Cement Industry Heat Recovery & Manufacturing Solutions
Improving Efficiency, Reliability & Emissions Performance in Cement Production
Tailored rotary gas heater solutions for SCR and FGD
Durable heat exchange systems for flue gas applications
Cement production is one of the most energy-intensive and thermally demanding industrial processes in the world. High kiln temperatures, abrasive dust, and continuous operation place extreme stress on equipment—while producers face mounting pressure to reduce fuel costs, improve reliability, and lower carbon intensity.
For more than 100 years, LJUNGSTRÖM has delivered engineered heat transfer systems, waste heat recovery technologies, and advanced manufacturing solutions designed for harsh, high-temperature environments. Today, we help cement producers capture lost heat, stabilize critical systems, and extend the life of aging assets—without disrupting production.
The Challenges Facing Cement Producers
Cement plants operate under some of the harshest industrial conditions, including:
Extremely high exhaust temperatures from kilns and preheaters
Significant waste heat loss through stacks and exhaust streams
Heavy dust loading and abrasion that degrade heat transfer equipment
Rising fuel and electricity costs
Increasing CO₂ reduction and sustainability pressure
Without targeted modernization, these challenges result in lost energy, higher operating costs, reduced reliability, and increased emissions exposure.
How LJUNGSTRÖM Supports
the Cement Industry
Waste Heat Recovery for
Cement Kilns & Process Systems
Cement production generates substantial recoverable thermal energy from kiln exhaust, clinker coolers, and process air systems.
LJUNGSTRÖM waste heat recovery solutions help cement plants:
- Capture heat from kiln and preheater exhaust streams
- Reduce stack temperatures and thermal losses
- Produce usable energy for process heating or power generation
- Improve overall plant energy efficiency and emissions performance
Our systems are engineered to operate reliably in dust-laden, high-temperature cement environments.
High-Efficiency Heat Transfer in Harsh Service
LJUNGSTRÖM designs regenerative and recuperative heat exchangers built to withstand the abrasive, corrosive, and cyclic conditions common in cement production.
These systems help:
- Improve thermal efficiency across process air and exhaust systems
- Stabilize operating temperatures
- Reduce fuel consumption per ton of clinker
- Support consistent kiln and process performance
By recovering and reusing heat, cement producers unlock measurable energy savings without increasing operational complexity.
Modernization for Aging
Cement Plant Equipment
Many cement plants operate equipment that is 30–50+ years old. LJUNGSTRÖM specializes in targeted modernization and life-extension strategies that reduce risk while maximizing return on existing assets.
We support:
- Replacement and upgrades of heat exchanger internals and structural components
- Early detection of wear, fouling, and degradation
- Reduction of collateral damage to downstream fans, ducts, and process equipment
- Upgrade planning aligned with kiln shutdowns and maintenance outages
This proactive approach minimizes unplanned downtime and improves long-term reliability.
Advanced Manufacturing Built for Cement Operations
LJUNGSTRÖM’s vertically integrated advanced manufacturing capabilities eliminate supply-chain uncertainty for large, complex, and outage-critical cement plant components.
Benefits include:
- Shorter and more predictable lead times
- Precision fabrication of large structural and thermal components
- Tight quality control from engineering through fabrication
- Reduced execution risk during shutdowns and rebuilds
With in-house manufacturing, cement producers receive fit-for-purpose components designed to survive abrasive, high-temperature service.
Designed for Abrasive,
Dust-Laden Environments
Cement production environments are among the most punishing in heavy industry. LJUNGSTRÖM products are engineered to withstand:
- Extreme temperatures and thermal cycling
- Improve energy intensity metrics
- High particulate loading and abrasion
- Fouling and erosion of heat transfer surfaces
- Continuous, high-duty operation
The result is
longer service life, improved reliability, and lower total cost of ownership.
Supporting Decarbonization
and Alternative Fuels
Heat recovery and efficiency improvements play a critical role in reducing cement’s carbon footprint.
LJUNGSTRÖM solutions help cement producers:
- Lower indirect CO₂ emissions
- Improve energy efficiency per ton of cement produced
- Support alternative fuel strategies by stabilizing thermal systems
- Prepare plants for future carbon reduction and capture initiatives
Efficiency improvements today create flexibility for tomorrow’s regulatory landscape.
LJUNGSTRÖM Products
for the Cement Industry
Waste Heat Recovery Systems
LJUNGSTRÖM air preheaters improve thermal efficiency in fired heaters, boilers, and process units by recovering heat from flue gas to preheat combustion air.
Designed to:
- Process heating including CCUS
- Power generation support
- Preheating combustion or process air
Medium High-Temperature
Heat Exchangers
Engineered for cement service, LJUNGSTRÖM heat exchangers deliver reliable performance in abrasive, dust-heavy environments while improving thermal efficiency.
Structural and Thermal Components
LJUNGSTRÖM manufactures large, custom components including:
- Ducting, housings, and casings
- Structural steel supports and platforms
- Thermal assemblies and custom-fabricated components
All built to withstand cement plant operating conditions.
LJUNGSTRÖM Services
Advanced Manufacturing
for Cement Components
LJUNGSTRÖM provides vertically integrated advanced manufacturing for large, complex, and shutdown-critical cement plant components—reducing lead times, ensuring precise fit, and lowering outage risk.
Manufacturing Capabilities Include:
- Large-scale structural fabrication
- Precision machining and assembly
- Thermal and ducting components
- Custom components built to OEM or reverse-engineered specifications
Choose LJUNGSTRÖM
Century
Proven
100+ years of experience in harsh industrial environments
Heat Transfer Expertise
Deep expertise in heat transfer and waste heat recovery
Refinery-Proven Performance
Proven performance in abrasive, high-temperature service
Integrated Capabilities
Integrated engineering and advanced manufacturing
Lifecycle
Value
Focus on efficiency, reliability, and lifecycle value
Cement Plant Performance Starts With Smarter Heat Management
Cement plants don’t lose value due to lack of production—they lose it through wasted heat, aging equipment, and avoidable downtime.
LJUNGSTRÖM helps cement producers:
Recover Lost Thermal Energy
Improve Energy Efficiency
Extend
Asset
Life
Reduce Operational
and Outage
Risk
For more than a century, LJUNGSTRÖM has helped the cement industry turn heat into performance.
Ready to discuss solutions that work for your needs?
No matter the challenge, our experts are here to help you achieve unmatched efficiency and reliability. Let’s discuss your needs today.