Through its production approach based on industrialized R&D projects and continuous process optimization, Limak Çimento’s Anka Plant has secured its position among the world’s most energy-efficient cement plants.
Having hosted hydrogen usage trials for over a year, the Anka Plant is now recognized among global pioneers in this field. With an alternative fuel usage rate of up to 60%, it has surpassed the European Union cement industry average.
Since commencing operations in 2018, the plant has maintained its leadership in specific energy consumption within Turkish cement sector. Pursuing a “best practice globally” approach, efficiency projects concluded in the first quarter of 2025—including reducing clinker usage, optimizing grinding systems, and implementing a new single-chamber design in the Roller Press + Ball Mill line—have enabled the plant to lower total specific energy consumption below 65 kWh/ton. This achievement has positioned it among the global best in energy efficiency, while adding an annual reduction of 80,000 tons of CO₂ emissions to its sustainability record.
Efficiency-Focused Grinding Optimization
The grinding optimization process, initiated in 2023 through collaboration between Limak Cement Technical Organization (LCTO) and Anka Plant experts, was carried out with advanced R&D support on the Ball Mill and Roller Press units. During this process, various types and dosages of grinding aids and strength-enhancing additives were tested. As a result, clinker usage in the high-strength product class was reduced from 82% to 75% while maintaining the same mineral additions—marking a critical step toward Limak Çimento’s decarbonization goals.
Single-Chamber Design and Energy Gains
One of the key drivers of efficiency improvement was the transition to a new single-chamber design in the ball mill. This design allowed more effective use of ball surface area, enhancing grinding efficiency. The next focus was on the roller press system, where particle size distribution was optimized, further improving mill performance. This optimization reduced specific power consumption (SPC), enabling the ball mill to operate more effectively with finer material.
As a result of these comprehensive efforts, specific energy consumption at the Anka Plant decreased from 30 kWh/ton to 23 kWh/ton while achieving a Blaine fineness of 3800. This remarkable accomplishment not only surpassed global competitors using only ball mill and HPGR systems but also pushed total specific cement production below 65 kWh/ton—setting a new, exceptionally challenging global benchmark for energy efficiency in the cement industry.
Tangible Gains in Sustainability and Carbon Footprint
Limak Çimento pursued clinker reduction without compromising product quality, developing new, more efficient mix formulations. This led to a significant reduction in clinker usage and prevented tens of thousands of tons of annual carbon emissions.
Commenting on the Anka Plant’s achievement, Limak Çimento Group CEO Erkam Kocakerim said: “We believe that the most effective model for organic growth in the modern world can only be achieved by continuously developing our scientific expertise and innovation capacity. In line with this approach, in the field of efficiency—one of our seven core decarbonization pillars—our R&D and Innovation Center (LCTO) and the skilled teams in our plants are continuously raising the bar through data analysis and system optimization. The global success of our Anka Plant represents a strategic milestone in the energy-efficiency leg of our sustainability journey. At Limak Çimento, we will continue to uphold our pioneering role in the sector with our roadmap focused on innovation, sustainability, and efficiency.”
