Energy_Efficiency_in_Cement_Industry-- 8000BR1104.pdf

7/25/2019 Energy_Efficiency_in_Cement_Industry-- 8000BR1104.pdf

1/8

Schneider Electric Case Study

Big Picture Strategies Contribute

to Energy Efficiencyin the Cement Industry

Make the most of your energySM

A Cement Manufacturing FacilityUSA


2/8

While there are a number of factors influencing the attitudes and opinions towards

energy efficiency most notably the increasing cost of energy and a rising social

conscience legislative drivers likely will have the greatest impact on changing

behaviors and practices. Internationally, governments are introducing energy

saving targets and effecting regulations to ensure they are met.

For businesses, it is important to highlight that decreasing energy consumption

contributes both directly to the cost of goods sold and indirectly by impacting the

cost of energy generation emissions. Both factors improve financial performance,

as well as contribute to sustainable development efforts.

Social pressure to meet the needs of the present without compromising future

generations also play a critical role. Implementing an energy solution helps

companies meet their own needs and is another factor in expanding the scope

of energy efficiency solutions.

As an energy intensive industry, cement manufacturers must be ready to

undertake major efforts to contain energy consumption.

Energy Consumption in the Cement IndustryOver four million British Thermal Units (BTUs) of energy are required to

manufacture one ton of cement, approximately 90 percent of which is thermal

energy and 10 percent is electrical energy. In terms of the cost per ton, these

percentages may change based upon the different unit costs of energy.

The following average figures illustrate the energy challenge facing

cement manufacturing:

More than 80 percent of the electricity consumed in a cement plant is

motor/machine driven

Finish grinding consumes 40 percent of electric power

110 kWh of electricity is required to produce one ton of cement

Energy consumption by the cement industry is estimated at about two percent

of the global primary energy consumption

Energy costs can contribute up to 40 percent of operation costs

Schneider Electric Case Study > A Cement Manufacturing Facility

2 I Big Picture Strategies Contribute to Energy Efficiency in the Cement Industry


3/8


Big Picture Strategies Contribute to Energy Efficiency in the Cement Industry I

Understanding and Containing Energy in theCement IndustryCement producers are working together and partnering with government

agencies to contribute to sustainable development and to share best practices.

Energy efficiency is a key focus of these initiatives. Three of the more prominent

examples include:

The Cement Sustainability Initiative (CSI)

The Cement Sustainability Initiative (CSI) is a sector project from World Business

Council for Sustainable Development (WBCSD) and it joins the major global

cement producers in a common alliance to discuss and propose strategic

solutions addressing critical issues, including energy, health, emissions

and more.

U.S. Energy Star cement manufacturing

A proposed partnership between the U.S. Environmental Protection Agency,

the Energy Star program and cement companies would take a structured

approach to improving energy efficiency, including strategic and corporate

recommendations, assessment, key performance indicators (KPIs) and

reporting tools.

The China example

In 2007, China spurred investment in renewable energy by introducing several

environmental and energy efficiency actions and laws to shape energy-saving

guidelines for cement manufacturing plants.

Energy Efficiency Challenges for theCement IndustryCement manufacturers face a myriad of challenges when attempting to optimize

energy usage, including:

Absence of energy efficiency as corporate culture

It is very common for energy efficiency to be treated as a corrective tool rather

than a routine behavior. Using energy efficiency actions as a remedy may fix

immediate problems and momentarily reduce consumption, but it doesnt

generate a positive cycle in the plant or a long-term strategy.

Lack of online and integrated information

A recent ARC Advisory Group survey demonstrated that just 10 percent of

industrial users have immediate access to the impacts of energy cost changes.

Some users dont realize their energy efficiency problems until long after the root

events have occurred. When information is available, its often not granular down

to every load.

As part of their five-year plan,

China intends to cut energy

consumption per unit of gross

domestic product (GDP) in the

cement industry by 25 percent

throughout five years.


4/8

To minimize these issues, users need a deeper understanding of how energy is

used and the ability to identify the drivers and root causes for increased energy

consumption per unit of production. This understanding requires timely access

to accurate energy information as well as the operational context of how that

energy was used.

Some users have the energy consumption information, but its not cross-

referenced with production information, so users cant identify the difference

between overconsumption generated by legitimate process requirements

against overconsumption caused by problems or under performance.

In this situation, forecasting is a challenge since there is no complete model

about how energy has been used.

Energy not treated as a process variable

In many plants it is very common for electrical and process control to be treated

as two separate departments. In this situation there are classic information silos

with no connection between them, and energy information isnt used as an

active process variable. An optimum process analysis must take into account

energy consumption.

No benchmarking

Some companies dont compare plant performance against other plants or

unitary processes to identify best practices and energy-saving opportunities.

It is very common for success cases to be isolated and not shared with other

branches or plants.

