Process Optimization


Process optimization is to improve the plant performance in terms of:

  • Improved capacity utilization.
  • Reduced power consumption.
  • Reduced fuel consumption.
  • Reduction of wear rate of dynamic equipment.
  • Improved product quality.
  • Improved equipment availability.
  • Improved working environment due to reduction in dust nuisance.
  • Reduced dust emission.
  • Conservation of natural resources like water, minerals and fossil fuel.

Coverage/ Methodology:

It covers:

  • Collection of plant data and interaction with plant personnel.
  • Down time analysis of all the major equipments and identification of bottlenecks/ problem areas.
  • Carrying out process measurements during steady operation of plant covering temperature, pressure, flow & power.
  • Carrying out mass gas and heat balancing of Pyro section.
  • Finding out efficiency of all the process fans.
  • Particle size analysis for all the raw materials, fuel, clinker & cement.
  • Proximate & Ultimate analysis of fuels.
  • Recommendation of measures for improvement of plant operations on short term and long term basis with financial implications.
  • Estimation of Capital Investments of the proposed measures.
  • Estimation of Return on investment in terms of Simple Payback period.


Plant Optimization will lead to increased profitability due to:

  • Reduction in unit cost of production.
  • Improved availability of the plant.
  • Increase in plant life.
  • Improved working environment.
  • Reduction of heat & power consumption.
  • Conservation of natural/ mineral resources.