Расход цемента на: Расход цемента на 1 куб раствора: сколько нужно мешков

«Расчёт нужного количества цемента в строительстве?» – Яндекс.Кью

Из чего делают бетон? Бетон это материал, используемый как в частном, так и в промышленном строительстве, представляет собой жидкую серую массу, которая при затвердевании превращается в аналог камня.

Но не всё так просто как кажется на первый взгляд. Даже незначительные изменения пропорций в составе могут привести к совершенно другому результату. В итоге может получиться бетон, сильно отличающийся по техническим характеристикам от того который нужен. https://tsn-pro.ru/iz-chego-delajut-beton/

Состав бетонной смеси

1. Цемент;

2. Песок/Щебень/гравий;

3. Вода;

4. Химические добавки.

Чтобы получить желаемый результат, необходимо грамотно подойти к выбору ингредиентов и разобраться в чем роль каждого.

1. Прогнозируем назначение конструкции из бетона, сроки и условия использования.

В первую очередь рассчитываем примерный период эксплуатации, нагрузку, условия окружающей среды и пр. Если нужно создать незначительные бетонные элементы, не требующие высоких характеристик, то рецепт бетона будет один, если что-то сложнее и более износостойкое, то другой. По этим данным понимаем, какая должна быть пластичность смеси и марка бетона.

    2. Определяемся с маркой цемента.

Имея представление о назначении объекта, выбираем цемент. Качество бетона на 80% зависит от марки вяжущего связующего вещества в его составе (200, 300, 400, 500, 600). Цифровое значение показывает прочность цемента при сжатии. Необходимо брать марку цемента чуть выше, чем марка бетона, которую планируется получить. Так же немаловажным условием является свежесть материала.

   3. Выбираем заполнители.

Песок бывает с мелкими, средними и крупными гранулами (от 1,2 до 3,5мм). Для качественной бетонной смеси берут речной или морской, чтобы в его составе не было примесей, грязи и пыли. Песок нужно предварительно подготовить, промыть и дать отстояться. Важно следить за процентом влажности материала, чтобы не нарушать водные пропорции бетонной смеси.

В качестве наполнителя часто используют гравий, щебень и керамзит, у которых аналогично с песком есть несколько видов фракций (от 3 до 70мм). Размер камней в щебне не должен превышать трети толщины конечного изделия, а количество мелкой фракции быть не менее трети от всего объема щебня в составе. Если использовать разные размеры наполнения, то будет больше заполняемость пустот, а значит, потребуется меньшее количество цемента в составе.

  4. Берем чистую воду.

Количество воды должно соответствовать необходимой подвижности бетонной смеси. Учитываться должна и та вода, которая содержится в ингредиентах, еще до их смешивания.

  5. Рассчитываем пропорции нужной марки бетона

Количество цемента всегда берется за единицу, все остальные значения будут относительно него. В домашних условиях пропорции берутся относительно десятилитрового ведра. Принято считать, что в среднем в таком ведре может поместиться 14кг цемента (в зависимости от плотности), 15-16 кг песка ( в зависимости от влажности) и 16 кг щебня (в зависимости от фракции).

