Energy Efficiency in Cement Industry: A Case Study of Lafarge Cement, Zambia

Abstract 

The main aim of this research is to determine how energy improvement, efficiency and conservation can be achieved in industry such as the cement plant. Energy, is an essential ingredient for socio-economic development and economic growth. The objective of the energy system is to provide energy services. Energy services are the desired and useful products, processes or indeed services that result from the use of energy, such as for lighting, provision of air-conditioned indoor climate, refrigerated storage, transportation, appropriate temperatures for cooking, industrial processes such as conversion of raw materials to final products, etc. The energy chain to deliver these cited services begins with the collection or extraction of primary energy, which is then converted into energy carriers suitable for various end-uses. These energy carriers are used in energy end-use technologies to provide the desired energy services

It is a well-known fact that Energy is one of the most important catalysts in wealth generation, economic growth, and social development in all countries. In industry particularly in cement plants, the energy cost forms about 35 to 45% of the total cost of production. Out of this, thermal energy constitutes around 70%, whereas electrical energy about 30%, which may vary from plant to plant and local conditions. Energy cost is a major factor in pricing of a product and thus the energy cost needs to be minimized to the extent possible to ensure profitable operations and to reduce the deficit in the energy sector. The energy input to the cement plant includes both thermal and electrical energy and cost of these two forms of energy needs to be controlled.

Table of Contents

1. Introduction8

1.1 Background of Study8

1.2 Problem Statement11

1.3 General Objective11

1.4 Specific Objectives12

1.5 Research Questions12

1.6 Rationale12

1.7 Significance Of Study12

CHAPTER TWO: LITERATURE REVIEW13

2.0 Introduction13

2.1.1Cement making process14

2.4 ELECTRICAL EFFICIENCY23

2.7.0 Solar Energy38

2.8.0 Conserve limited natural resources45

CHAPTER THREE: METHODOLOGY AND DESIGN50

3.1 Introduction50

3.2 RESEARCH DESIGN50

3.3 RESEARCH STUDY AREA50

RESEARCH STRATEGY50

SAMPLING FRAME51

SAMPLING SIZE AND SAMPLING TECHNIQUES51

3.7 Data Collection Techniques51

3.8 Data Analysis53

3.9 Limitations of Study53

3.10 Ethical Considerations54

CHAPTER FOUR:  DATA PRESENTATION55

4.1 INTRODUCTION55

4.2 DEMGRAPHICS55

CHAPTER FIVE65

5.0 DISCUSSION OF RESEARCH FINDINGS65

5.1 RESEARCH FINDINGS65

5.2 Discussions66

5.3 Level of Education and Experience against Knowledge about Energy Efficiency in cement66

5.4 Possibility of Having All Improved Energy Efficiency67

5.5   considering improving on Energy Efficiency through integration?67

CHAPTER SIX:  CONCLUSIONS, IMPLICATIONS AND RECOMMENDATIONS68

6.1 INTRODUCTION68

6.2 CONCLUSION AND IMPLICATIONS68

6.3 RECOMENDATIONS69

References70

7.0. Appendices72