THE CHALLENGE

A major cement producer approached A³&Co.® with a specific objective: aligning their fuel budget deviation and effectively reducing a deficit of $ 300K by half. Previous engagements with large consulting firms revealed that their formulaic techniques were not suitable for the unique needs of the business. The use of archetypes and benchmark data proved ineffective in finding a realistic path to lasting change. The cement producer required a customized solution that would enable them to achieve their cost-cutting goals while strategically supporting the business. They sought a thought partner who could reinvent their energy infrastructure and take ownership of the change throughout its implementation.

THE SOLUTION

After A³&Co.® was chosen as the preferred partner by this major cement producer to help tailor a solution according to their specific business needs. The initial step involved collaborating of A³&Co.® advisory team with client team and their technical office to gain an outside-in perspective on their future capabilities. This served as the foundation for a structured process that facilitated exploration of key issues and better organization of outputs related to thermal energy consumption, electrical energy consumption, and alternative fuel maximization levels. The comprehensive inventory of services, along with the solid foundational and strategic work output, formed the basis for extensive recommendations, laying the groundwork for the development of a detailed action plan. 

This long-term plan was designed to be implemented over a six-month period, requiring both specificity and adaptability in their roadmap. Utilizing A³&Co.® methodology, a thorough audit consisting of weighment and measurements was conducted over a period of five days. This audit successfully identified the gaps in the operation of the kiln and cooler, resulting in a reduction of thermal energy by 40 Kcal/kg kk. Additionally, power consumption gaps of 5 KWh/t cement produced were identified.

OUR RESULTS-DRIVEN ENERGY MANAGEMENT METHODOLOGY: A SCIENTIFIC APPROACH TO EFFICIENCY
By thoroughly assessing and measuring all energy utilization sources and identifying gaps through a scientific benchmarking of similar operations, a scientific-based methodology was employed. This methodology involved implementing realistic actions with minimal capital expenditure (CAPEX) requirements.

THE OUTCOMES
By the end of the project, our client was achieving significantly different results. including cost reductions of greater than 20%, decreased thermal and electrical energy consumption, while experiencing increase in Alternative Fuel Substitution Rate. Among various significant outcomes, the project successfully addressed challenges and sustainable impact, highlighted by:

• A thorough assessment report of the Pyro-line.
• Benchmarking of the line against design values, similar plants, and standard targets.
• Assessment of cooler efficiency.
• Preheater False Air Assessment
• Detailed action plan to enhance heat consumption.
• Development of daily heat consumption automatic calculation tools.
• Performance Tracking Tools for daily operation and energy performance.
• Establishment of a set of operating targets.
• Fully detailed process measurements plan
• Weekly on-site follow-up for actions raised from the optimization action plan.
• Development of a fuel flexibility strategy.
• Enhancement of the existing alternative fuel system utilization.
• Detailed assessment of related fuel investment opportunities.
• Optimal fuel mix considering cost and technical impact.
• Success Criteria & KPIs for monitoring.

The implementation of the identified gaps and actions resulted in clear and tangible outcomes, as demonstrated by the graphs below showcasing the top results achieved by our client through A³&Co.® Energy Management Solution.

The collaboration with A³&Co.® not only effectively addressed immediate challenges but strategically positioned the cement company for sustainable success in the dynamic and competitive cement market.

We’d welcome the opportunity to discuss how these insights can benefit your Energy Optimization agenda. Feel free to get in touch, and we can arrange a brief meeting.