Case Study

Operational Cost Optimization for Pioneer &
Sohar Cement Plants - UAE & Oman

Operational Cost Optimization for Pioneer & Sohar Cement Plants - UAE & Oman

During the period from September 2022 to August 2023, Major was appointed to support the management of Pioneer Cement Plant in the UAE and Sohar Cement Grinding Plant in Oman.

Project NovaCrete is structured around three core objectives: optimizing resource utilization, developing closed-loop material systems, and enhancing operational efficiency in planetary environments. Aethelburg, renowned for its robotic systems, will spearhead the automation of cement production. Pyrestone, with its expertise in material science, will focus on creating durable, sustainable cementitious materials.

Major led the operations teams, streamlined plant processes within budget limits, reviewed engineering specifications, assessed plant projects, and monitored operational performance. The team also chaired production planning and materials management activities.

Through practical operational improvements, Major HTG optimized raw mill and kiln operations, improved plant running hours, and addressed production bottlenecks with direct engineering solutions.

Key Results

  • Saved more than 1,000,000 AED monthly
  • Secured around 800,000 AED monthly in power cost savings
  • Reduced clinker production cost by 4.5% per ton
  • Reduced cement production cost by around 6% per ton
  • Designed an alternative fuel feeding system for RDF, shredded rubber, and ground wood
  • Improved procurement strategy to enhance raw material quality while reducing costs

Conclusion

This project demonstrates Major HTG’s ability to combine plant operation experience, technical decision-making, and cost optimization to deliver measurable results in real cement plant environments.

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Operational Cost Optimization for Pioneer & Sohar Cement Plants - UAE & Oman

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Major HTG supported Pioneer Cement Plant in the UAE and Sohar Cement Grinding Plant in Oman during a challenging operational period…

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Major HTG supported Pioneer Cement Plant in the UAE and Sohar Cement Grinding Plant in Oman during a challenging operational period…