Solar Solution For Cement Factory
Get a solar system for your cement factory with trusted installation partners
India has the 2nd place in terms of cement production across the world. In the union budget of 2024, our finance minister allocated Rs. 11,11,111 crore (around 3.4% of our total GDP) for infrastructure. There are significant opportunities for the construction and infrastructure sector and the Indian cement industry will get the highest benefit from this.
A cement producer usually pays 30% – 40% of the production cost just to fulfil the energy requirements. With solar solutions for cement factory, you can sustainably reduce operational costs and increase the profitability of your business.
Working Mechanism of a Cement Factory/Cement Manufacturing Process
Every cement factory follows these steps for cement production:
In the first step, the hard materials are crushed in two stages either in a wet or dry process. Soft materials are also broken down and passed through screens to remove odd particles based on size.
After this, the mixture is stored in silos (for the dry process) or slurry tanks (for the wet process). A partial fusion is done by heating the ground and blending raw materials to make cement clinker. This heating process works at a temperature of 1450℃ in kilns.
After a few hours of heating, the clink becomes clinker which is a type of granulated spherical stone. These rounded nodules have a size of around 1mm – 25mm across.
The clinker is finely processed with a ball mill with a small amount of anhydrite/gypsum (5%) for producing Portland cement. To make blended cement, the cement clinker is inter-grinded with different materials such as granulated blast furnace slag, fly ash, artificial (metakaolin) / natural (Volcanic ash), limestone dust, and anhydrite/gypsum.
Important Raw Components Used in Cement Production
The main raw components of cement production are clay or shale, limestone and marl. The 4 primary components of Portland cement are Dicalcium Silicate (2CaO SiO2), Tricalcium Aluminate (3CaO Al2O3), Tricalcium Silicate (3CaO SiO2), Tetracalcium Aluminoferrite (4CaO Al2O3Fe2O3). A small amount of Magnesium is also used in this production.
Machinery in a Cement Factory
Here are the important machines used in a cement factory
- Machines for Crushing: Jaw crusher, impact crusher, hammer crusher, vertical shaft crusher, gyratory crusher, etc.
- Sintering Kiln: Pusher Kiln, roller hearth kiln or rotary kiln
- Activated Carbon Machinery: Activated carbon rotary kiln, pyrolysis plant, waste gasification plant, etc.
- Cement Plant Solution: Cement grinding station, cement silo, raw mill grinding solution
- Dust Collector: Electric precipitator, air box pulse dust collector
- Cooling: Rotary cooler and clinker grate cooler
- Separator: Cement separator
- Cement Grinding: Ball mill, GGBS plant, cement vertical mill, vibration ball mill, stirred ball mill, etc.
- Lime Processing Plant: Hydrated lime plant, lime slaker
Electricity Consumption in a Cement Factory
The cement production process usually consumes a high amount of power. Even per unit production power consumption sees a downturn over time, but it is still too high.
A cement factory that produces around 2 million tons of cement per annum will require electricity of around 200-300 KWh every year.
Note: The actual electricity load may vary depending on the cement factory’s production volume, size of the boilers, and capacity. The load factor for a cement factory is 80%.
Why Install Solar For Cement Factory?
Here are the reasons to get solar solution for a cement factory:
- Operational Cost Reduction
Cement production activity includes different machinery, HVAC systems, lighting, etc. This results in a huge electricity demand for the overall process. Traditionally, companies use grid electricity/diesel generators/ coal to fulfil this power requirement.
The price of fossil fuels and grid electricity is continuously increasing over time. Therefore, in the long run, these energy sources will be unsuitable. Using solar energy, cement factories can get a reliable option for long-term cost savings in the production process.
- Faster ROI (Return on Investment)
Solar investment is secured and is a highly lucrative option for cement factories. The payback period for solar installation in a cement factory is around 4-5 years. In other words, after installation, a solar system will give your initial money back within the next 4 – 5 years. Then, you will continuously get free electricity for the next 21 – 25 years.