90000 Control Engineering | Reduce Energy Consumption: Cement Production 90001 90002 90003 Cement producers have faced a significant rise in energy costs with the introduction of dry-process kilns, with a record average consumption of 100-200 kWh per ton of cement, according to the 2009 Cement Plant Operations Handbook. This complex challenge, coupled with rising fuel and energy costs, has prompted cement manufacturers to implement energy management programs to help reduce costs while maintaining competitiveness and increasing profits.90004 90002 Many cement producers have lowered energy costs up to 20% by adopting a holistic approach to industrial energy management. This strategic process helps customers identify cost-saving measures and evaluate the tools best suited to specific plant needs, including: 90004 90007 90008 Power and energy management systems 90009 90008 Variable frequency drives 90009 90008 Model predictive control systems 90009 90008 Energy assessments. 90009 90016 90002 These tools help cement manufacturers: 90004 90007 90008 Find and eliminate operating inefficiencies 90009 90008 Modify equipment and processes 90009 90008 Drive energy efficiency in product design 90009 90008 Expand plant operations to include comprehensive energy management programs that will quickly provide measurable results and remarkable cost savings.90009 90016 90002 This is a time of unprecedented complexity for cement producers. Managing production while balancing supply, pricing, demand, process efficiencies, compliance with regulations, and other demands can be difficult. At the same time, the rising cost of energy, including water, air, gas, electric and steam (WAGES) resources, compounds these challenges. 90004 90002 90032 90004 90002 As Paul Scheihing, technology manager, Industrial Technologies Program, U.S. Department of Energy, explained, «The cost of purchasing the energy needed for production by an industrial facility is viewed as managed input and typically receives significant attention, while the use of that energy once it is inside the factory is often viewed as simply the cost of doing business.While not true in all industrial facilities, experience has shown that unless the facility actively manages energy use and has a documented plan for doing so, these facilities are significantly less energy efficient than they could be. Without performance indicators that relate energy consumption to production output, it is difficult to measure or document improvements in energy intensity. » 90004 90002 For the first time in industrial applications, the automation control, optimization, and information solutions necessary to conquer this energy challenge are in place or readily available to be applied immediately to achieve measurable results.90004 90002 90039 Energy assessment 90040 90004 90002 Prior to beginning any energy management program, conducting an energy assessment can help companies identify a wide range of changes that they can make to help reduce consumption. These can be simple, such as a walk-through of a building or facility to identify quick-hit opportunities, or much more detailed efforts. Assessments can help establish the scope of an energy savings effort, define key metrics, and put resources in place to take a holistic view of energy for the entire organization.90004 90002 Recommendations resulting from the assessment may include low-investment or no-investment behavioral modifications, such as shifting maintenance operations to nonpeak times, or may be more involved, such as programming changes to equipment. Evaluation and prioritization of capital improvement opportunities can also be included in the analyses. 90004 90002 90039 Energy monitoring 90040 90004 90002 After an assessment, the first step toward managing energy consumption is to gain awareness of energy usage patterns and trends throughout the facility.Building management personnel can leverage the facility’s metering infrastructure, including power monitoring devices, historical utility bills, and prior energy or process assessments, to collect data about all the energy resources in relation to equipment usage and environmental conditions. This process should include all points where energy is used, from an industrial process to critical building systems. 90004 90002 90053 This data is then logged and time-stamped in an energy historian software program in order to establish trends or discrepancies in energy quality and consumption, and to establish benchmarks for future improvement.With this big-picture view of a facility’s overall WAGES use, building management personnel can then identify and make operational changes to help reduce energy consumption and related costs, such as shedding loads or temporarily lowering power levels when the facility is approaching peak use. 90004 90002 90039 Energy metering 90040 90004 90002 The first step is to meter the main incoming utilities and divide the plant into energy allocation centers (EAC). 