Cement Industry: Smarter Cement Solutions
The cement industry is focusing on enhancing sustainability and efficiency through key upgrades, including modernizing plants, optimizing ball mills, and using alternative fuels like waste and biomass.
These efforts aim to reduce carbon emissions, increase production capacity, and improve energy efficiency, supporting the industry’s broader decarbonization and sustainability goals.
Our Approach
At PT Carbon Process Engineering, we support the cement industry in achieving more sustainable and efficient operations through targeted modernization and process optimization. Our approach combines deep technical expertise with practical implementation capabilities — delivering real, measurable results.
Our Core Services
- Upgrading and Modernization of existing cement plants and key equipment
- Project Management for the installation of new production facilities
- Engineering and Tender Support: plant concept design, process calculations, flow sheets, and technical documentation
- Advanced Precalcining Systems for reduced energy consumption and lower NOₓ emissions
- Ball Mill Upgrades for raw material and cement grinding lines
- Integration of Alternative Fuels such as biomass, waste, sludge, tyres, and other by-products
- Decarbonization Strategy Development
- Consulting and Supervision across all project stages
Practical Impact
We Deliver
- Heat consumption reduced to below 2.9 MJ/kg clinker (5-stage systems)
- Exhaust gas temperatures under 280°C (5-stage systems)
- Electric power savings with low-pressure loss cyclones
- Up to 100% petcoke usage and compatibility with low-grade fuels
- Cement mill capacity increased by up to 20%
- Raw mill capacity increased by up to 40%
- Alternative fuel share up to 30%+, with integrated ash recovery
- Immediate reduction in carbon emissions and improved resource efficiency
Key Measures Applied
- Implementation of modern precalciner systems with compact design
- Engineering and CFD simulations for gas flow and combustion optimization
- Upgrading burner systems and exhaust gas paths
- Ball charge optimization and liner reconfiguration in mills
- Replacement of mixing chambers, sealing of air leakage points
- Installation of modern filtration plants and spark catchers
- Automation system upgrades to improve thermal and process stability
- Promotion of co-processing practices and regulatory alignment for alternative fuel access
We help our clients unlock the full potential of their cement operations — boosting performance, reducing emissions, and future-proofing production in a carbon-constrained world.
