Energy Action Plan for a Cement

Manufacturing Facility

(Case Study: UltraTech Cement)

Submitted by:
Name:Khaled Al-Ozaibi
[Link]: 12323938
Department of Chemical Engineering

Submitted by:
Name:Prithvi Singh
[Link]: 12410843
Department of Chemical Engineering

Submitted to:
Course Instructor: Rohan Kumar
Course Code: PTE315
Date: 01/05/2025

Student’s Signature:

Evaluator’s Signature and Date:

Marks Obtained:__________________ Max. Marks :.................................................

Energy Action Plan for a Cement Manufacturing Facility

Case Study: UltraTech Cement Limited

[Link] Overview
UltraTech Cement Limited, a subsidiary of the Aditya Birla Group, is India's largest
manufacturer of grey cement, ready mix concrete (RMC), and white cement. With over 23
integrated plants, 1 clinkerisation plant, and more than 100 RMC plants across the country,
UltraTech has a cement production capacity of over 130 million tonnes per annum.
UltraTech’s facilities are strategically located close to raw material sources and markets to
minimize logistics costs and improve operational efficiency. The company operates using
stateof-the-art technology, maintaining a strong focus on sustainability and energy efficiency
in cement production.

Operational Highlights

• Advanced Production Technology: The plants use the dry process with 5-stage
preheater kilns and precalciners for maximum fuel efficiency.

• Energy Management: UltraTech has implemented Waste Heat Recovery Systems

(WHRS) in many units and is rapidly increasing its share of renewable energy (solar
+ wind).

• Environment Commitment: Recognized as 2.91x water positive, meaning it

recharges nearly three times the water it consumes. The company is also a founding
member of the Global Cement and Concrete Association (GCCA) and adheres to
low carbon pathways.

• Digitalisation & Industry 4.0: Uses real-time process control, AI-driven kiln
monitoring, and predictive maintenance tools to enhance productivity and reduce
energy waste.

Key Features of UltraTech’s Cement Facility:

• Installed Capacity: Over 130 million tonnes per annum (MTPA).

• Technology: Uses dry process with preheater and precalciner systems to enhance
energy efficiency.
Certifications: ISO 50001 (Energy Management), ISO 14001 (Environmental
Management).
 • Sustainability: Committed to reducing carbon intensity and increasing the use of
alternative fuels and raw materials.

• Water Positive: Achieved “2.91x water positive” status — meaning it recharges nearly
three times the water it consumes.

• Energy Efficiency: Integrates waste heat recovery systems (WHRS) and has a
growing portfolio of solar and wind energy projects.

Raw Materials Used in Cement Manufacturing:

1. Limestone – Primary raw material providing calcium carbonate.

2. Clay/Shale – Provides silica, alumina, and iron oxide.

3. Gypsum – Regulates the setting time of cement.

4. Bauxite and Iron Ore – Additional sources of alumina and iron.

5. Fly Ash and Slag – Supplementary cementitious materials used in blended cements
(e.g., PPC, PSC).

Cement Manufacturing Process

Equipments Used in Cement Manufacturing

🔹 1. Raw Material Extraction and Handling

• Excavators / Draglines – for mining limestone and clay

• Dumpers / Haul Trucks – transport raw materials from quarry to crusher

• Belt Conveyors – transport raw materials across different units

🔹 2. Crushing and Pre-Blending

• Primary Crusher – Jaw Crusher or Gyratory Crusher

o Reduces large rocks to 100–150 mm

 • Secondary Crusher – Cone Crusher, Impact Crusher, or Hammer Crusher

o Further reduces size to < 25 mm

• Stacker and Reclaimer

o Stacker: stacks crushed raw materials in layers

o Reclaimer: retrieves materials from the pile for uniformity

🔹 3. Raw Mill (Grinding)

• Ball Mill or Vertical Roller Mill (VRM)

o Grinds raw materials into fine powder (raw meal)

• Dust Collectors / Bag Filters

o Prevents dust from polluting the environment

🔹 4. Blending and Homogenization

• Blending Silos / Air Merge Blenders

o Mix and homogenize raw meal for uniform chemical composition

• Aeration System – helps with mixing inside silos

🔹 5. Preheater and Precalciner

• Cyclone Preheater (multi-stage)

o Uses hot gases to preheat the raw meal

• Precalciner

o Partial calcination of CaCO₃ using secondary firing of fuel

🔹 6. Rotary Kiln

• Rotary Kiln – long steel cylinder (~3–5 m diameter, 60–100 m long)

o Key equipment for clinker formation

 • Burner Pipe – injects fuel (coal, petcoke, or alternative fuels)

