Statistical Process Control for Energy Consumption Monitoring in an Iranian Cement Factory

In this paper, to assess the energy consumption monitoring in an Iranian cement factory, statistical process control (SPC) is deployed on clinker production process, which consumes more than 90% of the total energy consumption in considered cement factory. Clinker energy consumption records from February 2013 to January 2016, are retrieved focusing the monthly average index of thermal energy consumption. This index places the studied plant in the group of high energy consumption compared to the targeted values given in the ISIRI 7873 standard. The trial control limits for the existing process are established so that phase I of the process improvement could be started using these control limits for process monitoring. The reasons for new assignable causes would then be identified and rectified until there are no more assignable causes and the process is said to be under statistical control. The process capability ratio value of -0.69 indicates inefficiency of the process withrespect to the control limits. So, the process needs to be reviewed and the establishment of proper saving actions is necessary to improve energy efficiency.

Keywords:

Statistical process control , Cement industry , I-MR control chart , Energy monitoring , ISIRI 7873 standard