Implementation of Green Manufacturing Through Energy

Audits at a National Cement Plant

A Firdaus1, U Amrina1
1
Universitas Mercu Buana, Jalan Meruya Selatan No 1, West Jakarta, Indonesia
alfa_firdaus@mercubuana.ac.id, uly.amrina@mercubuana.ac.id

Abstract. A state-owned cement company wants to implement green manufacturing by

conducting an energy audit to assess its energy performance. Energy sources used at the plant
are electrical, thermal and renewables. The total energy consumption at the plant in 2020 was
7.9 million GJ (Giga Joule). Based on the Specific Heat Consumption (SHC) calculation, the
thermal energy intensity is 4.17 GJ/ton kiln or higher than the national average SHC value of
3.45 GJ/ton kiln. While the calculation results of the Specific Power Consumption (SPC) shows
the value of 90.88 kWh/ton cement or lower than the national average SPC value of 92.9
kWh/ton cement. Furthermore, this study has obtain a base-load value of energy consumption
which is 10,205 GJ, while the baseline value which is the pattern of energy consumption follows
the following equation: Y = 10,205 + 0.35X 1 + 4.07X 2 ; with Y = Energy Consumption (GJ), X 1
= Cement Production (Tons), and X 2 = Kiln Production (Tons). This study has successfully
identified 22 points of potential thermal energy savings and 13 points of potential electrical
energy savings with a total potential savings of 143,453 GJ per year or approximately 1.74% of
its energy consumption in 2020.

Keywords: energy audit, green manufacturing, cement plant

1. Introduction
The use of considerable energy in the cement production process requires the cement industry to
carry out energy management in accordance with Government Regulation No. 70 of 2009 article 2
paragraph 2 and the Ministry of Energy and Mineral Resources Regulation No. 14 of 2012, which states
that consumers of energy sources and energy users which uses energy and/or energy sources greater
than or equal to 6,000 (six thousand) Tons of Oil Equivalent (TOE) per year are required to conserve
their energy through energy management. One of the obligations in implementing energy management
is to conduct energy audits regularly, at least once every 3 years [1].
Energy audit has many definitions, This study will refers to the definition of the ISO 50002 standard,
which defined an energy audit as a systematic analysis of energy use and energy consumption within a
defined energy audit scope, in order to identify, quantify and report on the opportunities for improved
energy performance [2]. It is based on appropriate measurement and observation of energy use, energy
efficiency and consumption. Energy audits are planned and conducted as part of the identification and
prioritization of energy saving opportunities through more efficient application of technology, both
technically and economically [3]. Audit outputs includes a detailed report containing information on
current energy utilization and performance as well as recommendations along with related benefits and
costs of implementation program [4].
 In general, the purpose of energy audit activities is to identify energy saving opportunities and
provide recommendations for energy saving measures that can be followed up by the company.
Specifically, the objectives of this study are:
1. Identify, analyze, and evaluate electrical system and production process equipment to improve
energy use efficiency without reducing product quality and quantity.
2. Create a profile of electrical and thermal energy consumption at the plant.
3. Formulate recommendations to improve the efficiency of the use of energy towards the
implementation of green manufacturing.

