The document discusses energy efficiency measures in cement industries. It notes that the cement industry accounts for over 5% of global greenhouse gas emissions. Several opportunities for improving energy efficiency are identified, including upgrading kilns, recovering waste heat, improving raw material preparation, and implementing process controls. The cement industry in Nepal is one of the most energy intensive sectors and consumes more energy per unit of production compared to other countries. Adopting advanced efficient technologies could help reduce energy use and emissions in Nepal's cement industries.

1. Energy efficiency measures in cement industries
Ramhari Poudyal PhD candidate
Dr. Pavel Loskot
Swansea University, U.K.
Electrical and Electronic Engineering Department

2. Introduction
• In 1824 Joseph Aspdin, an English mason, patented a cement he called
“Portland” because it resembled stone quarried on the isle of Portland off the
English coast[20].
• The cement industry accounts for over 5% of the world’s total and around
20% of industry sector's total anthropogenic GHG emissions
• The cement industry is one of the most energy-intensive and highest CO2
emitting industries and one of the key industrial contributors to air pollutions
(PM, SO2, etc.) in the world.
• The cement industry is one of the Nepal’s most high energy intensive
sectors.
• About 40% of CO2 emission come from the burning fuels to heat the cement
Kiln, and remainder of CO2 emission comes from electricity use and
transportation.
• Producing one ton of cement releases an estimated 0.73 to 0.99 ton CO2
depending on the clinker per cement ratio and other factors
• More than 50% of CO2 emissions from cement industry are process related
emission from calcinations process and has nothing to do with fuel use.

3. per capita cement consumption (Kg) in 2015
0
200
400
600
800
1000
1200
1400
1600
1800 1683
1581
911
770 744
616
546
330 329
232 225 202 140 80
Per Capita Cement Consumption (Kgs) in 2015

4. Challenges and barriers of cement industries
Forces of Change Barriers to Sustainability
Stakeholder Demands
Customer Needs
Emerging Economies
Environmental Concerns
Regulateries Policies
Innovation
Transparency
Energy Prices
Global Consolidation
Mature Material
Resource Intensity
Capital intensity
Lack of trust
Standards and specifications
Company inertia
Market pressures
Commodity product

5. Energy use & emissions in the cement industries
• China, India and the USA are top three cement producers in the world
• China’s cement Industry accounted for more than 50% of the world’s total cement production
• The cement industries is one of the energy-incentive and highest CO2 emitting industries and one
of the key industrial contributors to air pollutions(PM,SO2,..etc.)
Cement
Milling
57%
Clinker
Production
27%
Raw Material
preparation
12%
other 4%

6. OVERVIEW OFCEMENT INDUSTRIES:
Cement Demand January 2017
-20%
-10%
0%
10%
20%
30%
Cement demand January 2017- YoY
change %
In Nepal, the demand for cement is about 5 - 10 million tonnes annually as it
is one of the fundamental construction materials

7. OVERVIEW OFCEMENT INDUSTRIES:
• Cement industry is the largest source of particulate matter (PM) emissions in China,
accounting for about 40% of industrial PM emissions and 27% of total national PM
emissions.
• Fuel use for production of one ton of clinker can vary from 3Gj to 5.46GJ depending
on the type of production technology n other factors.
• Electricity demand for production of one ton of cement ranges from 90 kWh to 140
kWh depending on type of technology and other factors.
• Studies in China, India, the U.S.A. Thailand and other countries have shown that
significant energy saving and CO2 emissions reduction can be achieved by
commercially available

8. OVERVIEW OFCEMENT INDUSTRIES:
Energy Efficiency is a very new concept for Nepal as its high energy consumption,
Nepalese cement industries must have strengthened its efforts in Research and
Development to improve its energy efficiency.
The objective of this study is to access the energy performance of existing cement
industries of Nepal
The primary objective of this study is to identify specific energy efficiency measures
and evaluate the potential and economics of energy savings, CO2 emission reduction for
the cement industry.
The study will briefly describe the various stages in the cement production process of
UCIL and HCIL
This study will help to build up policy recommendations. Presently, Nepalese
government have limited data and acquisition capacity. Limitations of literatures around
international journal, no energy audit culture in industry are significant barriers of this
study.

