reported 2025
Process, quality, and energy optimizationOrganization-reported
Kiln optimization at Tokuyama Nanyo
ABB reports 3% lower kiln thermal energy and about 70% fewer manual operator tasks.
Tokuyama Corporation · Nanyo cement plant, JapanIndustry memory
What the industry learned—and what it must not forget.
A chronological record of incidents, field studies, improvements, and compliance milestones. Individuals are omitted; systems and decisions remain visible.
1981–2025documented history
Source-backed chronology
Forty-four years of public plant experience
Historical event facts remain part of the record. Old legal limits or procedures do not become current guidance.
historical trials; updated 2025
Process, quality, and energy optimizationOrganization-reported
Lower clinker LSF while preserving strength
Supplier reports mortar strength 58 to 65 MPa, reference concrete 28-30 to 32-34 MPa, and clinker LSF reduced from 98 to 95 while maintaining cement strength.
Golden Bay Cement Company · Portland cement plant, New Zealandreported 2025
Energy and environmental performancePeer-reviewed / validated
Thermoelectric generation from cement-plant waste heat
Measured 3.1 gross and 2.0 net kWh/t clinker; system thermal efficiency 5.0% peak and 4.3% average. USD241000/y is a typical full-scale projection, not an observed Alpena saving.
Amrize · Alpena cement plant, Michigan, USA2025
Energy and environmental performanceImplementation milestone
Brevik industrial-scale carbon-capture milestone
At opening, first CO2 had been captured, liquefied, and temporarily stored without disrupting cement production. 400000 t/y and 50% are design/target figures, not a completed annual result.
Heidelberg Materials · Brevik cement plant, Norwayreported 2024
Process, quality, and energy optimizationOrganization-reported
Model-predictive control on two cement mills
Supplier reports more than 6% lower specific energy, nearly 8.5% higher production rate, and 97% availability over a two-month period.
CCB · Cement operation, Belgiumprogram outcome published 2024
Energy and environmental performancePeer-reviewed / validated
Low-carbon fuel demonstrations in Canada
NRCan reports increased injection; Brookfield displaced up to 15% of traditional fuels with tires and indicated 20-30% GHG reduction per tonne of coal replaced. Richmond's 50% or more is expected capability.
Lafarge Canada · Richmond and Brookfield cement plants, Canada2023
Energy and environmental performanceImplementation milestone
Portland-limestone cement and automatic auxiliary shutdown
EPA cited the actions while recognizing the plant as ENERGY STAR certified for 2023.
Ash Grove Cement Company · Seattle cement plant, USA2023
Energy and environmental performanceImplementation milestone
Preheater, combustion, and alternative-fuel integration
EPA cited lower CO2 from alternative fuels while both plants maintained high energy efficiency and 2023 certification.
GCC · Rapid City and Pueblo cement plants, USA2022
Energy and environmental performanceOrganization-reported
Oro Grande kiln-fan VFD replacement
EPA award profile reports 18% energy-efficiency improvement for the project.
CalPortland Company · Oro Grande Cement Plant, USA2022
Energy and environmental performanceOrganization-reported
Mojave kiln-exhaust baghouse fan improvement
EPA award profile reports 40-50% fan-efficiency improvement.
CalPortland Company · Mojave Cement Plant, USAreported 2021
Reliability and maintenanceImplementation milestone
Continuous gearbox monitoring at Radotín
Plant and supplier report earlier detection, less damage exposure, plannable repairs, and a long-term support contract; no quantified availability delta.
Ceskomoravsky Cement · Radotin cement plant, Czech Republic2020
Process, quality, and energy optimizationOrganization-reported
Roller-press raw grinding replaced two ball-mill circuits
Supplier reports 350 t/h at 13.36 kWh/t, more than 8 kWh/t lower, nearly 40% energy saving, and about EUR1.5 million lower annual energy cost.
Siam City Cement Public Company · Factory 1, Saraburi, Thailand2020 data; 2023 publication
Process, quality, and energy optimizationPeer-reviewed / validated
Advanced control on a kiln and grate cooler
About 4.6% cumulative kiln fuel saving, 15% lower mean NOx, 32% lower NOx standard deviation, about 10% mean cooler electricity saving, and service factor above 94% after more than two years.
Industrial cement producer · Site confidential, Italy2019
Regulatory and compliance historyRegulator / government
Lehigh multi-plant Clean Air Act settlement
EPA estimated about 4500 t/y NOx and nearly 1000 t/y SO2 reductions.
Lehigh Cement and Lehigh White Cement · 14 kilns at 11 facilities, USA2017
Safety and occupational healthRegulator / government
Falling material inside a downcomer duct
Falling material struck the technician inside the duct.
Argos USA LLC · Roberta Cement Plant, Alabama, USA2016
Regulatory and compliance historyRegulator / government
CEMEX five-plant Clean Air Act settlement
EPA described more than 4000 tons of NOx reduction as settlement impact.
CEMEX Inc. · Knoxville; Demopolis; Louisville; New Braunfels; Odessa, USA2008-2009
Process, quality, and energy optimizationOrganization-reported
Moisture-tolerant online raw-mix control
Industry report says the system achieved LSF 80 +/-5 for each 180-tonne mixing-bed segment.
CEMMAC · Portland cement plant, Slovakia2008
Regulatory and compliance historyRegulator / government
St. Marys Dixon Clean Air Act settlement
EPA estimated about 2700 t/y NOx reduction and about USD1.9 million control investment.
St. Marys Cement and St. Barbara Cement · Dixon Plant, Illinois, USA