+86 0371 8654 9132

how to reduce cost of clinker manufacturing

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 ...

More

How Does Clinker Cooler Reduce Cement Production Energy ...

The main power consumption of a clinker cooler is its cooling fans. It usually takes 1.9-2.3 m 3 under standard conditions to cool 1 kg clinker from 1400 ℃ to 65 ℃, and the power consumption of the whole system is about 7 kWh. If the air consumption per kilogram of clinker cooling is reduced from 2 m 3 to 1.7 m 3, the air consumption efficiency will be 15% lower than that of other cement ...

More

Reducing CO2 through clinker replacement GCP Applied ...

The economic benefit from the lower clinker factor largely depends on the cost differential between the SCM and the clinker, but can be significant. The below table summarizes various means of reducing CO 2 emissions and highlights the importance of reducing clinker factor in comparison to other approaches such as improving grinding efficiency.

More

Cement Production: Focus on what really counts Endress ...

Think for example of the energy costs in the clinker manufacturing process, which can represent up to 75% of the variable costs. But to efficiently lower your expenses without compromising the quality of your products, accurate process data derived from reliable instruments is key.

More

The ever-shrinking clinker factor: Threat or opportunity?

To reduce the amount of CO 2 that is produced during the production of concrete, we can reduce the amount of clinker in the cement and/or reduce the amount of cement in the concrete. For people who are in the business of selling cement to make concrete, this does not sound like a great choice.

More

Modern Processing Techniques to minimize cost in Cement ...

competition, rising input costs, lower realisation and reducing profit margins. The need of the hour is to offset the continual increase in input costs and minimising the producing cost through optimised operations. This can be achieved by incorporation of modern processing techniques in cement production.

More

Reducing Cost of Production in Cement Plant

Nov 20, 2019  One of the major factor contributing to the success of an enterprise / organization is the Cost of Production reduction / optimization. The route to which demand Operational Excellence ...

More

Manufacturing of GREEN CLINKER UltraTech Cement ...

As per cement manufacturing process, Lime Stone mining is basic essential need and it has been optimized as per business benchmark. Hence, only way to reduce cost of production is by modifying the pyro process as it involves large energy all raw material consumption. Target setting Reduce cost by Rs. 5 crore/ annum. Project timeline

More

Clinker Production - an overview ScienceDirect Topics

G. Habert, in Eco-efficient Construction and Building Materials, 2014 Energy efficiency. Energy demand in clinker production has been significantly reduced over the last few decades. The theoretical minimum primary energy consumption (heat) for the chemical and mineralogical reactions is approximately 1.6–1.85 GJ/t (Klein and Hoening, 2006).However, there are technical reasons why this will ...

More

Top 5 Ways Manufacturers Reduce Material Costs

Jul 11, 2016  (Average reported impact: 2.7% of Cost of Goods Sold – “COGS”) This activity focuses on better aligning supplier geographically to the production location they feed.

More

Optimize clinker production performance - Endress+Hauser

It is the stage in which most of the operating costs in cement manufacturing appear and is also where most opportunities for process improvement exist. The main challenges at this stage in the clinker production are preventing blockages in the preheater, measuring the process accurately and maximizing production in this hot and rough environment.

More

Reduce Manufacturing Costs Vorne

Problem: We want a simple and effective way to reduce manufacturing costs; one that can be applied to all equipment in our plant (i.e., we want to spend less). Strategy: Focus on addressing the top sources of lost production time with a secondary focus on emergent problems (losses that are trending higher).

More

Three Ways To Lower Your Manufacturing Costs

Sep 26, 2017  While the quickest and easiest way to reduce per unit costs is usually to increase production volumes, not everyone has the budget to scale up. Here we discuss three ways to trim expenses without ...

More

Top 5 Ways Manufacturers Reduce Material Costs

Jul 11, 2016  (Average reported impact: 2.7% of Cost of Goods Sold – “COGS”) This activity focuses on better aligning supplier geographically to the production location they feed.

More

Reducing the CO2 emissions in Croatian cement industry ...

Jan 01, 2013  When calculated, the specific cost of reduction of clinker to cement ratio is between (−0.4) and 0.5 €/t CO 2 reduced. For the use of alternative fuels the specific cost is between (−7) and (−5) €/t CO 2 reduced, while the specific cost of an energy efficient combustion process is between 8 and 17 €/t CO 2 reduced.

More

Operations-driven sustainability McKinsey

Most of those emissions are generated in the production of clinker, the main ingredient of Portland cement. With tight control over material properties and production processes, some construction companies and suppliers of concrete products have been able to reduce their consumption of clinker by 10 percent or more, substituting materials such ...

More

14 Ways to Reduce Materials Cost of Goods Sold in Your ...

Production methods are usually established to minimize the costs of the highest component of production, either labor or materials, at the time the method is established. If, for example, the cost of the raw material is low, the volume of excess material or “scrap” may not be considered to be important relative to the labor cost.

More

Must-know: The cost elements of cement - Market Realist

Aug 18, 2014  The second major component in the production of cement is the cost of raw materials. The primary raw material that’s used is limestone. Raw materials account for 30%–40% of the cost

More

10 Simple Ways to Cut Business Costs - American Express

1. Reduce supply expenses. Save money on office supplies by contacting vendors to let them know you’re price shopping. Look outside your pool of traditional vendors. Large discount suppliers like BJ's, Amazon or Wal-Mart can often beat traditional office supply vendor prices. 2. Cut production costs.

More

How to Reduce Production Cost Bizfluent

Sep 26, 2017  Reducing these costs even slightly on a percentage basis can have a substantial impact on the cost of production. Sometimes companies can reduce component costs by buying in bulk or substituting less expensive components that satisfy the requirements. Sometimes a design will allow for fewer fasteners or less material without affecting quality ...

