1. Introduction
As a requirement of the ‘Energy Efficiency Strategy
Document 2012 – 2023’, published in the Official Gazette (no. 28215,
25 February 2012), industrial companies in Turkey are required to be
ISO 50001 EMS certified by 1 January 2015. The certification is also
a requirement of the ‘Regulation about the Changes in the Regulation
for the Increase of Efficiency in Energy Sources and Energy Use’,
published in the Official Gazette (no. 28952, 25 April 2014), in order for
companies to participate in energy efficiency project competitions
and to receive financial support from the state. Possession of the
ISO 50001 EMS Standard document will be compulsary for all
transactions related to the state in the near future.
Unlike other management systems standards, the ISO 50001
EMS reduces the costs of energy and production from the moment
of implementation. ISO 50001 EMS is particularly important for the
cement industry, in which energy costs can represent 50 – 70% of the
overall production costs.
RAISING
Mahmut Selekoglu, Energy
Management & Energy
Efficiency Consultant, Turkey,
describes how energy
management systems are
helping to reduce costs and
improve efficiency in the
Turkish cement industry.
THEBAR
/1

2. Energy demand and energy
Worldwide energy demand is constantly increasing; however,
resources are limited. The annual worldwide growth rate
of energy demand is 1.6%, which is double the annual
population growth rate of 0.8%. In Turkey, the annual growth
rate of energy demand is four times that of the annual
population growth rate. It has been forecast that two thirds
of worldwide potential energy efficiency resources will not be
utilised until 2035.
Although Turkey imports three quarters of its energy
resources, power is still wasted. According to data from
the Turkish Energy Ministry, the amount of energy supplied
in 2012 was 120.1 million TEP, but the amount of energy
demanded totalled 89 million TEP. This means that more than
a quarter of the supplied energy was wasted.
Energy intensity, which is the most important indicator of
energy efficiency, is very high in Turkey. The country’s energy
intensity value is 1.5 – 2 times the energy intensity values
in more developed countries. The current account deficit of
approximately 80% caused by energy imports should also
be noted. The best solution to meet this energy demand
is to use energy more efficiently. This is particularly the
case in Turkey, as energy resources are limited and energy
demand is constantly increasing. Better energy management
systems, such as the ISO 50001 EMS Standard, are required
to increase energy efficiency. The main advantages of ISO
50001 EMS are:
ll Energy efficiency.
ll Optimal use of resources.
ll Improved environmental impact.
ll Decreased costs.
ll Continuous improvement.
ll Extensive monitoring and control of all
activities.
ll Being result-oriented.
ll Less documentation.
ll Customer confidence.
ll A healthy flow of information.
An example of the energy planning
process in a cement plant
Adapting the Energy Planning Process, which is
essentially the backbone of the ISO 50001 EMS
Standard, by taking into consideration the processes
of the cement industry, significant energy uses and
variables affecting energy use, is very important to
the success of the ISO 50001 EMS Standard.
Electricity and fuel consumption
2011
Electricity: 190 000 kWh.
Petcoke: 150 000 t.
Natural gas: 975 000 m³.
Fuel oil: 180 t.
Diesel: 5750 t.
Total (US$): 55 million.
2012
Electricity: 210 000 kWh.
Petcoke: 165 000 t.
Natural gas: 1 025 000 t.
Fuel oil: 200 t.
Figure 1. Potential energy efficiency utilisation by 2035.
Unused Potential for
Energy Eff.
Used Potential for
Energy Eff.
Industry Transport Electricity Buildings
%100
%80
%60
%40
%20
Table 1. Specific energy consumption (2009 – 2013)
Consumption of specific electrical energy
Units 2009 2010 2011 2012 2013
Preblending
(kWh/t of raw material)
0.20 0.35 0.40 0.40 0.35
Crushers
(kWh/t of raw material)
I 1.10 1.0 0.95 0.80 0.80
II 0.75 0.90 0.80 0.90 0.85
Raw mills (kWh/t of
raw material)
I 27.0 25.0 26.0 25.0 26.0
II 18.0 15.5 17.0 20.0 19.0
Rotary kilns (kWh/t of
clinker)
I 36.0 33.0 37.0 35.0 34.0
II 28.0 25.95 26.23 30.0 28.0
Coal mill (kWh/t of
coal)
I 23.0 24.19 25.14 25.0 23.0
Cement mills (kWh/t of
cement)
I 37.5 35.74 36.47 38.0 35.0
II 30.0 34.71 35.3 38.57 36.0
III 35.0 34.09 35.87 41.0 36.0
Packaging units
(kWh/t of cement)
0.8 0.6 0.75 0.8 0.7
Compressors
(kWh/t of cement)
3.0 2.10 2.0 2.0 2.0
Social facilities
(kWh/t of cement)
0.04 0.25 0.32 0.2 0.2
Lighting (kWh/t of cement) 0.38 0.3 0.4 0.03 0.3
Electrical energy losses
(kWh/t of cement)
2.1 3.0 2.5 2.3 2.2
Gasoline (kWh/t of cement) 0.091 0.085 0.036 0.04 0.05
Diesel (kWh/t of cement) 0.374 0.436 0.418 0.50 0.45
kcal/kg of clinker Specific heat energy
Units 2009 2010 2011 2012 2013
First rotary kiln 860 845 835 825 825
Second rotary kiln 820 800 805 810 805
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3. Diesel: 6500 t.
