Vol. 7(4), pp.

53-58, July 2015

DOI: 10.5897/JETR2015.0545
Article Number: 2229DA854095
ISSN 2006-9790
Copyright 2015
Author(s) retain the copyright of this article
http://www.academicjournals.org/JETR

Journal of Engineering and Technology

Research

Full Length Research Paper

Cement production optimization modeling: A case

study BUA plant
Joseph Sunday Oyepata* and Otunuya Obodeh
Mechanical Engineering Department, Faculty of Engineering, Ambrose Alli University, Ekpoma, Edo State, Nigeria.
Received 24 March, 2015; Accepted 6 June, 2015

This paper deals with cement production optimization modeling using Particle Swarm Optimization
(PSO) and the results was compared with Genetic Algorithm (GA) and Pattern Search (PS). This
optimization modeling took into account mixtures of primary fuel (mineral coal, pet-coke and heavy oil)
and its alternative fuel which is agricultural waste (rice husk, sugar waste and ground shell). The
optimization simulation models predict the cost benefit to the manufacturer using alternative fuel,
environmental impact to world and finally the quality of the cement produced to the end user.
Production cost for one ton of cement using PSO ($23 = 4945), GA ($33 = 7095), PS (38.2 = 8170). The
oxides in this research work met standard cement specification: Silica Modulus (M.S-2.9), Alumina
Modulus (M.A- 1.3), Lime Saturation factor (LSF-93.3%). The results show that the cost of cement
production can be reduced by 30 to 70% with the use of alternative fuel (Rice husk, Sugar cane waste,
ground nut shell) and without greatly affecting the final product.
Key words: Fuel mixture, energy consumption, cement cost, cement quality.

INTRODUCTION
In cement production energy consumption takes the
largest bulk of production cost. Due to this impact the
cement manufacturers are always concerned about using
alternative fuel mixture with low production cost without
losing the quality of the final product and less
environmental impact to the society. The process
consists basically the replacement of the primary fuels by
residues generated by other industries such as used
tires, waste oils and other industrial wastes, agricultural
waste, municipality waste, among others (Kleppinger,
1993).
This research work presents the possibility of using the

mixture of mineral coal, petroleum coke, heavy oil,

agricultural waste (rice husk, ground nut and sugar cane
waste), etc. as fuel feed stock. This mixture is intended
for a rotary kiln, clinker production; mainly dry process
with a pre-heater and calciner. The optimization
procedure will take into account process restrictions such
as specific heat consumption, cement quality and
environmental impact.
Primary fuels used in cement industry are mineral coal,
petroleum coal, gas oil and natural gas. These provide
most of the energy needs of the World today. Coal and
natural gas are used in their natural forms, but petroleum

*Corresponding author. E-mail: [email protected], [email protected]. Tel: +234-8156466900, +2347080890545.

Author(s) agree that this article remain permanently open access under the terms of the Creative Commons Attribution
License 4.0 International License

