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FEATURE SAVING ENERGY IN A CEMENT PLANT Rising Energy Costs, Increasing Pressure To Produce Returns, And The Environment Are Creating Tremendous Interest In Energetically Optimized Plant Concepts. By Dr. Stefan Lindner and Thomas Walther E nergy supplies and changes in the climate are two of the major concerns of our day and age. In the opinion of the majority of scientists, the increasing demand for energy is accelerating the rate of climatic change, and that is something that the energyintensive cement industry wants to work against. Many cement plants are putting their money on attaining the highest possible efficiency in their production plants and on replacing primary raw materials and fuels by secondary materials in order to meet their obligations to reduce their CO2 emissions. Energy consumption, the associated pollutant emissions and the consumption of natural resources are undoubtedly the factors with the greatest ecological impacts in cement production, particularly as temperatures of more than 1,450 C have to be maintained in the kilns. From the point of view of production and environmental compatibility, the use of secondary fuels is a practicable alternative to regular fuels. Research and monitoring of the emissions into the atmosphere produced when secondary fuels are burnt in a rotary kiln have clearly shown that they are no different to those produced by burning primary fuels. crete goods and prefabricated concrete parts since 1930. It employs some 1,000 people at 40 production works in Germany and Austria. The Rohrdorf cement works has an annual capacity of approximately 1 million tons. Therefore every opportunity offered by modern technology is taken to minimize its environmental impact, and there are constant endeavors to prevent harmful effects occurring. The works facilities have changed over the course of time, and are now equipped with state-of-the-art technology. What has not changed is the way we strive to achieve the highest quality, be a reliable business partner, and do our best to protect the environment around the Rohrdorf cement works. Rohrdorf cement works faced the challenges of using secondary fuels efficiently, ensuring the trouble-free operation of the plant and the stability of the process. A modern process control system had to be installed in order to achieve these objectives. There are a number of advantages to the use of secondary fuels, for example: ■ Conservation of non-renewable fuels. ■ Energy is obtained from materials in line with the principles of recycling management strategies. ■ Minimization of CO2 emissions by partial use of fuels with biogenic percentage. Südbayerische Portland-Zementwerk GmbH is part of the Rohrdorfer Baustoffgruppe. The company has been manufacturing cement, transit-mixed concrete, con- 8 CEMENT AMERICAS • Fall 2013 • www.cementamericas.com