Simulation of Cement Mill to Predict and Mitigate the Over-Heat Phenomenon: an Approach to Optimize the Energy Consumption in Cement Industry

Himawan Tri Bayu Murti Petrus, Jonas Kristanto, Kevin Cleary Wanta, Agus Prasetya


being one of the most energy-intensive industries, cement industry requires to evaluate the energy efficiency of their operating units, one of them is cement mill. Functioning as a mixing unit of several materials, i.e., clinker, limestone, gypsum, and trass with their initial heat and propensity of heat generation during milling, over-heat in the cement mill occurs frequently. It should be avoided in order to establish efficiency. Therefore, a mathematical model was generated in this study to predict and to mitigate this overheat phenomenon. This cement mill mathematical model has been generated using mass and energy balances. The output of the model is temperature profile versus residence time with targeted water content of the product that the optimum residence time can be calculated. Based on the temperature profile with a targeted water content of the product, it can be concluded that the optimum operating condition of the cement mill lies in the range of 5 to 30 seconds of materials residence time in the cement mill

Full Text:



Worrell, E., Price, L., Martin, N., Hendriks, C., and Media, L., O., 2001, Carbon Dioxide Emissions from the Global Cement Industry, Annu. Rev. Energy Environ., 26, 303 – 329.

U.S. Energy Information Administration, 2016, Chapter 7, Industrial sector energy consumption, International Energy Outlook 2016,

Madlool, N.A., Saidur, R., Hossain, M.S., and Rahim, N.A., 2011, A critical review on energy use and savings in the cement industries, Renewable and Sustainable Energy Reviews, 15, 2042 – 2060.

Wang, J., Dai, Y., Gao, L., 2009, Exergy analyses and parametric optimizations for different cogeneration power plants in cement industry, Applied Energy, 86, 941 – 948.

PT. Indocement Tunggal Prakasa Tbk. (2018) 2018 Annual Report of PT. Indocement Tunggal Prakasa Tbk. Available at: papers://d3978ab58702-4bf9-be6f-7c3f6904d049/Paper/p5081.

Aplak, H. S. and Sogut, M. Z. (2013) ‘Game theory approach in decisional process of energy management for industrial sector’, Energy Conversion and Management. Elsevier Ltd, 74, pp. 70–80. doi: 10.1016/j.enconman.2013.03.027.

Subic, A. et al. (2013) ‘Performance analysis of the capability assessment tool for sustainable manufacturing’, Sustainability (Switzerland), 5(8), pp. 3543–3561. doi: 10.3390/su5083543.

Hoenig, V. et al. (2013) ‘Energy efficiency in cement production; part 1’, Cement International, 11(4), pp. 46–65. Available at: dd.

Smith, J. M., Van Ness, H. C. and Abbott, M. M. (2001) Introduction to Chemical Engineering Thermodynamics. 6th edn. New York: McGrawHill.

Green, W. G. and Perry, H. R. (2013) Perry’s Chemical Engineers’ Handbook, Journal of Chemical Information and Modeling. doi: 10.1017/CBO9781107415324.004.

Holman, J. P. (2009) ‘Heat Transfer’, p. 752. doi: 10.1115/1.3246887.


  • There are currently no refbacks.

Creative Commons License
This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License.
View My Stats
Flag Counter