- Greenhouse Gas Emission Reduction
During cement production, a significant amount of greenhouse gas (GHG) emissions occur. The solar energy doesn’t have any type of emissions. Therefore, it will reduce GHG emissions as well as the carbon footprint.
- Tax Benefits
The Indian government is continuously trying to boose the usage of solar energy across different industries. Therefore, you can claim up to 40% of Accelerated Depreciation Benefits through different schemes.
Why Choose Us To Get Solar Solution For Cement Factory?
These are some unique advantages of choosing Das Energie for solar installation at a cement industry facility:
Free Expert Advice:
You can get free guidance from our expert solar energy advisors with a single request. Just fill out the form and wait for our call.
Verified & Trusted Installation Partners:
To ensure a top-quality service, we only onboard experienced, licensed and verified installation partners.
No Forceful Sale:
We will never force you to buy as soon as possible or a specific solar system. We give you 100% right to decide.
Detailed Solar Quotation:
Our installation partner will visit the installation site and you will receive a detailed quotation. This will include every small detail about your system.
Post-Installation Support:
If you contact us for any support even after the installation, you will get the support from us. No worry! We are here for you.
No Spam Calls:
We never spam you via marketing calls or emails. We usually contact based on the personalised request for solar installation for cement plant.
Process of Solarizing Cement Plants
On grid solar system is the best option to solalize cement factories. This is the process to get solar installation from us:
Step 1: Discuss With Our Expert Advisor
Once you enquire, we will call you and ask about your specific needs. After the on-call discussion, you have to book a site inspection if you want to know the actual price.
Step 2: Site Inspection & Final Quotation
After checking the installation our installation partner will send you a final quotation with all the details about the solar system such as the name and brand of the components, prices, warranty information, etc.
Step 3: Solar in The Cement Industry Installation
Once you select the final quotation, our installation partner will complete the solar installation as soon as possible.
Why Choose On-Grid Solar Power Solution For Cement Factory
At Das Energie, we always recommend an on-grid/grid-connected solar system for cement factories. Here are the reasons for this:
- These systems are connected to power grids. Therefore, you don’t need to buy solar batteries to store the excess energy.
- It uses the net meter that calculates both side transactions which helps to get a reduced electric bill.
- These systems are effective in terms of easy installation process and low maintenance charge.
- Cement plants generally have high power consumption and on-grid solar is the best option for this.
Cost of Solar Systems for Cement Manufacturing Industry
To know about the actual pricing for your cement factory, please contact our team via call 9830795307 or drop us an email at connect@dasenergie.com
Contact us Now! Our energy experts are waiting for you!!
Various Solar Solutions for Cement Factory
We at Das Energie offer different types of solar solutions for cement factories. Here are some of our solutions:
- Grid-connected/On Grid Solar Plant,
- Solar Submersible Pump
- Solar Street Light with the Factory Premise
- Solar Carport in Cement Factory
ROI of Investing in Solar Power Systems for Cement Factory
Follow this table to learn about the ROI of investing in solar power systems for cement factory(s):
| Solar System Size | Monthly Generation | Monthly Savings |
| 300 kW | 45,000 unit | Rs. 5,40,000 |
| 500 kW | 75,000 unit | Rs. 9,00,000 |
| 700 kW | 1,05,000 unit | Rs. 12,60,000 |
Note- Per day electricity generation = 5 units and 1 kWp = Rs. 12
Top Cement Companies That Use Solar Power
Here are the plans of different cement companies in India in terms of solar energy usage:
Ultratech Cement: India’s largest cement company, Aditya Birla Group’s Ultratech Cement has announced a complete transition to renewable energy by 2050 using solar and wind energy.
Shree Cement: Shree Cement is one of the top cement manufacturers in India that installed a 19.5 MW solar power plant in Andhra Pradesh’s manufacturing unit. In FY 25, the company plans to invest an additional Rs. 1,000 crore to increase its renewable energy portfolio. This will include 132 MW solar capacity across five states – Jharkhand, Rajasthan, Haryana, Uttarakhand, and Uttar Pradesh.
These are some other cement companies that are looking to use solar energy in cement manufacturing plants to get the same benefits.