2. Methods
2.1. Energy Audit
The Energy Audit Process refer and based on the ISO 50002, as shown below [2]:

Figure 1. Energy Audit Process

The process consists of the following stages, as illustrated in Figure above:
1. Energy audit planning (5.2)
Energy audit planning activities are essential to define the energy audit scope and the objective(s),
and to gather preliminary information from the organization.
2. Opening meeting (5.3.) and Data collection (5.4)
The purpose of the opening meeting is for the energy auditor to brief interested parties regarding
the energy audit objectives, defined energy audit scope, boundaries and methods, and to review
the arrangements for the energy audit (e.g. site safety inductions, access, security, etc.).
Data Collection: Where available, the energy auditor shall collect, collate and record the
appropriate energy data that support the audit objectives
3. Measurement plan (5.5)
For any on-site data measurement and collection, the energy auditor and the organization shall
come to an agreement on a measurement plan. The data measurement plan may be revised based
upon the energy auditor's findings during the energy audit.
4. Conducting the site visit (5.6)
• Management of field work
• Site visits
5. Analysis (5.7)
• Analysis of current energy performance
• Identification of improvement opportunities
• Evaluation of improvement opportunities
6. Energy audit reporting (5.8)
The energy audit report shall include the following topics:
• Executive summary
• Background
• Energy audit description
• Opportunities for improving energy performance
• Conclusions and recommendations
7. Closing meeting (5.9)
After conducted the Energy Audit, the next step is to implement the recommendation and
monitoring the implementation of conservation energy (see the Life Cycle of Energy Audit).
2.2. Significant Energy Use
ISO 50001 standard defines Significant Energy Use (SEU) as an “energy use accounting for substantial
energy consumption and/or offering considerable potential for energy performance improvement.”
Again, it is up to the organization to set the criteria for determining significance [5]. This provides
organizations with implementation flexibility, because designation of an energy system, a process, or a
production line as an SEU triggers the following: identifying and planning for effective operational
control and maintenance activities; evaluating the impact of the SEU on the ability of the organization
to meet its objectives and targets; outlining the procurement process for related energy services,
products, or equipment; ensuring the competence, training, and awareness of persons associated with
SEUs; and monitoring, measurement, and analysis [6].
Developing, implementing, and documenting (as necessary) these processes could require significant
organizational resources. Organizations with a number of energy systems and limited resources will find
it useful to begin with what is achievable, and, as necessary, add to or even designate different SEUs in
subsequent ISO 50001 cycles, as objectives, targets, or policy changes. For an example and discussion
of how other considerations might be incorporated into the SEU selection, see Level 2 Step 2.5.3 of the
U.S. DOE’s e-Guide 2.0, which describes how legal requirements (reduction of greenhouse gas
emissions) or business plan priorities (reducing monthly energy expenditures) can be used as additional
criteria for the selection of SEUs [7].
Although the concept of SEUs makes sense and may have been implemented by organizations with
mature energy management programs under other names, ISO 50001 takes this concept one step further.
The standard formally links the SEU designation to five other components of the energy management
system already described: operational control and maintenance activities; objectives and targets; the
procurement process; competency, training, and awareness; and monitoring, measurement, and analysis.
This delivers the benefit of a systematic approach to the management of SEUs while providing flexibility
in the designation of SEUs [8].

2.3. Energy Baseline dan Baseload

An energy baseline is established by the organization based on a data period that represents the
organization’s energy use and consumption [9]. Annex A of the ISO 50001standard elaborates on this.
The data period is to account for variables that impact energy use and consumption, such as weather,
seasons, business activity cycles, and other conditions. The organization compares this baseline with the
performance in later years in order to evaluate its energy performance. The baseline is adjusted under a
set of defined conditions, such as a change in the processes, operational patterns, or energy systems of
the organization. While Baseload is a parameter that shows the amount of energy needed even though
production is not running, while the baseline is a parameter that can be used as an initial basis which is
then used as a reference to measure the success of implementing energy conservation in 1 period. The
period taken is usually within 1 year of production to be adjusted to other performance periods (KPIs)
at the location of energy users. Baseload and baseline are obtained by connecting energy consumption
with production [10].

2.4. Energy Performance Indicators

The comparison of change in energy performance indicators (EnPIs) from the baseline to the reporting
year is at the heart of the ISO 50001 standard. The EnPIs are quantitative measures of performance,
ranging from a simple metric to a complex model with more than one variable. This is how organizations
measure their continual improvement, compared with the baseline. An organization can have many
EnPIs depending upon its complexity and needs. EnPIs can be chosen at different organizational levels,
such as the facility, production line, process, or a business unit level. Again, this flexibility in designating
EnPIs allows an organization to select EnPIs that, taken together, will meet the varied needs of different
levels of the organization. Some EnPIs will be of interest to the management (business unit annual
energy consumption), while other EnPIs provide utility managers with timely feedback so that they can
ensure an energy system is operating as expected (e.g., kW/Nm3 for a compressed air system).
EnPIs can answer at least two questions: How well did the organization do compared with its target
(retrospective) and how well is this system presently performing compared with a target. The latter EnPI
provides information to operators who can correct system performance as soon as it is noticed, and thus
contribute toward achieving the larger organizational targets. This is a very complex topic and data
collection and processing can be expensive to implement, if an organization does not have existing
equipment in place to measure, record, and analyze performance at the appropriate line or process. On
the other hand, if an organization develops its EnPIs with an eye on outcomes, it can use this information
to manage its performance where it will have impact and savings [11].

