Sustainable use of energy in the cement industry

Sustainable energy use in the cement industry

 Humat Al Ard magazine’s interview with the head of the projects and development sector atCEMEX CompanyEgypt

Engineer/ Ahmed Othman:

• We are committed to decarbonizing our operations.
• Our primary goal is to reduce energy consumption.
• We will continue to drive innovation and adopt new technologies.

The steps of the Earth Guards were effective in advancing sustainable development and calling for the implementation of green transformation measures in all sectors. Her call was not an empty form of appeal, but rather - with a sense of patriotism - she made her call to achieve sustainable development a realistic act. This was represented by the “Earth Guards Shield” competition, which I launched in cooperation with the Ministry of Social Solidarity. To honor institutions that fulfill their societal responsibilities, as well as to honor individuals who achieve Sustainable Development Goals (SDGs) in their projects. This shield was won by companies with the ability to combine profit with environmental and social responsibility, including: CEMEX Egypt.

Although the cement production process has been known to be energy-intensive, the use of technology has played a vital role in raising the efficiency of this process. Hence, CEMEX has achieved exemplary performance and many achievements, through its efforts in improving energy consumption. Therefore, Homat Al-Ard magazine decided to meet with the head of the company’s projects and development sector. In order to shed light on some of these achievements, she met with engineer Ahmed Othman.

Our first question was about the prevalence of energy consumption in thecement industry, trying to find out the reasons for CEMEX’s focus on energy efficiency, and to find out whether this focus is for the purpose of reducing costs, or for the purpose of sustainability?

To this, Engineer Ahmed Othman, responded, saying: Our vision at CEMEX represents a basic pillar of all our efforts, and this vision is summed up in providing innovative and sustainable solutions in the construction industry, with a focus on aligning those efforts with our climate action program “The Future Starts Now”; We therefore committed to decarbonising our operations, and worked on several paths; In order to achieve this.

He added that energy efficiency is a very important aspect in reducing the carbon footprint, and it is an aspect that requires innovation in the use of technology. Adopting innovation must not be at the expense of cost, as the convergence of sustainability and profitability guarantees continued value creation.

Desiring to clarify the main aspects and pillarsthat CEMEX takes as a strategy to raise the efficiency of energy consumption - we asked the head of the projects sector at CEMEX Egypt: He explained it by saying: Our initiatives to raise the efficiency of energy consumption require focusing - in particular - on electricity. Because it is the main energy source in cement factories, where the large consumption of electrical energy - by factory equipment - requires detailed analysis and auditing. In order to identify opportunities to control our energy consumption, and thus reduce it. By focusing on electricity, we can make a big difference in energy consumption. Which enhances the overall efficiency of all our operations.

Regarding the aspects of that strategy, he continued, saying: There are two main aspects that form the core of our strategy, to improve the energy consumption process:

First - Reducing the specific energy consumption per ton of cement:Our primary goal is to reduce the specific energy consumption per ton of cement produced. To achieve this, we have established key indicators that build on each other, including: conducting continuous audits and monitoring of the energy consumed, monitoring energy demand against production plans, improving the reactive energy compensation process, and more.

Other - Opportunities to reduce energy tariffs: CEMEX is considered one of the first companies in the field of exploring opportunities to reduce energy tariffsenergy, with the aim of reducing the unit cost of electricity per ton of cement produced. This includes a comprehensive analysis of various factors and indicators in our operations; To determine cost impacts, and implement measures to improve energy consumption.

Then we moved on to ask our guest about the strategies that CEMEXactually implemented, and what are the most important achievements of the energy efficiency initiatives launched by the company? Here he elaborated, saying: Detailed and comprehensive energy efficiency data is crucial; To make progress in the energy consumption process, that is why we have identified key indicators for monitoring and analysis. Our strategies include several aspects, such as: improving the energy consumption of auxiliaries in the event of production cessation, as well as improving operation schemes and the number of starts and stops for major, high-energy-consuming equipment.

Here he pointed to another aspect, which is improving the efficiency of the equipment itself, especially old and obsolete equipment, engines, and machines. This includes: creating an energy-saving operating mode - Power Saving Mode, using highly efficient equipment, and partially replacing fossil fuels with alternative fuels in our furnaces.

The head of the projects and development sector at CEMEX continued, saying: Since we began implementing our strategy to improve energy consumption, we have replaced 100% of traditional lighting with LED lamps and smart controls. Which led to saving a large amount of energy consumed. We also neutralized harmonics, which are unwanted voltages and currents, in addition to dismantling reactive power sources by 60.%

Our interest in the accuracy of standards has greatly increased the accuracy of the measurement system. Resulting in a tolerance of +/- 2%, also by switching to high efficiency motors we reduced equipment loads by 2 MWh. Finally, we expanded power and control networks by 30%; In support of the company’s roadmap and directions to reduce carbon dioxide.

At the end of our meeting with him, Engineer Ahmed Othman explained CEMEX’s future endeavors,We asked about CEMEX Egypt’s future plans, related to further improving the efficiency of energy consumption? He said: CEMEX Egypt, as part of our global parent company, remains committed to improving energy consumption and striving towards achieving sustainability in the cement industry. Our achievements - so far - attest to the sincerity and dedication of our efforts in reducing our environmental impact and raising the efficiency of our energy consumption in various aspects of our operations.

At the conclusion of her meeting with the head of the company’s projects and development sector, the Earth Guards extended sincere thanks to CEMEX Egypt; For its efforts in improving the energy use process. In addition, Homat Earth magazine will continue to take into account the commitment of major companies to enhance energy efficiency in their industrial operations.