MotorMaster+ Helps CEMEX Cement Plant Save 2 Million kWh and Nearly $200,000 Per Year
November 22, 2005
The CEMEX experience shows that manufacturers can save energy and money by retrofitting their inefficient motors with energy-efficient ones that are more suitable for their plant's particular operations.
Following a MotorMaster+ analysis, this cement manufacturing plant in Davenport, California, retrofitted 13 inefficient, worn-out motors with new ones. The new motors are not only more efficient, they also work better in a cement plant's dusty environment. The results are noteworthy: the plant is now saving 2.1 million kWh or more annually, along with $168,000 in energy costs and $30,000 in maintenance costs.
Before the new motors were installed, energy costs were continually rising at this cement plant. In addition, motor shutdowns were hampering production and driving up maintenance costs. So, plant personnel decided to use MotorMaster+ software to evaluate 13 older motors on some cement blowers and silo pumps. They found that all the motors were less than 80% efficient. Cement dust was also seeping into the units that had ventilation openings in the casings; this was causing overheating and contributing to the shutdowns.
The best option appeared to be to retrofit the older units with efficient totally enclosed, fan-cooled (TEFC) motors. Staff selected TEFC motors because they are cooled by external fans, which makes them much more suitable for use in dusty plants.
CEMEX is headquartered in Monterrey, Mexico. It operates in 50 countries and has 12 cement plants in the United States alone. Products include ready-mix concrete, asphalt, aggregates, and industrial sands. The company purchased the Davenport plant from RMC Pacific Materials in early 2005.
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