3. Result and Discussion

3.1. Significant Energy Use
One of the main keys to implementing an energy management system is determining significant energy
use (SEU). Significant energy use takes into account the large energy consumption and/or the large
supply of potential energy performance improvements. Determining SEU is a stage in energy planning.
Several important factors in determining SEU are systems or equipment that are included in the SEU
group, SEU driver parameters, and factors that affect the use of energy (operators, maintenance, and so
on). The stages in determining the SEU are:
1. Identify facilities, parts, or processes that use significant energy;
2. Calculating energy use by making mass and energy balances, tabulations, and Sankey diagrams;
3. Identify SEUs with a total energy use of around 80% of the total energy use in the
organization/factory.
The determination of SEU can be done in several ways, including by:
1. Create energy balances to identify energy use in equipment or processes;
2. Ranking the energy use of the plan with techniques; energy balance, ranking method, and other
data analysis techniques
3. Identify SEU by ranking method by displaying it on a graph
In general, there are two types of energy consumed at the Cement Plant, namely electrical energy and
thermal energy. The following will describe the Significant Energy Use (SEU) for the two types of
energy:
1. Electrical Energy
Electricity consumption of the Cement Plant for production in 2020 was 191,799.97 MWh. The
distribution of electrical energy consumption can be described as follows:

Figure 2. Significant Energy Use for Electrical Energy

Based on the pie chart, the main equipment for the production process at Semen Gresik Rembang
which consumes the most electrical energy in 2020 can be sorted as follows: Finish Mill (34%),
Raw Mill (30%), Kiln (24%), Coal Mill (7.5%), Packer & Palletizer (2.5%), Limestone Crusher
(1.5%) and Clay Crusher (0.5%).
2. Thermal Energy
The main equipment for the production process at the Cement Plant which consumes the most
thermal energy in 2020 can be sorted as follows: Kiln (99.43%), FM (0.56%) and RM (0.01%).
3.2. Energy Baseline dan Baseload
Linearization of the relationship between energy consumption vs production is done by linear regression,
where the X axis is production and the Y axis is energy consumption. The correlation between X
(production volume) and Y (energy consumption) is acceptable (there is a good correlation) if the value
of R2 is above 0.7 [12]. In this study, regression analysis was carried out on total energy consumption
data (coal, IDO and electricity) as well as production data consisting of cement and kiln/slag during
2020 to see the related relationship between cement and kiln production as a driver of energy
consumption at the Cement Plant. The results of the regression analysis obtained a baseline model with
2 independent variables as follows: Y = 10,205 + 0.35X 1 + 4.07X 2 . With Y = Energy Consumption
(GJ), X 1 = Cement Production (Tons), and X 2 = Kiln Production (Tons).
Based on the results of the regression modeling for the 2020 period, it is known that the value of R2
is far above the minimum value of 0.7, which is 0.998. It means that production volume is the main
factor that has a strong influence on energy consumption. From the results of the analysis, it is found
that the trend of cement and slag production is in line with the trend of energy consumption which results
in a high R2 value, with a 95% confidence interval. This regression model can be used by the
management of the Cement Plant to predict the amount of energy consumption in the future if the
production value is known. Furthermore, the baseload value is obtained by determining the point of
intersection of the baseline equation with the Y-axis (energy consumption), namely by giving the value
X = 0. Thus, the baseload for Cement Plant in 2020 is 10,205 GJ.

