energy efficiency in the cement industry

ENERGY EFFICIENCY IN THE CEMENT INDUSTRY
Proceedings of a seminar organised by the Commission of the European Communities, Directorate-General
for Energy and CIMPOR Cimentos de Portugal E.P. with the co-operation of Cembureau European Cement
Association, and held in Oporto, Portugal, 6–7 November 1989.
Particular thanks are due to Mr V.Teixeira Lopo, President of CIMPOR, and to Mr A.Soares Gomes,
Director, for help in the organisation of this symposium, and to NIFES Consulting Group for editorial
assistance.
ENERGY EFFICIENCY IN THE
CEMENT INDUSTRY
Edited by
J.SIRCHIS
Directorate-General for Energy,
Commission of the European Communities,
Brussels, Belgium
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Energy efficiency in the cement industry.
1. European Community countries. Industries. Energy.
Conservation

I.Sirchis, J.
658.26
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PREFACE
The existence of significant uncertainty as to the long-term prospects for energy supply and demand
following the rapid fall in oil prices, has stimulated both the international energy situation as well as that of
the Community and made it essential that the substantial progress already made in restructuring the
Community’s energy economy be maintained and, if necessary, reinforced.
The European Energy Policy objectives for the year 1995 call for adequate energy supply, controlled

energy prices and increased environmental concern. All of these constraints necessitate the rational
exploitation of the primary energy forms by the EEC Member States.
The above objectives can be attained either by energy saving or by increased energy efficiency, or finally
through the development of new technologies to augment both saving and efficiency. Better insulation, heat
and material recycling, or application of improved processes, are typical examples.
Cement production is one of the most energy intensive sectors and requires a great quantity of energy.
Although much progress has already been achieved today in the field of the energy economy in the cement
industry in EEC countries, some stages of cement production still offer opportunities for further
improvement.
CONTENTS
PREFACE v
OPENING SESSION
Chairman: V Teixeira Lopo, President CIMPOR

OPENING ADDRESS—ENERGY POLICY OF THE COMMISSION OF THE EUROPEAN
COMMUNITIES
F KINDERMANN, Commission of the European Communities
2
OPENING SPEECH—A POLICY OF ENERGY EFFICIENCY
NUNO RIBEIRO DA SILVA, Secretary of State for Energy
6
FIRST SESSION
Chairman: Professor Veiga Simao, President of LNETI

ENERGY SAVING AND ENVIRONMENTAL IMPACT IN THE CEMENT INDUSTRY
A SOARES GOMES, CIMPOR, Cimentes de Portugal, Portugal
16
ENERGY OUTLOOK IN WEST GERMANY’S CEMENT INDUSTRY
A SCHEUER and S SPRUNG, Forschungsinstitut der Zementindustrie, Düsseldorf 30, Federal
Republic of Germany

20
OUTLOOK OF LATIN AMERICAN CEMENT INDUSTRY
JESUS GARCIA DEL VALLE and ALEJANDRO TORRES Asland Tecnologia SA, Madrid,
Spain
29
ENERGY OUTLOOK IN THE JAPANESE CEMENT INDUSTRY
YUKIO NAKAJIMA, Nihon Cement Co Ltd., Tokyo, Japan
42
DISCUSSION 49
SECOND SESSION—PART 1—SPECIFIC TECHNOLOGIES AND CEC DEMONSTRATION
PROJECTS
Chairman: J Sirchis, Commission of the European Communities

TRADITIONAL AND ADVANCED CONCEPTS OF WASTE HEAT RECOVERY IN
CEMENT PLANTS
E STEINBISS, KHD Humboldt Wedag AG, Cologne, Federal Republic of Germany
52
DISTRICT HEATING BASED ON WASTE HEAT FROM CLINKER COOLER 64
BO AHLKVIST, Cementa AB, Sweden
HEAT RECOVERY ON THE SMOKE OF THE CEMENT KILN AND UTILIZATION OF THE
RECOVERED ENERGY
J-F BOUQUELLE, Département Projets Ciments d’Obourg, Obourg, Belgium
69
UTILIZATION OF WASTE HEAT FROM THE CEMENT ROTARY KILN
K-H WEINERT, Interatom GmbH, Bergisch Gladbach, Federal Republic of Germany
74
ENERGY SAVING BY UTILISATION OF HIGH EFFICIENCY CLASSIFIER FOR
GRINDING AND COOLING OF CEMENT ON TWO MILLS AT CASTLE CEMENT
(RIBBLESDALE) LIMITED, CLITHEROE, LANCASHIRE, UK
P F PARKES, Castle Cement, Clitheroe, United Kingdom