More

Cement clinker - Wikipedia

Cement clinker is a solid material produced in the manufacture of Portland cement as an intermediary product. Clinker occurs as lumps or nodules, usually 3 millimetres (0.12 in) to 25 millimetres (0.98 in) in diameter. It is produced by sintering (fusing together without melting to the point of liquefaction) limestone and aluminosilicate materials such as clay during the cement kiln stage.

More

Energy Consumption Benchmark Guide: Cement Clinker Production

Canadian cement clinker production capacity is about 14.1 million tonnes per year. In 1998, clinker production totalled 12 million tonnes for a capacity use of 85 percent. With more than 1100 ready-mixed and other plants across the country using Portland cement to make concrete, the industry employs some 22 000 people and generates more than $3 ...

More

Operating costs: Understanding and reducing them for your ...

Sep 03, 2019  Below are eight ideas that can help you reduce the operating costs of your business and enable you to reduce overhead and generate more revenue. 1. Embrace technology. There are dozens of online systems and software programs that can automate and streamline small business functions. These systems can cover an array of areas of operation ...

More

Energy optimization in cement manufacturing

costs. Efforts to reduce demands by using higher effi ciency equip- ... the air into the grate cooler to reduce the temperature of the hot clinker leaving the kiln 1. All these airflows ... The cost of production is directly in-fluenced by the the energy usage. Dif-

More

Optimize clinker production performance - Endress+Hauser

It is the stage in which most of the operating costs in cement manufacturing appear and is also where most opportunities for process improvement exist. The main challenges at this stage in the clinker production are preventing blockages in the preheater, measuring the process accurately and maximizing production in this hot and rough environment.

More

Three Ways To Lower Your Manufacturing Costs

Sep 26, 2017  While the quickest and easiest way to reduce per unit costs is usually to increase production volumes, not everyone has the budget to scale up. Here we discuss three ways to trim expenses without ...

More

Reduce Manufacturing Costs Vorne

Problem: We want a simple and effective way to reduce manufacturing costs; one that can be applied to all equipment in our plant (i.e., we want to spend less). Strategy: Focus on addressing the top sources of lost production time with a secondary focus on emergent problems (losses that are trending higher).

More

Energy Consumption Benchmark Guide: Cement Clinker Production

Canadian cement clinker production capacity is about 14.1 million tonnes per year. In 1998, clinker production totalled 12 million tonnes for a capacity use of 85 percent. With more than 1100 ready-mixed and other plants across the country using Portland cement to make concrete, the industry employs some 22 000 people and generates more than $3 ...

More

Operations-driven sustainability McKinsey

Most of those emissions are generated in the production of clinker, the main ingredient of Portland cement. With tight control over material properties and production processes, some construction companies and suppliers of concrete products have been able to reduce their consumption of clinker by 10 percent or more, substituting materials such ...

More

Increase capacity and cut CO2 emissions with calcined clay ...

Manufacturing clinker is energy and emissions intensive. The less clinker you can use, the less impact you have on the environment. With our clay calciner system you can reduce process emissions by up to 40% and get a cost-effective, quality product that meets your strength and colour expectations – all while reducing your operating costs.

More

How to reduce costs in a factory? The lean approach ...

Over-production: producing more than current orders call for, “just in case”. It might stay in inventory for a long time and lose value. Defects: processing some material in a way that is not satisfactory. I already detailed the costs of defects before. So, how to reduce all this waste? The production organization needs to be completely ...

More

Cement clinker - Wikipedia

Cement clinker is a solid material produced in the manufacture of Portland cement as an intermediary product. Clinker occurs as lumps or nodules, usually 3 millimetres (0.12 in) to 25 millimetres (0.98 in) in diameter. It is produced by sintering (fusing together without melting to the point of liquefaction) limestone and aluminosilicate materials such as clay during the cement kiln stage.

More

Pet coke in cement clinker - SlideShare

Jul 11, 2015  Pet coke in cement clinker 1. What is PET-COKE * Petroleum coke is a by-product / undesirable product of oil refining cracking process. * The most attractive thing for use of Pet-coke is the high calorific value having lower cost as well as lower handling cost per unit of heat content. 2.

More

Operating costs: Understanding and reducing them for your ...

Sep 03, 2019  Below are eight ideas that can help you reduce the operating costs of your business and enable you to reduce overhead and generate more revenue. 1. Embrace technology. There are dozens of online systems and software programs that can automate and streamline small business functions. These systems can cover an array of areas of operation ...

More

Manufacturing process of cement - Wet Process Cement ...

Jul 09, 2020  Jul 9, 2020 cement manufacturing process, cement production process, clinker, flow diagram of cement production, manufacturing process of cement by wet process, preheating tower Cement is the most significant material used in construction and

More

(PDF) CO2 emission reduction in the cement industry ...

The study showed that the benefit of the calcium looping technology is that the lime removed from the cycle could be used for the production of clinker, and therefore reduce the CO2 emissions from the cement industry. Furthermore, by improving the energy efficiency of the clinker production process CO2 emissions can also be reduced.

More

3.1 CO2 Cement Production - IGES

Background Paper Industrial Processes Sector 178 2.3 Activity data 2.3.1 Clinker data IPCC recommends using clinker data, rather than cement data, to estimate CO2 emissions because CO2 is emitted during clinker production (not cement production).

More

Heavy industry and the net-zero economy Energy Climate ...

Reducing clinker content by 70% is feasible, and could save about three-fifths of projected cement emissions globally in 2050 at very little cost. The process of producing clinker itself can also be made cleaner by using ingredients such as graphene , and by substituting the fossil fuels – mainly coal – used to power cement kilns.

More