Total (US$): 65 million.
2013 (present)
Electricity: 220 000 kWh.
Petcoke: 168 000 t.
Natural gas: 1 030 000 t.
Fuel oil: 200 t.
Diesel: 6500 t.
Total (US$): 70 million.
2014 (forecast)
Electricity: 215 000 kWh.
Petcoke: 170 000 t.
Natural gas: 1 000 000 t.
Fuel oil: 200 t.
Diesel: 6000 t.
Total (US$): 75 million.
Variables affecting energyconsumption
Variables that affect energy consumption at the plant
include: raw material and fuel characteristics; power
quality, design changes; demand conditions (according to
the changes of product plans); maintenance; number of
failures; shift/operator changes; differences of production
processes; motivation and moods of operators; climate
conditions, and so on.
Furthermore, the activity of the staff can have an
impact on energy consumption. Staff directly affecting
consumption (in order of priority) are: central control room
operators; maintenance employees; technicians; engineers;
technical chiefs; managers (technical and procurement);
procurement staff.
In 2013, the rainy winter months caused a 5% increase
in the moisture content of raw materials, which resulted in
a 2% rise in the energy consumption of the crusher and raw
mills. In April – June 2013, bad grindability of exported coal
resulted in an increase in energy consumption of 2 kWh/t
of coal at the coal mill. Kiln 1 saw a 5% increase in electrical
and heat energy consumption in March due to unexpected
failures, while kiln 2 recorded a 7% decrease in energy
consumption in April as a result of annual revision.
Energy review study
Energy usage areas and consumption amounts in 2013 are
shown in Table 2. As illustrated in the table, 98.8% of energy
consumption was realised in the main production units,
which are defined as ‘significant energy usage areas’. These
units include preblending, crushers, raw mills, rotary kilns,
coal mills and cement mills.
Requirements
Requirements for the plant (both legal and otherwise) are
listed below:
ll System Connection and System Use Agreements with
TEIAS.
ll Presence of an electrical engineer.
ll Subscription contract with an electricity distribution
company.
ll Declaring annual energy consumption and energy
production (if it is available).
ll Permission for alternative fuels (waste) incineration.
ll Sulfur rate in fuel.
ll Energy benchmarking study.
ll Filling out questionnaires for the ministries concerned, as
well as TUIK.
ll Permission for fuel import.
Table 2. Energy consumption of units in 2013
Unit Energy consumption (%)
Preblending 0.03
Crushers 0.12
Raw mills 2.90
Rotary kilns 89.25
Coal mills 0.52
Cement mills 6.0
Sum of energy consumptions 98.8
Closed clinker stockpile 0.04
Packaging 0.08
Additive drying 0.01
Social facilities 0.08
Lighting 0.04
Electricity losses 0.44
Workshop operation building and
water pumps
0.19
Erection and maintenance 0.06
Sum of energy consumption 1.2
Sum of plant’s energy
consumption
100
Figure 2. First energy performance indicator and energy
baseline.
Figure 3. Second energy performance indicator and
energy baseline.
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4. ll Reactive Energy/Active Energy ratio.
ll Requirements of Energy Efficiency Law, No. 5627.
ll Presence of an energy manager and creating an energy
management team.
ll Requirements of Strategy Document for Energy Efficiency.
ll Rates of harmonic distortion for voltage and current.
ll Sustainability Report commitments of the group to which
the company belongs.
ll Energy reporting and benchmarking studies of the group
to which the company belongs.
Energy performance indicators and baseline
The criteria for the determination of energy performance
indicators involves choosing values that represent the energy
performance of the plant and units that can be measured and
monitored. For determining the energy baselines, the plant
obtains an average of the energy performance indicators
from the past four years (at least). Energy performance
indicators and energy baselines are reviewed during energy
management meetings, which take place every three months,
and in the assessment of management review. These values
are reviewed and updated in case any important changes in
energy use and energy consumption have occured.