90004 90002 For electricity, producers might install main incoming utility meters on: 90004 90007 90008 Generators 90009 90008 Plant substations 90009 90008 Kiln (s) 90009 90008 Motors over 200 hp 90009 90008 Major electrical consumers per EAC.90009 90016 90002 For fossil fuels, producers might use the following metering scheme: 90004 90007 90008 Main incoming gas meter (s) 90009 90008 Kilns 90009 90008 Major gas consumers. 90009 90016 90002 Production equipment monitoring also provides knowledge about how specific assets consume energy. Identify useful data collection points across equipment and processes, and program the information system to store and analyze that data. 90004 90002 90039 Load profiling 90040 90004 90002 Load-profiling exercises chart energy consumption patterns by measuring and recording energy usage to identify peak demand periods, correlate consumption with facility activities and production in real time, and forecast energy demand.90004 90002 90039 Power quality monitoring 90040 90004 90002 Gathering and reviewing power quality information can help identify power system anomalies and calculations like the cost of a power outage. 90004 90002 Power quality monitoring measures, displays, records, trends, and alarms on power quality parameters, such as: 90004 90007 90008 Harmonics 90009 90008 Voltage excursions 90009 90008 Distribution system events. 90009 90016 90002 With a log of historical data, building management staff can identify power quality issues, such as voltage sags or harmonics that can cause damage to equipment inside the plant and cause power factor problems on the energy grid.By knowing these risks, manufacturers can better protect their equipment and avoid incurring penalty fees from utility companies. 90004 90002 90039 Improve efficiency 90040 90004 90002 Next, cement producers can implement control strategies like emergency load-shedding, cost allocation, and demand management to help improve energy efficiency throughout the plant. 90004 90002 90039 Emergency load-shedding 90040 90004 90002 To justify the cost of an emergency load-shedding system, simply identify what a power outage would cost in lost production, using data collected during the assessments conducted earlier.Most cement producers find that an emergency load-shedding solution will pay for itself in one or two outages. 90004 90002 Emergency load-shedding applies to sites with generation or multiple utility sources and helps producers: 90004 90007 90008 Protect generators from dangerous, damaging overloads 90009 90008 Maintain critical loads during outages 90009 90008 Optimize sources and critical loads 90009 90008 Eliminate the costs associated with damaged equipment and downtime. 90009 90016 90002 90039 Energy consumption, cost allocation, shadow billing 90040 90004 90002 By reviewing energy usage data collected previously, cement producers can reveal where energy dollars are consumed, and in what proportion.This can help allocate costs by department, process, or facility; verify the accuracy of utility bills through «shadow billing»; and evaluate alternate energy rates and contracts. 90004 90002 90039 Demand management 90040 90004 90002 A demand management system limits energy demand through load shedding and peak shaving strategies. It helps reduce demand charges and manage real-time power purchases or to minimize load during a curtailment period. 90004 90002 90148 For example, a steel mill was using 90,000 MWh of electrical energy per month, at a cost of $ 2.7 million each year. By replacing the facility’s unreliable demand management system and updating its control algorithms to more efficiently shed loads, improve power factor, and reduce voltage sags, the $ 300,000 system experienced a complete payback in five months. In addition, the company is enjoying an ongoing savings of $ 70,000 per month from reduced damage levels. 90004 90002 90039 Motor management 90040 90004 90002 Nearly 70% of all electricity used in industry is consumed by some type of motor-driven system.In a 10-year life cycle, a motor could accumulate energy costs amounting to 100 times its original purchase value. 90004 90002 However, cement producers can significantly reduce motor energy usage by implementing intelligent motor control solutions, such as variable frequency drives (VFDs). 90004 90002 In cement plants, VFDs are used to save energy and control process parameters, and retention times in applications with variable torque characteristics such as gas flow and fluid flow or in constant torque applications such as material handling and grinding equipment.Drives also are used to power roller mills for grinding different blaine of slag for cement, and for starting and running multiple roller mills, ball mills, and overland conveyors. 