81
DISCUSSION 86
SECOND SESSION—PART 2—ENGINEERING AND ENERGY MANAGEMENT
‘HOLDERBANK’S’ ENERGY MANAGEMENT IN THE 1990s
M BLANCK, ‘Holderbank’ Management and Consulting Ltd, Holderbank, Switzerland
90
ENGINEERING AND ENERGY SAVINGS
J DUMAS, CITEC, Guerville, France
102
ENERGY SAVINGS IN CEMENT KILN SYSTEMS
E BIRCH, F L Smidth and Co AS, Valby, Denmark
112
HIGH ENERGY SAVINGS THROUGH THE USE OF A NEW HIGH-PERFORMANCE
HYDRAULIC COMPONENT THE K-TECH PROCESS
M PALIARD and M MAKRIS
, CLE, Paris La Defense, France G MENARDI and M BAILLY
,
Ciments de Champagnole, Dole, France
125
ENERGY MANAGEMENT IN THE UK CEMENT INDUSTRY
T M LOWES and K W BEZANT, Blue Circle Industries plc, Greenhithe, Kent, United Kingdom
136
WASTE GAS HEAT RECOVERY IN CEMENT PLANTS
M NETO, Souselas Cement Plant, CIMPOR, Portugal
144
DISCUSSION 148
THIRD SESSION—RODND TABLE DISCUSSION
Chairman: Professor Mario Nina, University of Lisbon K W Bezant, BLUE CIRCLE, United
Kingdom F Aellen, HOLDERBANK, Switzerland Professor G Parisakis, University of Athens, Greece
J Sirchis, Commission of the European Communities E Steinbiss, KHD, BR Deutschland H

Takakusaki, NIHON CEMENT CO, Japan
152
CLOSING SESSION
Chairman: V Teixeira Lopo, President of CIMPOR

CONCLUSIONS 158
vii
D QUIRKE, CEMBUREAU CEC, Ministry of Industry
LIST OF PARTICIPANTS

INDEX OF AUTHORS 189
viii
160
OPENING SESSION
Chairman: V Teixeira Lopo, President CIMPOR
OPENING ADDRESS
“ENERGY POLICY OF THE COMMISSION OF THE EUROPEAN
COMMUNITIES”
F.KINDERMANN
Head of Division
Commission of the European Communities
Directorate-General for Energy
Technology Directorate
Programme Management: Solid Fuels and Energy Saving
If one goes back to the roots of the European Community, one discovers that two of the three Treaties deal,
partly of completely, with energy.
– The Treaty establishing the EUROPEAN COAL AND STEEL COMMUNITY (ECSC) was signed in Paris
in 1951.
– The Treaty establishing the EUROPEAN ATOMIC ENERGY COMMUNITY (EAEC or EURATOM)
was signed in Rome in 1957.

Therefore, one could say that, from the beginning, the founders of Europe regarded energy as a very
important brick for the construction of a real Community and one could even say that a good deal of the
integrated Common Market has already been realised for coal, steel and uranium.
In spite of this, I must admit that there was virtually no real common energy policy existing before the
first oil crisis back in 1973. Until then, the energy sector in the Community was characterised by twelve
distinct national markets with a matching number of national policies which were more or less coordinated
on the European level. It was only under the influence of the 1973 shock that quantified targets for selected,
energy carriers in the Community were defined. Of course, the main concern was, at that time, to substitute
oil and to reduce the dependency of the Community. Therefore, alternative energy sources, solid fuels and
energy efficiency, played a very important role, and it should be noted that the latter two are of very great
Importance to the cement industry, which is characterised by a high energy demand.
Anyway, once the European Energy Policy was established, it led very quickly to tangible results. In fact,
the consumption of imported oil was halved within 10 years, from 62% in 1973 to 31% in 1985, and energy
efficiency raised by ±20%. This forced the Commission to propose new targets for 1995, which were
adopted by the Council in September 1986.
I will not go into these in great detail as we all know very well that, since then, conditions on the energy
market have changed drastically: oil prices went down, as did coal prices on the world market; natural gas is
pressing for a higher market share; and in some countries, nuclear energy continues to expand. In addition
to this, there is more and more concern about the environment and particularly about the so-called
greenhouse effect. For these reasons, I would like to mention today only three of the present targets which
are of importance to industry and will remain vaild in future too:
– Energy efficiency will remain one of the most important topics of Energy Policy, for the reasons of
economy as well as of environment.
– Solutions are needed to establish a well-balanced relationship between Energy and the Environment.
This will certainly become even more important in future and will require adequate developments.
– Technology will have to play an extremely important role in achieving the targets.
It is quite interesting to see that these three items were amongst the Community’s targets from the
beginning. Yet, importance shifted from aspects of substitution and economics to the protection of the
environment. In addition, there are the requirements of the integrated Market for Energy or, in short, 1992.
In fact, National as well as Community policies have to change to meet the situation that will exist after

