ONESTONE CONSULTING S.L.

Trends in the performance management of cement plants

Benchmarking the performance of cement plants is the trend in the global cement industry and is now widely used. The following article outlines the major implications and focus areas of this approach.

1 Introduction

Cement plants are operating continuously for 24 hours a day and when possible for about 330 days a year without interruption. The rest of the year the plants have their annual shutdown for major repairs. Each day of unscheduled shutdown results in a loss of income, which can be as high as 0.3 million US$ for a standard 1.0 million tons (Mta) capacity plant and cement prices in the range of 100 US$/t. Accordingly plant managers have to concentrate on keeping the plant running and optimising the production costs. These production costs differ greatly depending on region, plant...

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