Whether it’s due to the booming market or ever-tightening greenhouse gas emissions targets, choosing to upgrade your cement plant is a major business decision. And any cost-effective solution requires strategically planned delivery in order to minimise disruption to your operations. No matter where a cement plant is based in the world, localised fluctuations in supply and demand, alongside continually-evolving legal and regulatory frameworks mean cement factory operators need to keep pace with change, or better still, ahead of the curve. We take a closer look at the two most common reasons to upgrade your operations. Increased Capacity When demand outweighs supply, you know it’s time to increase capacity. By 2025, it is forecasted that global demand for cement is expected to rise by around 2.9% annually to reach an estimated 4.7 billion metric tons. This demand is due to increased urbanisation, and large-scale infrastructure projects, predominantly sited in Asia and Africa. To maintain market share, upgrading your existing plant offers competitive advantages and economic benefits. Here are four reasons to upgrade: 1. Improve the accuracy of processing technology and cement production 2. Use updated equipment to drive efficiencies in production 3. Increase production line automations to cut production times 4. Optimize production to reduce wastage and become more energy efficient. Improved Sustainability With every business in the world needing to comply with ever-tightening greenhouse gas emissions targets, and environmental regulations, it’s important for the cement industry to find more sustainable solutions. At present, the industry accounts for around 7% of global CO2 emissions. CO2 emissions occur at the process stages of cement production, so this is where we find the biggest opportunity to reduce emission and improve energy efficiency. This includes the transportation of raw materials and products, the burning of fossil fuels, and the use of electrical energy. Emissions vary depending on a number of factors, including: cement production technology the quality of raw materials and additives transportation type use of waste and energy efficiency fuel usage Thankfully, there are a number of ways the industry can reduce carbon emissions. Here are three viable approaches: Firstly, carbon capture and storage can stop CO2 from reaching the atmosphere. Research shows that this could capture up to 90% of emissions in cement production. Secondly, cement production releases heat. Waste heat recovery can be used to produce carbon dioxide-free energy electricity. Thirdly, clinker-free or ‘novel’ cements could help to massively reduce carbon emission alongside clinker substitutions which reduce dependence on energy-intensive clinker production. A Greener Future For The Cement Industry The cement industry is facing a real and ongoing challenge, and there’s no easy way forward. On one hand, cement plants need to increase capacity to meet global demand for concrete. On the other hand, cement producers must find ways to drastically reduce carbon emissions. Sintek’s deep respect for people and the planet means we’re focussed on leaving behind a greener world for future generations. That’s why we’ve established Minerva Engineering, a research and development company exploring possible solutions that will reduce the carbon footprint of the cement industry. Right now, Minerva Engineering is examining grinding efficiency and calcined clay production technologies, with a focus on reduced energy consumption. Learn more about the valuable work being carried out by Minerva Engineering.