1992. Energy is an area where this transition now has to be made in order to have the integrated European
energy market followed by a true common energy policy at Community level.
The integration of Europe’s internal energy market is already underway, and a number of new initiatives
in this field have been launched since the beginning of 1989. These include new schemes for greater cross-
frontier trade and competition in the gas and electricity sectors, a mechanism for taking into account the
European dimension In the planning of major energy investments, and a new system allowing the
transparency of gas and electricity prices. Other measures to ensure the 1992 deadline will follow.
In the longer term, however, it will be the Commission’s task to propose to the Member States, a concise
framework for an effective Community energy policy. Therefore, a new review of longterm energy
prospects is at present underway, i.e., the 2010 study. A first disscussion paper, entitled “Major Themes in
Energy to 2010” was realised by the Commissioner for Energy, Mr Antonio Cardoso e Cunha, at the World
Energy Conference in Montreal last September.
As the Commissioner said in Montreal, the essential question facing all of us is the following: “Can we
continue to develop the world’s energy supplies, on a secure and economic basis, sufficient to maintain
economic growth while at the same time ensuring that the global environment is protected and indeed
improved?” The “Major Themes in Energy” shows possible alternative paths for our energy future. One is a
“convential route” with continuing growth in energy consumption and CO
2
emissions. Another path
suggests a way of controlling energy consumption and its environmental impact whilst maintaining
economic growth—in other words, meeting the challenge of
sustainable energy growth. In the months
ahead, the Commission will refine its analysis, taking into account the reactions in the Community and
Internationally, to this document.
However, the preliminary findings were already communicated to the international press in early October.
In this context, it is quite clear that the major constraint, or challenge, facing energy policy in the next few
years will be the
environmental one. We have seen, for example, how much attention was focused on this
issue recently at the world Energy Conference in Montreal. But we cannot afford either to neglect the more
traditional concern of energy policy makers, that of security of supply. This is particularly true at a time

when the world’s need for oil and other energy supplies continues to grow steadily month by month. Action
OPENING ADDRESS 3
must be taken to curb this trend in order to preserve as far as possible our energy resource base and to
protect the global environment.
With these two fundamental concerns in mind, it is quite clear that the major priority will have to be
given to
energy efficiency. In order to reduce the growth in energy consumption and the associated
pollution.
Thus, the political target is set, and all possible actions have to be put in hand to reach it. Of course, this
covers political and financial measures as well as technology but for reasons of time, I would like to
concentrate on the latter one.
An excellent technical base to build upon has been created by the Community’s energy demonstration
programme which was set up in 1978 and concentrated on three major areas:
– Energy saving or energy efficiency;
– New and renewable energy sources;
–Solid fuels.
I feel I shouldn’t go into too much detail because the area of interest to your industry will be presented
during the course of the next two days. But, in order to let you have an idea of what is involved, I would
like to give you some figures on the total programme and on the part devoted to energy saving.
1978–1989 Total Programme Energy Saving %
Number of projects 1,698 738 43.5
Total aid (MECU)
881.7 327.7 37.2
These figures prove that in the past, the Community already gave the appropriate attention to all the
possibilities of saving energy and improving energy efficiency. Let me just say that the main technical areas
were, and still are:
– Buildings
– Transport
– Industry
The demonstration programme, as it stands now, has pratically come to an end. An independent evaluation

was carried out last year which highlighted the remarkable results obtained in the different areas, but also said
that much more should be done to assure a widespread use of the results, and to match the new targets for
energy at the beginning of the next century.
The Commission adopted this line and, consequently, proposed to the Council that the replacement for
the existing demonstration and hydrocarbon technology scheme should be the THERMIE programme, a new
programme for demonstrating new energy technologies and promoting their commercialisation in the
European market. As for the current programmes, THERMIE will concentrate on the state beyond R&D by
providing risk finance for the testing of new energy technologies on a nearly commercial scale. It will
however, be more selective than its predecessor schemes and give more emphasis to the promotion and
replication of successfully demonstrated technologies. The current plan is that the Energy Council and the
European Parliament should give their consent to this new programme in time for it to start at the beginning
of next year.
4 ENERGY EFFICIENCY IN THE CEMENT INDUSTRY
THERMIE will cover a wide range of energy technologies including most renewable energies and energy
efficiency technologies, as well as clean coal combustion and hydrocarbon projects. These technologies will
certainly have a key role to play in assuring the Community’s energy future and preserving its environment.
They will also be of benefit to other countries outside Europe, particularly in the Third World where the
Community has cooperation and technology transfer programmes. I have no doubt that companies,
universities, and all those working in the Community in the energy saving field will find that THERMIE
provides a valuable new impetus to, and support for their pioneering activities.
In addition, the launching of THERMIE proves that the Community in conscious of tomorrow’s
problems and is ready to take its responsability.
OPENING ADDRESS 5
A POLICY OF ENERGY EFFICIENCY
SPEECH OF HIS EXCELLENCY THE SECRETARY OF STATE FOR
ENERGY
NUNO RIBEIRO DA SILVA
The aim of the Common Energy Policy in Portugal for the period up to 1995 is a 20% saving energy
consumption. If this is accomplished, it will represent:
– An annual saving of at least 2 million tons equivalent of oil (14 million barrels), corresponding to

