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Understanding energy use in cement production starts with identifying the most energy-intensive processes. Cement manufacturing requires both thermal and electrical energy, with consumption distributed across several stages.

The highest energy demand is typically found in:

• raw material grinding,
  
• preheating,
  
• kiln operation,
  
• clinker cooling,
  
• final cement grinding.
  

While the kiln is the largest consumer of thermal energy, grinding processes account for a significant proportion of electricity use. According to the International Energy Agency, clinker production remains the most energy-intensive stage of manufacturing due to the high temperatures required for the calcination process.

Material handling systems often receive less attention than kilns or mills, yet they operate continuously throughout the production process. Conveyors, elevators, feeders, pumps and fans collectively contribute significantly to a plant's electricity bill.

Many facilities still use fixed-speed equipment designed for peak loads rather than actual operating conditions. As a result, systems frequently consume more energy than necessary.

Common optimisation measures include:

• installing high-efficiency motors
  
• optimising conveyor speeds
  
• reducing idle running time
  
• improving fan control strategies
  
• automating material flow management
  

Automation plays a key role in reducing electricity use by ensuring equipment operates according to real-time production requirements rather than fixed parameters. Similar principles are applied across industrial sectors, including industrial automation in automotive manufacturing. Combined with modern energy saving solutions, manufacturers can improve performance while lowering operating costs.

Variable speed drives (VSDs) allow motor speed to be adjusted according to process demand rather than running continuously at full capacity. This approach is especially beneficial for equipment whose load varies throughout production.

By matching motor output to actual requirements, VSDs can reduce energy consumption while improving process control and equipment lifespan. Research published in MDPI Sustainability identifies drive technology as one of the key approaches for improving industrial energy efficiency in cement plants.

Many cement plants know that energy savings are possible but lack visibility into where losses occur. This is where energy monitoring in cement plants becomes essential.

Monitoring systems provide real-time information on energy consumption across production areas, making it easier to identify inefficiencies, detect abnormal equipment behaviour and establish performance benchmarks. There are a few areas that should be monitored, for example motor energy consumption, griding operations or energy use per tonne of cement.

Modern manufacturers increasingly combine monitoring tools with advanced analytics and automation platforms. Solutions such as Mitsubishi Electric's energy saving solutions help provide greater transparency into plant performance and support data-driven optimisation strategies.

Successful energy-efficiency initiatives depend on measurable results. Without clear indicators, it can be difficult to assess progress, identify improvement opportunities, or justify future investments.

Within energy management in cement manufacturing, companies typically monitor a range of operational, energy and sustainability indicators to evaluate performance. These may include electricity and thermal energy consumption, energy costs, equipment reliability, production efficiency and carbon emissions. Tracking such metrics over time helps operators understand whether implemented measures are delivering the expected benefits and where additional optimisation may be required.

Improving efficiency does not necessarily require a complete plant modernisation project. Many facilities achieve significant savings through targeted upgrades and process optimisation. When planning equipment upgrades or modernising production systems, manufacturers can also explore machine building solutions and the four pillars of machine building for further insights into improving industrial performance.

Potential improvement measures include:

• retrofitting variable speed drives
  
• replacing older motors with high-efficiency alternatives
  
• implementing energy monitoring systems
  
• optimising kiln control strategies
  
• introducing predictive maintenance
  
• upgrading automation systems
  
• improving heat recovery processes

A phased approach often delivers the best results. By establishing a baseline, identifying the largest energy consumers and prioritising high-impact opportunities, cement manufacturers can improve performance while controlling investment costs. Digitalisation also plays an increasingly important role.

As the industry moves towards lower-carbon production, efficiency improvements will remain one of the most practical and cost-effective ways to support sustainable cement production and accelerate the transition to a green cement factory.

Sources:

• IEA, Technology Roadmap: Low-Carbon Transition in the Cement Industry – https://www.iea.org/reports 
  
• IEA, Cement: Production, Energy Demand and Emissions – https://www.iea.org/energy-sys
  
• Cantini et al., Technological Energy Efficiency Improvements in Cement Industries, Sustainability 13(7), 3810 – https://www.mdpi.com