Ingeniero Industrial

LBNL-54036

ERNEST ORLANDO LAWRENCE BERKELEY NATIONAL LABORATORY

Energy Efficiency Improvement Opportunities for Cement Making
An ENERGY STAR Guide for Energy and Plant Managers

Ernst Worrell and Christina Galitsky
Environmental Energy Technologies Division

Sponsored by the U.S. Environmental Protection Agency

January 2004

Disclaimer This document was prepared as an accountof work sponsored by the United States Government. While this document is believed to contain correct information, neither the United States Government nor any agency thereof, nor The Regents of the University of California, nor any of their employees, makes any warranty, express or implied, or assumes any legal responsibility for the accuracy, completeness, or usefulness of any information,apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by its trade name, trademark, manufacturer, or otherwise, does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof, or The Regents ofthe University of California. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof, or The Regents of the University of California. Ernest Orlando Lawrence Berkeley National Laboratory is an equal opportunity employer.

LBNL-54036

Energy Efficiency Improvement Opportunities for Cement Making AnENERGY STAR Guide for Energy and Plant Managers

Ernst Worrell and Christina Galitsky

Energy Analysis Department Environmental Energy Technologies Division Ernest Orlando Lawrence Berkeley National Laboratory University of California Berkeley, California 94720 January 2004

This work was funded by U.S. Environmental Protection Agency’s Climate Protection Partnerships Division as part of ENERGYSTAR. ENERGY STAR is a government-backed program that helps businesses protect the environment through superior energy efficiency. The work was supported by the U.S. Environmental Protection Agency through the U.S. Department of Energy Contract No. DEAC03-76SF00098.

Energy Efficiency Improvement and Cost Saving Opportunities for Cement Making An ENERGY STAR Guide for Energy and PlantManagers
Ernst Worrell and Christina Galitsky Energy Analysis Department Environmental Energy Technologies Division Ernest Orlando Lawrence Berkeley National Laboratory January 2004

ABSTRACT The cost of energy as part of the total production costs in the cement industry is significant, warranting attention for energy efficiency to improve the bottom line. Historically, energy intensity hasdeclined, although more recently energy intensity seems to have stabilized with the gains. Coal and coke are currently the primary fuels for the sector, supplanting the dominance of natural gas in the 1970s. Most recently, there is a slight increase in the use of waste fuels, including tires. Between 1970 and 1999, primary physical energy intensity for cement production dropped 1%/year from 7.3MBtu/short ton to 5.3 MBtu/short ton. Carbon dioxide intensity due to fuel consumption and raw material calcination dropped 16%, from 609 lb. C/ton of cement (0.31 tC/tonne) to 510 lb. C/ton cement (0.26 tC/tonne). Despite the historic progress, there is ample room for energy efficiency improvement. The relatively high share of wet-process plants (25% of clinker production in 1999 in the U.S.) suggeststhe existence of a considerable potential, when compared to other industrialized countries. We examined over 40 energy efficient technologies and measures and estimated energy savings, carbon dioxide savings, investment costs, and operation and maintenance costs for each of the measures. The report describes the measures and experiences of cement plants around the world with these practices and...