something like Esc. 45bn at today’s prices.
– A consequent drop in the emission of CO2 into the atmosphere of around 6 million tons annually.
Such an increase in energy efficiency will have repercussions in the balance of payments and will lead to
improvements in the quality of the environment; there will, moreover, be an increase in the competitiveness
of the economy in general.
To these results would have to be added the internal and external effects of these moves to diversify
sources, above all those which aim to maximise the use of natural and renewable resources.
These were, and indeed are, the fulcral points in the search for technical and financial instruments for a
concerted policy of energy efficiency, set up with the consumer in mind.
The first element which ties these instruments together is the fact that they aim to support operations,
systems and sectors which are highly diversified and made up of a large number of distinct, financially
limited activities. This is a broad characterisation of the system of energy demand, a system requiring not
only special attention but also a framework for the unavoidable “confrontation” with the supply side.
The complementary nature of the various instruments should also of course be mentioned:
Firstly, as already mentioned, they open the door to all forms of rational association of the three most
important components of a logical use of energy in the widest sense:
– the management of energy at the level of the company or the region;
– the conservation of energy in the widely differentiated systems used by the consumer;
– the diversification of sources of energy with all those possible forms available for its use and
transformation.
Secondly, within the purview of these instruments, as in no other, we find all those Involved in economic
activities which it is really important to mobilize, from central and local administration to companies,
cottage industries and services.
The only exception here is the domestic consumer, who of course demands a very different type of action.
Finally, the new Instruments contribute even more to efficient and continuing support at all stages of the
prjects, beginning at R.D. & D. or in studies of project potential, continuing through the legal framework
and feasibility studies and ending at the point of incentives to investment.
But perhaps the most important of the aspects referred to here is the fact that the new instruments
contribute overall to providing a reply to many of the questions which are raised in a continuing policy of
energy efficiency:

– A more exhaustive study of the resources of the country, including not only renewable energy but also
the potential of economy of energy at end-user level;
– Diffusion of tried and tested energy technology and useful equipment into all areas of production and use
of energy:
– Increase in production and quality of equipment, systems and energy services;
– Development of decentralised means of electrical energy production with a resultant drop in the costs
and thereby the creation of profit potential at local or company level.
– Breaking down of legal barriers which hinder full use of resources, along with rulings on the contractual
conditions of supply of energy to the public network:
– Increase in the viability, through financial support of energy projects, which may otherwise be of only
minor interest from the narrow vieuwpoint of the consumer:
– Creation of incentives and opportunities for new forms of financing, over and above supports and loans,
all with a view to maximising results. Here specifically we can refer to the suppliers of energy, who
finance their system through third parties.
From among these instruments, of a somewhat varied nature, the following can be pointed out:
I) SYSTEMS OF FINANCIAL INCENTIVES
1. SIURE incentive system for the rational use of energy
2. The Community programme VALOREN
3. The Community programme of pilot studies in the field of energy
4. PEDIP
II) REGULATORY INSTRUMENTS
1. Regulation of independant production of electrical energy
2. Regulation on the management of energy consumption
3. Regulation on the thermal characteristics of buildings
A POLICY OF ENERGY EFFICIENCY 7
III) SYSTEM OF ALTERNATIVE FINANCING
– Financing by third parties
I would like to take advantage of the present occasion, albeit in a necessary summary fashion, to take stock
of the situation regarding these instruments in the two years of a coherent energy policy which has gone
hand in hand with a community policy for this sector.