3.3. Energy Performance Indicators

The indicator used to calculate energy performance in the cement industry is SEC or Specific Energy
Consumption. Energy can be thermal, electrical energy or the total sum of electrical and thermal energy
used in the production process. SEC value, can simply be calculated by dividing the amount of energy
used (both thermal and electrical) by the amount of production. The following will describe the Specific
Energy Consumption (SEC) for the two types of energy:
1. Electrical Energy
The Specific Power Consumption (SPC) value for electrical energy in 2020 was 90.88 kWh/ton
of cement products. The SPC achievement in 2020 was lower than the national average of 92.9
kWh/ton of cement. The following is the SPC of factories in the world, East Asia, and India as an
international benchmark [13]:
Table 1. International Benchmark for SPC (kWh/ton)
China / Korea /
Year Global India
Japan
2013 102 100 79
2014 101 99 77
2015 101 91 82
2016 103 103 75

2. Thermal Energy
The Specific Heat Consumption (SHC) value for thermal energy in 2020 was 4.17 GJ/ton of
clinker products. The SHC achievement in 2020 was higher than the national average of 3.45
GJ/ton of clinker. The following is the SHC of factories in the world, East Asia, and India as an
international benchmark [13]:
Table 2. International Benchmark for SHC
China / Korea /
Year Global India
Japan
2013 3.53 3.30 3.07
2014 3.51 3.27 3.06
2015 3.51 3.27 3.10
2016 3.53 3.31 3.06
3.4. Energy Conservation Opportunity (ECO)
In every energy conversion process there will be energy loss. It is impossible to eliminate energy losses.
What can be done is to optimize energy utilization or to reduce energy losses. In the operation of an
equipment, minimizing energy loss can be done by controlling the critical parameters that have the most
influence on energy performance. One method of increasing the efficiency of energy utilization
equipment that is commonly used in the cement industry is by recovering wasted energy, such as
exothermic waste heat from reactors. This heat can be recovered and used to supply the existing heat
needs in other production areas. Another effort to increase energy efficiency is the application of energy-
saving equipment. Energy-saving equipment is equipment that has high efficiency.
The following Figures is a recap of the potential for energy efficiency (thermal and electrical) at the
Cement Plant. The percentage value is obtained from the comparison between potential energy savings
and total energy consumption in 2020 which is 7,997,634 GJ. From the Figures, it can be seen that the
total potential for thermal and electrical energy savings is approximately 1.74% and this value has met
the 1% target of energy saving potential at the plant. Meanwhile, the total ECO that is prioritized to be
implemented first is around 0.74%.

Energy Saving
No Energy Conservation List (ECOLIST) Priority
% GJ

A Perbaikan Pola Operasi & Optimalisasi Kapasitas Produksi Kiln

1 Perencanaan produksi kiln untuk meminimalkan frekuensi kiln standby 0.36 28,978 4
2 Perencanaan produksi kiln untuk mendapatkan utlisasi kapasitas produksi kiln pada level optimal 0.02 1,705 17
3 Peningkatan kualitas inspeksi dan pemeliharaan untuk menurunkan frekuensi unplanned shutdown 0.02 1,461 15

B Penutupan False Air

1 Pemeriksaan & perbaikan keausan (thermal corrosive) center tube cyclone preheater 0.01 456 6
2 Pemasangan gland packing pada tutup poke hole, seal shaft damper dan damper tipping valve preheate 0.02 1,548 5
3 Perbaikan lidah dan ceramic blanket expansion joint pada preheater dan hot gas duct cooler outlet 0.02 1,548 9
4 Modifikasi flap damper pada hopper feeding AF (Alternative Fuel) di Calciner 0.02 1,548 2
5 Perbaikan lamela untuk kiln inlet seal (blanket, wire rope & bandul) sesuai spesifikasi awal 0.02 1,548 11

C Optimasi Kualitas Raw Mix & Raw Coal

1 Chemical analysis pada preheater dust return secara berkala 0.01 456 3
2 Chemical analysis pada fuel ash kiln burner & calciner burner secara berkala 0.01 456 3
3 Ultimate analysis untuk fuel batubara yang dipergunakan 0.01 456 10