54

J. Eng. Technol. Res.

and other fossil fuels such as shale and bituminous

sands require distillation and refinement to produce
consumable fuels. These fuels exist in the following
forms: Gaseous, liquid, and solid. The high cost of fossil
fuels and most importantly, their damaging effect on the
environment underscore the need to develop alternative
fuel mixture for many industrial systems that rely on fossil
fuels. Increased use of renewable and alternative fuels
can extend life cycle of fossil fuel supplies and help
resolve the present world global warming (Green House
Gases) which is associated with the use of conventional
fuels (Joseph and Obodeh, 2014).
Justification of the study
The cement manufacturing industry is under increasing
pressure to reduce, cost of cement production and Green
House Gas (GHG) emissions, such as carbon monoxide
(CO), carbon dioxide (CO 2) and nitrogen oxide (NOx)
(Conesa et al., 2008). It is estimated that 5% of global
carbon dioxide emissions originate from cement
production (Hendriks et al., 1998). These call for use of
alternative fuel mixtures in cement plant which does not
only afford considerable energy cost reduction, but also
have significant ecological benefits of conserving nonrenewable resources, the reduction of waste disposal
requirements and reduction of Green House Gas
emissions (Murray and Price, 2008). Use of low-grade
alternative fuel mixtures in rotary kiln systems reduces
GHG (Gabbard, 1990).
The finite nature of global fossil fuel resources, high
prices and most importantly, their damaging effect on the
environment underscore the need to develop alternative
fuels for many industrial systems that rely on fossil fuels.
Increased use of renewable and alternative fuels can
extend fossil fuel supplies and help resolve air pollution
problems associated with the use of conventional fuels
(Kntee et al., 2004).
Cement producers worldwide are striving to lower their
production costs. One effective method of achieving this
is the use of alternative fuels. Use of low-grade
alternative fuels such as waste coal, tyres, sewage
sludge, and biomass fuels (such as wood products,
agricultural wastes, etc.) in precalciners is a viable option
because combustion in a precalciner vessel takes place
at a lower temperature (Roy, 2002; Smidth & Co., 2000).
In precalciners where kiln exhaust gases pass through,
the NOx emissions are much reduced due to re-burn
reactions. There is an increased net global reduction in
CO2 emissions when waste is combusted in the cement
kiln systems as opposed to dedicated incinerators,
resulting in reduction in the CO2 penalties. Since
alternative fuels are often deemed cheaper than
conventional fossil fuels, the possibility of a competitive
edge is generated (Hewlett, 2004).
The use of alternative fuels in cement manufacture is
also ecologically beneficial, for two reasons: The

conservation of readily non-renewable resources, and the

reduction of waste disposal requirements. The use of
alternative fuels in European cement kilns saves fossil
fuels equivalent to 2.5 million tonnes of coal per year
(Cembureau, 1999).
Particle Swarm Optimization helps in the selection
alternative fuel available among the spool of alternative
fuel. The choice to be considered should at least have
the following:
1. Kiln Stability
2. Best net calorific value
3. Economic and environmental importance
Particle swarm optimization helps in selecting raw
materials simultaneously with fuels involving any
combination and number of fossil fuels and waste derived
fuels. The selection of the best possible solution is based
on an economic objective function that accounts for the
cost of raw materials, fossil fuels, alternative fuels and
emissions.
Particle Swarm Optimization is initialized with a
population of random solutions which is similar in all the
evolutionary algorithms. Each individual solution flies in
the problem space with a velocity which is adjusted
depending on the experiences of the individual and the
population. As mentioned earlier, PSO and its hybrids are
gaining popularity in solving scheduling problems. A few
of these works tackle the flow shop problem though
application to hybrid flow-shops with multiprocessor tasks
is relatively new (Yao et al., 2007).
This research work reviews in detail some of the main
alternative fuels used in cement production and
optitmization. It focuses on types of alternative fuels
used, the environmental and socio-economic benefits of
using alternative fuels, challenges associated with
switching from conventional or fossil to alternative fuels,
combustion characteristics of the alternative fuels
concerned, and their effect on cement production and
quality (Winter et al., 1997). The aim of this research
work is to provide empirical evaluation of alternative
fuels. It offers an invaluable source of information for
cement manufacturers that are interested in using
alternative fuels. Researchers and students would also
find this information valuable for their academic work and
development.
The successful conduct of this research work would
lead to reduction of primary fuel consumed and
substituting the primary fuel with alternative fuel mixtures
in BUA cement plant, since energy cost is the largest
variable of the production cost. Through the particle
swarm optimization model, it is possible to foresee
(Carpio et al., 2005) the raw material composition when
alternative fuel mixtures has been decided to be used as
secondary fuels in cement plant.
It is also possible to calculate the substitution levels of
the primary fuel by alternative fuel mixtures derived

Oyepata and Obodeh

from agricultural wastes (rice husk, ground nut and sugar

waste), being considered the acceptable and lowest
pollutant emissions levels such as carbon dioxide, carbon
monoxide and sulphur etc.