1.
SIURE incentive system for the rational use of energy
This is “par excellence” the national system of support for the rational use of energy, having taken over in
May 1988 from the previous system (SEURE) which had been operative since August 1986.
From among the alterations introduced the following are worthy of mention:
– An open door policy for all sectors of activity (with the exception of domestic consumption);
– Application to operations and cost centres as diversified as pilot studies, projects and R & D
operations—over and above investment in fixed assets;
– Articulation with regulations in force for major consumers (to the standa&rd of the RGCE norms);
– Probality of application to the system of “financing by third parties);
– Increase in joint participation when operations can be included in the VALOREN programme;
– Progressive increase in the incentives for R.D. & D. operations with those of the existing Community
programme of demonstration projects and with the THERMIE programme in the future.
With three applications already accepted (August and September 1988 and January 1989) and two
underway (May and September of this year) the system has already proved that it is much better adapted to
the requirements and characteristics of its potential beneficiaries.
The situation is at present as follows:
. The total investment made up to now (Esc. 17.8bn.) has already way outstripped the values of the old
systems, as indeed has the number of applications, already up to 217, as compared with 245 in the two years
of SEURE.
. The 82 operations approved in the three phases already completed is more than those of SEURE (75);
moreover approvals represent 66% acceptance of the projects proposed, whereas in SEURE the rate was a
mere 31%.
. There are already 30 applications in the area of feasibility studies (an area not considered before). There
have been 8 approvals and 10 are under consideration. Of the 30, 25 relate to cost control and plans for
rationalization of energy;
The diversification of sectors and activities is manifest in those projects which have been approved, with
emphasis on textiles and clothing, ceramics and glass, foodstuffs, agrilture and fishing.
. From the total of applications approved, the forecast of annual energy economy is around 40.500 tons of
oil, corresponding to Esc. 911m in foreign currency.

In geographical terms, it is the regions of the centre and the north which show a more entrepreneurial
spirit, if we consider the level of investment and subsidies which have been given. Stange to say, it is the
Lisbon region that has seen most operations (28), possibly because there are many pilot studies included,
and projects with a high level of energy economy.
8 ENERGY EFFICIENCY IN THE CEMENT INDUSTRY
. As a final point, the Esc. 1.16bn in subsidies already given represent nearly 29% of the total investment
associated with the same companies; by comparison, during the period of SEURE the total was 19%.
As has already been mentioned, increases in the subsidies may be possible, as well as joint financing
through the VALOREN programme, as long as the operations come within the terms of reference of the
programme.
I would like to take this opportunity to announce that the whole community and national process has been
completed, allowing for joint financing of SIURE through PEDIP, in the case of applications which cannot
be included in the VALOREN programme, but which relate to the operations to be developed in the
extracting and transformation industries.
In this way, there will be close on Esc. 2.2bn available between 1989 and 1992 as reinforcement of the
budget available for SIURE, and Esc. 2.4bn through the country’s Budget applications for the same period.
1.2)
THE COMMUNITY VALOREN PROGRAMME
This programme is available to provide finance for operations which aim at rational use of energy in small
and medium industrial and services companies. The aim is above all to stimulate regions of various
potential renewable energy sources.
The programme has been operative from October 1987 for applications for public or comparable
infrastructures.
The VALOREM programme can, as has been seen, provide joint finance for incentives which are taken
through SIURE, as long as the operation is included among its objectives, in terms of investment, budget
and others regulations. The joint financing began in 1988, immediately after the first applications for SIURE
funding.
The committed funds in this operation of the VALOREM programme valid until the end of 1991, were
Esc. 5.6bn up to the end of this past September, and this has already gone beyond the 50% of the Esc. 10.
5bn earmarked for these specific projects.

On this situation the following points can be made:
The VALOREM programme has already supplied close on Esc. 915m through SIURE, in terms of the 3
applications which have already been processed.
This sum corresponds to approximately 79% of the subsidies provided by SIURE and up to 26% of funds
available through the VALOREM programme for these projects up to December 1991.
Given that SIURE only started in August 1988, this information should be more widely known, with a
view to attracting more applications.
. The commitments undertaken in participation in energy projects relating to the public or comparable
infrastructures represent already 68% ot the total allowed for. There are in fact regions, such as the North
and Centre, wich show greater dynamism and which have already gone beyond the forecats, while the
Alentejo, the Algarve and above all the Azores are still considerably behinhand.
In terms of type of energy or sector of activity, it is found that the use of biomass (kindling wood, stalks
from vines, biogas…) is the source of the largest number of applications. These have already gone beyond
the forecast limit and have made it necessary to reappraise the distribution of available funds.
The projects for the use of water have not been confirmed, because the authorisation for such use has not
come through yet. These projects are already sufficient to take up all of the funds available for this area. For
this reason, and also because the average duration of these investments goes beyond the end of 1991 have
meant that studies are underway with the Portuguese Small Hydro-Power Association to find alternative
A POLICY OF ENERGY EFFICIENCY 9
ways for the VALOREM programme to be associated with the investment which was caused by the new
legislation regarding the independent producer.
The VALOREN programme has been available as finance for important actions involving energy sources
which are part of the country’s natural resources and the technologies which are associated with them, as
well as information relating to the possibilites of rational use of energy (for example, through finance for
the IAPMEI “Energy-bus”).
The steady increase in the proportion of energy consumption in the GPD, as well as the recent boom in
consumption, bearing especially on domestic consumption and services, has led to the VALOREN
programme becoming actively involved in a major campaign to inform the public— in fact all consumers—
that energy must be used sparingly and that there should be greater awareness of the need for its rational use.
1.3)

