This is a presentation by Engineer Osama Aly Ahmed Engineering Consultant, Rabeen Group at the 3rd Annual East Africa Cement, Concrete and Energy Summit

1. Establishment EnMS Project
Egyptian Cement Plant
With assistance from UNIDO Team.
The 3rd Annual East Africa Cement,
Concrete and Energy Summit
Eng. Osama Aly Ahmed

2. The Client one of the recent
& modern cement plant in Egypt
• Our Case Story Egyptian cement plant
• Produce around 5500 t /day clinker
• The plant is designed by Sinoma Co.
• Around 780 labors (direct- indirect)
• Thermal energy: heavy oil , switch on Coal on October 2016

3. The main aims of the energy analysis and budget include identifying and
documenting all of the SEU (Significant Energy User) within the defined
boundaries, obtaining a baseline of energy performance, identifying
indicators to use in measuring progress against the baseline,
Setting energy objectives and targets and, finally, establishing an energy
action plan. The energy management system must be evaluated at least
once a year and are improvements made based on the results of the
evaluation. In more detail this will include:
Outline Steps

5. 1. Recording main electricity bills and sub-meter data
2. Analyzing past, present and future energy use;
3. Identifying and quantifying significant energy users (SEU);
4. Identifying drivers affecting SEU levels;
5. Developing baselines and performance indicators for each SEU;
6. Review operational control for all SEUs
7. Technical energy audits
8. Identify opportunities for improved performance, review and decide on action plans.

6. EnMS Project
Client prefer to approach to systematic his energy usage
Client has desired owning certified to EnMS Standard to be matching with our Country trends
and international trends in keeping our energy resources and reducing CO2 emissions
This Client reduced kWh/ton by close to 16.5 % over 2 years
• It did this without any financial investment.
• It did it with increasing output and change fuel type with lower one
• It did it through a systematic approach to improving performance through improved
operation and maintenance.
• It simultaneously improved reliability and productivity.

7. The purpose of EnMS
Access to energy is becoming more costly and environmentally damaging
The era of cheap energy is over (in many countries!)
Role of energy efficiency
Benefits of a systematic approach to energy management
All the above through Energy Management System
Based on the concept of:
Plan
Do
Check
Act
The scope in saving energy is related to a 3 axis target of increasing running time ,
Decreasing stoppage time and keeping maintenance to scheduled periods only

8. Project Timeline & Milestones
Feb 14th, 2017
Project Kick off
July 18th, 2017
Mid Planning
Presentation
Sept
End of Planning
Nov
UNIDO Audit
Result
Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
March 16th, 2017
1st meeting at site
Kick off , management awareness, 2 days user and 5 meetings on site

10. The Team
1- Plant General Manager as an energy representative
2-Production Manager as energy Manager
3-Electrical Maintenance Manager
4-Quality Control Manager
5-Mechanical Maintenance Manager

11. EnMS Project
Management Commitment
• Policy:
Managing Director of Client has approved the Energy policy , communicate between the
team for using data to show performance and will be published in some common areas
in the plant and head office to be informed to all company staff
The organization shall ensure that any person(s) working on its behalf, related to significant
energy uses, are competent on the basis of appropriate experience. The organization
shall identify training needs associated with the control of its significant energy uses and
the operation of its EnMS.
The organization shall provide training or take other actions to meet these needs.

12. EnMS Project
• Scope:
We shall focus on Electricity & heavy fuel oil
And Quarry is excluded from boundaries
because diesel is small quantities and it is not
controlled by the plant.
• Boundaries:
Our boundaries will cover the production line( Raw mill, Kiln, Cement mill
including utilities) as well as the road leading to the plant
(17km lighting), and all the buildings within and including the plant fence.

13. Scope & Boundaries

14. EnMS Project
• Legal :
• Compliance with applicable legal and other requirements related to energy use
and efficiency either of ( Energy Ministry laws or Environment Ministry
instructions and laws )
• Compliance purchasing energy efficient products and services
• All documents are organized and shared to achieve more control and accessible

15. Existing EnMS Self Assessment
Top management is committed for improvement of energy management and
provides all required information and necessary recourses
to achieve objectives and targets.