Two energy performance indicators and two energy
baselines were identified for the whole plant (performance
indicators and baselines were also defined for different levels
of units):
ll First energy performance indicator and energy
baseline: total energy consumption in terms of TEP
per 100 t of cement produced was classed as the first
energy performance indicator and the average specific
energy consumption over the past four years was
defined as the first energy baseline (Figure 2).
ll Second energy performance indicator and energy
baseline: since CEM I is the most produced cement
type, the specific electrical energy used to produce
CEM I was defined as the second energy performance
indicator. The average specific electrical energy
consumption over the past four years was defined as
the second energy baseline (Figure 3).
Measurement methods for energy performance
indicators
The methods for measuring electrical and heat energy, which
make up the plant’s total energy consumption, are outlined
below.
First energy performance indicator
ll Measurements of electrical energy: there are energy
analysers capable of metering each unit and all
significant equipment. All analysers communicate
with the CCR automation system via fibre cable
infrastructure; therefore, energy consumption data
is recorded on an online automation system. Energy
consumption data for each unit and all significant
equipment is stored in the system as kWh.
ll Measurements of heat energy: consumptions of coal,
petcoke, natural gas, waste (if available), etc., are
weighed continuously by 0.5% precision dosing scales.
Data flows through the online automation system
and is stored, as well as electricity. Heat energy is
calculated as kCal by multiplying the fuel consumption
by the lower heating value of fuel.
ll Calculation of TEP: on the last day of each month
at midnight, total kWh and kcal values that were
stored in the automation system are converted to
TEP using conversion factors. These values are then
added together. Therefore, the value of total energy
consumption for 1 month is determined as TEP.
ll Calculation of tonnes of cement: the cement produced
in each mill is weighed by means of dosing scales (in
tph). Weighing information is both reported manually
and stored in the automation system. The amount of
Figure 4. Energy performance indicators and energy
baselines of units – raw mill no. 1 (kWh/t of product).
Raw Mill #1 - kWh/t product
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
30,00
25,00
20,00
15,00
10,00
5,00
0,00
Per. Ind.
Baseline
Figure 5. Energy performance indicators and energy
baselines of units – kiln no. 2 (kCal/kg of clinker).
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Rotary kiln #2 - kCal/kg clinker
840,00
820,00
800,00
780,00
760,00
740,00
720,00
Per. Ind.
Baseline
Table 3. Energy performance indicators and energy
baselines of units
Unit Performance
indicator
Baseline
Crusher no. 1 kWh/t raw
material
0.80 kWh/t raw material
Preblending kWh/t raw
material
0.30 kWh/t raw material
Raw mill no. 1 kWh/t product 18 kWh/t product
Rotary kiln
no. 1
kWh/t clinker 35 kWh/t clinker
Rotary kiln
no. 2
kCal/kg clinker 790 kCal/kg clinker
Coal mill no. 1 kWh/t coal 27 kWh/t coal
Cement Mill
no. 1
kWh/t cement 35 kWh/t cement
Cement mill
no. 2
kWh/t cement 37 kWh/t cement
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5. each cement type produced each month is measured
in tonnes.
ll TEP/100 t of cement: at the end of each month, the
value of ‘TEP/100 t of cement’ is calculated by dividing
the total monthly energy consumption as TEP by the
monthly cement tonnage, which is multiplied by 100.
Second energy performance indicator
At the end of month, the value of ‘kWh/t of CEM I’ is
calculated by dividing the total monthly electrical energy
consumption for CEM I type cement by the amount of CEM I
produced.
Methods of determination and verification in
energy performance improvement
An Operating Committee meeting is held during the first
week of each month in order to examine the change in the
energy performances of the plant and individual units. During
the meeting, the previous month’s Business Activity Report,
which is prepared by the Operating Bureau and approved by
the energy and production managers, is examined in detail.
The change in each unit’s energy performance indicators, and
reasons for these changes, are analysed both numerically and
graphically.
Improvements in the energy performance are determined
by comparing the individual units’ energy performance
indicators with their baselines (Table 3) and with monthly
target values. Improvements in energy performances
are verified by a decrease in energy costs, and, therefore,
a decrease in product costs for that month. If energy
performance has not improved, the precautions to be
taken are discussed at the meeting and action plans for
improvement are drawn up.
