Kiln production optimization is achieved through quality, process, mechanical and operational adjustments of the running kiln after an audit, often eliminating the need for stage 2 optimization.
KILN optimization
for CLINKER PRODUCTION
Sustainable performance, proven results:
Optimized clinker production with zero investment
Service phases
Phase 1
- Optimization of kiln production through quality, process, mechanical, and operational adjustments of the running kiln after an audit of the key operation parameters
- Usually provides the major operation benefits
- Many times the phase 2 might not be required, as the desired result was already achieved in phase 1
Phase 2
- Mechanical measurements and assessment of the main equipment
- Further optimization through small mechanical modifications
- Requires a planned maintenance shutdown of the kiln of about 20 days
- Low cost modifications that do not involve new equipment
Process Optimization & Mechanical measurements
Improving the kiln operation and lifetime without new equipment or big investments
Performance Increase
By improving the kiln capacity, thermal substitution, specific heat consumption, clinker quality and other main KPI’s
Lifetime and Operational Improvement
By optimizing the hot stabilization, burner stabilization and stability control processes of running kilns
Cost Reduction
By decreasing manufacturing variable costs and through CO2 emissions savings
How much?
Pay only for what you get
- All the conditions are transparently laid out and discussed with the customer beforehand
- The service is paid proportionally to the improvements ($ per %improvement) plus travel expenses for our experts
2 - 12 months
payback
- The plant defines the goals
- The price is calculated from the plant’s own savings in the reduction of the variable costs of the first year
100%
based on RESULTS
- The payment is only for the proven achievements from the performance test
- If the final improvement is less than 3%, it is free of charge
Stage One
Stage Two
During a typical maintenance shutdown of around 20 days, small mechanical modifications are implemented to further enhance the kiln efficiency and performance.
Results
Immediate performance results after each stage! The final achievements are defined by a performance test at the end of the activities. The project may last from 1 to 12 months, depending on the full scope.
Mechanical measurements in Kilns
Rotary Kiln Optimization
Our optimization efforts include targeted interventions to stabilize and increase the efficiency of your equipment. We rely on precise measurements and innovative methods to achieve better stability and performance.
Hot Kiln Stabilization
- Ensuring consistent and stable operation at high temperatures.
Burner Stabilization
- Achieving stable and efficient combustion.
Overall Stability Control
- Implementing advanced control systems for reliable and consistent kiln operation.
Get a detailed benchmarking report
Our detailed report helps you identify areas for improvement by showing you how your performance compares to similar plants, providing a clear path to optimization.
Cost optimization: reduced variable costs, improved equipment reliability, and longer refractory lifetime.
Cost Optimization: Reducing Variable Costs
Improved equipment reliability & longer refractory lifetime
Our goal is to reduce variable manufacturing costs through simple yet effective measures. This includes:
- Change in production system parameters that improve the quality and properties of the finished product
- Optimization of the clinker factor for cement
- Reduction of specific thermal and electrical consumption in kilns
- Minimization of strength standard deviation at 28 days
- Identification of improvement opportunities with cement additives
- Use of alternative fuels
The costs for this service are covered by the savings generated from reducing variable costs in the first year.
Why ChristIan PFEIffer?
No major investments required
Our services are based on cost effective adjustments and do not require significant capital expenditures.
Pricing is based on your results
Our performance-based fees are directly tied to your achieved, measurable improvements.
Positive environmental impact
Our optimizations lead to reduced specific net CO₂ emissions and more efficient resource use.
Commence immediate financial savings
Our services provide fast, measurable results, ensuring lasting operational improvements.