ADVANCING TOWARD NET-ZERO: REPURPOSING DEDUSTING EXHAUST AIR FOR HYBRID AIRSLIDE CONVEYING IN CEMENT MANUFACTURING

Abstract

The cement industry is among the most energy- and carbon-intensive sectors worldwide, contributing significantly to global CO₂ emissions through high thermal and electrical energy demands. On average, cement plants consume nearly 100 kWh of electricity per ton of cement, with a substantial portion dedicated to material handling and auxiliary systems such as airslides. Conventional airslides rely on dedicated blower fans, which add notably to a plant’s overall electrical load. This study presents a hybrid airslide conveying system designed to enhance energy efficiency and support the transition toward net-zero cement manufacturing. The proposed system repurposes the exhaust airflow from dedusting units and excess blower pressure as the conveying medium for airslides, replacing the need for separate blower fans. By utilizing this secondary airflow—traditionally released into the atmosphere—the system reduces redundant electrical consumption without requiring major capital investment or structural changes. Implementation across two stages—first through dedusting stack integration and later by recovering blower discharge pressure—resulted in annual electricity savings exceeding 141,000 kWh, equivalent to Rs 2.26 million in cost reduction and a CO₂ emission decrease of approximately 29 tonnes per year per plant. Considering there are about 3,117 cement plants globally, if this approach were applied to just 80% of them, the collective impact could exceed 350 GWh of electricity savings and over 72,000 tonnes of CO₂ reduction annually.Furthermore, as several additional air-conveying systems exist within each plant, broader implementation could yield even higher savings, potentially scaling these reductions into the hundreds of thousands of tonnes of CO₂ per year worldwide. This hybrid approach therefore offers a practical, low-cost pathway toward large-scale decarbonization, aligning directly with global sustainability, energy efficiency, and circular economy goals for net-zero industrial operations..

Keywords:

Cement industry, Energy optimization, Airslide conveying, Dedusting units (bag filters), Electrical energy savings, CO₂ footprint reduction, Sustainable manufacturing