Technical Reviews and Benchmarking

Over the course of several decades we have successfully conducted any number of Technical Reviews and Energy Reviews both at home and abroad, performing customised analysis and optimisation of the production processes of many plants. In connection with our integrated studies we have developed and progressively refined our own scientifically based assessment methods. Depending on the objective of the review we can currently provide you with three different types of Technical Review and Energy Review (Basic, Advanced and Detailed). You will receive the review results in the form of a report in German, English or Russian. We will consult you in advance to decide on the specific performance indicators to be studied in each case. We guarantee that our project management, review activities and assessment satisfy the highest standards in terms of technical expertise, accuracy and confidentiality.

Technical Reviews: The purpose of our Technical Reviews is to identify the optimisation potential in the customer's specific cement production process (from quarry to despatch) and to assess it from an economic point of view. In all of this you benefit from our many years of international experience in the field of thermal and mechanical process engineering as well as environmental technology. Our Technical Reviews for rotary kiln plants and mills provide you with an independent and sound assessment of the state of your installation. Alongside the entire production process, we also incorporate product quality into the assessment. A further focal point of our work is the development of innovative solutions for emissions reduction (nitrogen oxides, sulphur dioxide, carbon dioxide etc.).

Energy Reviews: Our Energy Reviews involve performing sound energy efficiency analyses to suit your specific requirements. In doing so we examine a specific area of the production facilities or the entire production line. This enables us to identify potential savings in certain production processes and to check the potential for enhancing energy efficiency in the production line as a whole. Our experts can also perform tailor-made individual assessments on site. In this process we assess the energy data gathered or measured and compare this with our extensive database and the BAT (Best Available Techniques) parameters (Benchmarking). This provides you with an independent, transparent analysis of the electrical and thermal energy efficiency of your installations as compared to other plants.

You can benefit from our expertise, successfully employed in practice and backed up by scientific research in the field of cement production, from qualified specialists with extensive knowledge about the latest methods and measurement techniques, from our accredited laboratories and from our many years of experience in international service projects.

Depending on the objective we can always provide you with three different types of Technical Review or Energy Review (Basic, Advanced and Detailed).

• Basic Review: Expert assessment based on available plant data
  The foundation for Basic Reviews is the data which is available at the cement plant and supplied to VDZ in the form of a completed questionnaire.
   
• Advanced Review: Expert assessment based on available plant data and on-site inspection (without on-site measurements)
  Advanced Reviews provide a more detailed overview of the state of the technical installations at a cement plant: On-site inspections detect any uneconomical practices and technical shortcomings. The result of the review is a report which identifies improvement measures and possible ways of cutting production costs and/or proposes further action.
   
• Detailed Review: Complex on-site measurements and analysis of results (mass and air flows, emissions, particle size distribution etc.)
  Detailed Reviews are advisable if the data quality produced by an Advanced Review is not sufficient to justify the costs of recommended improvements with high CAPEX (e.g. plant modernisation). We therefore always conduct Detailed Reviews on a customer-specific basis with regard to objectives and the scope of the measurements.

Services associated with Technical Reviews:

• Integrated assessment of your plant/plant sections in terms of quality, production performance, emissions, costs and industrial safety aspects
• Transparent, independent analysis and assessment
• Comparison of your plant with the data available to VDZ and BAT values (Best Available Techniques)
• Performance of bottleneck analyses and optimisation measurements
• Identification and quantification of potential for optimisation, identification of improvement measures at your plant
• Development of innovative solutions for emissions reduction (nitrogen oxides, sulphur dioxide, dust, greenhouse gases etc.)

Services associated with Energy Reviews:

• Transparent analysis of the electrical and thermal energy efficiency of your plant independently of the provider
• Comparison of your plant with the data available to VDZ and BAT values (Best Available Techniques)
• Determination and analysis of the energy demand of your production processes
• Performance of optimisation measurements
• Assessment of the energy management system of your plant
• Identification and quantification of savings potential at your plant
• Expert assessment of your production processes in terms of CO₂ abatement measures.