The paper presents an advanced exergoenvironmental and thermo-sustainability analysis of a dry process, 5-million-ton capacity cement plant with real-time operational data. The analysis was based on component-wise modelling by separating the exergy destruction (ED) into endogenous, exogenous, avoidable and unavoidable parts for the two production lines, L1 and L2. The result shows an exergy efficiency ([Formula: see text]) of 55.58% for L1 and 58.22% for L2. Additionally, the overall exergoenvironmental factor (EEF) was calculated at 6.47% for (L1) and 5.89% for (L2), with the rotary kiln (RK) having the highest (EEF) of 53.7%. Conversely, the advanced exergy analysis showed that the plant's mainstream ED rates are endogenous and unavoidable. The component sustainability index (SI) for L1 and L2 ranged between [Formula: see text] and [Formula: see text], respectively. Similarly, the sustainability results show that the environmental destruction coefficient (EDC) and the environmental destruction index (EDI) were high in L1. Nonetheless, the study identified components with high potential for improvement, making system design and optimization suggestions possible.
Keywords: Cement; Efficiency; Endogenous; Exergoeconomic; Exergy.
© 2023. The Author(s), under exclusive licence to Springer-Verlag GmbH Germany, part of Springer Nature.