A critical review on energy use and savings in the cement industries
TL;DR: In this article, a state-of-the-art review on the energy use and savings is presented to identify energy wastage so that necessary measures could be implemented to reduce energy consumption in this sub-sector.
Abstract: The cement sub-sector consumes approximately 12–15% of total industrial energy use. Therefore, a state of art review on the energy use and savings is necessary to identify energy wastage so that necessary measures could be implemented to reduce energy consumption in this sub-sector. In this paper energy use at different sections of cement industries, specific energy consumption, types of energy use, details of cement manufacturing processes, various energy savings measures were reviewed and presented. Various energy savings measures were critically analyzed considering amount of energy that can be saved along with the implementation cost. Amount of CO2 reduction has been presented along with the payback period for different energy savings measures as well. This study complied a comprehensive literature on the cement industries in terms of Thesis (MS and PhD), peer reviewed journals papers, conference proceedings, books, reports, websites. It has been observed that China producing major share of global cement production. Coal contribute major share of fuel used in cement industries. However, along with conventional fuels, industries are moving towards the use of alternative fuels to reduce environmental pollution. It was reported that cement industries are moving from wet process to dry process as it consume less energy compared to wet process.
Citations
More filters
TL;DR: In this paper, three strategies of CO2 reduction including energy saving, carbon separation and storage as well as utilizing alternative materials in detail have been reviewed and the barriers against worldwide deployment of such strategies are identified and comprehensively described.
903 citations
TL;DR: An overview of the technical and economic aspects, as well as the market evolution of the organic Rankine Cycle (ORC) is presented in this article. But it is not a suitable working fluid for these systems since there is as yet none that provides all aspects that must be taken into account in ORCs.
Abstract: This paper presents an overview of the technical and economic aspects, as well as the market evolution of the Organic Rankine Cycle (ORC). This is an unconventional but very promising technology for the conversion of thermal energy, at low and medium temperatures, into electrical and/or mechanical energy on a small scale. As it makes a greater and/or more intensive use of its energy source, this technology could facilitate an electricity supply to unconnected areas, the self-production of energy, the desalination of seawater for human consumption, or even to increase the energy efficiency in the industrial sector respecting the environment. A look at the scientific publications on this topic shows an open research line, namely the selection of a suitable working fluid for these systems, since there is as yet none that provides all aspects that must be taken into account in ORCs. Furthermore, a description and an analysis of the applications of the proposed technology is carried out, specifying the main providers, which at the present time is limited mainly to the range 0.2–2 MWe with a cost of around 1 and 4 × 103 €/kWe. Lower powers are in pre-commercial status.
468 citations
22 Sep 2020
TL;DR: In this article, a review of the available solutions that can be implemented within the next decade and beyond to reduce greenhouse gas emissions from cement and concrete production is presented, which reveals credible pathways for sustainable concrete use that balance societal needs, environmental requirements and technical feasibility.
Abstract: The use of cement and concrete, among the most widely used man-made materials, is under scrutiny. Owing to their large-scale use, production of cement and concrete results in substantial emission of greenhouse gases and places strain on the availability of natural resources, such as water. Projected urbanization over the next 50–100 years therefore indicates that the demand for cement and concrete will continue to increase, necessitating strategies to limit their environmental impact. In this Review, we shed light on the available solutions that can be implemented within the next decade and beyond to reduce greenhouse gas emissions from cement and concrete production. As the construction sector has proven to be very slow-moving and risk-averse, we focus on minor improvements that can be achieved across the value chain, such as the use of supplementary cementitious materials and optimizing the clinker content of cement. Critically, the combined effect of these marginal gains can have an important impact on reducing greenhouse gas emissions by up to 50% if all stakeholders are engaged. In doing so, we reveal credible pathways for sustainable concrete use that balance societal needs, environmental requirements and technical feasibility. Concrete is one of the most widely used man-made materials and is critical for the ongoing urbanization of the global population. However, owing to its widespread use, concrete can have a negative impact on the environment. This Review provides medium-term and long-term solutions to address the environmental concerns surrounding concrete production.
354 citations
TL;DR: In this article, the authors studied the management of GHG emissions in the cement production chain and found that the use of clinker substitutes in cement varied from 3% to 36.4% and the highest near term potential to avoid emissions is replacing clinker with mineral components.
325 citations
Cites background from "A critical review on energy use and..."
...…production emissions are improved energy efficiency through improved technology, better process integration, and fuel switching together with the use of clinker substitutes like waste fly ash and slags from power production and minerals processing (McLellan et al., 2012, Worrell et al., 2008)....
[...]
TL;DR: The cumulative global capacity of organic Rankine cycle (ORC) power systems for the conversion of renewable and waste thermal energy is undergoing a rapid growth and is estimated to be approx. 2000 MWe considering only installations that went into operation after 1995 as mentioned in this paper.