90004 90002 A China-based cement plant used VFDs to significantly reduce its energy consumption in its dry-process kilns, responsible for production of 1.4 million tons of cement each year. Traditional damper control systems used a fixed amount of energy, so fans at the plant always ran at full capacity even when the facility was not producing product-wasting energy and causing unnecessary wear on the equipment.By using variable frequency drives to automate the speed control of its kiln head exhaust fan, kiln main electric fan, high-temperature fan, coal mill exhaust fan, and kiln tail exhaust fans, the system now only uses the amount of energy necessary to produce the required amount of airflow. As a result, the company reduced specific energy consumption by 10%, generating annual savings of $ 124,000. 90004 90002 Typical VFD applications in a cement plant include: 90004 90007 90008 Induced draft / forced draft fans 90009 90008 Kiln drives 90009 90008 Mill drives 90009 90008 Material handling systems 90009 90008 Centrifugal pumps and fans 90009 90008 Compressor controls.90009 90016 90002 90039 Power factor 90040 90004 90002 Power factor (PF) measures how well cement producers use the power they draw from the grid. A PF of one is equivalent to 100% efficiency; in other words, all the power drawn is used. A PF of zero means there is an entirely reactive power flow. 90004 90002 To improve power factor, companies can implement of VFDs, use synchronous motors (such motors inherently have a PF of one), or install power factor correction capacitors. Power factor correction capacitors are used to improve the poor power factor of induction motors.90004 90002 90039 Optimize efficiency 90040 90004 90002 Once cement producers have addressed opportunities for improved efficiency, the next step is to examine opportunities for optimizing the entire process. Indeed, controlling a major process unit effectively usually means dealing with multivariable systems, but it is extremely unlikely that treating each control loop independently will provide optimal control since in most situations, the control action of one loop affects the other loops.Model predictive control (MPC) technology, a multivariable control algorithm, can provide: 90004 90007 90008 An internal dynamic model of the process that is subject to process constraints and based on a fixed frequency cycle 90009 90008 A history of past control moves to determine deviations 90009 90008 An optimization cost function over the prediction horizon to calculate the optimum control moves and control future behavior. 90009 90016 90002 MPC technology allows the controller to receive information about the current operating condition of the process, then uses a model to predict process response to a sequence of future moves in manipulated inputs over a specified timeline, or «prediction horizon.»Next, an optimal control problem, solved online, determines the best sequence of future moves in multiple manipulated variables to minimize a particular objective function while obeying various process constraints. A fraction of the resulting control trajectory is then applied to the process and new process measurements reflecting modified operating conditions are obtained, allowing comparison of process outputs to desired reference trajectories. With this new information, the system repeats the optimization and control move process.90004 90002 MPC systems can deliver optimization across key areas of the production process through applications for raw material preparation, including pyro-processing, cement grinding, and material blending. Energy savings can be generated by optimizing the combustion process, controlling temperature profiles, optimizing the heat recuperation process, and others. On average, MPC systems allow cement plants to reduce their energy consumption by 3% to 5%, as well as provide better product quality and capacity improvements.90004 90002 90039 Energy management profit 90040 90004 90002 Armed with optimized production information, manufacturers can then project, in advance, how much energy will be required for similar loads or batches. Cement producers can then include energy requirements in resource planning and scheduling decisions in the same way they consider the availability of raw materials or other inputs on the bill of materials. 90004 90002 Empirically tying WAGES consumption requirements to the bill of materials allows a plant manager or production scheduling manager to make proactive production decisions and better manage energy investments in a way that will generate a greater return.For example, by knowing that certain cement batches require more natural resources, managers can move those batches outside peak windows. 