how to reduce cost of clinker manufacturing

Paving the way for sustainable decarbonization of the …

Using a lower clinker-to-cement ratio (CCR) decreases clinker use and can reduce carbon emissions of 12 ± 3% after accounting for projected changes in cement …

17 Ways To Reduce Manufacturing Costs in 2024

Here are 17 practical ways to reduce manufacturing costs in 2024: 1. Embrace Lean Manufacturing. Implement lean principles to identify and eliminate waste in your production processes. Streamline workflows, optimize resource utilization, and continuously assess and refine your operations to enhance overall efficiency.

Alternative Fuels in Cement Manufacturing

The cement manufacturing industry is also under increasing pressure to reduce emissions. Cement manufacturing releases a lot of emissions such as carbon dioxide (CO 2) and nitrogen oxide ... 40 percent of production costs (Giddings et al., 2000; EC ... The process of clinker production in kiln systems creates favourable conditions …

Energy Efficiency Improvement and Cost Saving …

The cost of energy as part of the total production costs in the cement industry is significant, ... share of wet-process plants decreased from 60% in 1970 to about 7% of clinker production in 2010 in the U.S. The remaining plants suggest the existence of a considerable potential, ... seek opportunities to reduce production costs without ...

What is Cement Clinker? Composition, Types & Uses

This concept is used in producing a type of clinker with up to 30% less carbon dioxide emission. Energy efficiency improves and the electricity costs for the manufacturing process are about 15% lower as well. Use of Clinker: Conversion to Cement. Clinker, combined with additives and ground into a fine powder, is used as a binder in cement …

How Cement is Made

Stage of Cement Manufacture. There are six main stages of the cement manufacturing process. Stage 1: Raw Material Extraction/Quarry The raw cement ingredients needed for cement production are limestone (calcium), sand and clay (silicon, aluminum, iron), shale, fly ash, mill scale, and bauxite. The ore rocks are quarried and crushed into smaller …

Near-term pathways for decarbonizing global concrete production …

Here, we show that a combination of manufacturing and engineering decisions have the potential to reduce over 76% of the GHG emissions from cement and concrete production, equivalent to 3.6 Gt CO2 ...

Using alternative fuels in cement production

Kiln fuel typically represents approximately 25% of clinker production costs, with fossil fuels costing around $100/t. Alternative fuels often cost much less, and can even command a gate fee (negative cost). Another key driver is sustainability. While all fuels release CO 2 when burned, some alternative fuels are considered CO 2 neutral.

Cementing your lead in the green transition | McKinsey

The cost of lower-carbon-clinker production could be up to 45 percent higher than that of traditional clinker, 2 Sebastian Reiter, ... These offerings could reduce the cost of decarbonization on the cement and concrete manufacturing side while enabling maximum performance of the materials and the lowest CO 2 footprint possible.

Sustainable alternatives to CO2 reduction in the cement …

This modernization also implies a substantial investment, although cement cost is maintained as energy costs are being reduced [7]. 3. Changing fuel type. Furnaces used in cement production are flexible regarding fuel and may be substituted by ecological alternatives as biomass, thus expecting to reduce 15% of total CO 2 emission.

AI Kiln Solution For Optimized Control How To Reduce …

the clinker silo. In the production line, water is used to cool the clinker. The cooling of the clinker also has a great influence on its quality. III. PROBLEM STATEMENT: KILN CONTROL AND QUALITY CLINKER PRODUCTION The primary control objective in the industry is to achieve an optimum balance between quality and production, and this is

Cement substitution with secondary materials can reduce …

We also show that nearly all of the highest cement producing nations can locally generate and use secondary CMs to substitute up to 50% domestic Portland …

Kiln electrification key to decarbonisation of manufacturing …

Clinker is the primary raw material in cement. Nearly 90 per cent of the total CO2 emissions (scope 1 and 2) come from clinker production. Around 40 per cent of these emissions are thermal emissions from burning fossil fuels, 50 per cent are process-related emissions and the remaining 10 per cent mostly come from electricity consumption.

