Proceedings of the International Conference on Sustainable Energy: Toward Energy Transition and Net-Zero Emission (ICOSE 2025)

<Previous Article In Volume
Next Article In Volume>

Optimization of Fly Ash Usage in Cement Manufacturing Process at Finish Mill to Increase Production Capacity by 11%

Authors
Muziibu Alfisyah1, *, Agus Prasetya1, Joko Wintoko1
1Department of Chemical Engineering, Universitas Gadjah Mada, Yogyakarta, Indonesia
*Corresponding author. Email: muziibualfisyah@mail.ugm.ac.id
Corresponding Author
Muziibu Alfisyah
Available Online 26 December 2025.
DOI
10.2991/978-94-6463-944-5_26How to use a DOI?
Keywords
fly ash; cement manufacturing; Six Sigma; process optimization; sustainability
Abstract

This study presents the optimization of fly ash utilization in the cement manufacturing process at PT Indocement Tunggal Prakarsa Tbk., Plant 9/10, Cirebon. Fly ash, a non-hazardous by-product from nearby coal-fired power plants, was previously disposed of in landfills, creating environmental issues. By applying the Six Sigma DMAIC methodology, identified and resolved key operational constraints in the Finish Mill, including equipment modification (aeration system), operator training, SOP refinement, and troubleshooting standards. The project successfully increased fly ash substitution from 6% to 11%, resulting in a production capacity improvement of 11% (from 183 tph to 203 tph) and significant cost savings of IDR 57.5 billion annually. Beyond financial impact, the initiative supports Indocement’s 2030 sustainability commitments by reducing CO₂ emissions, conserving water, conserving raw materials, and creating positive socio-economic effects through waste valorization and job creation. This case demonstrates the strategic role of alternative material utilization in enhancing both industrial efficiency and environmental sustainability in the cement sector.

Copyright
© 2025 The Author(s)
Open Access
Open Access This chapter is licensed under the terms of the Creative Commons Attribution-NonCommercial 4.0 International License (http://creativecommons.org/licenses/by-nc/4.0/), which permits any noncommercial use, sharing, adaptation, distribution and reproduction in any medium or format, as long as you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons license and indicate if changes were made.

Download article (PDF)

<Previous Article In Volume
Next Article In Volume>
Volume Title
Proceedings of the International Conference on Sustainable Energy: Toward Energy Transition and Net-Zero Emission (ICOSE 2025)
Series
Atlantis Highlights in Sustainable Development
Publication Date
26 December 2025
ISBN
978-94-6463-944-5
ISSN
3005-155X
DOI
10.2991/978-94-6463-944-5_26How to use a DOI?
Copyright
© 2025 The Author(s)
Open Access
Open Access This chapter is licensed under the terms of the Creative Commons Attribution-NonCommercial 4.0 International License (http://creativecommons.org/licenses/by-nc/4.0/), which permits any noncommercial use, sharing, adaptation, distribution and reproduction in any medium or format, as long as you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons license and indicate if changes were made.

Cite this article

risenwbib
TY  - CONF
AU  - Muziibu Alfisyah
AU  - Agus Prasetya
AU  - Joko Wintoko
PY  - 2025
DA  - 2025/12/26
TI  - Optimization of Fly Ash Usage in Cement Manufacturing Process at Finish Mill to Increase Production Capacity by 11%
BT  - Proceedings of the International Conference on Sustainable Energy: Toward Energy Transition and Net-Zero Emission (ICOSE 2025)
PB  - Atlantis Press
SP  - 389
EP  - 415
SN  - 3005-155X
UR  - https://doi.org/10.2991/978-94-6463-944-5_26
DO  - 10.2991/978-94-6463-944-5_26
ID  - Alfisyah2025
ER  -