Energy Consumption and Pollution Reduction in Cement Industry


 It is highly energy intensive process and produces large quantities of gaseous pollutants like Carbon dioxide, Sulphur dioxide and Nitrogen Oxides. Reduction in energy     consumption and reducing pollutant formation is a key Challenge for Cement Industry.  Contact us for detailed discussion.

Cement Production involves calcination of Raw meal generated by Coal or petcoke Combustion in Kiln and Calciner. The Conversion of raw meal to Clinker happens in “Pyro Section”. Almost 60% of the Calcination of raw meal is completed in Calciner and the remaining in long, rotating, horizontal Kiln. The raw meal is preheated in a series of Preheated Cyclone before Calcination. The hot clinker is cooled in air coolers, crushed in crushers to fine particle size. Calcination of raw meal can be expressed as CaCO3———–> CaO+ CO2       Endothermic Reaction The heat required for calcination is supplied by combustion of Primary fuels like Coal, Petcoke, Tyres or Alternative fuels.   Due to high temperature, thermal NOx is produced. Side product of Calcination is Carbon dioxide.

Challenges in Cement Industry

Our Contribution


 FluiDimensions has in-depth Cement Process knowledge and strong experience of Application of CFD and process Modeling to improve the performance of Cyclone   Separators, improve Combustion, Calcination and pollutant reduction in Calciners, and Kiln. We have provided design and process solutions to reduce thermal, electrical power   consumption and pollutants emissions.


  • Redesigned Cyclones to reduce pressure drop and collection efficiency
  • Developed Software for Automated CFD Cyclone Design
  • Developed and Validated Coal Combustion Model to be used for Kiln Burner Design
  • Burner Design for Cement Kiln for CO, NOx, SOx reduction using Coal, Petcoke and Alternate Fuel
  • Reduction of CO in Cement kilns for different units 
  • Modeling of Calciner for NOx Reduction using Raw Meal Split, TA Split and fuel split
  • Improvement in combustion efficiency
  • usage of Alternate fuel

Successfully improved collection efficiency of ESP by using simpler guide vanes 

  • Design modifications in the bag house to improve bag life and pressure drop reduction
  • Design Evaluation

Redesigned ducting network to reduce pressure drop 

Developed Process model for the performance analysis of the entire pyro section