Benchmarking and Energy Saving Tool for the Cement Industry

BEST Cement

BEST-Cement for China has been developed by Lawrence Berkeley National Laboratory in collaboration with the Energy Research Institute, the China Cement Association, the China Building Materials Academy, and Shandong University with financial support of the U.S. Environmental Protection Agency, Energy Foundation, and Dow Chemical Company.

BEST-Cement is a process-based tool based on all commercially-available efficiency technologies used anywhere in the world applicable to the cement industry, designed for use in China. No actual cement facility with every single efficiency measure included in the benchmark will likely exist; however, the benchmark sets a reasonable standard by which to compare. The energy consumption of the benchmark facility will differ due to differences in processing at a given cement enterprise. The tool accounts for these variables and allows the user to adapt the model to operational variables specific for their cement facility.

In order to model the benchmark so that it represents a facility similar to the user's cement facility, the user first inputs production variables in the input sheet. These variables allow the tool to estimate a benchmark facility that is similar to the user's cement plant, giving a better picture of the potential for that particular facility, rather than benchmarking against a generic one.

The production variables required include the following: the amount of raw materials used in tonnes per year (limestone, gypsum, clay minerals, iron ore, blast furnace slag, fly ash, slag from other industries, natural pozzolans, limestone powder (used post-clinker stage), municipal wastes and others); the amount of raw materials that are prehomogenized and proportioned (in tonnes per year); the amount of additives that are dried and ground (in tonnes per year); the production of clinker (in tonnes per year) from each kiln by kiln type; the amount of production of cement by type and grade (in tonnes per year); and, the energy used by fuel type.

The tool offers the user the opportunity to do a quick assessment or a more detailed assessment - this choice will determine the level of detail of the energy input. The detailed assessment will require energy data for each stage of production while the quick assessment will require only total energy used at the entire facility. The benchmarking tool provides two benchmarks - one for Chinese best practices and one for international best practices.

After benchmarking the cement plant's performance, BEST-Cement can be used to evaluate the impact of selected energy efficiency measures. BEST-Cement for China provides information on approximately 50 energy-efficiency measures that can be used in cement plants, including their cost, energy savings, simple payback time, carbon dioxide emissions reduction, etc. The user selects the degree or share of implementation for each of the measures, and the BEST Cement then calculates the overall cost to implement the chosen measures along with the related energy and emissions savings, cost savings, payback period and a re-calculated benchmark.

BEST Cement is designed for cement facilities that produce 325, 425, 525 and 625 cement grades (of Portland, common Portland, slag, fly ash, Pozzolana, and/or blended cement types).

To download the BEST-Cement tool, please complete the download form. To download the BEST-Cement for China Handbook in English and in Chinese, please see the Downloads below.

Purpose: 
Process-based benchmarking and energy savings tool for cement industry
Audience: 
Engineers and managers of cement industry, energy efficiency researchers
Languages: 
English |
Chinese

BEST-Cement Tool Download Form

Instructions for downloading BEST-Cement for China:

Latest Version 5.4 - December 15, 2009

BEST Cement requires a PC computer that runs Windows 2000 or XP. The Microsoft .NET Framework version 2.0 is required to run the application. If the Microsoft .NET Framework is not installed on the user computer, the user would need to install the Microsoft .NET Framework runtime and associated files first.

Save the file to a temporary directory. The full installation file is a self-extracting executable file. If the user does not change the default extraction directory, the BEST Cement program installer should start automatically after the extraction. If the installer does not start automatically, please find the setup.exe in the temporary directory and run the setup.exe. During the installation, shortcuts are created on user computer's desktop and in the programs.

In the application's installation directory, there is a "demos" sub-directory. In this sub-directory, there are several data files which can be used for demonstration. In order to use one of these files, click on "Start" on the front page of the BEST program, then click on "Load a Saved Assessment". You can then choose whether to load example data for the English or Chinese version of the tool. Example data are available for either a detailed (Facility.Det) or a quick (Facility.Quick) assessment.

If the user has previously installed BEST Cement for China, please remove the previous version before installing the new version: Start -> Control Panel -> Add/Remove Programs, remove "BEST Cement".

BEST-Cement for China is updated periodically, so please re-visit this website for the latest version.

Please fill out the form below for BEST-Cement Tool. You will receive an e-mail with a link to download the software.

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