D Optimasi Parameter Operasi Pembakaran

1 Meningkatkan kontrol proses di kiln dengan expert control (PxP) 0.16 13,032 16
2 Optimasi parameter operasi cooler 0.01 1,169 14
3 Turunkan temperatur exit preheater dari 358oC menjadi 320 - 330oC 0.003 215 1

E Perbaikan & Penambahan Fasilitas Penunjang (Auxiliary)

1 Perbaikan gas analyzer kiln inlet dan pengukuran temperatur di inlet kiln 0.003 228 18
2 Pasang fasilitas pengukuran untuk analisa False Air di kiln system 0.0003 25 19
3 Pasang fasilitas pengukuran T & P di gas duct outlet calciner, tertiary air inlet calciner, outlet lower cyclo 0.02 1,548 9
4 Pasang fasilitas untuk pengambilan sample hot material pada lower cyclone 0.01 456 6
5 Pasang fasilitas gas analyzer di gas duct outlet calciner, tertiary air inlet calciner, outlet lower cyclone 0.06 4,645 8
6 Kalibrasi secara berkala alat timbangan kiln feed, deviasi < 2% 0.0000 2 12
7 Kalibrasi secara berkala alat timbangan coal feed di calciner & kiln burner, deviasi < 2% 0.003 215 7
8 Drop test untuk dust return exit preheater dan produksi clinker 0.0000 2 13

Summary 0.77 61,698

Summary (Prioritized) 0.53 42,526

Figure 3. Thermal Energy Saving Potential

 Energy Saving
No Energy Conservation List (ECOLIST) Priority
% GJ

A Optimasi Parameter Operasi

1 Meningkatkan kontrol proses di Raw Mill dengan expert control (PxP) 0.05 4,189 10
2 Meningkatkan kontrol proses di Finish Mill dengan expert control (PxP) 0.05 4,189 9

B Penutupan False Air

1 Inspeksi rutin dan penutupan kebocoran ducting area Raw Mill 0.003 244 2
2 Inspeksi rutin dan penutupan kebocoran ducting area Kiln & Coal Mill 0.003 244 4

C Peningkatan Kondisi Peralatan

1 Inspeksi rutin terhadap saluran pipa supply udara kompresor untuk mengurangi kebocoran 0.006 491 5
2 Modifikasi shaft seal dengan material backlite pada Fan Main Bag Filter Main, SP Fan dan Cooler EP Fan 0.02 1,548 7
3 Penggantian shaft impeller & bearing Fan Main Bag Filter yang bending (deform) 0.003 215 8

D Sistem Kelistrikan
1 Menggunakan motor listrik yang lebih efisien 0.56 44,421 13
2 Optimalisasi pemakaian penggunaan variable speed drive motor fan 0.05 8,329 11
3 Mengganti bahan sirip fan dengan FRP 0.21 16,658 12

E Sistem Tata Cahaya

1 Mengganti lampu dengan tipe yang lebih hemat 0.01 1,165 6
2 Memanfaatkan cahaya matahari 0.0003 24 1
3 Memasang sensor dan mengurangi jam operasi lampu 0.0005 39 3

Summary 0.97 81,756

Summary (Prioritized) 0.20 20,677

Figure 4. Electrical Energy Saving Potential

4. Conclusion
Based on this study's results for the SHC and SPC values, the benchmarking results show that the
Cement Plant is a company that operates a cement production facility with thermal energy consumption
which is classified as poor because it is above the national average value and electrical energy
consumption is classified as good because it is below the national average value. Overall, the
performance of the energy management system at the Cement Plant is quite good, and from a review of
the energy management system (based on ISO 50001 tools) it has an average result of 4.6 out of 5
targets. This study has successfully identified 22 points of potential thermal energy savings and 13 points
of potential electrical energy savings with a total potential savings of 143,453 GJ per year or
approximately 1.74% of its energy consumption in 2020. The potential for energy efficiency can be
implemented in stages over a period of several years in order to improve the plant towards the
implementation of green manufacturing.

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