A Literature Review on Energy, Exergy, and Exergoeconomic Analyses in Cement Rotary Kilns

Year 2025, Issue: Erken Görünüm - Early Pub Issues, 1 - 17

Evren Kodanli , İbrahim Uzun

Abstract

The cement production industry is one of the most energy-intensive sectors globally, with energy costs constituting approximately 30-40% of total production expenses. Among the various stages of cement production, the rotary kiln process is particularly energy-intensive, making its efficiency a critical factor in reducing energy consumption and environmental impact. This article offers a comprehensive review of previous studies on energy analysis, exergy analysis, exergy balance, exergy efficiency, and exergoeconomic analysis in the cement industry. The reviewed studies indicate that exergy efficiencies in cement production units vary between 16% and 67%, with significant exergy losses occurring in the rotary kiln due to its irreversible nature. The primary objective of this study is to consolidate findings from the literature, providing a more comprehensive understanding of energy and exergy flows in cement production processes. By identifying key trends, gaps, and opportunities for improvement, this review aims to make a significant contribution to energy savings and sustainability in the cement industry. The findings emphasize the potential of strategies such as waste heat recovery, the use of alternative fuels, and advanced process optimization techniques to enhance energy efficiency and reduce environmental impacts. However, the review also identifies a significant gap in the literature: the lack of integration of advanced optimization techniques, such as artificial neural networks (ANNs) and the Taguchi method, into cement production processes. These techniques have demonstrated significant potential in other industrial sectors but remain underexplored in the context of cement rotary kilns. This study proposes the integration of these advanced methods as an innovative approach to further enhance energy efficiency and sustainability. In conclusion, this review not only consolidates existing knowledge but also offers a roadmap for future research and industrial applications. By addressing the identified gaps and implementing the proposed strategies, the cement industry can transition towards more sustainable and energy-efficient production processes, contributing to global efforts to reduce energy consumption and greenhouse gas emissions.

Keywords

Cement Factory, Rotary Kiln, Energy, Exergy, Literature Review

Project Number

1

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