Objective of the study

The overall aim of the study is to develop readily and
commercially available alternative fuel mixtures for
achieving better stability of kiln operations, energy
reduction
and
negative
environmental
impact
minimization. The specific objectives are:
1. To carry out theoretical analysis and mathematical
model using particle swarm optimization.
2. To determine the correlation between the cement
standard results and empirical (experimental) results.
3. Comparing Particle Swarm Optimization model with
other optimization model (Genetic Algorithms and Pattern
Search)
4. To determine the effect of alternative fuel mixtures on;
clinker quality, environmental impact, clinker production
cost and cement production.

55

Raw materials and fuel mixture model

The material and fuel mixture optimization, was consider for the
stable operation of the rotary kiln, the quality of the clinker
produced, the minimum cost of the composition used and the
electric power; all these variables are considered in the nonlinear
model proposed through the following objective function, Equation
(1) (Carpio, 2004, 2005).

C Pic Xi Pe A exp

( B. S )

(1)

The first term (linear) represents the raw materials and fuels
(primary and alternative) costs used in the clinker production (p i, is
the raw materials and fuels costs i = 1,2....... 10, that participate in
the burning, with their respective percentages X 1, X2,......X10). The
objective function (C) of the model tried to obtain a minimum cost in
the clinker production, considering the raw materials costs as well
as the consumption of the energy required for grinding.
The second term (nonlinear) represents electricity cost (p e) and the
energy consumption required in kWh/t for the grinding process of a
certain specific surface (S is the specific surface area in cm 2/g, A
and B are constants that depend on the clinker composition).
Based on raw material, fuels chemical composition values and on
the Equation (1), an objective function was set up, which represents
costs minimization problem, considering the operational and
environmental costs presented as it follows:
MINCost1 X 1 Cost 2 X 2 Cost3 X 3 Cost 4 X 4 Cost5 X 5 Cost6 X 6 Cost7 X 7

MATERIALS AND METHODS

The methodology of research is to use the Particle Swarm
Optimization, Genetic Algorithm and Pattern Search simulation
modeling. This will be generated from MATLAB software. Data used
for this research was obtained from BUA cement plant laboratory
and other foreign major cement group laboratory, such as Lafarge
Group and Holcim Group, which are the largest cement
manufacture in the world, while Flsmidth are the designer and
manufacturer of cement equipment. The research results obtained
(through optimization) will be compared with standard cement
result.
Table 1 gives detail analysis of the raw material used to produce
the raw meal for the kiln feed. Tables 2 and 3 are the detail analysis
of primary fuels and alternative fuels (agricultural waste) used
respectively for the production of cement.

Data processing
The method of analysis was the use of Particle Swarm
Optimization, Genetic Algorithm and Pattern Search simulation
model. This was generated from MATLAB software.
Different sets of data were used at each stage. Thus the data were
used at each simulation stage are based on the Raw material
percentage (%) and Alternative Fuel percentage (%).
The following training procedures were used:
1. A training set used in determining the Particle Swarm
Optimization, Genetic Algorithm and Pattern Search simulation.
2. A validation set, used in estimating the Particle Swarm
Optimization Genetic Algorithm and Pattern Search and decide
when to start training.
3. Testing of the Particle swarm optimization Genetic Algorithm and
Pattern Search tool with other optimization tools
4. Inputting the result of the simulations and also checking that all
the constraint X1, X2, X3 X10 are satisfied.

Cost8 X 8 Cost9 X 9 Cost10 X 10 Cost EE 5.76MS 5.82 e 0.2MS 0.98S

M .S

6.20 X 1 63.62 X 2 94.70 X 3 3.6 X 4 2.0 X 5

1.59 X 1 26.84 X 2 5.1X 3 93.95 X 4 1.38 X 5

(2)

(3)

The constraints

52.18 X 1 1.03 X 2 1.01X 3 0.11X 4 0.18 X 5 64

(4)

52.18 X 1 1.03 X 2 1.01X 3 0.11X 4 0.18 X 5 71.2

(5)

6.20 X 1 63.62 X 2 94.70 X 3 3.60 X 4 2.0 X 5 20.0

(6)

6.20 X 1 63.62 X 2 94.70 X 3 3.60 X 4 2.0 X 5 24.50

(7)

1.12 X 1 17.19 X 2 3.67 X 3 0.98 X 4 1.07 X 5 3.80

(8)