90004 90002 At this point in the industrial energy management process, energy and its associated greenhouse gas emissions are no longer fixed allocations that are simply part of unavoidable overhead. Manufacturers who add WAGES resources to the bill of materials can actively manage it as an input to achieve higher profitability. In addition, this unit-level energy consumption information becomes valuable input to sustainability scorecards and other reporting mechanisms, allowing companies to better optimize their full supply chain to enhance sustainability and energy programs.90004 90002 For example, in the cement factory of the future, a manufacturer might wish to enhance operations to support an ideal «sustainability score.» The company might choose a production facility based on the price of slurry, and on the potential carbon or energy footprint of shipping the raw materials to the facility. Additionally, the transportation routes for the outbound product can be optimized to account for weather factors that might impact the energy needed to store the product. 90004 90002 90039 Holistic energy management 90040 90004 90002 Manufacturers who have adopted this holistic approach to energy management have been able to do so by leveraging existing automation and power system investments to make more of their WAGES resources.Using intelligent automation solutions to get the big picture of energy use in a cement plant helps to identify where operational changes can be made to reduce energy consumption and costs. 90004 90002 90039 Key concept: Affinity laws — a little less speed, a lot less energy 90040 90004 90002 VFDs employ affinity laws to reduce energy use by using the minimum amount required by the motor application. For example, in centrifugal applications such as fans and pumps, a reduction in speed translates to a proportional reduction in flow (head pressure varies as the square of speed).A reduction in speed also translates into a reduction in energy (power varies as the cube of speed). Therefore, a flow rate of 50% equates to a power requirement of only 12.5%. In other words, a fan speed of 80% equates to a 50% reduction in energy. 90004 90002 90039 Typical audit scope and timeline 90040 90004 90232 90233 90234 90235 90002 90004 90238 90235 90002 Assessment 90004 90238 90235 90002 Audit 90004 90238 90247 90234 90235 90002 Approximate time to complete 90004 90238 90235 90002 2-3 days 90004 90238 90235 90002 2-3 weeks 90004 90238 90247 90234 90235 90002 Energy-saving project identification 90004 90238 90235 90002 x 90004 90238 90235 90002 x 90004 90238 90247 90234 90235 90002 Utilities usage review 90004 90238 90235 90002 x 90004 90238 90235 90002 x 90004 90238 90247 90234 90235 90002 Detailed utilities 90293 analysis 90004 90238 90235 90002 90004 90238 90235 90002 x 90004 90238 90247 90234 90235 90002 Detailed quotations for sustainability projects 90004 90238 90235 90002 90004 90238 90235 90002 x 90004 90238 90247 90234 90235 90002 Return on investment calculation for projects 90004 90238 90235 90002 90004 90238 90235 90002 x 90004 90238 90247 90234 90235 90002 Prioritization of projects 90004 90238 90235 90002 90004 90238 90235 90002 x 90004 90238 90247 90347 90348 90002 Courtesy: Rockwell Automation 90004 90002 — Patrick Murray is manager of industry sales, Rockwell Automation.Edited by Mark T. Hoske, CFE Media, 90352 Control Engineering 90353, www.controleng.com. 90004 90002 www.rockwellautomation.com 90004 90002 www.controleng.com/channels/sustainable-engineering.html 90004 90002 90039 References 90040 90004 90002 Phil Kaufman, White Paper: «Industrial Energy Optimization: Managing Energy Consumption for Higher Profitability,» pub. SUST-WP002B-EN-P, January 2011. 90004 90002 Philip A. Alsop, PhD, Hung Chen, PhD, and Herman Tseng, PE. The Cement Plant Operations Handbook, Fifth Edition, October 2007.90004 90002 Craig Resnick, «Sustainable Production Imperatives and Opportunities from Rockwell Automation,» ARC Advisory Group, ARC View, May 2009. 90004 90002 George Seggewiss, PEng, Nathan Schacter, PEng, Greg Obermeyer, PEng, and Gary Bankay, «Considerations for Implementing MV Drives in a Cement Plant,» IEEE Conference 2008. 90004 90002 — 90004 90002 90352 Control Engineering 90353 webcasts include more on Ethernet. 90004 90002 https://www.controleng.com/media-library/webcasts.html 90004 .90000 • China: cement consumption 2010-2020 90001 • China: cement consumption 2010-2020 | Statista 90002 90003 Other statistics on the topic 90004 90005 90003 Please create an employee account to be able to mark statistics as favorites. Then you can access your favorite statistics via the star in the header. 90004 Register now 90003 Please authenticate by going to «My account» → «Administration».Then you will be able to mark statistics as favourites and use personal statistics alerts. 90004 Authenticate 90003 Save statistic in .XLS format 90004 90003 You can only download this statistic as a Premium user. 90004 90003 Save statistic in .PNG format 90004 90003 You can only download this statistic as a Premium user. 90004 90003 Save statistic in .PDF format 90004 90003 You can only download this statistic as a Premium user.90004 90003 Show source references 90004 90003 As a Premium user you get access to the detailed source references and background information about this statistic. 90004 90003 Show details about this statistic 90004 90003 As a Premium user you get access to background information and details about the release of this statistic. 