• Kiln Drive and Gear System – rotates the kiln at controlled speed

• Kiln Shell Scanner – monitors temperature to prevent hot spots

🔹 7. Clinker Cooler

• Grate Cooler (or Planetary / Rotary Cooler)

o Rapidly cools clinker from ~1400°C to ~100°C

• Cooler Fans – force air through the hot clinker

• Heat Recovery System – sends hot air back to preheater

🔹 8. Cement Grinding

• Cement Mill – Ball Mill or Vertical Roller Mill

Grinds clinker with gypsum (and additives for blended cement)

• Separator / Classifier – separates fine and coarse particles

• Dust Collection Systems – bag filters, electrostatic precipitators

🔹 9. Storage and Packing

• Cement Silos – vertical storage units for finished cement

• Packing Machines – automatic machines for 50 kg or bulk bags

1. Raw Material Extraction

Materials Used:

• Limestone (CaCO₃) – main source of calcium

• Clay/Shale – provides silica (SiO₂), alumina (Al₂O₃), and iron oxide (Fe₂O₃)

• Other Additives – iron ore, bauxite (used in small amounts to correct composition)

Process:
 • Mined from open-pit quarries using blasting or drilling.

• Large chunks of rock are transported to

crushing plants.

🔹 2. Crushing and Grinding

• Primary Crushing: Jaw crushers or gyratory

crushers reduce large rocks to smaller pieces
(~6 inches).

• Secondary Crushing: Further reduces to ~3/4 inch size.

• Grinding Mills: Ball mills or vertical roller mills grind the material into raw meal (fine
powder).

Goal: Ensure particle size uniformity for better

chemical reactions in the kiln.

🔹 3. Raw Meal Homogenization

• The powdered raw meal is stored in blending

silos. Homogenization ensures uniform
chemical composition.

• Mixing is done by aeration (air blowing) or mechanical stirrers.

🔹 4. Preheating and Precalcining

• The homogenized raw meal enters the preheater tower, which has 4–6 cyclone stages.

• Hot gases from the kiln (1000°C+) pass upward and preheat the meal.

• Then the meal enters the precalciner, where about 90-95% of CaCO₃ is decomposed:

CaCO3→CaO+CO2

Advantage: Reduces the load on the main kiln and

improves energy efficiency.

🔹 5. Clinker Formation (Kiln Phase)

 • Preheated material enters the rotary kiln, a long, slightly inclined steel cylinder (~60–100
m long). Kiln temperatures reach 1400–1500°C in the sintering zone.

Key Reactions:

• Formation of clinker minerals:

o C₃S (Tricalcium silicate) – responsible for early strength

o C₂S (Dicalcium silicate) – contributes to later strength

o C₃A (Tricalcium aluminate) – affects setting and heat evolution

o C₄AF (Tetracalcium aluminoferrite) – gives color and helps in the melt

Clinker:

• Marble-sized gray balls.

• Hot and glowing when discharged.

🔹 6. Clinker Cooling

• Clinker is rapidly cooled in grate coolers or rotary coolers using ambient air.

• This process:

o Preserves the desired mineral phases.

o Recovers heat (hot air goes back to preheater).

Target temperature after cooling: ~100°C.

🔹 7. Final Grinding and Mixing

• Clinker is mixed with gypsum (3–5%) to

control setting time.

• Mixture is ground to a very fine powder in

cement mills.

Clinker+Gypsum→Cement

Particle size: Fineness is usually ~300–400 m²/kg (Blaine fineness)

🔹 8. Storage, Packing, and Dispatch

• Finished cement is stored in silos to prevent moisture.

• Packed in 50 kg bags or dispatched in bulk trucks.

• Distributed to construction companies, retailers, etc.

