Heat energy consumption for clinker making can be reduced below 2.85 GJ/t-clinker. Savings of 14.3 kg of standard coal per ton of clinker can be realized (NDRC, 2011. p.37)

 In a Chinese plant with 2500 tpd capacity, the installation of this technology reduced annual energy consumption by 571.5 TJ (19 500 tce) (NDRC, 2011. p.37)

 In a Chinese plant with 3000 tpd capacity, the installation of this technology reduced annual energy consumption by 633 TJ (21 600 tce) (NDRC, 2011. p.37)

N/A

 Installation of this technology in a Chinese plant with 2500 tpd capacity required an investment of 35 million RMB, and took one year to complete. The economic benefits of saved energy was about 34.5 million RMB, resulting in a payback time of around 1 year (NDRC, 2011. p.37)

 Installation of this technology in a Chinese plant with 3000 tpd capacity required an investment of 35 million RMB, and took one year to complete. The economic benefits of saved energy was about 37.2 million RMB, resulting in a payback time of 10 months (NDRC, 2011. p.37)

Savings vary between 2.5 to 10% and typical values are estimated to be 2.5 to 5%.

For modern dry kilns with capacities more than 2500 tpd, savings are reported to reach 0.29 GJ/t-clinker (NDRC, 2012. p.66)

In a 4500 tpd Chinese plant, annual energy consumption was reduced by 395.6 TJ (13500 tce) with the installation of a process control and optimization system (NDRC, 2012. p. 66)

In a 4000 tpd Chinese plant, annual energy consumption was reduced by 351.7 TJ (12000 tce) with the installation of a process control and optimization system (NDRC, 2012. p. 66)

The costs of process control optimization measures/techniques vary widely and can be up to $6.8 million [1€=$1.35 US] 
The economics of advanced process control systems are very good and estimated payback periods can be as short as 3 months. In general, estimated payback period is less than 2 years.

In a 4500 tpd Chinese plant, installation of a process control and optimization system required an investment of 980 thousand RMB, and took one month. The system provided annual savings of 8 million RMB, resulting in a payback time of 2 months (NDRC, 2012. p. 66).

In a 4000 tpd Chinese plant, installation of a process control and optimization system required an investment of 990 thousand RMB, and took one month. The system provided annual savings of & million RMB, resulting in a payback time of 1.5 months (NDRC, 2012. p. 66).

Fuel savings up to 3.0 GJ/t-clinker can be realized. Electricity consumption can increase by around 9 kWh/ton clinker.

In a case in UK, two wet process kilns with a total heat requirement of 5.65 GJ/t-clinker were replaced with a single pre-heater/pre-calciner kiln resulting in energy saving of 36% (down to 3.5 GJ/t-clinker).

Emission reductions are estimated to be:

 284 kg CO2/t-clinker in Chinese context.

 297 kg CO2/t-clinker in Indian context

 233 kg CO2/t-clinker in the United States.

Fuel consumption is estimated be reduced by around 0.12 to 0.4 GJ/t of clinker. 

 in China, switching to better refractories may reduce CO₂ emissions by 11 to 38 kg per ton of clinker. 

Switching to higher quality refractories may cost around US $0.25/annual tonne clinker capacity. Estimated payback period is approximately 1 years.

Savings up to 2.4 GJ/t clinker can be obtained. 

 Savings of  1.6-2.0 GJ/t clinker are reported from India depending on pre-heater/pre-calcination system configuration

 In China, CO₂ emissions can be reduced by 227 kg/t clinker by converting VSKs to pre-heater/pre-calciner kilns.  

Costs of such conversions can be between US $28-41 per annual ton of clinker production. 

Moving from 4 stage to 5 stage, or from 5 stage to 6 stage can reduce the specific heat energy consumption between 0.08 to 0.1 GJ/t clinker

 In India reductions between 0.06 to 0.1 GJ/t clinker are reported.  

 CO₂ emissions can be reduced by 7.6 – 9.5 kg/t-clinker.

  CO₂ emissions can be reduced by 7.9 – 9.9 kg/t-clinker.

Following savings in electricity consumption are reported in literature: 

• 2.26 kWh/t-clinker (UNFCC)
• 2.5 kWh/t-portland cement (US-EPA)

 In India savings in the range of 1.0-1.3 kWh/t of clinker are reported. 

Following cost informatin is provided in the literature: 

• US $0.23 per annual ton clinker capacity (UNFCC)
• US $3.43 per annual ton portland cement capacity (US-EPA)

 In India Installation costs of this technology is reported to be US $4000-5000 per meter. 

US-EPA reports a US $0.17/ton-portland cement reduction in operating costs. 

0.5 – 1% reduction in electricity use of the kiln drive can be achieved  by replacing a DC motor with AC motor.

Using high-efficiency motors to replace older motors, or instead of re-winding old motors, may reduce power costs by 2 to 8%. 

Electricity savings are  0.55-3.9 kWh/t clinker 

The capital cost for single pinion drive with an air clutch and a synchronous motor is around 6% higher than standard kiln drive.

Depending on the secondary air temperature, reduction of the primary air ratio by 5-10% will lead to a fuel energy saving of 0.05-0.08 GJ/t-clinker at conventional kilns and about half of this at precalciner kilns. The electrical energy demand will remain almost unchanged as the higher consumption for control fittings and air delivery channels can be offset by the reduction of the primary air.

Four channel pulverized coal injection burner is expected to reduce primary air usage by 4% and reduce kiln energy consumption by 0.020 GJ/t-clinker (NDRC, 2009. p.44).

By replacing the existing burner in a 2500 tpd kiln with a four channel pulverized coal injection burner and making necessary adjustments in their fan, Hunan Yintaishan Cement Co. Ltd. reduced its annual energy consumption by 16.2 TJ (553 tce) (NDRC, 2009. p. 45)

By retrofitting a more efficient burner in a 2500 tpd kiln, Ningxia Qingtongxia Cement Co. Ltd., reduced its energy consumption by 17 TJ/y (583 tce/y) (NDRC, 2009. p. 45)

By retrofitting a more efficient burner in a 5500 tpd kiln, Hebei Yanzhao Cement Co. Ltd., reduced its energy consumption by 35.7 TJ/y (1218 tce/y) (NDRC, 2009. p. 45)

Four channel pulverized coal injection burner is expected to reduce NOx emissions by 41% (NDRC, 2009. p.44).

In Hunan Yintaishan Cement Co. Ltd., retrofitting a four channel pulverized coal injection burner and making necessary fan adjustments in a 2500 tpd kiln took three days and costed 0.5 million RMB. The retrofit provides annual savings of 0.44 million RMB and had a payback time of 1.1 years (NDRC, 2009. p.45).

In Ningxia Qingtongxia Cement Co. Ltd., retrofitting a new burner in a 2500 tpd kiln took one month and costed 0.47 million RMB. The retrofit provides annual savings of 0.47 million RMB and had a payback time of 1.2 years (NDRC, 2009. p.45).

In Hebei Yanzhao Cement Co. Ltd., retrofitting a new burner in a 5500 tpd kiln took three days and costed 0.6 million RMB. The retrofit provides annual savings of 0.83 million RMB and had a payback time of 9 months (NDRC, 2009. p.45).

Assuming a reduction of excess air between 20% and 30%, indirect firing may lead to fuel savings of  0.015 -0.022 GJ/t  clinker. 

The advantages of improved combustion conditions will lead to a longer lifetime of the kiln refractories and reduced Nox emissions. These co-benefits may result in larger cost savings than the energy savings alone.

US $5 million for an annual production capacity of 680,000 ton clinker, or US $7.4/t annual clinker capacity.