting power consumption.
“We’re continually exploring ways to reduce energy consumption in feeding and dosing applications,” says Peter Norek, Global Product Manager-Feeding and Dosing Technologies. “We’ve introduced digital features like Pfister® Smart Aeration, which reduces compressed air usage by up to 90 per cent, patented FEEDFlex™ technology, which enables much lower fossil fuel dosing, and the FDC controller upgrade, which includes a new motor, enhancing efficiency and reducing electricity consumption. These are all simple upgrades with a positive environmental impact.”

Part 1 of 3. Read parts 2 and 3 in the June and July issues of Indian Cement Review

(Communication by the management of the company)

Concrete

Star Cement launches ‘Star Smart Building Solutions’

Published

on

By

Shares

Star Cement has launched ‘Star Smart Building Solutions,’ a new initiative aimed at promoting sustainable construction practices, as per a recent news report. This venture introduces a range of eco-friendly products, including tile adhesives, tile cleaners and grouts, designed to enhance durability and reduce environmental impact. The company plans to expand this portfolio with additional value-added products in the near future. By focusing on sustainable materials and innovative building solutions, Star Cement aims to contribute to environmentally responsible construction and meet the evolving needs of modern infrastructure development.

Image source:https://www.starcement.co.in/

Continue Reading

Concrete

Nuvoco Vistas reports record quarterly EBITDA

Published

on

By

Shares

Nuvoco Vistas reported its highest-ever quarterly consolidated EBITDA of Rs.556 crore in Q4 FY25, with annual EBITDA at Rs.1,391 crore. Cement sales reached 19.4 MMT in FY25, with Q4 contributing 5.7 MMT. Revenue rose 4 per cent YoY to Rs.3,042 crore in Q4. Net debt reduced by Rs.390 crore to Rs.3,640 crore. The company received NCLT approval for acquiring Vadraj Cement, targeting 31 MMTPA capacity by FY27. Key marketing initiatives, expanding RMX and MBM businesses, and a focus on sustainability (457 kg CO2/tonne) drove performance. Nuvoco remains focused on premiumisation, operational efficiency, and market expansion.

Image source:nuvoco.com

Continue Reading

Concrete

UltraTech Cement increases capacity by 1.4Mt/yr

Published

on

By

Shares

UltraTech Cement has expanded its production capacity by 1.4 million tonnes per annum (Mt/yr) through a combination of debottlenecking efforts and operational efficiency upgrades across several of its plants. The enhancements include an addition of 0.6Mt/yr in grinding capacity at the Nagpur facility in Maharashtra and a combined 0.8Mt/yr at the Panipat and Jhajjar units in Haryana. With these upgrades, the company’s total domestic grey cement capacity has risen to 184.8Mt/yr, while its global capacity now stands at 190.2Mt/yr.

Continue Reading

Trending News

SUBSCRIBE TO THE NEWSLETTER

 

Don't miss out on valuable insights and opportunities to connect with like minded professionals.

 


    This will close in 0 seconds