At present, the domestic demand for cement is declining, and the industry expects that the demand will fall to about 1 billion tons in the next few years. With the aggravation of overcapacity and fierce market competition, reducing production costs is the key to the survival of enterprises.
Energy is the main component of cement production cost, and energy consumption varies greatly among different enterprises due to equipment, management and other factors. So according to the national standard, the same is the production of a ton of cement, the energy cost gap between the level 1 benchmark enterprises and the level 3 benchmark enterprises? For reference
only, from clinker burning to cement grinding, the three-level energy consumption cost gap is enlarged
layer by layer according to GB 16780-2021 "Energy Consumption Limit of Cement Unit Products". The energy consumption limit of cement industry is divided into three grades: Grade 1 (advanced value), Grade 2 (access value) and Grade 3 (limited value). Grade 1 has the lowest energy consumption and Grade 3 is the lowest qualified line for existing enterprises. In terms of
clinker coal consumption, the limit is 94 kgce/t for Grade 1, 100 kgce/t for Grade 2 and 109 kgce/t for Grade 3. Based on the conversion of 5,500 kcal steam coal at 863 yuan/ton (standard coal conversion coefficient of 0.7857), the physical coal consumption of Grade 1 is about 119 kg/ton of clinker, and the coal consumption cost is about 103 yuan/ton; the physical coal consumption of Grade 2 is about 127 kg/ton of clinker, and the coal consumption cost is about 110 yuan/ton; Grade 3 physical coal consumption is about 139 kg/ton clinker, and the coal consumption cost is about 119 yuan/ton. In terms of coal consumption alone, Grade 1 saves 16 yuan per ton of clinker compared with Grade 3, and Grade 2 saves 9 yuan compared with Grade 3. In terms of
clinker power consumption, the limit for Grade 1 is 48 kWh/t, Grade 2 is 57 kWh/t, and Grade 3 is 61 kWh/t. Based on the industrial electricity price of 0.6 yuan/kWh, the electricity consumption cost of Grade 1 clinker is about 29 yuan/ton, Grade 2 is about 34 yuan/ton, and Grade 3 is about 37 yuan/ton. Grade 1 saves 8 yuan per ton of clinker compared with Grade 3, and Grade 2 saves 3 yuan compared with Grade 3.
AI production diagram is only for reference
. The total energy consumption cost of Grade 1 clinker is about 132 yuan/ton, that of Grade 2 clinker is about 144 yuan/ton, and that of Grade 3 clinker is about 156 yuan/ton. In the clinker sector, grade 1 saves 24 yuan per ton compared with grade 3, and grade 2 saves 12 yuan per ton compared with grade 3.
Then look at the process of conduction from clinker to cement. Calculated by 65% clinker proportion, the energy consumption cost of clinker is transferred to finished cement products: about 86 yuan/ton for Grade 1, 94 yuan/ton for Grade 2 and 101 yuan/ton for Grade 3. In terms of power consumption of
cement preparation section, the limit for level 1 is 26 kWh/t, level 2 is 29 kWh/t, and level 3 is 34 kWh/t. The corresponding power consumption cost for level 1 is about 16 yuan/ton, level 2 is about 17 yuan/ton, and level 3 is about 20 yuan/ton.
By adding the clinker conduction cost and grinding power consumption, the total energy consumption cost of one ton of cement is about 102 yuan for Grade 1, 111 yuan for Grade 2 and 122 yuan for Grade 3. Grade 1 saves about 21 yuan per ton compared with Grade 3, and Grade 2 saves about 11 yuan per ton compared with Grade 3. From clinker firing to cement grinding, every link is enlarging the gap, eventually converging into a gap of 21 yuan/ton between grade 1 and grade 3.
Of course, this is only based on the comparison of the gap between the advanced value and the limit value. In fact, there are still quite a number of cement enterprises in China whose energy consumption still fails to meet the requirements of the limit value. The energy cost gap between these enterprises and the advanced value may reach about 35 yuan/ton.
21 yuan may be the full thickness
of profits in the current market, even if 21 yuan sounds small, but it is very important in the current industry environment.
In 2025, the profit of the cement industry was only 26 billion yuan, which was 86% less than peak of 186.7 billion yuan in 2019. In the first quarter of this year, the domestic cement industry fell into the loss situation of the whole industry again. The national average price of cement is at the lowest point in ten years, and the bulk ex-factory price of P.O42.5 in some areas has fallen below 150 yuan/ton. The cost difference of
21 yuan/ton means that
level 1 enterprises can use the 21 yuan saved by energy consumption to reduce the price and grab the share, and still maintain the profit; level 3 enterprises sell the same price, the energy consumption cost is 21 yuan more than others, and the gross profit is directly cut by half or more. This is not the difference between "earning more and earning less", but the dividing line between "living" and "not living". Level
2 enterprises are not easy either-they spend almost 10 yuan/ton more than Level 1, and they are also passive in the fierce competition for share. From level 2 to level 1, the difference of 10 yuan means greater flexibility and thicker safety cushion in the price war.
The
energy consumption gap is not the gap of "earning more and earning less", but the demarcation line of "living or not". Grade 1 saves 21 yuan per ton compared with Grade 3. At a time when the cement industry is generally losing money, this 21 yuan or even 35 yuan can bring great market operation space for cement enterprises.
Note: Some cement enterprises use a large number of alternative fuels and use photovoltaic power generation on a large scale, so the energy cost may be lower, which is not considered separately here.
On July 29-30, China Cement Network will hold the 15th China Cement Energy Conservation and Environmental Protection Technology Exchange Conference and the 7th Intelligent Summit Forum in Wuhu, Anhui Province. The conference will focus on the path of energy conservation and carbon reduction technology and the intelligent operation and maintenance scheme of cement clinker production line. Help cement enterprises to save energy in depth and further reduce production costs.
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