Chemical Composition of OPC

Compound Chemical Formula Typical %

Lime CaO 60–67%

Silica SiO₂ 17–25%

Alumina Al₂O₃ 3–8%

Iron Oxide Fe₂O₃ 0.5–6%

Gypsum (SO₃) 2–4%

🌍 Environmental Aspects

• CO₂ Emission: ~0.9 ton of CO₂ per ton of cement.

o 50–60% from calcination

o 30–40% from fuel combustion

• Solutions:

o Alternative fuels (biomass, RDF)

o Carbon capture technologies

o Use of supplementary cementitious materials (e.g., fly ash, slag)

Sustainability and Innovation at UltraTech
UltraTech is not just a cement manufacturer; it's a sustainability-driven enterprise. The
company aligns its operations with global climate goals and is committed to becoming net
zero by 2050. Here are some key sustainability and innovation highlights:

• Alternative Fuels and Raw Materials (AFR): Utilizes industrial and municipal waste
as partial fuel replacement, reducing dependence on fossil fuels.
• Green Building Certifications: Supplies eco-friendly materials for LEED and
GRIHA-certified green buildings.
• Digital Control Rooms: Centralized control systems monitor energy and emissions in
real time, enabling proactive adjustments.
• Water Management: UltraTech is a pioneer in water stewardship, adopting rainwater
harvesting, zero liquid discharge, and efficient recycling.

2. Identification of Key Issues:

Cement manufacturing is inherently energy-intensive due to the high-temperature
processes and the mechanical operations involved. Despite being an industry leader,
UltraTech Cement, like others in the sector, faces several energy-related challenges
that affect operational efficiency, costs, and environmental performance. These issues
are outlined below:

1. High Thermal Energy Consumption

• , the heart of cement manufacturing,

requires extremely high kiln temperatures
(~1450°C).
• A significant portion of energy (~60-70%)
is used for heating the kiln.
• Coal, petcoke, and natural gas are the
primary fuels used, making operations both expensive and emission-intensive.

2. High Electrical Energy Demand

• The grinding and blending operations (raw mill, cement mill, and finish grinding) are
power-intensive.
• Around 90–100 kWh of electricity is consumed per tonne of cement produced.
• Major power-consuming equipment includes grinding mills, fans, compressors, and
conveyors.

3. Low Energy Efficiency in Legacy Equipment

• Despite modernization, some plants still operate older motors, drives, and mechanical
systems.
 • These outdated systems lead to higher specific energy consumption and frequent
breakdowns.
• Improper insulation and leakage in duct systems can also result in energy loss.

4. Limited Use of Alternative Fuels

• The use of Alternative Fuels and Raw Materials (AFR) such as RDF (Refuse
Derived Fuel), biomass, and industrial waste is still below its potential.
• Barriers include logistical challenges, high preprocessing costs, and regulatory hurdles.

5. Inadequate Energy Monitoring and Control

• In some plants, lack of real-time energy tracking tools limits operational visibility.
• Suboptimal process control can lead to frequent deviations from ideal process
conditions.

6. High Carbon Emissions and Regulatory Pressure

•
Cement production contributes around 6–8% of global CO₂ emissions, primarily
from: o Calcination of limestone (chemical reaction)
o Combustion of fossil fuels
• Increasing environmental regulations are driving the need for cleaner production and
carbon reduction technologies like carbon capture and storage (CCS).

7. Water and Waste Heat Underutilization

• In some units, waste heat recovery systems (WHRS) are either not installed or
underutilized.
Opportunities exist to harness heat from kiln exhaust and clinker coolers for power
generation or pre-heating purposes.

8. Dependency on Non-Renewable Energy Sources

• Despite recent investments in solar and wind energy, the majority of energy used is
still non-renewable.
• Rising fossil fuel prices and energy insecurity pose financial and operational risks.

Conclusion
These key issues form the foundation for the next step: designing a comprehensive Energy
Action Plan. Addressing them will enhance energy efficiency, reduce operating costs, lower
emissions, and align with UltraTech Cement’s long-term sustainability goals.
3. Proposed Energy Action Plan
Based on the key issues identified, the following Energy Action Plan is proposed for
UltraTech Cement to improve energy efficiency, reduce costs, and minimize environmental
impact. The plan is divided into three phases: short-term, medium-term, and long-term
measures.

A. Short-Term Measures (0–1 Year)

These are low-investment, high-impact actions that can be implemented quickly:

1. Comprehensive Energy Audits

• Conduct plant-wide audits to identify areas of energy loss and improvement.