1.12 X 1 17.19 X 2 3.67 X 3 0.98 X 4 1.07 X 5 6.83

(9)

0.47 X 1 9.65 X 2 1.43 X 3 92.97 X 4 0.31X 5 1.32

(10)

0.47 X 1 9.65 X 2 1.43 X 3 92.97 X 4 0.31X 5 5.40

(11)

0.80 X 1 0.17 X 3 0.08 X 5 6.5

(12)

28.2 X 5 33.7 X 6 43 X 7 13.517 X 8 15.479 X 9 17.8 X 10 3.60

(13)

1.30 X 5 4.00 X 6 1.54 X 7 0.04 X 8 0.17 X 9 0.02 X 10 5.0

(14)

0.05 X 1 3 X 2 0.78 X 3 0.20

(15)

56

J. Eng. Technol. Res.

Table 1. Data of raw meal material preparation used.

Material
Notation
Cao
SiO2
Al2O3
Fe2O3
MgO
SO3
Na2O
K2O

Limestone
X1
52.18
6.20
1.12
0.47
0.80
0.05
0.07
0.20

Clay
X2
1.03
63.62
17.19
9.65
3.00
0.30
3.00

Laterite
X3
1.0
94.70
3.67
1.43
0.17
0.78
0.50
1.28

Iron
X4
0.11
3.60
0.98
92.97
-

Table 2. Data of fuel composition employed as primary fuels.

Component
Notation
C
H
N
O
S
Cl
P2O (In ash)
Na2O (In ash)
K2O (In ash)
CaO (In ash)
Fe2O (In ash)
Al2O (In ash)
SiO2 (In ash)
MgO (In ash)
NiO (In ash)
LHV (kJ/kg)

Mineral coal % weight

X5
70.60
4.30
1.20
11.8
1.30
0.07
0.02
0.05
0.12
0.18
0.31
1.07
2.00
0.08
28,800

Pet coke % weight

X6
89.50
3.08
1.71
1.11
4.00

Heavy oil uses % weight

X7
84
12
Trace
1
3.00

0.04
33,700

43,000

Table 3. Data of fuel composition employed as alternative fuels.

Component
Notation
C
H
O
N
S
Cl
LHV(kJ/kg)

Rice husk % weight

X8
37.48
4.41
33.27
0.17
0.04
0.09
13,517

Sugar cane % weight

X9
41.16
5.08
37.42
0.14
0.02
0.01
15,479

Ground nut shell % weight

X10
45.9
5.34
36
1.09
0.01
17.8

0.05 X 1 3.0 X 2 0.78 X 3 2.07

(16)

0.07 X 1 0.3 X 2 0.5 X 3 0.33

(18)

0.07 X 1 0.3 X 2 0.5 X 3 0.03

(17)

0.2 X 1 3 X 2 1.28 X 3 0.31

(19)

Oyepata and Obodeh

57

Table 4. Summary of result.

Objective function cost (C)

= 22.9646 US$ = 4945(naira)
X1= 1.2495
X2 = 0.1687
X3 = 0.0436
X4 = 0.0120
X5 = 7.4977e-06
X6 = 4.197e-08
X7 = 3.898e-7
X8 = 5.4881e-07
X9 = 0.2326
X10 = 5.64749e-06

Oxides composition
in clinker (%)

CaO =65.42
SiO = 22.65
Al2O3 = 4.5
Fe2O3 = 3.4
MgO = 1.01

0.2 X 1 3 X 2 1.28 X 3 1.82

Modulus

Specific heat consumption

= 3.6Gj/ton of clinker

M.S = ((SiO2/(Fe2O3 + Al2O3)) = 2.9

M.A=(Al2O3/Fe2O3) = 1.3
LSF
=
(((CaO+0.75)/((2.8SiO
+(1.18Al2O3 *0.68Fe2O3)) *100% =
93.3%
S.R = (SiO2/((Fe2O3+ Al2O3)) = 2.87
A.R = (Al2O3/Fe2O3) = 1.3

Mineral Coal X5 =0.00021

Pet Coke X6 = 0.000014
Heavy oil X7 = 0.000017
Rice Husk X8 = 0.0000074
Sugar cane waste X9 = 3.6
Ground nut shell X10 = 0.0001