Abstract: The cumulative global capacity of organic Rankine cycle (ORC) power systems for the conversion of renewable and waste thermal energy is undergoing a rapid growth and is estimated to be approx. 2000 MWe considering only installations that went into operation after 1995. The potential for the conversion of the thermal power coming from liquid-dominated geothermal reservoirs, waste heat from primary engines or industrial processes, biomass combustion, and concentrated solar radiation into electricity is arguably enormous. ORC technology is possibly the most flexible in terms of capacity and temperature level and is currently often the only applicable technology for the conversion of external thermal energy sources. In addition, ORC power systems are suitable for the cogeneration of heating and/or cooling, another advantage in the framework of distributed power generation. Related research and development is therefore very lively. These considerations motivated the effort documented in this article, aimed at providing consistent information about the evolution, state, and future of this power conversion technology. First, basic theoretical elements on the thermodynamic cycle, working fluid, and design aspects are illustrated, together with an evaluation of the advantages and disadvantages in comparison to competing technologies. An overview of the long history of the development of ORC power systems follows, in order to place the more recent evolution into perspective. Then, a compendium of the many aspects of the state of the art is illustrated: the solutions currently adopted in commercial plants and the main-stream applications, including information about exemplary installations. A classification and terminology for ORC power plants are proposed. An outlook on the many research and development activities is provided, whereby information on new high-impact applications, such as automotive heat recovery is included. Possible directions of future developments are highlighted, ranging from efforts targeting volume-produced stationary and mobile mini-ORC systems with a power output of few kWe, up to large MWe base-load ORC plants.
308 citations
References
More filters
TL;DR: In this article, the authors evaluated the environmental impact of four cement manufacturing processes: (1) the production of traditional Portland cement, (2) blended cement (natural pozzolans), (3) cement where 100% of waste cement kiln dust is recycled into the kiln process, and (4) Portland cement produced when CKD is used to sequester a portion of the process related CO2 emissions.
994 citations
TL;DR: A comprehensive literature review about industrial energy saving by management, technologies and policies has been presented in this paper, where the authors have found that in the industrial sectors, a sizeable amount of electric energy, emissions and utility bill can be saved using these technologies.
Abstract: An industrial sector uses more energy than any other end-use sectors and currently this sector is consuming about 37% of the world's total delivered energy. Energy is consumed in the industrial sector by a diverse group of industries including manufacturing, agriculture, mining, and construction and for a wide range of activities, such as processing and assembly, space conditioning, and lighting. This paper presents a comprehensive literature review about industrial energy saving by management, technologies and policies. Latest literatures in terms of thesis (MS and PhD), journal articles, conference proceedings, web materials, reports, books, handbooks on industrial energy management, policies and energy savings strategies have been compiled. Energy saving by management including energy audit, training programs and housekeeping beside some energy management practices in the world has been reviewed. Energy saving technologies, such as use of high efficiency motors (HEMs), variable speed drives (VSDs), economizers, leak prevention and reducing pressure drop has been reviewed. Based on energy saving technologies results, it has been found that in the industrial sectors, a sizeable amount of electric energy, emissions and utility bill can be saved using these technologies. Payback periods for different energy savings measures have been identified and found to be economically viable in most cases. Finally, various energy-saving policies for few selected countries were reviewed.
700 citations
TL;DR: A comprehensive literature review about electric motor energy analysis is presented in this article, where different types of losses that occur in a motor have been identified and ways to overcome these losses explained and an energy audit that helps to identify motor energy wastages have been discussed extensively.
Abstract: The industrial sector is the largest users of energy around the world. Industrial motor uses a major fraction of total industrial energy uses. This paper describes a comprehensive literature review about electric motor energy analysis. This paper compiles latest literatures in terms of thesis (MS and PhD), journal articles, conference proceedings, web materials, reports, books, handbooks on electrical motor energy use, losses, efficiency, energy savings strategies. Different types of losses that occur in a motor have been identified and ways to overcome these losses explained. An energy audit that helps to identify motor energy wastages have been discussed extensively. As motors are the major energy users, different energy savings strategies such as use of high-efficient motor, variable speed drive (VSD), and capacitor bank to improve the power factor to reduce their energy uses have reviewed. Different policy measures (i.e. regulatory, voluntary and incentives based) to save motor energy use have been reviewed and presented in this paper. In this review, computer tools that can be used to analyze electric motors energy used has been discussed. Cost parameters to carry out economic analysis have been shown as well. Moreover, payback period for different energy savings strategies have been identified.
398 citations
TL;DR: In this article, a comprehensive literature review about compressed air energy use, savings, and payback period of energy efficient strategies is presented, where various energy-saving measures, such as use of highly efficient motors, VSD, leak prevention, use of outside intake air, reducing pressure drop, recovering waste heat, and use of variable displacement compressor to save compressed-air energy have been reviewed.
Abstract: Compressed-air systems account for about 10% of total industrial-energy use for few selected countries as found in literatures. Compressed air is typically one of the most expensive utilities in an industrial facility. This paper describes a comprehensive literature review about compressed air energy use, savings, and payback period of energy efficient strategies. This paper compiles latest literatures in terms of thesis (MS and PhD), journal articles, conference proceedings, web materials, reports, books, handbooks on compressed air energy use, efficiency, energy savings strategies. Computer tools for compressed air analysis have been reviewed and presented in this paper. Various energy-saving measures, such as use of highly efficient motors, VSD, leak prevention, use of outside intake air, reducing pressure drop, recovering waste heat, use of efficient nozzle, and use of variable displacement compressor to save compressed-air energy have been reviewed. Based on review results, it has been found that for an electric motor used in a compressed-air system, a sizeable amount of electric energy and utility bill can be saved using high efficient motors and applying VSDs in matching speed requirements. Also, significant amounts of energy and emission are reducible through various energy-saving strategies. Payback periods for different energy savings measures have been identified and found to be economically viable in most cases.
365 citations
TL;DR: The organic rankine cycle (ORC) was defined as a bottoming cycle in this article, which refers to the power cycle that uses waste industrial heat for power generation by supplementing heat from any f...
359 citations