Krzysztof Lokaj | Manager | Africa Development | Wärtsilä Energy | mail me |
Africa’s cement industry is expanding quickly, driven by urbanisation, infrastructure investment and rising demand for housing. However, behind this growth lies a persistent operational challenge: reliable and affordable access to electricity.
Cement production requires large amounts of energy and remains highly sensitive to power interruptions. Kilns operate continuously, while sudden shutdowns disrupt production and increase costs. In many African markets, limited access to grid power and volatile energy prices force cement producers to invest in on-site power generation capabilities.
In this context, the question facing the cement industry is no longer whether companies should generate their own power. In many cases, they must. Instead, the focus has shifted to identifying the technology that provides the most practical and resilient solution. Africa’s cement industry increasingly requires energy systems that can support stable production and long-term cost efficiency.
The technological options typically include open-cycle gas turbines, reciprocating gas engines, and, in some cases, coal-fired steam turbines. However, only one of these technologies offers the optimal balance of flexibility, reliability and affordability for highly demanding cement operations.
Flexibility in matching industrial power demand
An essential factor to consider when assessing options involves understanding how power demand fluctuates within cement plants. Although production processes often run continuously, electricity demand varies according to grinding operations, maintenance cycles and seasonal production patterns.
By design, engine power plants are well-suited to adapt effectively to changing demand profiles. Plant operators can adjust power output from each engine between 10% and 100% within minutes. In addition, these plants consist of multiple engines operating in parallel. As a result, operators can switch independent units on or off to match real-time demand.
More importantly, flexible engines operate stably at very low loads while maintaining high efficiency. Consequently, operators gain a responsive tool for managing fluctuating power requirements. This capability also allows the power plant to maintain high electrical efficiency across a broad range of output levels.
This operational flexibility also plays a critical role in supporting the integration of intermittent renewable energy in microgrids. As Africa’s cement industry increasingly turns to solar and wind energy to reduce carbon emissions, flexible engine capacity can provide the dispatch dependability needed in hybrid power plant configurations.
Open-cycle gas turbines, by contrast, lose significant efficiency when they operate below full capacity. Industrial users rarely operate at a constant full load. Therefore, lower efficiency translates into higher long-term fuel consumption and offsets the turbines’ lower upfront cost. In a sector where energy costs account for a significant share of operating expenses, long-term efficiency differences outweigh initial capital cost advantages.
Unlike engines, operators cannot switch turbines on and off multiple times during the day. Turbines also require continuous operation to avoid thermal stress and increased maintenance costs. Consequently, this lack of operational flexibility undermines efficiency and limits the performance of renewables in hybrid microgrid configurations.
Reliability and scalability as baseline requirements
For cement plants, a dependable electricity supply remains the highest priority. Reciprocating engine power plants typically achieve availability rates above 98%. Therefore, they suit industrial environments where companies require constant access to energy.
One reason for this reliability lies in the modular nature of engine-based plants. Unlike turbine power plants, these configurations allow operators to service individual units without shutting down the entire plant. Technicians can carry out servicing on site while the remaining engines continue operating. Furthermore, spare parts planning, local technical support, and straightforward servicing procedures help minimise downtime.
The modular structure of engine power plants also allows companies to expand generation capacity gradually. As cement plants increase production, operators can install additional generating units without redesigning the entire power system. At the same time, companies avoid building oversized plants. This structural flexibility reduces investment risk and allows power infrastructure to grow alongside industrial demand.
In this regard, engine power plants offer a level of adaptability that other generation technologies struggle to achieve. Such adaptability continues to support the long-term growth of Africa’s cement industry.
Coal, a cheap option with considerable downsides
Some companies still consider coal-fired power plants as an alternative for captive power in certain countries, especially where cheap coal resources remain locally available. However, coal-based generation presents several challenges for industrial users.
Much like open-cycle gas turbines, coal plants are designed mainly for steady and continuous operation. Therefore, they are less suited to environments where operators must adjust power output frequently and rapidly. Startup times can extend for many hours, while maintenance often forces operators to take large sections of the plant offline. As a result, this lack of flexibility negatively affects project economics.
Environmental considerations also represent a major downside for coal. Financing institutions, investors and plant owners are paying closer attention to emissions profiles and long-term climate risks. Consequently, coal-based power plants often face significant financing barriers.
Preparing for an evolving energy landscape
Energy systems across Africa continue to evolve. New gas infrastructure, renewable energy projects, and volatile fuel markets are reshaping the landscape. Therefore, industrial power solutions must accommodate these transformations.
No single power technology is universally optimal. However, when companies consider sustainability, scalability, reliability, operational flexibility and long-term efficiency together, engine-based power plants emerge as a compelling option for many cement producers across the continent. As Africa’s cement industry continues expanding, dependable and flexible power solutions will remain essential for sustainable growth.