COMMUNITY PROGRAMME FOR DEMONSTRATION PROJECTS
This programme was created and is run by the Office of the Director-General of Energy (DG XVII) of the
European Community Commission. It is at the heart of this seminar and since 1975 has been responsible for
financing important projects in various energy sectors during the precompetition stage.
It is also the Community programme which is best-known among Portuguese industrialists, according to
a survey conducted by the Ministry of Energy and industry. This is by no means by chance.
Since 1986, the date of the our accession to the Community, we have participated—in the sense that the
Portuguese entrepreneurs, in conjonction with Universities or national laboratories have made applications
to the programme.
Since great care always been given to the choice and preparation of good projects, the percentage of
approvals has always been high, and this has allowed us to get support for a percentage which has always
been higher than our overall weight in the total.
In the four competitions which have taken place, a total of Esc. 2.55bn in support has been given to
Portuguese projects, representing 22% of the total investment of nearly Esc. 11.5bn. However, in the last
two years alone, the support has totalled Esc. 1.8bn, out of a total of Esc. 9.8bn of total project costs.
In terms of the “quota” received, and without taking into account the part of the competitions relating to
solid fuels (that is, carbon fuels), in which, understandably, we saw only 3 out of the 4 projects approved, the
grants awarded represented in the last two years 8.5% and 7.7% of the available funds.
For the values relating to the past years, a large proportion is taken up by the CIMPOR project which is
presented here today. Apart from its innovation in European and Community terms, there are two aspects to
the projects which are worthy of mention here.
Firstly, there is the adoption and adaptation of a Japanese technology for the cement industry which is of
great interest in the energy sector.
Secondly, there is the system of recovery of heat from gases from the furnace exhausts, which will also
contribute to diminishing pollution in terms or dust and the combustion products of coal.
Next year, the present demonstration programme will be replaced by the recently approved THERMIE
programme, which draws on a different philosophy, due in large measure to the suggestions which we put
forward.
In this way, innovatory projects will continue to be supported, with an assessment procedure which is
more rigorously controlled. Moreover, THERMIE will open up the possibility of support to projects already

presented, where these are put forward in new contexts, geographical, economic, social and energy oriented
within, and in some cases outside the EEC.
10 ENERGY EFFICIENCY IN THE CEMENT INDUSTRY
This new approach will undoubtedly bring in its train more and better opportunities for Portuguese projects
and for the diffusion of the results obtained through the present programme.
Less widely-known, but capable of being very interesting at the level of back-up for these Community
programme is the part of SIURE which allows for incentives for demonstration projects and pilot studies, as
well as research and development of new forms of production and distribution of energy.
From among 14 applications presented for this tranche of SIURE, 4 to date have already been approved,
3 are under review, 2 were rejected and another 3 were asked to reformulate their terms and resubmit.
From among the projects already approved, the CIMPOR project already referred to looms largest.
Exceptionally, this project will receive an additional grant of 100m escudos, not only in view of the risk
involved but also the great scope for reproduction, even if only at a national level.
II.1)
REGULATION FOR INDEPENDENT PRODUCTION OF ELECTRICITY
The launch of this regulation in May 1988 was a real success, such was the interest among individuals,
companies and local authorities.
The conviction that decentralised production by agents independent from EDP would reduce production
costs for small units and stimulations could lead to 6.500GWh/year being made available. This led to the
new legislation, which is innovatory above all in terms of the full and rational legal framework in which this
activity can now be undertaken.
The recent law on production is applicable to all forms of the production electricity from any renewable
source, or from recycled thermal effluents. However, in the early days up to the present, the speediest and most
exciting reply has been in the area of water resources.
The main characteristics of this legislation are well known, and I consider it more interesting on this
occasion to refer to some points which give an idea of the interest it has awoke.
The right to use any water, as indeed any utility in the public domain, is subject to specific authorisation.
Up to now, 702 requests to produce electrical energy have been put in to the Office of the Director General
of SEARN. The difficulties in the management of water resources which this avalanche has created are not
difficult to imagine.