90004 90003 Bookmark statistics 90004 90003 As soon as this statistic is updated, you will immediately be notified via e-mail. 90004 90003 Yes, save as favorite! 90004 90003…and make my research life easier. 90004 90003 Change statistics options 90004 90003 You need at least a 90041 Single Account 90042 to use this feature. 90004 90003 Basic Account 90004 90003 Get to know the platform 90004 90003 You only have access to basic statistics. 90049 This statistic is 90041 not included 90042 in your account. 90004 90003 Single Account 90004 90003 Your perfect start with Statista 90004 90057 90058 90041 Instant access 90042 to 1m statistics 90061 90058 90041 Download 90042 in XLS, PDF & PNG format 90061 90058 Detailed 90041 references 90042 90061 90070 90003 Corporate Account 90004 90003 Full access 90004 90003 Corporate solution including all features.90004 90003 * All products require an annual contract; Prices do not include sales tax. 90004 90003 90041 The most important statistics 90042 90004 90003 90041 The most important statistics 90042 90004 90003 90041 The most important statistics 90042 90004 90003 90041 The most important statistics 90042 90004 90003 90096 Further related statistics 90097 90004 90003 Learn more about how Statista can support your business .90004 90003 DBS Group Research. (November 28, 2018). Cement consumption in China from 2010 to 2020 (in billion metric tons) [Graph]. In Statista. Retrieved July 12, 2020 року, from https://www.statista.com/statistics/1042516/chinese-cement-consumption/ 90004 90003 DBS Group Research. «Cement consumption in China from 2010 to 2020 (in billion metric tons).» Chart. November 28, 2018. Statista. Accessed July 12, 2020. https://www.statista.com/statistics/1042516/chinese-cement-consumption/ 90004 90003 DBS Group Research.(2018). Cement consumption in China from 2010 to 2020 (in billion metric tons). Statista. Statista Inc .. Accessed: July 12, 2020. https://www.statista.com/statistics/1042516/chinese-cement-consumption/ 90004 90003 DBS Group Research. «Cement Consumption in China from 2010 to 2020 (in Billion Metric Tons).» Statista, Statista Inc., 28 Nov 2018, https://www.statista.com/statistics/1042516/chinese-cement-consumption/ 90004 90003 DBS Group Research, Cement consumption in China from 2010 to 2020 (in billion metric tons) Statista, https: // www.statista.com/statistics/1042516/chinese-cement-consumption/ (last visited July 12, 2020) 90004 90003 We use cookies to personalize contents and ads, offer social media features, and analyze access to our website. In your browser settings you can configure or disable this, respectively, and can delete any already placed cookies. For details, please see your browser’s Help section (by pressing F1). Please see our privacy statement for details about how we use data. 90004 OK.90000 Cement Industry Overview 90001 90002 Economics of the U.S. Cement Industry 90003 90004 90005 Information on aspects of the U.S. cement industry including imports, exports, ownership, economic cycles, employment, and trends. (Updated May 2013) 90006 90007 90008 Introduction 90009 90004 The cement industry is the building block of the nation’s construction industry. Few construction projects can take place without utilizing cement somewhere in the design. Annual cement industry shipments are currently estimated at $ 7.5 billion for 2012; up from $ 6.6 billion in 2011. U.S. cement production is widely dispersed with the operation of 107 cement plants in 36 states. The top five companies collectively operate 49.6 percent of U.S. clinker capacity with the largest company representing 14.2 percent of all domestic clinker capacity. An estimated 76.7 percent of U.S. clinker capacity is owned by companies headquartered outside of the U.S. 90007 90008 Cement Consumption 90009 90004 In 2012 the United States consumed 76.7 million metric tons of portland cement, reflecting a 9.1 percent increase over 2011 levels. The economic downturn, resulting from the mortgage foreclosure crisis and subsequent collapse of the U.S. banking system, hit the construction sector particularly hard. Residential construction spending, for instance, declined over 55 percent from 2005 peak levels to 2011 trough levels. While the construction sector is still depressed, 2012 witnessed the first increase in construction activity in seven consecutive years.Fortunately for the cement industry, the extraordinarily long period of sub-trend economic growth and depressed housing market has created a large amount of pent-up demand which will result in strong growth rates in the years to come. 90007 90004 Cement consumption is dependent on the time of year and prevalent weather conditions. Nearly two-thirds of U.S. cement consumption occurs in the six months between May and October. The seasonal nature of the industry can result in large swings in cement and clinker (unfinished raw material) inventories at cement plants over the course of a year.Cement producers will typically build up inventories during the winter and ship them during the summer. 