• Use data to prioritize equipment upgrades and process modifications.

2. Operational Optimization

• Fine-tune kiln operation parameters using advanced sensors and AI-based monitoring.

• Minimize air leakages and maintain optimal fuel-air ratios to improve thermal
efficiency.

3. Lighting and Motor Upgrades

• Replace all conventional lighting with LED systems.

• Upgrade inefficient motors and drives to IE3 or IE4 energy-efficient models.

4. Compressed Air System Optimization

• Fix air leaks and install pressure regulators.

• Optimize compressor loading and unloading cycles.

B. Medium-Term Measures (1–3 Years)
These initiatives involve moderate capital investment but
provide significant energy and cost savings:

1. Waste Heat Recovery Systems (WHRS)

• Install or expand WHRS to capture heat from kiln

exhaust gases and clinker coolers.

• Use recovered heat for generating electricity or

preheating raw materials.

2. Alternative Fuels and Raw Materials (AFR)

• Increase the use of RDF, biomass, and industrial waste.

• Develop partnerships with municipalities for steady AFR supply.

3. Promoting Blended Cement

• Increase production of Portland Pozzolana Cement (PPC) and Portland Slag

Cement (PSC).

• These require less clinker, reducing both thermal energy use and CO₂ emissions.

4. Variable Frequency Drives (VFDs)

• Install VFDs on fans, pumps, and conveyors to reduce power consumption during
lowload operations.

C. Long-Term Measures (3+ Years)

Strategic investments to ensure sustainable energy practices in the future:

1. Renewable Energy Integration

• Expand captive solar PV

installations and wind farms.

• Aim for a significant share of energy

from renewables by 2030.

2. Carbon Capture and Storage (CCS)

• Explore pilot-scale CCS technology

for CO₂ capture from kiln flue gases.
 • Participate in research consortiums and public-private partnerships.

3. Digitalization and Industry 4.0

• Deploy smart control systems for real-time optimization of energ y consumption.

• Use AI, IoT, and Machine Learning for predictive maintenance and performance
benchmarking.

4. Employee Training and Awareness

Train staff on energy-efficient practices and develop a culture of energy
consciousness.

• Implement an internal reward system for energy-saving suggestions.

Expected Outcomes:
Metric Before After Implementation

Specific Heat Consumption ~720 kcal/kg clinker ≤ 690 kcal/kg clinker

Power Consumption ~90–100 kWh/tonne ≤ 80 kWh/tonne

AFR Usage 10–15% 25–30%

Renewable Energy Share 5–8% 25–30%

CO₂ Emission Intensity ~590 kg/tonne ≤ 500 kg/tonne

4. Visual Representation
This s includes simple, impactful diagrams and charts to visualize the energy action plan and
reinforce understanding. These visuals are ideal for inclusion in your PowerPoint presentation
and can be customized with UltraTech branding if needed.
A. Energy Flow Diagram – Cement Plant (Current Scenario)

Major Energy Consumption Points: Kiln, Cooler, Grinding Opportunities:

WHRS, AFR, VFDs

Proposed Energy Action Plan – Gantt Chart (Timeframe: 3 Years)

Action Item Q1 Q2 Q3 Q4 Year 2 Year 3

1. Energy Audit
✔️

2. Kiln Optimization & Air Leakage Control

✔️ ✔️

3. LED Lighting & Motor Efficiency Upgrade

✔️ ✔️

4. Compressed Air System Optimization

✔️ ✔️
5. Installation of WHRS
✔️ ✔️ ✔️

6. AFR Usage Expansion

✔️ ✔️
✔️ ✔️

7. VFD Installation on High-Load Motors ✔️ ✔️

8. Renewable Energy Expansion (Solar/Wind) ✔️ ✔️

 9. Digital Energy Monitoring Tools ✔️
✔️
10. Carbon Capture Pilot Program

11. Staff Training & Awareness Programs

✔️ ✔️ ✔️ ✔️ ✔️ ✔️

C. Pie Chart – Energy Use Breakdown in Cement Production

Energy Use Breakdown in Cement Production

Electricity Thermal (Kiln): Other Utilities Compressed Air

D. Bar Chart – Before & After Energy Efficiency (Example)

Before & After Energy Efficiency

800
700
600
500
400
300
200
100
0
Power (kWh/tonne)Thermal (kcal/kg) CO₂ Emissions AFR Usage (%) Renewable Share (%)
(kg/t)CO₂

Before After
5. Team Collaboration Reflection

The preparation of this report on the Energy Action Plan for a Cement Manufacturing Facility
was a collaborative effort between two team members. The project provided an opportunity to
apply theoretical knowledge to a practical scenario while also developing soft skills such as
teamwork, communication, and time management.