The 370 requests which have a solid foundation and obvious know-how of the field and his use represent
close on 1.015MW, greater than the biggest power station In Portugal (Alto Lindoso, which generates
625MW). Forecasts point to a production of approximately 4.025GWh, i.e. around 20% of the domestic
electricity production in 1988.
The authorisation process is not limited to the use to which the water is to be put. Among other things, it
is essential that the interested parties cleraly justify their technical and economic aims; that there should be
no other intentions for the same site; and that different uses are not being considered for the same water
resources.
As for any overlaps, in terms of requests made by different groups for the same site, the decision on
which takes priority should not be based simply on legal points. We have found that in many cases a
solution has been or is being found through discussions with the interested parties. There have also been
examples or collaboration from the official services involved.
Given the large number of interested parties—companies, local authorities and individuals—and given
the variety of motives know-how and financial capacity, I consider it of paramount importance to encourage
all forms of collaboration which are being found. This applies to the equating of interests, technical
expertise and management of the resources in question.
A POLICY OF ENERGY EFFICIENCY 11
I would like here to draw attention to the creation of the Portuguese Association of Small Hydro
Producers. This I consider to be indicative of the dynamism of the sector and the professionalism and
enthusiasm of those involved.
The initial members of the Association bear the responsability of making it a real partner In the dialogue
between the various entities in the sector. The Association must consider all applications from would-be
members, and should even encourage those who work in the sector and are interested in their activities for
widely differing reasons. The question of how representative the Association happens to be is fundamental
to relations with third parties and for this reason, with in the Association, mutual understanding and
interchange of ideas among the members become much more important. Should this spirit prevail I have no
doubt at all the Small Hydro-Electric scheme will be of benefit to everybody involved.
This whole process shwows how business peopple are reacting to the liberalization of the energy sector
which is underway in our country.
As far as the use of small power stations for the production of electricity is concerned, all the 6 requests

for authorisations which have been handed in to the Office of the Director General of Energy relate to
premises destined for the generation of heat and electricity. The fuels to be used are forest waste in 4 cases
and gas in each of the other two. The total power potential is around 130MW, with a forecast annual
production of the order of 800GWh. This demonstrates how much greater is the potential of these systems
than those in the field of Small Hydro- Power.
We know of a large number of other new projects of the same type as these, among them the CIMPOR
project, with its total close on 9MW, For theses projects, no authorisation for electrical installations was
necessary and they therefore do not figure in this survey.
II.2)
REGULATIONS FOR THE MANAGEMENT OF ENERGY CONSUMPTION
This legislation dates from 1982, altough it only reached the statute books in 1987. Its objective was to lay
down the structures for operations which will hopefully be undertaken by the major electrical energy
producers, in the sense of rationalising consumption and bringing about a progressive drop in energy use.
This legislation, which covers all sectors, is based on two ideas: one, that the energy problems of the
country will not just go away; and two, that the entitles involved are not just the State and those on the
supply side. Major consumers must also bear the responsability of bringing about a dowturn in consuption
and a diversification of sources.
Seen from this angle, there are 106 rationalisation plans which have been submitted for approval to the
Office of the Director General of Energy. The period of validity for these schemes is 5 years, from the total,
33 have already been approved and 15 were considered inadequate in terms of the targets established. After
5 years of use, these 33 will bring out an annual saving of at least 30,000 tons equivalent of oil, i.e. Esc.
675m in foreign exchange.
The approach of the Secretary of State is not bound by the mere wording of the regulations. It is rather to
awake the spirit of collaboration among those who run the companies in the sector, since they are the ones
who will benefit first and foremost from the new procedures for management of energy deriving from the
legislation. The fact that applicants for state aid must fulfil the regulations has also helped to spread on them
regulations.
It has been recognised that the greatest possible cost control should be exercised over investment and
development plans in the energy field. For this reason, the costs of auditing can be in part offset by
12 ENERGY EFFICIENCY IN THE CEMENT INDUSTRY