90007 90004 The majority of all cement shipments, approximately 70 percent, are sent to ready-mix concrete operators. The rest are shipped to manufacturers of concrete related products, contractors, materials dealers, oil well / mining / drilling companies, as well as government entities. 90007 90004 The domestic cement industry is regional in nature. The cost of shipping cement prohibits profitable distribution over long distances.As a result customers traditionally purchase cement from local sources. Nearly 98 percent of U.S. cement is shipped to its customers by truck. Barge and rail modes account for the remaining distribution modes. 90007 90008 Imports Fill Production Gap 90009 90004 According to PCA estimates, U.S. cement plants achieved an average capacity utilization rate of 63 percent in 2012. At this operating rate, domestic production alone does not satisfy total United States cement consumption. The gap between domestic production and consumption was filled in 2012 by over seven million metric tons of imported cement and cement clinker.Over 80 percent of cement and clinker imported in 2012 came from five major countries: China, Canada, Columbia, Mexico, and the Republic of Korea. 90007 90004 Exports of cement exceeded 1 percent of total U.S. production. Nearly all exports service the neighboring Canadian and Caribbean markets. 90007 90004 Information and statistics used in this summary are presented in reports compiled by PCA from various government and private sources. For additional information of the U.S. cement industry, refer to the Market Economics pages of our web site.90007 90008 Efficiency Gains 90009 90004 According to PCA’s Labor-Energy Input study, labor efficiency, measured in cement tons per employee hour, has more than doubled in the past 30 years. This spike in labor efficiency is the result of industry efforts to increase efficiency by automating production and closing small kilns. The average kiln in use today is capable of producing 89.9 percent more clinker than an average kiln produced 20 years ago: 678,000 metric tons in 2012 compared with 357,000 metric tons in 1992.90007 90004 The cement industry has boosted efficiency by concentrating new capital investment in plants that use the dry process of cement manufacture, and by phasing out operations that rely on the more energy-intensive wet process. Since 1974, the number of wet process kilns has dropped from 234 to 25 — a decline of 89 percent — while the number of dry process kilns has only been reduced from 198 to 124. Well over three quarters of existing U.S. clinker production capacity has been built since 1975 — all utilizing the dry manufacturing process.Currently, about 93 percent of the cement produced in the United States is manufactured using dry process technology. 90007 90008 Sustainable Manufacturing 90009 90004 As cement producers continue to search for alternative fuels, many people wonder what types of fuel can be used in the combustion process. 90007 90004 The average energy input required to make one ton of cement is 4.4 million Btu-the equivalent of about 389 pounds of coal. The U.S. cement industry uses energy equivalent to about 12.6 million tons of coal every year. According to the Energy Information Agency (EIA), U.S. cement production accounts for about 0.26 percent of energy consumption-lower production levels than steel production at 1.1 percent and wood production at 0.7 percent. From the PCA publication: 90005 U.S. and Canadian Labor-Energy Input Survey 2012 90006, the cement industry has improved energy efficiency by over 41 percent from 1972. 90007 90004 Finding ways to reduce both energy needs and reliance on fossil fuels is a top priority for cement companies.Although coal, petroleum coke, and other fossil fuels have been traditionally burned in cement kilns, many cement companies have turned to energy-rich alternative fuels. Today, many plants use a wide variety of alternative fuels as part of their overall energy scheme; ranging from 10 to 70 percent of their energy requirements. Often consumer wastes or byproducts from other industries are efficiently burned as fuel. Recovering their energy value in cement making is a safe and proven form of recycling.90007 90004 Fuels like coal and coke contain carbon and release larger quantities of heat when they’re burned. Coal and coke, however, are not the only fuels that contain carbon. Tires are also a great source of hydrocarbons (carbon and hydrogen). Using tires for combustion in a cement kiln produces 25 percent more energy than coal and it can also result in lower emissions. In fact, any material with high carbon content could be used as a fuel. Paper, packaging, plastics, saw dust, and solvents all are suitable for use as alternative fuels.Because of the extremely high temperatures (well above 3,000 degrees Fahrenheit), these materials burn quickly and extremely efficiently. 