Methods and criteria for energy review
improvements
An energy review study is carried out periodically every
two years. The energy management team, assigned by the
General Manager, conducts this study under the supervision
of the energy management representative. Members of the
energy management team include the Energy Management
Representative (Chairman), the Energy Manager certified
person/persons, the Mechanical Maintenance Chief, the
Raw Material Chief, the Clinker Production Chief, the Cement
Production Chief, the specialist responsible for environment
(participation needed) and the Purchasing Chief (participation
needed).
The energy review study is also partially carried out on a
more frequent basis in case of significant changes in systems
Table 4. Action plan 2013
Objective Target Job title Cost Period Saving
(TEP)
Payback
time
1. To reduce
energy
consumption
3 kWh/t of product
decrease in raw mill
energy consumption
Taking bag filters no. 1 and 2
out of service
_ Immediately 300 Immediate
Hot oil heat exchanger system
for the crusher
€50 000 5 months 1550 3 months
Solving the wear problem on
the mill table of raw mill no. 1
€30 000 15 days 500 5 months
Insulating the inlet pipes of
raw mills
€25 000 1 month 400 6 months
Insulating the bag filter’s body €40 000 2 months 650 8 months
Expert control system for the
raw mills
€200 000 6 months 1300 8 months
4 kWh/t of clinker and
15 kcal/kg of clinker
decrease
Increase the precision of kiln
coal supply (buying 1 x 20 t, Cl
1 weigher)
€75 000 8 months 550 9 months
Expert control system for
rotary kiln
€250 000 6 months 2000 9 months
2. Waste heat
recovery
40 million kWh/year of
electricity saving
Establish 5 MW power plant
using waste heat
€15 million 14 months 3440 12 months
3. Using
advanced
technology
2 kWh/t of cement
decrease in cement mill
energy consumption
More efficient dynamic
separator for cement mill
€100 000 8 months 4000 13 months
Replacing 30 motors with
more efficient ones on the
cement mill
€60 000 12 months 2200 17 months
1.5 kWh/t of coal
decrease in coal mill
energy consumption
Replacing 20 motors with
more efficient ones on the
coal mill
€50 000 12 months 2000 18 months
4. CO2
reduction
80 000 t of CO2
/year
decrease for plant
Implementation of the 2014
Action Plan
Total
€15.88 million
12 months 18 590 18 months
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6. and processes, and when starting up a new unit. When taking
account of such changes, objectives, targets, performance
indicators and baselines are investigated and, if necessary,
they are updated and an action plan is formed.
Energy review objectives:
1. To reduce energy consumption.
2. Waste heat recovery.
3. Using advanced technology.
4. CO2
reduction.
5. Creating awareness on energy efficiency for all
employees.
6. Using alternative fuels (waste).
Energy review targets:
1. 3 kWh/t decrease in raw mill energy consumption.
2. 4 kWh/t and 15 kcal/kg decrease in kiln energy
consumption.
3. 40 million kWh/year electricity saving.
4. 3 kWh/t decrease in cement mill energy consumption.
5. 1.5 kWh/t decrease in coal mill energy consumption
6. 80 000 t CO2
/year decrease for the plant.
7. 4 hours pa training per employee.
8. 5000 tpa petcoke saving by using 10 000 tpa of waste.
Areas for improvement
ll Taking two bag filters out of service.
ll Reducing the moisture of raw material.
ll Solving the wear problem on the mill table in raw mill no. 1.
ll Removing fresh air suction at the inlet gas pipe of raw mill
no. 2.
ll Removing fresh air suction from the body of the bag filter.
ll Renewing the low-precision old weigher for rotary kiln no.
1’s coal supply.
ll Using the expert system for the process control of the
rotary kilns and mills.
ll Waste heat recovery.
ll Exchanging the static separator of cement mill no. 3 with a
dynamic separator, which is more efficient.
ll Switching 100 electrical motors with more efficient ones.
ll Reactive power compensation and solving harmonic
distortion (legal obligation).
ll Increasing the amount of secondary fuel (waste) used.
ll Increasing cyclone efficiency for rotary kiln no. 1.
ll Improving clinker cooler efficiency for rotary kiln no. 2.
ll Detecting air leakage on compressed air lines.
ll Using LED-type lighting fixtures for outdoor lighting.
Conclusion
The only solution to meet increasing energy demand is
to use energy in an efficient manner. A successful energy
management system is required to achieve energy efficiency.
The ISO 50001 EMS is a guide to help companies implement
efficient energy management systems and reduce costs.
Bibliography
• IEA, World Energy Outlook.
• EIA, International Energy Outlook, 2013.
• www.enerji.gov.tr.
• www.tuik.gov.tr.
• ISO 50001 EMS Standard.
• TS EN ISO 50001 EnYS Standardı.
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