subsidies from SIURE, as long as methods and content correspond to the models prepared by the Office of
the Director General of Energy.
In this field, as has already been noted, there have been 25 applications to SIURE.
As an immediate consequence of the enrgy audits undertaken, SIURE is in a position to support further
studies relating to the creation and implementation of measuring systems, the recording and cost control of
consumption and the infrastructures necessary for the management of energy in premises where it is
consumed. This control exists as a parallel to the managemment of production, raw materials and personnel.
II.3)
REGULATIONS ON THE THERMAL PROPERTIES OF BUILDINGS
This legislation is still at the review stage, and is in the hands of various Ministries involved.
The legislation represents the first step towards standardisation of the regulations for buildings with the
aim both of lowering the heating and cooling requirements and of improving the quality of the environment.
With this in mind, are plans for cheking the minimal thermal characteritics of office and residential
buildings and the other passive systems used their construction.
As a first approach, using simple, easily understood and easily applied calculations, a start is to be made
on improving buildings which have a life span of 20–30 years. The reason for this is to avoid mortgaging
the future of energy.
These regulations, which should be on the statute books from January 1991, draw in their train further
regulations on the characteristics and dimensioning of active systems of air conditioning in the same
buildings. These regulations are being drawn up in the Council of Public Works, Transport and
Communications.
The great challenge now is to get them known among owners, designers and builders, and also in the
training of teams in Local Authorities, who will oversee and approve the regulations.
III)
FINANCING BY THIRD PARTIES
The projects for rational use of energy require consistent technical and financial support based on turnkey
principles and to this and the Office of the Secretary of State of Energy is actively promoting the creation in
Portugal of service companies which provide what is known as “financing by third parties”.
At this point in time there are at least 4 Portuguese companies of thie type operating in the market or in
the process of setting up.

A system of finance specifically for projects which generate energy savings is different from leasing
operations, from credit operations involving suppliers of equipment and from other forms of finance. The
fundamental differences are threefold:
. The contract is specific to the supply of a consultancy service and technical assistance, a financial
package for the total investment and the guarantee of concrete results;
. The financing entity takes responsability not only for turning the project into a reality but also for
operating the system on site for the duration of the contract;
. The investment, along with associated services and charges, is paid off through the measurement of
energy saved, taking the initial situation as a point of departure. The return is normally within the
parameters of the savings achivied.
A POLICY OF ENERGY EFFICIENCY 13
Altough there are no public funds for this, the Office of the Secretary of State, along with the European
Commission, is actively seeking the structure and support mechanisms for this system of financing. To this
end, these groups can apply for support through SIURE, and it is hoped, through the VALOREN
programme. At this time, ways of channelling venture capital available through PEDIP are also being actively
sought for this type of company.
This then is the situation regarding the major instruments created by the Office of the Secretary of State
for Energy with a view to improvements in energy efficiency. And over and above this attempt to show the
country what is happening—as well as the European Community represented here—I wished to take
advantage of the fact that CIMPOR is also tied in with events.
If there was a “Portuguese Nobel prize for energy savings” it should be awarded, in our opinion, to
CIMPOR. This company realised at a very stage that is needed to manage its energy consumption
efficiently, and to this has: a) diversified its energy sources by using old tyres and even coal (which was
then made available for other consumers); b) recovered thermal effluents from furnaces, not only in
absorption systems for air conditioning but also recovery boilers where electricity is now generated; c)
exercised systematic control over consumption; and d) made savings in electrical energy through
management of overheads and control of heavy electrical equipment used for ventilation and crushing.
CIMPOR now has a body of knowledge and experience in these matters which I am sure would ne made
available to other companies and other countries. Moreover, the company has used in the best possible way
the domestic and community financial instruments available to it.

If you will forgive the play on words, I should like to end by expressing my heartfelt wish that the same
spirit should become a concrete reality in other companies and consumers in Portugal. By the same token I
hope that the work begun today will be crowned with success.
14 ENERGY EFFICIENCY IN THE CEMENT INDUSTRY
FIRST SESSION
Chairman: Professor Veiga Simao, President of LNETI
ENERGY SAVING AND ENVIRONMENTAL IMPACT IN
THE CEMENT INDUSTRY
ANGELO SCARES GOMES
CIMPOR, Cimentos de Portugal, Portugal
Summary
Since 1986 CIMPOR’s Maceira cement plant has had a tyre burning installation working
regularly in two dry-process kilns, each with a capacity of clinker production of 1350 ton/day.
The amount of tyres consumed per year could be doubled, at least, but the factory is now facing
many obstacles in the acquisition of used tyres, due to the lack of appropriate legislation and
mechanisms. The low amount of tyres burned is the main cause of the present reduced
economic profitability of the installation.
1.
INTRODUCTION
The subject of this address has been deliberately requested within the context of the general outline
conceived in the initial stages of organisation of this Seminar. The concern to include this subject in the
programme is understandable. Currently questions related to the environment are of great importance, and
they are not separate from the problems involved in energy saving.
It is an incontestable fact that the greatest contribution of the cement industry to the improvement of the
environment has always been, and still remains, the resolution of the problems raised in the industry itself.
The great progress recorded in this matter over the past 20 or 30 years is also incontestable.
So, for the cement industry the use of derivatives from other industries or activities is a question of
relative importance, but it is still one more contribution on behalf of the environment. This utilization,
which has been common practice for several years, has been even further increased in recent years as a
result of the 1973 and 1978 oil crises.