16. Energy Consumption
Year
Production
ton
Electrical
Consumption
kWh
Thermal
Consumption
kWh
2017
1,919,620 177,475,230 1,614,559,748
2016
1,869,519 173,518,399 1,495,250,058
2015
1,702,324 142,398,400 1,708,479,463
2014
1,200,450 126,719,700 1,198,732,500
2013
1,523,185 131,376,400 1,530,907,499

17. 2015 Thermal and electrical
energy balance
Pie chart 2015 Thermal and
electrical energy mix balance in
kWh
Pie chart 2015 Thermal and
electrical energy balance in EGP
Series1, crusher,
1667100, 1%
Series1, raw mill,
49816400, 38%
Series1, kiln,
33651400, 25%
Series1, cement
mill, 45061500,
34%
Series1,
packing,
1937400,
2%
Series1,
Adminstration,
330800, 0%
crusher
raw mill
kiln
cement mill
packing
Adminstration

18. SEU
S SEU
Yearly
consumption
kWh
Yearly Driver
1 Raw mill 1734257 2015
2 Kiln 33651400 2015
3 Cement mill 4122578 2015
4 Kiln (heat) 1708479463 2015
Total 1747987698 2015

19. SEU Graph
•Rem
Raw mill
Kiln
Cement mill
Kiln (heat)
Remember this figure well , I will return back
to it again

20. Non SEU
S SEU
Yearly
consumption
kWh
Yearly Driver unit
1 Administration building 330800 2015
2 Crusher 1667100 2015
3 Packing 1937400 2015
Total 3935300

21. SEU & Non SEU
SEU
Non SEU

22. Baseline
• Energy baseline
• The organization shall establish an energy baseline(s) using the information in the initial
energy review, considering a data period suitable to the organization's energy use and
consumption. Changes in energy performance shall be measured against the energy
baseline(s).
A Year 2015 was selected as a baseline
Results were good and stable to built on
We do not need financial investment until AFTER we start to show savings
Viable investment projects may follow later

23. Measurement of
Consumption & Driver
• Our measurement analysis is based on production is collected daily from
weigh feeder average records from the CCR, which is verified monthly
against inventory calculations monthly. Consumption is taken manually
from meters on section feeders.
• No need for modern factory to apply EnMS but traditional plants need
EnMS needs it more
• The data for production from both methods shall be compared during the
base period to check the percentage in error

24. Energy Reviews ERs
The organization shall develop, record, and maintain an energy review. The methodology and
criteria used to develop the energy review shall be documented Looking at just the vertical
cement mill , it is possible to calculate the energy intensity index (EII) by comparing the
baseline data with new monthly data. This should be less than 1, indicating improvement on
the baseline. that this has already been achieved. The difference between the actual and
expected consumption values should be negative and the cumulative summation CUSUM of
the difference should be on an infinite downward trend. The trend of specific energy
consumption can be seen in the Figure.
It is important to not lose sight of customer satisfaction throughout an efficiency drive. The
average properties for cement produced during each month. It shows that the average
surface area according to Blaine was 3424cm2/g. There is significant potential to increase the
amount of energy saved by reducing the separator rotor speed, while remaining within the
customers’ requirements. Continued monitoring of the coarse portion that is recycled from
the separator is recommended so that the separator speed can be kept as low as possible
without allowing the coarse fraction through the separator.
The great advantage of daily monitoring of energy users consumption to detect any
malfunction either in equipment itself or in quality raw material of cement

28. Opportunity List
We Develop a list of all potential ideas contains of 65 items and we Select some items for
implementation & Prioritization
Plan and manage their implementation is an important point to soft start our system
Training will be required to raise awareness among staff and among management
and also training of operational and maintenance staff in the energy impact of their
day to day activities and decisions.