9. Supply Demand Scenario of cement
3.3 3.6 3.9 4.3 4.7 5.2 5.6 6.2 6.8 7.4 8.1
3.3 3.6 4
4.5
5
5.5
6.1
6.8
7.5
8.4
9.3
3.3
3.5
3.8
4.1
4.5
4.8
5.2
5.6
6.1
6.6
7.1
0
5
10
15
20
25
30
FY11 FY12 FY13 FY14 FY15 FY16 FY17 FY18 FY19 FY20 FY21
Consumption -
Pessimistic
Consumption - Optimistic
Consumption - Most
likely

10. Location of Cement Plant

11. List of Cement Industries (in Pipeline)
S.No. Name of the plant Capacity (TPD) Location
1 HongshiShivam
Cement
10,000 Nawalparashi
2 Sourya Cement 1200 Udayapur
3 Riddhi Siddhi Cement 2200 Makawanpur
4 CG Cements 6000 Palpa
5 Dang Cement 1200 Dang
6 Samrat Cement 1200 Dang

12. Energy Efficiency measures for Raw Materials preparation in Cement plants [36]
Energy Efficiency Measures for
Raw Materials production
Fuel Savings
(GJ/t)
Electricity
Savings (kWh/t)
Estimated payback
period (Years)1
CO2 Savings
(KgC/t)
Efficient transport system - 3.4 >10 0.78
Raw meal blending - 1.7 – 4.3 N/A 0.4 – 1.0
Process control vertical mill - 1.4 – 1.7 1 0.3 – 0.4
High-Efficiency Roller Mill - 10.2 – 11.9 >10 2.3 – 2.7
High-Efficiency Classifier - 4.8 – 6.3 >10 1.1 – 1.4
Slurry blending and homonizing - 0.5 – 0.9 <3 0.1 – 0.2
Wash Mills with Closed Circuit
Classifier
- 8.5 – 11.9 >10 2.0 – 2.7
Roller Mills for Fuel Preparation - 0.7 – 1.1 N/A 0.2 – 0.3

13. Efficiency Opportunities Applicable to all Kiln Types
Efficiency
Measures
Capital
cost
($/t)
O & M
Cost ($/t)
Payback
period
(Years)
Fuel
Savings
(GJ/t)
Electric
Savings
(kWh/t)
CO2Saving
s (KgC/t)
Lifetime
(Years)
Improved
refractories
N/A N/A 0.4 – 0.61 - 10.3– 15.5 N/A
Kiln shell heat loss
reduction
0.25 1 0.1 – 0.632 - 2.8 – 10.3 20
Energy
Management &
process control
0.3 –
1.7
<2 0.1 – 0.2 1.5 – 3.2 2.9 – 5.9 10
Adjustable speed
drive for Kiln fan
0.23 0 2 – 3 - 6.1 1.4 10

14. Efficiency
Measures
Capital cost
($/t)
O & M Cost
($/t)1
Payback
period
(Years)
Fuel Savings
(GJ/t)
Electric
Savings
(kWh/t)2
CO2Saving
s (KgC/t)
Lifetime
(Years)
Preheater Kiln
upgrade to
precalciner
Kiln
9.4 - 28 -1.1 5 0.16 – 0.7 - 4.1 – 18.1 40
Long dry kiln
upgrade to
preheater /
precalciner
Kiln
8.6 – 29 >10 1.4 - 36 40
Older dry Kiln
upgrade to
multi – stage
preheater Kiln
28 – 41 >10 0.9 - 23 40
Convert to
reciprocating
grate cooler
0.4 – 5.5 0.11 1 – 2 0.27 -3.0 6.3 20
Kiln
Combustion
system
improvements
1.0 0 2 – 3 0.1 – 0.5 - 2.6 – 12.9 20
Energy Efficiency Opportunities Applicable to Rotary Kilns

15. Energy Efficiency Opportunities Applicable to Rotary Kilns
Indirect firing 7.4 N/A 0.015 –
0.022
- 0.39 – 0.57 N/A
Optimize heat recovery /
upgrade clinker cooler
0.1 –
0.3
1 – 2 0.05 –
0.16
-2 0.8 – 3.7 20
Seal replacement N/A < 0.5
=
0.011 - 0.3 N/A
Low-temperature heat
recovery for power
(Capital costs given in
$/kW)
800 –
1250
($/kW)3
0.007 <3 - 20 – 35 4.6 – 8.1 N/A
High-Temperature heat
recovery for Power
2.2 –
4.4
0.22 –
0.33
3 - 22 5.1 35
Low-pressure drop
cyclone
3 >10 - 0.7 – 4.4 0.16 – 1.0 20
Efficient Kiln drives +0 – 6
%4
N/A - 0.55 – 3.9 0.13 – 0.9 10

16. Energy Consumption Situations
Energy
consumption for
each section in
cement industry
Raw material
grinding
24%
Cement mill
38%
Raw mill
homogenisin
g
6%
Kiln
22%
Mines &
crushing
5%
Material
handling &
packing
5%

17. The cost structures of cement production
33%
27%
15%
15%
15%
The cost structures of cement production
Coal Electricity Raw materials Depreciation Others

18. Comparison of energy consumption with selected countries [source:
Indian Cement Review, Sept, 2013]
Country Specific Electrical Energy
Consumption kWh/t of cement
Specific thermal energy
consumption Kcal/Kg
clinker
India 82 725
Spain 92 836
Germany 100 836
Japan 100 836
Brazil 110 884
Italy 112 908
China 118 956
Mexico 118 1003
Canada 140 1075
USA 141 1099
World Average 100 – 110 850 – 860

