Assessment of Energy Efficiency in a Cement Production Line in Sokoto State, North West Nigeria

Cement production is among the most energy-intensive industrial processes, and energy efficiency improvement represents both an economic priority and a carbon emissions reduction imperative for Nigerian manufacturers operating in an environment of unstable grid power supply and rising energy costs. This study assesses energy efficiency across the kiln, grinding, and auxiliary operations of a cement production line in Sokoto State, North West Nigeria. Energy auditing is conducted using the International Organization for Standardization 50001 energy management standard framework. Specific energy consumption values (thermal energy per tonne clinker and electrical energy per tonne cement) are calculated from production records and fuel consumption logs and benchmarked against international best available technology benchmarks for the cement industry. Thermal imaging is applied to identify heat loss points in the rotary kiln shell, preheater cyclone system, and cooler exit gas streams. Power quality monitoring at key electrical distribution points identifies opportunities for power factor correction and variable speed drive retrofitting. Alternative fuel substitution potential using agricultural waste, including rice husks and groundnut shells, is evaluated based on calorific value, chlorine content, and ash chemistry. A prioritised energy efficiency improvement roadmap is developed, including return-on-investment analysis for each identified measure. The study supports the company's compliance with the Nigerian Energy Commission's industrial energy efficiency guidelines and contributes to decarbonisation efforts in the North West manufacturing sector. Keywords: energy efficiency, cement production, Sokoto, energy audit, thermal energy consumption