Cement plants are among the largest consumers in the industrial sector in terms of electrical energy consumption.
Waste heat released to the atmosphere during the clinker production phase is converted into electrical energy thanks to the Waste Heat Recovery System (WHR). In this way, while protecting the environment by using the heat thrown into the nature, it also contributes to the country’s economy with electricity production.
In March 2019, Sönmez Cement started to invest in waste heat recovery system with CTP Team S.R.L. (Italy) and CTN Machinery consortium within the scope of sustainable environmental policies based on energy efficiency. The first test production at the plant was carried out in September 2020. Within the scope of the investment, the ORC (Organic Rankine Cycle) system, which is the most efficient technology, was selected for the Waste Heat Recovery System. ORC technology has zero water consumption as well as high efficiency. The facility, which has 8350 kW turbine (Turboden-Italy) installed power, 56.000.000 kWh/year production capacity and two waste heat boilers, is the facility with the largest ORC technology installed among cement factories in the world as of the date of commissioning.
While this installed power corresponds to the annual electrical energy consumption of approximately 20,000 households, it prevents 30,000 tons of CO2 emissions and gives nature as a gift of 70,000 trees annually.
In July 2019, Sönmez Cement signed a contract with KHD Humboldt Wedag to reduce fuel consumption per tonne clinker and increase production efficiency and increased the clinker cooling unit by 6.6 meters.
In the scope of the project;
- Cooling efficiency has been increased by increasing the cooling unit area from 113.7 m2 to 141.4 m2,
- Cooling fans have been replaced with new high-performance fans,
- Cooling unit fixed plates have been replaced with new technology plates,
- The hydraulic piston diameters of the cooling unit have been enlarged.
The assembly works were completed in a very short time, such as 22 days, and the project successfully reached its goal.
1st stage additional packaging unit was commissioned in July 2016 in order to meet the increasing domestic and international demand for bagged cement, to prevent operational time losses due to product diversity, and to increase loading speeds. In this way, the bagged cement packaging capacity has been doubled.
Produced by Keramik Makina San. ve Tic. A.S., 1st palletless packaging production line, with a production capacity of 2,400 bags/hour, was commissioned in December 2016.
With the aim of increasing its export targets with the commissioning of the port business, Sönmez Cement has doubled the packaging speed and maximized the quality of product packaging by establishing the 2nd palletless packaging production line with a capacity of 2,400 bags/hour produced by Keramik Makina San. ve Tic. A.Ş. in September 2021 next to the existing palletless packaging production line with the aim of improving the product packaging speed and quality.
Sönmez Cement can produce kraft and polypropylene (PP) bags, palletized packages, stretch hood and sling bags in weights of 50kg, 42.5kg and 21.25kg in its palletless packaging production lines with a capacity of 4,800 bags/hour.
Starting clinker and cement production in Adana Yumurtalık Free Zone in the third quarter of 2014, Sönmez Cement started its port management investment in January 2016 in order to continue its export activities without interruption. The facility, which was completed and commissioned in November 2017, has 2 docks that can serve dry cargo and general cargo ships. Sönmez Cement contributed to the country’s economy and export targets with its port investment.
Port management, which has a cement and clinker loading capacity of 2,000,000 tons/year, can carry out the fast and safe evacuation of bulk, bagged, big-bag, tracked, chested, sheet metal, roll sheet, ingot mine, pipe, machine, block stone/marble, bale, roll paper, roll cable and similar loads for 3rd parties as of February 2021.