High efficiency motors & drives

In a typical cement plant, there may be 500 to 700 motors of different sizes, used primarily to move the fans, the kiln, to transport the material and most importantly for grinding. High-efficiency motors and drives can help reduce power use in cement kilns. Although rewiring the old motors is a more common practice in industry, replacing the old motors with new and more efficient ones may prove more beneficial. If the replacement does not influence the process operation, motors may be replaced at any time.

Development Status Products
Commercial
clinker, Cement

High efficiency motors & drivesCosts & Benefits

Parent Process: Cement Plant General
Energy Savings Potential

Power savings may vary considerably between different plants, ranging from 3 to 8%. 

By retrofitting 13 motors with high efficiency ones a cement plant in Davenport, California, has saved 2.1 MWh of electricity annually.
CO2 Emission Reduction Potential
Costs

For a 5000 tons per day plant, it is estimated that replacing all motors in plant fan systems with high-efficiency motors costs US $0.22 per annual ton of cement capacity. 

The cement plant in Davenport, California, has reduced its annual energy and maintenance costs by US $168 000 and US $30 000 annually. The implementation costs amounted to US $ 134 000 (including a rebate from the local utility company) giving a payback time of around 8 months.  

High efficiency motors & drives Publications

Energy Efficiency Improvement Opportunities for the Cement Industry

Date: 

Jan
2008

Source: 

Lawrence Berkeley National Laboratory

Format: 

PDF

Type: 

Publications

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.

http://www.energystar.gov/ia/business/industry/LBNL-54036.pdf?5d92-a6b3

Page Number: 

21

High efficiency motors & drives Case Studies

CEMEX: Cement Manufacturer Saves 2.1 Million kWh Annually with a Motor Retrofit Project

Date: 

Nov
2005

Format: 

PDF

Type: 

Case Studies

A motor system improvement project was completed at the CEMEX cement plant in Davenport, California, in June 2004, where 13 motors were retrofitted and resulted in annual energy and energy cost savings of more than 2 million kWh and US $168,000.

http://www.nrel.gov/docs/fy06osti/38223.pdf

Page Number: 

2