Raw Material Preparation

Raw materials are essential for the core business activities and have a significant influence on production costs and product quality. They are not renewable and are of limited availability.

Increased complexity in this field, of securing and providing raw materials for cement production, is due to:

• High raw material demand for large kilns
• Stricter quality specification for the raw mix (alternative raw materials and fuels)
• Increased environmental regulations
• Rising costs
• Growing numbers of cement types

Holzinger Consulting provides accurate answers to these questions:

• Does your plant provide an optimised mix for clinker production?
• Does it provide optimum fineness for the raw meal and raw mill feed?

Raw Meal Preparation

Defines the following process steps in term of

• Clinker quality –> cement clinker factor –> thermal and electrical energy consumption of raw meal and cement and finally, cement production costs
• Electrical energy consumption of raw meal preparation
  Example of savings potential (in a mid-sized plant with… output/week):

  	Blasting	Crushing	Grinding
  Actual	0.2 kWh/t	2 kWh/t	20 kWh/t
  Future	0.3 kWh/t	1.8 kWh/t	18 kWh/t
  Savings	-8 mio USD/a	2 mio USD/a	24 mio USD/a

Holzinger Consulting finds accurate answers to these questions:

• Does your plant provide the correct feed size for your mills in raw material and cement grinding?
• Has your plant the correct blasting and quarry management in place?

Clinker Production

Process and equipment has been developed and improved with the aim of performing these steps economically

• High availability
• Low heat consumption
• Low power consumption
• Stable operation
• Good, uniform clinker quality

How is your kiln running? Holzinger Consulting finds accurate answers.

Cement Grinding

More than 60% of total cement plant electrical energy consumption is utilised in grinding systems. Higher AFR utilisation and new cement types also make it necessary to adjust and adapt cement mills – both internal configuration as well as operation.

A review of a plant’s specific system set up does save energy costs, but the most significant benefit is generated by increased cement production and hence Sales opportunities.

Expert knowledge at Holzinger Consulting can provide reviews of all plant systems and identify the most significant benefits for your plant.