29. 29
Typical Sources of False Air
Missing bolts
Fan Seals
Doors
Doors Flap Seals
Kiln Inlet SealClinker Chute
Expansion Joints
Classifier Seal
Feeding Point
Feeding Point
Doors
Doors
Fan Seals
Poke Holes
Flanges
Tie Rod Seals
Kiln Hood Seals
Fan Seals
Seals
Seals
Casing cracks Casing wear &
corrosion
Isolation
dampers
Expansion Joints
 Look for gaps / cracks / missing bolts / missing packing etc…
 Listen for whistling air
 Look for dust blowing out during start up
Rule 2

30. 30
Oxygen survey
Vertical Mill Power Optimisation (1) –
Operation actions
Mill feedrate uniformity
Feed size control
Feedrate vs mill ΔP control
Gasflow control
Metal detection & removal
Mill outlet temperature control
Good SOPs for start up
Set operation targets and limits
Feedrate
Bed depth
Vibration
Grinding pressure
 ΔP
Gasflow
Temperature
Mill drive power
Water injection
Representative product
sample
Operating inspection plan
Check instrument accuracy
KPIs
Feedrate
kWh/t (Mill + Fan)
RF > 95%
Annual incident stops < 100
Minimise false air
ΔP monitoring
Optimise gasflow control on
mill for mill on /off conditions

31. 31
Vertical Mill Power Optimisation (2) – Shutdown
checks and actions
Roller and track wear profile
Reliable bed depth
measurement - calibration
Accumulator
pressures and
condition
Casing wear / cracks
Separator wear
Feed to table centre Optimum ΔP vs
nozzle ring area
Sealing
Roller seals
Dam ring adjustment
to follow table wear
Inspection plan for mill stops
Nozzle ring free of
stones
Clean build up
in gas duct
Aim to change table &
roller liners at the same time
Track water pipe
condition Sealing for external recirculation

32. 32
Rules for
Heat Consumption
1) Prepare a consistent raw mix
2) Control oxygen level in kiln and pre-heater
3) Optimize fuel combustion
4) Master kiln stability
5) Optimize cooler efficiency
6) Master pre-heater and calciner operation
7) Optimize kiln throughput
8) Maximize reliability factor
9) Minimize cement kiln dust or kiln dust loss
10) Apply operating procedures with skilled operators
Notes on specific processes

33. 33
Golden Rules for
Power Cost Reduction
1) Minimize False Air
2) Manage Equipment Idling
3) Vertical Mill Power Optimization
4) Efficient Gas Handling
5) Power Monitoring
6) Production Management
7) Mastering Quality Impact on Power Consumption
8) Mill Feed Size Control
9) Minimize Compressed Air

34. Problem or Challenges
1- Instability due to Management changes
2- There are some deviations between energy meters and bills
3-High coal consumption is due to coal fineness which is 12~17%. So the flame in
kiln moved back towards kiln inlet, which caused coal falling down into the clinker,
and caused mechanical incomplete combustion. Therefore, coal powder coming
out from mill shall be controlled within 8~10%, no more than 10%.
The secondary reason of high coal consumption is the humidity of coal powder
which is 1.5~2%. As humidity increases by 1%, the heat consumption of 1kg clinker
will increase by 50Kcal. Therefore, the humidity of coal powder shall be controlled
at 1%, maximum no more than1.5%.

35. Conclusion
The implementation of energy management systems in cement plants is both easy
and cost effective, given strong commitment from management and the availability
of adequate technical resources. In the case of the Egyptian cement plant, zero or
low cost measures have proven to be a strong tool in convincing all company staff of
the potential benefits that can be achieved if a commitment to continuous
improvement becomes an integrated part of the company’s culture and day-to-day
behavior
In general, management should provide all necessary resources and required
information to enable the company to achieve its energy objectives and targets.
New concept of cement industry rely on producing cement by low cost,
as we know energy represent 40% of the cost of ton cement produced
We should improve EnMS through strategic planning and performance development
business ,
that what global cement companies doing!

36. Discussion
At last not final we would be glad to introduce our consultation service for Cement
manufacturing Training courses in addition to Energy management through I Capital Africa
Institute for Ethiopian or any African industrial firms
Together to Reduce energy consumption (kWh or GJ, etc.)
• Reduce cost
• Reduce GHG emissions
Thanks your interest to all Attendees
Special Thanks to Adama Science Technology University,
I Capital Africa Institute team