19. Efficiency Margin Sector- wise in % in
different Industries of Nepal
0.00%
2.00%
4.00%
6.00%
8.00%
10.00%
12.00%
14.00%
16.00%
18.00%
20.00%
Efficiency Margin Sector- wise in % in different Industries of Nepal

20. Energy Management
Why Energy
Management?
Reduce
Pollution CO2 ,
NOx, SOx
Save
money
$ £
Motivate
Staff
Mitigate
Volatility

21. Energy saving option and the payback period of investment for cement
sector [Danida /ESPS,2005].
Option Payback of investment
Improvement of power factor 1.5 years
Convert delta to star connection for motors loaded
below 50% of full load
1 year
Installation of the high-efficiency dynamic separator
of raw mill
2 years
Replacement of the Airlift with Bucket Elevator for
Raw – meal Transport to the Silo
3 years
Replacement of existing cyclones with low-pressure
drop (LP) Cyclones
2 years
Control raw meal feed size by the installation of
tertiary crusher
1.5 years
Install demand controller for management of
electrical demand
1. year

22. Causes of kiln stoppage in UCIL
0%
5%
10%
15%
20%
25%
30%
35% 34%
27%
10%
7.00%
6%
4%
2.50% 2.50% 2% 2%
1.00% 1% 1% 1%
Causes of Kiln Stoppage in UCIL, Nepal in FY 2013/14

23. Comparative Analysis of Heat consumption & Thermal Load &
Electricity consumption 2016 – 17 in Kcal/kg-cl.
0
200
400
600
800
1000
1200
1400
1600
1800
2000
2016 2017 Designated Current
Electricity Consumption
Average Heat Consump
Average Thermal Load
(Kcal/kg-Cl.

24. Max, Min & Avg. of Monthly Clinker Production CUF % 2012 – 2017
0
10
20
30
40
50
60
2012 2013 2014 2015 2016 2017
Minimum
Maximum
Average

25. Energy use in Nepalese Cement industry (ZIZ/NEEP 2012)
9%
91%
Energy use in Nepalese Cement industry (ZIZ/NEEP 2012)
Electrical
Thermal(Coal)

26. Specific energy consumption in Nepalese cement sector
Types of Cement Plant Electrical
(Weighted
Average)
Thermal
(Weighted
Average)
Limestone–based cement plant 149KWh/MT* 5,411 MJ/MT**
Clinker – based cement plant 49KWh/MT* -
Waste Heat Recovery for power generation:

27. Waste Heat Recovery for power generation:
Waste heat from the cement kiln is usually used for drying of raw materials and fuel.
Heat recovery for power is most economical for long dry kilns, but long dry kilns with
preheaters in China and Europe have power production installations.
It has been reported that there are at least 33 cogeneration units in various cement plants
with total capacity about 200 MW in Japan . In China, about 24 Kilns having the ability of 2000
ton per day and above have cogeneration units with supplementary fired boilers to meet about
22 – 36 KWh/t clinker.
In cement industries, there are the tremendous amounts of wastage like heat, recovery of
waste heat is a significant challenge to make cement plant more energy efficient.
In dry process cement plants, nearly 30-40% of the total heat input is rejected as waste heat
from the exit gases of preheater and coolers. In UCIL, on average 105% of heat input is being
lost as waste heat.
In a cement plant, having preheater exit gas temperature of 350-400ᵒC and cooler vent air
temperature of 250-275ᵒC, there is potential to generate about 4-5 MW of power from waste
heat alone. The total electricity demand in UCIL is around 6.6 MW per day. If possible, waste
heat recovery can contribute to 50% of the total electricity demand [UCIL Maintenance Report
2017].

28. Conclusion
Cement industry needs to prioritise from among the numerous suggested actions and
choose a set of energy efficiency measures that suit well with its business strategy and
corporate philosophy.
An understanding of the barriers is a vital first step in developing programs and policies
to promote further implementation of energy efficiency opportunities. Also, once the
barriers have been identified and are understood, it is essential to develop effective
programs and policies to overcome the obstacle to adoption. Such programs an
This research reviewed the literature of energy efficiency improvements practices
around the globe. Nepal could be benefited if this practice would implement in all of the
cement industries of Nepal.
In Nepal’s cement industries, we found that average consumption of electrical and
thermal energy is higher in one unit of production. Emission is also soaring which could be
reduced by adopting newly advanced efficient technologies.

29. Thank You Very Much for Listening!!!
Any Question???
Ramhari Poudyal
PhD candidate
Swansea University, UK
Electrical & Electronic Engineering Department
847043@swanse.ac.uk
rhpoudyal@gmail.com