(20)

EquationS (4) and (5) show the percentage of calcium oxide (CaO)
contained in raw meal (clinker) 1 ton should be between 64 to
71.2%, Equation (6) and (7) show the percentage of silicon oxide
(SiO2) is contained in calcareous granules 1 ton should be between
20 to 25%. EquationS (8) and (9) show the percentage of aluminum
trioxide (Al2O3) is contained in the calcareous grains per 1 ton
should be between 4 and 7%. EquationS (10) and (11) show the
percentage ferrous trioxide (Fe2O3) is contained in calcareous
granules 1 ton should be between 2 to 5%. Equation (12)
represents the percentage of magnesium should be less than or
6.50%. Equation (13) represents the heat value (Heating Value)
used in the production of clinker, which requires an amount of heat
equal to 3.6 GJ per ton of clinker. Equation (14) represents the
percentage of sulfur (Sulphur) should be less than or equal to 5% of
the sulfur from the fuel type. Equations (15) to (16) is the equation
of an acid and a base of clinker, which comes from the ingredients
used in the production of each species which is between 0.2 and
2.07%; Equation (17) to (18) is the best of sodium oxide (Na2O)
should be between 0.03 to 0.33% equations (18) to (19) values.
Best of potassium oxide (K2O) should be between 0.31 to 1.76%
(Joseph and Obedeh, 2014).

RESULTS AND DISCUSSION

Optimization simulation runs results at 20 using Matlab
software (Matlab 7.13). The grinding process of the
2
cement a specific surface area S = 0.38 cm /g were
used. The laptop used was Intel(R) Core i5-2540M
CPU at 2.60 Hz RAM 4.00 GB, system type 32-bit
operating system. In this case, the required chemical
composition is sought for a cement type produced in a
rotary kiln, dry process with heat specific consumption of
3600 clinker kJ/kg. The parameters of PSO, GE and PS
used a population of 100 particles; C1 = C2 = 2.0; initial
weighted (theta) of 0.9 with linear decline up to 0.3;
search space of the variables to be optimized in the
interval 0 < Xn < 3, where n=1,.., 10. The cost used for
this simulation are local market cost based in Nigeria
where one (1) dollar $ = 215 naira.
The PSO has the lowest standard deviation and best

average cost of producing one (1) ton of cement. All the

constraints in the Equations (1) to (20) are all satisfied for
PSO, GA and PS. To produce one (1) ton of cement
using PSO, GA, PS model, it is expected that an average
cost of $ 23 = 4945 naira, GA = $33.0 = 7095 naira and
PS = $38.2 =8170 naira respectively are needed to
produce one ton of cement. PS has the highest cost of
producing one ton of cement Table 4.
The results in the above solution correspond to a final
clinker composition, satisfying all objective function,
constraint and restriction in the equation, with all
parameters within standard cement allowable range. The
solution for the optimization model is a function of the
specific heat consumption and of the operational and
environmental restrictions.

Conclusion
In cement production equipment optimization, the
operating rate is different from design rate of the
equipment. The design rate gives room for increasing or
decreasing the feeding phase for the raw meal and the
fuel usage in a rotary kiln allows some freedom for
change in the composition of raw meal (raw mix and
corrective materials) and fuel consumption. The aim is to
minimize cost of production without losing the quality of
the final production, prolong the life of the equipment,
while satisfying the environmental and operational
restriction. The alternative fuel used is an agricultural
waste (sugar cane waste, ground nut shell and rice
husks) and primary fuel are mineral coal, pet-coke and
heavy oil. These Agricultural wastes present a great
potential use in the production of cement via rotary kilns.
A model is presented in this paper work in which the
composition of the raw meal and the fuels mixtures
enters as variables of a non-linear programing problem.
The solution to this optimization problem finds
composition values for the variable which will result is a
cement production with low free lime (CaO) 0.5-1.5, less

58

J. Eng. Technol. Res.

environmental pollutants and good quality cement

production.

Conflict of Interest
The authors have not declared any conflict of interest.
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