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Mining for energy efficiency in cement plants a teamwork approach

A team approach to identifying and implementing energy efficiency measures was used at a cement plant in California in order to identify and facilitate implementation of energy efficiency measures. A team of corporate, plant, utility, and energy efficiency experts was assembled to conduct a concentrated energy scoping study to identify efficiency opportunities. Much of the team has stayed involved over the subsequent years to help facilitate implementation of efficiency projects and maximize utility incentives, which offset a significant percentage of project costs. The cement manufacturing process is highly energy intensive. Energy can account for up to 40% of production costs. While solid fuels make up the largest amount of energy use, high electricity prices make electrical power the largest portion of actual energy costs. Energy efficiency initiatives cut these costs by reducing consumption and, in some cases, improve operational output. In the scoping study which was performed in 2007, the team identified eleven separate energy efficiency project ideas with 13,000 MWh of electrical savings opportunities. In the subsequent 3 years, a broad range of projects have been implemented, savings verified, and incentives earned from utility programs.