Preventive Maintenance

While many processes in cement production are primarily automated, there are still opportunities to increase energy savings through preventative maintenance. Preventative maintenance will assure that the equipment and other infrastructure is in good condition to deliver optimal outputs. In addition to energy savings, preventive maintenance can also help avoid problems with product quality, reduce downtime and improve capacity utilization.  Maintenance of the kiln refractories, or reduction of false air input into the kiln are among typical areas where preventive maintenance can focus.  Savings that can be harvested through preventive maintenance will depend on the measures already taken in a particular plant. 

Effective preventive maintenance will require the development and implementation of a carfelly crafted maintenance plan, as well as basic training of the employees.  

Development Status Products
Commercial
clinker, Cement

Preventive MaintenanceCosts & Benefits

Parent Process: Cement Plant General
Energy Savings Potential

Reduction of up to 5 kWh/t-clinker through various preventative maintenance and process control measures was reported  Typical savings are around 3 kWh/t clinker.

CO2 Emission Reduction Potential
Costs

Start-up and implementation costs of preventive maintenance tend to be very low, often resulting in payback times of less than one year. 

Preventive Maintenance Publications

Energy Efficiency Improvement Opportunities for the Cement Industry

The U.S. Environmental Protection Agency’s (EPA) energy guide, Energy Efficiency Improvement and Cost Saving Opportunities for Cement Making, discusses energy efficiency practices and technologies that can be implemented in cement manufacturing plants. This ENERGY STAR guide provides current real world examples of cement plants saving energy and reducing cost and carbon dioxide emissions.

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