Member 1: Khaled Al-Ozabi

“I took the lead in outlining the structure of the report and worked on key sections such as the
facility overview, identification of issues, and the development of the proposed energy action
plan. I also created the Gantt chart and helped with overall formatting and proofreading.
Through this project, I gained a deeper understanding of energy management in industrial
settings and improved my ability to coordinate tasks within a team.”

Member 2: Prithvi Singh

“My main responsibilities included researching UltraTech Cement’s current energy practices,
contributing to the identification of key energy issues, and designing visual representations
such as energy flow diagrams and data tables. I also reviewed and edited parts of the report to
maintain consistency. Working on this assignment strengthened my analytical and research
skills and helped me understand how collaborative efforts lead to a more comprehensive
outcome.”

Reflection on Teamwork
We maintained clear and regular communication throughout the project, dividing tasks based
on our strengths and supporting each other when needed. Brainstorming together led to better
solutions, and reviewing each other’s work helped us maintain quality. This teamwork
experience was both productive and enriching, preparing us for future academic and
professional projects that require collaboration.
Throughout the course of this project, we maintained active communication via regular
discussions and progress check-ins. We used online tools to share documents and update each
other on our parts. Our approach was based on mutual respect, where both opinions were
valued, and decisions were made collectively.
We encountered challenges such as aligning schedules and finalizing data sources, but we
resolved them through open discussion and flexibility. Dividing the work based on individual
strengths helped improve efficiency and allowed each member to contribute meaningfully.
This project emphasized the importance of clear communication, collaborative
problemsolving, and trust—all essential components of effective teamwork. It also gave us
a glimpse into what it feels like to work in an industry-style team environment, where every
member’s contribution is crucial to success.

Conclusion
This project focused on the creation of a comprehensive Energy Action Plan customized for a
cement manufacturing facility, specifically using UltraTech Cement—India's largest cement
producer—as a case study. Cement manufacturing is one of the most energy-intensive
industries in the world, and with growing environmental concerns and sustainability targets,
it has become imperative for companies to adopt efficient energy management practices.

Using UltraTech Cement, the biggest cement manufacturer in India, as a case study, this
project concentrated on developing a thorough Energy Action Plan tailored for a cement
producing facility. One of the most energy-intensive sectors of the global economy is cement
production, and as environmental concerns and sustainability goals have grown, it is now
essential for businesses to implement effective energy management strategies.

After reviewing the facility, we found a number of important energy-related problems. These
included minimal use of renewable energy, inefficient motors and lighting systems, substantial
heat losses in kilns and preheaters, and inadequate waste heat recovery systems. Energy
optimization is both economically and environmentally necessary because many of these
inefficiencies lead to higher carbon emissions and higher operating expenses.

A multi-phase Energy Action Plan was put up to solve these issues. Performing a thorough
energy audit to provide a baseline was a top priority in the plan. After that, plans were outlined
for installing VFDs, putting in place Waste Heat Recovery Systems (WHRS), switching to
LED lighting, and promoting the use of Alternative Fuels and Raw Materials (AFR). Utilizing
digital technologies and Internet of Things-based monitoring devices to guarantee real-time
tracking of energy consumption was another crucial component of the strategy. Programs for
staff awareness and training were also prioritized in order to foster an energy-efficient culture
across the entire campus.

The suggested timeline was graphically represented using a Gantt chart that spans three years.
It illustrated a staggered deployment strategy, with capital-intensive tactics like WHRS and
renewable energy integration coming after low-investment, high-impact measures like
lighting upgrades and energy audits. This planned schedule guarantees that the facility can
make shortterm improvements while pursuing long-term sustainability objectives.

6. References
[Link] Cement Sustainability Reports
2. Bureau of Energy Efficiency (BEE) guidelines
[Link] papers and textbooks on energy conservation in cement industries
[Link] or industry reports on AFR and WHRS