A new energy efficiency strategy

Implementing energy efficiency initiatives in cement plants goes beyond well-

known actions like applying variable speed drives and advanced process

optimization in grinding and kiln combustion. Cement companies must strive for

bigger changes to realize the greatest savings.

Sustainability task force

The first recommended action is to create an energy efficiency and sustainability

task force or department. This multidisciplinary team will be charged with

coordinating all transverse activities related to energy efficiency. Energy teams

also require a broad corporate involvement, from the corporate levels to

operational levels. As with any quality control approach, energy efficiency teams

have to use a systematic and simple approach of define, measure, analyze,

improve and control (DMAIC) to achieve long term results.

Measurements and management

After establishing a sustainability task force, the next step is to conduct a plant

assessment to identify bottlenecks and propose improvements for mechanical,

electrical and production processes. In addition, the task force can make



Energy consumption by the

cement industry is estimated at

about two percent of the global

primary energy consumption.


5/8



recommendations involving alternatives fuels and renewable energy actions.

But these actions wont bring any long term effect if online information isnt

always available. A metering system is necessary for generating data for real-

time actions, as well historic data for future crossed analysis. Water, air, gas,

electricity and emissions are metered, checked for data quality, and warehoused

for analysis. Advanced modeling and visualization help you reveal energy

inefficiencies, set priorities and keep each project on track.

An energy management system also is essential to track real-time power

conditions, analyze power quality and reliability, and respond quickly to alarms

to avoid critical situations. It helps you study trends to reveal energy waste or

unused capacity as well, as verify efficiency improvements and allocate costs to

buildings, departments or processes.

Central control room

An up-and-coming concept in cement manufacturing is the use of a central,

virtual control room. The central control room monitors several cement

plants in distant locations from a single location. Central control rooms in use

today monitor all energy consumption from different units and compare the

performance among different plants down to the equipment level and loads, all

from a single location.

It is even possible to outsource the remote monitoring to an energy

management technology supplier that manages the user information and

historic data in virtual servers.

Reporting tools

Reporting tools bring relevant and filtered information to all enterprise levels

allowing empowerment and company-wide commitment. Automated reporting

tools minimize manual data entry and can be customized to adhere to the CSI

and the Greenhouse Gas Protocol Initiative. A production management system

can gather data from distinctive sources and aggregate information to generate

decision reports and KPIs against established targets.

Production Energy OptimizationProduction energy optimization is a combined approach that integrates production

management with energy management systems. This solution crosses energy

information against production variables and business context.

The system also determines the historical correlation between energy

consumption and process variables to produce an energy model that states

energy consumption (MWh). This mechanism for modeling energy consumption is

a sophisticated tool to generate forecast.

More than 80 percent of the

electricity consumed in a cement

plant is motor/machine driven.


6/8

Power and Control IntegrationPhysically integrating process control, electrical distribution, motor control

and energy efficiency systems exchanges useful information for process

improvements. Integration based on Ethernet TCP/IP and Web tools, provides

the greatest openness and transparency at all levels of the enterprise. Ethernet

simplifies the overall communications infrastructure by expanding the horizon of

components and innovation, and provides consistency and simple integration of

plant floor with business level communications.

Intelligent motor control centers and networked intelligent relays not only provide

improved motor protection, but offer information granularity for a precise load

analysis. Virtually every single motor in the plant is delivering power information.

More than 80 percent of the electricity consumed in a cement plant is motor/

machine driven.

Choosing the Right PartnerThese recommendations are a small sample of how strategic actions and new

technologies can significantly contribute to energy containment in cement plant

operations. Its also important to choose a trusted engineering partner with proven

energy consulting experience. Properly integrating the right tactics with help from

the right partner can help cement manufacturers to optimize energy consumption

throughout their plants lifecycle and improve safety, productivity, cost efficiency

and environmental consciousness.




7/8



Make the most of your energySM

Schneider Electric provides inspired and comprehensive energy

solutions that transform the way businesses manage their

environment, efficiency, and costs.

As a global specialist in energy management with operations in

more than 100 countries, Schneider Electric offers integrated

solutions in energy and infrastructure, industrial processes, building

automation, and data centers/networks, as well as residential

applications. Schneider Electric is dedicated to making individuals

and organizations energy safe, reliable, efficient, productive, and

green from plant to plug.


8/8

Schneider Electric USA, Inc.

Automation and Control Center of Exce llence

8001 Knightdale Blvd.

Knightdale, NC 27545

Tel: 919-266-3671

www.schneider-electric.us

This document has beenprinted on recycled paper

Document Number 8000BR1104 April 2011 s

Schneider Electric Canada, Inc.

19 Waterman Avenue

Toronto, ON M4B 1Y2

Tel: 1-800-565-6699

www.schneider-electric.ca

Energy_Efficiency_in_Cement_Industry-- 8000BR1104.pdf

Documents

Transcript of Energy_Efficiency_in_Cement_Industry-- 8000BR1104.pdf