Based on a GIZ study in 200 Nepalese industry findings on the energy efficiency potentials and energy saving measures for cement sector in Nepal is presented.

1. Cement Sector
Energy Intensity 45% of manufacturing cost

2. Cement Manufacturing – technologies
• Limestone is the raw material used in the
manufacture of cement.
The thermal energy consumption average is
about 760 kcal/kg of clinker. Based on the
study of the latest cement plants, the target
energy consumption for a new cement plant
could beast below:
Specific Electrical Energy consumption : 75
units/ton of OPC – 43
Specific Thermal Energy Consumption : 715
kCal/kg of clinker

3. Area of saving
Mines and Crusher Raw mill grinding &
Short-term storage
• Increase operating capacity • Install variable louvre system for
of primary & secondary roller mill
crusher • Install high efficiency dynamic
• Reduce idle run of crushers separator for roller mills
and belts • Install belt and bucket elevator
• Reduce idle operation of in place of pneumatic conveying
dust collection equipment • Installation of efficient mill
Long-term intervals – diaphragm and liners
• Install slip power recovery
• Install bulk analyzer for
system / VFD for raw mill fan /
crushed limestone
ESP fan

4. Area of saving
Compressors & Electrical System
Compressed Air • Use energy efficient lighting
System • Distribute load on transformer
• Install screw compressors network in an optimum manner
with VFD in place of old • Improve power factor
compressors. – Individual compensation
• Install compressed air traps – Group compensation
for receivers – Centralized compensation
• Optimise compressor • Replace over sized motors
discharge pressure
• Replace with energy efficient
• Eliminate compressor air motors
leakages by a vigorous
maintenance programme • Use VFD for low / partial loads
• Maintain compressed air
filters in good condition