Cement Clinker Production

The use of RHA reduces the cost of blended cement production. Reduction in permeability and sulphate attack (sulphate source from the soil) are evidently reported for RHA blended concrete (Chindaprasirt et al., ... reported that using 16 % oil shale ash in OPC clinker production can reduce the clinkering temperature by approximately 10 % ...

15 Ways to Reduce Costs in Manufacturing

Brief Overview of the 15 Ways to Reduce Costs in Manufacturing. Manufacturing is a highly competitive industry, and cost reduction is a top priority for businesses looking to stay ahead. There are numerous ways …

The four major costs associated with cement production

1. Power and fuel. The cement industry is power-intensive, with power and fuel cost accounting for around 25-30 per cent of the total cost of sales of cement players. Coal is used to fire the kiln as well as to generate power for grinding the clinker.

Optimization of the Clinker Production Phase in a Cement …

Subsequently, clinker is grinded and combined with other components, such as calcium sulfate or pozzuolan, obtaining the desired type of cement. The clinker production phase at issue processes about 899000 tons per year of raw meal, using 59100 tons per year of fuel (coal); about 584000 tons per year of clinker are produced.

Global database of cement production assets and upstream …

The next step in the production process is the creation of clinker, which is the most energy and emissions intensive step in the cement production process. In clinker production the mixture of raw ...

Emission reduction through process integration and …

Various measures can be applied in the clinker manufacturing process to reduce the NO x, SO x, CO 2 and particulate matter emissions. ... Importantly, energy contributes around 25–35% cost of total cement production. Thus, the mass and energy balance studies were conducted as per the thermodynamic law for cold and hot streams …

A Co-Production System of Cement and Methanol: Unveiling …

The results demonstrate that the co-production system can achieve a 6.6% higher emissions reduction and a 21.2 % lower production cost of clinker by 2060 …

Thermodynamic modelling of cements clinkering process as …

World cement production is about 4.3 billion tons per year 1, with an average consumption of raw materials of about 1.6 tonnes for each tonne of cement manufactured 2.Valorisation of waste or by ...

Cementing your lead in the green transition | McKinsey

Strategically built megaplants could potentially reduce production costs for lower-carbon clinker by up to 60 percent, making it a more economically viable option …

Efficiency enhancement and cost reduction in cement clinker …

The application of exergy analysis to cement manufacturing increased system performance and positively affected production costs. In this study, the energy …

Cement industry greenhouse gas emissions

1. Introduction. Since 1950 the production of cement has gone up by a factor of 25, and China used more cement in 2011–2013 than the USA during the entire 20th century (Smil, 2013).Consequently, in 2010 the cement sector was responsible for 2823 million metric tons (Mt) of CO 2 emissions (OECD, 2012).This corresponded to …

Reactions in the cement kiln

Clinker liquid and nodule formation Above about 1300 °C the proportion of liquid starts to increase - by 1450 °C, perhaps 20-30% of the mix is liquid. The liquid forms from melting ferrite and aluminate phases and some belite. ... However, reading an article or two is perhaps not the best way to get a clear picture of a complex process like ...

1. Introduction

To date, clinker substitution has contributed on average to a 20–30 per cent decrease in CO 2 emissions per tonne of cement produced, compared to the 1980s. 57 The average clinker ratio was around 0.65 in 2014. 58 While the reduction in clinker use has been substantial, clinker ratios have recently levelled off (see Figure 6) and there is ...

Reducing the Clinker Factor – Part 1

The incentive to 'reduce the clinker factor' in cement products is two-fold. The primary motivation is to reduce the energy consumption and CO 2 emissions associated …

LCA and negative emission potential of retrofitted cement …

For the cement clinker production cases with increased use of miscanthus biomass, the negative climate impacts are further increased, providing additional mitigation in 2050 of − 128 gCO 2eq kg ...

Review on energy conservation and emission reduction …

The dry process of cement manufacturing utilizes 3.40 GJ of specific energy per ton of clinker production, while the wet process utilizes 5.29 GJ/t. It has been reported that the specific energy consumption value for many countries is less than 2.95 GJ per ton of clinker, while the minimum value in India is 3.06 GJ ( Madlool et al., 2011, 2012 ...