Methodology of industrial energy efficiency and application on the cement sector

Nowadays, Turkey attains seventy percent of total energy by importing. It is believed that this percentage will rise in the next year. Natural gas rate was 44,00% percent and electricity generation rate was 43,73% in total consumption in 2006. The supply of natural gas predominantly based on single resource, the price rise exaggerated, natural gas and petroleum used as a means of political pressure, threatens country?s security and economy. Some precautions must be taken for energy and environment concerns. These are energy efficiency increase studies and the increase of traditional energy sources such as lignite and hydro energy, and also renewable energy sources such as wind, geothermal, biomass and solar energy. The expression, " The cheapest and the best energy is saved energy" implies the importance of energy efficiency. In this study, engineering approaches which concerns energy efficiency studies and applications in industrial intuitions, technical and economic analysis etc. and all related work are explored. The studies were carried on a single cement plant, and extended to the entire field. In single plant based approach, the energy usage points in a plant and the related energy saving potentials and investment to the potential feed-back were determined. In addition, the amount of investment and their annual amortization expends related in energy saving were determined. The consumptions were compared with the annual energy saving vii revenue at the appropriate point, and the economical precautions were determined by most appropriate execution strategies. The specified technical and economic analysis and application strategies for the plant were collected in a diagram which is named ?energy saving supply curve?, and all energy efficiency execution strategies were composed in a forecasted period of time. The energy saving supply curve of Turkish cement industry was created for the period of 2005-2020. According to different scenarios, distributions of precautions in year and application times, primary product energy saving values, primary energy cost, specific primary energy consumption etc. and other values were plotted in there diagrams. With some rehabilitation and energy saving precautions between 1990-2004, as saving of 12,9 PJ/year was provided in primary energy consumption taking 1990 as a reference year. Its monetary equivalent is 52,8 million $/year. The specific primary energy consumption reduces from 4,12 GJ/ton-cement in the year 2004 to 3,03 GJ/ton-cement in 2020 if the interest rate is %12. The required investment to realize this reduction is 309 million $ in the 2010, and 434 million $ in the year 2020. If this programme is carried out, 26,04 PJ total primary energy saving can be provided in cement sector between 2004-2020 years, and its monetary equivalent is 8,95 PJ/$.