Analysis of energy-efficiency opportunities for the cement industry in Shandong Province,China: A case study of 16 cement plants

In this study, 16 cement plants with New Suspension Preheater and pre-calciner (NSP) kiln were surveyed. Plant energy use was compared to both domestic (Chinese) and international best practice using the Benchmarking and Energy Saving Tool for Cement (BEST-Cement). This benchmarking exercise indicated an average technical potential primary energy savings of 12% would be possible if the surveyed plants operated at domestic best practice levels in terms of energy use per ton of cement produced. Average technical potential primary energy savings of 23% would be realized if the plants operated at international best practice levels. Then, using the bottom-up Electricity Conservation Supply Curve (ECSC) model, the cost-effective electricity efficiency potential for the 16 studied cement plants in 2008 is estimated to be 373 gigawatt-hours (GWh), and total technical electricity-saving potential is 915 GWh, which accounts for 16 and 40% of total electricity use in the studied plants in 2008, respectively. The Fuel Conservation Supply Curve (FCSC) model shows the total technical fuel efficiency potential equal to 7949 terajoules (TJ), accounting for 8% of total fuel used in the studied cement plants in 2008. All the fuel efficiency potential is shown to be cost effective.