90007 90004 Burning alternative fuels in cement kilns offers several environmental benefits. This type of energy recovery conserves valuable fossil fuels for future generations while safely destroying wastes that would otherwise be deposited in landfills. According to the latest 90005 Labor-Energy Input Survey 90006, 11 plants used waste oil, 36 plants used tire derived fuel, and 13 plants reported the use of renewable fuels as part of their energy matrix.Solvents, unrecyclable plastics, and other materials are used as well. 90007 90004 The information in this article was taken primarily from PCA’s 90005 Labor-Energy Input Survey. 90006 90007 90004 Click here for more on Sustainable Manufacturing. 90007 90008 For More Information 90009 90004 90005 Innovations in Portland Cement Manufacturing, 2nd Edition 90006, SP400 90063 The definitive resource on all aspects of cement manufacturing addresses the current issues facing the industry.This two-volume, limited edition is a must have reference for personnel involved in the cement industry including production, quality assurance, process engineering, energy issues, health and safety, environmental issues, and analytical techniques. 90007 .90000 Global cement consumption up 9.9% last year — Products And Services 90001 90002 Global consumption of cement grew 9.9% last year to continue a strong rebound in demand as construction worldwide picks up since the economic downturn of 2008, according to a new report. 90003 90002 The ninth edition of International Cement Review’s Global Cement Report found that 3,294 million tonnes (Mt) were sold, topping the 2,998 million tonnes sold in 2009 which was a growth rate of 5.9%, strongly reversing a slowdown of 2.4% the previous year. Worldwide cement consumption is forecast to reach a record 3859Mt by 2012. 90003 90002 The report provides statistics for demand for the commodity in more than 160 countries, along with additional data for clinker consumption. China dominates world cement statistics, results show consuming more than a third of global output — or 1,851 million tonnes — in 2010 almost double 2004 levels. India, the closest rival to China for economic growth was the second-largest consumer at 212Mt, with the United States, the third-largest consumer, saw demand fall down to 69Mt.90003 90002 Turkey is the world’s leading export nation of cement and clinker, with sales of 19Mt in 2010 overtaking China which recorded close to 17Mt of export sales. Thailand was third with 14Mt of cement and clinker exports. 90003 90002 Bangladesh is the largest cement and clinker importer, with over 12 million tonnes of deliveries in 2010 followed by Nigeria at 7 million tonnes and the USA at close to 6 million — a sixth of 2006 levels. 90003 90002 Lafarge remains the world’s biggest selling company, shifting 141.2Mt last year to produce a turnover of EUR 15.8 billion, ahead of Holcim with cement sales of 136.7Mt and a turnover of EUR15.6 billion, a ahead of HeidelbergCement. Holcim still has the largest global cement capacity, at 212Mt, 11Mt higher than Lafarge. 90003 90002 Many cement suppliers in the Gulf region have seen their sales volumes and values ​​fall in the last year following an overall slump in construction activity, particularly in Dubai, which fuelled a boom in sales due to the intense building activity in the emirate in the last five years.UAE suppliers have even been selling into nearby Oman to retain margin, which has in turn hit the profits of Omani suppliers. Executives at Raysut Cement Company in Muscat told shareholders in its annual financial report that a decline in net profits was partly impacted by this regional competition. 90003 90002 Saudi Arabia remains the biggest GCC cement market, and has nine companies listed on the Tadawul, the stock exchange in Riyadh. Last year, Al Jouf Cement listed after a brief tender period.An analyst in Bahrain told CW that there would be «three or four» more companies to list in the Kingdom in the next few years, despite the fact that the market is becoming increasingly saturated due to the strict criteria on exporting, which results in the great majority of cement to be marketed domestically. 90003 90002 Results last year were strong last year for many of the publicly-traded Saudi suppliers, with only Yanbu Cement and Qassim Cement Company selling less than in 2009. 90003 90002 The analyst added that, as the companies originally may have listed to capture the profits of exporting before new strictures were put in place, there may be a consolidation among the listed companies.90003 90002 Companies to come on line in the next few years not seeking a listing include Gulf Cement Company in Riyadh, a separate company from both the Abu Dhabi-listed supplier based in Ras Al Khaimah and the company that is part of Al Khalij Holding in Qatar , all of which share the same name. The Saudi company is the brain child of Abdullah bin Mansour Souliman Al-Shugair, the vice chairman and managing director, who has numerous business lines. 90023 90003 .