Cement industry is one of the highest energy consuming industries. The quantity of fuel and energy needed accounts for most of the cost of cement manufacturing. Thermal power plants generate electricity but are harmful and ineffective by nature. As a backup mechanism to account for main grid failures, batteries can be utilized. In this paper the first ever investigation on battery’s depth of discharge (DOD) for four different kinds of battery technologies is carried out in the framework of cement industry. The intended battery technologies are the lead-acid battery (LA), lithium-ion battery (Li-ion), vana-dium redox battery (VR), and nickel–iron battery (Ni-Fe). Four hybrid energy generation models (HEGMs) for five cement plants of Pakistan using the HOMER pro software are proposed. Cement plants includes Askari Cement Plant, Wah (ACPW); Bestway Cement Plant, Kalar Kahar (BCPKK); Bestway Cement Plant, Farooqia (BCPF); Bestway Cement Plant, Hattar (BCPH); and DG Cement Plant, Chakwal (DGCPC). HEGM-1 comprises of a diesel generator (DGen), a photovoltaic system (PV), a converter, and a battery system. HEGM-2 comprises of a PV system, a converter, and a battery system. HEGM-3 is the grid-connected version of HEGM-1 and HEGM-4 is the grid-connected version of HEGM-2. A base-model consisting of grid only is used as a reference. A multi-criteria decision analysis (MCDA) is performed by formulating a cumulative objective function (COF) which includes net present cost (NPC), levelized cost of energy (LCOE), and greenhouse gas (GHG) emissions. The principal objective is the maximization of COF while simultaneously minimizing the objectives (NPC, LCOE and GHG emissions), based on optimal battery technology and DOD. The results reveal that VR is the most suitable battery technology with 10% DOD. It is achieved for DGCPC with HEGM-3 with 61.49% of NPC, 78.62% of LCOE and 84.00% of GHG emissions reduction as com-pared to the base model.

Cement manufacturing is one of the most energy-intensive industries in the world. Most of the cost of producing cement is accounted by fuel consumption and power expenditures. Thermal power plants are the major source of electricity in Pakistan. But they are not efficient and environmentally friendly. This study simulates four different models for five cement plants of Pakistan on Homer Pro software and compares the optimal solutions based on the net present cost (NPC), levelized cost of electricity (LCOE) and greenhouse gas (GHG) emissions. Model-1 consists of solar panels, electrolyzer, hydrogen tank, hydrogen generator and converter. Model-2 has only a diesel generator and acts as a base case in this study. Model-3 has solar panels and a battery-converter system. In Model-4, diesel generators, solar panels and converters are considered. Based on NPC, the most optimal model is Model-4, having a 0.249 $/KWh LCOE in islanded systems. The NPC and operating costs are US$540 million and US$ 32.5 million per year, respectively, with a 29.80% reduction in CO2 emissions when compared to the base case. Based on GHG emissions, Model-1 and Model-3 are the best models with 0% GHG emissions. Sensitivity analyses is also performed using the parameters of load, inflation rate and discounted rate. The results prove that the proposed hybrid micropower systems (HMS) can sustainably provide electricity for 24 hours a day to the sites under consideration with minimum objectives.