Aliveri Cement Plant

Aliveri Cement Plant is a cement plant in Greece. Its listed capacity is 3,300,000 t of cement. Cement plants heat limestone to 1,400°C in rotary kilns — one of the hottest industrial processes — and must control temperature precisely across the entire kiln length. It is operated by Heracles General Cement Co. By capacity it ranks #2 among 6 cement plants in Greece. It emits about 990,661 t CO₂e a year from Climate TRACE, roughly comparable to the annual emissions of 231k passenger cars. Its CO₂ per unit of capacity is 17% below the national median for this sector.

Facility data: Climate TRACE v6 (asset-level capacity & CO₂e, CC BY 4.0), id ct-1896841.

In context: how this facility compares

At 3,300,000 t of cement, Aliveri Cement Plant is around the median cement plant in Greece (3,100,000 t of cement). Subsector: cement. As cement plant, it requires high process heat (typically 800–1400°C) for its core industrial operations — heat that must be supplied by boilers, furnaces or direct combustion, and losses through uninsulated vessels and piping represent wasted fuel. Removable modular insulation can cut those losses by 80–96%, surface-cooling equipment to ≤45°C, with payback often under 2 years. Cement plants heat limestone to 1,400°C in rotary kilns — one of the hottest industrial processes — and must control temperature precisely across the entire kiln length.

Capacity & CO₂-intensity comparison computed from Climate TRACE industrial facilities data; sector role based on engineering reference.

What 990,661 t CO₂e a year looks like

This facility's estimated annual CO₂e (Climate TRACE, modelled) in everyday equivalents from the US EPA Greenhouse Gas Equivalencies calculator:

Equivalencies: US EPA Greenhouse Gas Equivalencies. Emissions: Climate TRACE.

Capacity vs largest cement plants in Greece

Listed capacity (t of cement), Climate TRACE v6 (asset-level capacity & CO₂e, CC BY 4.0).

Operator

Operated by Heracles General Cement Co. All facilities by this operator →

Local climate

Aliveri Cement Plant sits in a hot-summer Mediterranean climate zone (Köppen Csa), at 38.4°N in the northern hemisphere.

Köppen zone: Köppen-Geiger world climate classification (Kottek et al. 2006, 0.5° grid).

Site climate & environmental severity

The local climate sets how fast unprotected steel, protective coatings and the insulation on hot process equipment degrade at this site. It sits in a corrosive environment (estimated ISO 9223 class C4 — High), with marine corrosion the leading environmental stress.

In this site’s local climate, a bare 150 °C surface sheds about 1331 W/m² to ambient — roughly 1.02× the loss at a 20 °C reference; removable insulation recovers about 1264 W/m² of that. Reference-surface calculation at a 150 °C surface from WorldClim climate normals (ASTM C680 / ISO 12241) — an indicative per-climate comparison, not a measurement of this site’s specific equipment. Open method dataset: DOI 10.5281/zenodo.20787408 (CC BY 4.0).

Higher environmental severity is exactly where protective removable insulation pays back most: a sheltered micro-climate slows corrosion, UV and thermal-cycling damage and extends outdoor hardware service life. This is an indicative site-climate context — not a condition assessment of any specific plant or operator.

Indicative estimate via the ISO 9223:2012 informative method (atmospheric corrosivity from temperature, time-of-wetness and airborne salinity), using WorldClim climate normals, the Köppen-Geiger class and coast distance. Indicative, not a measured corrosion rate.

How it compares & nearby sites

The #2 largest of 6 cement plants in Greece by listed capacity (Climate TRACE).

Nearby industrial sites

• Pepsico -Ivi S.A · Food & Beverage
• ELVALHALCOR S.A. - ALUMINIUM ROLLING DIVISION · Metals Plant · 114,000 t CO₂
• Magoula Cement Plant · Cement Plant · 533,322 t CO₂
• Hellenic Petroleum Aspropyrgos Refinery · Refinery · 1,528,776 t CO₂
• Apropyrgos Cement Plant · Cement Plant · 293,439 t CO₂
• Hellenic Petroleum Elefsina Refinery · Refinery · 1,094,934 t CO₂

Location

Coordinates 38.37478, 24.06239. View on OpenStreetMap.

Heat loss & insulation profile

For a cement plant, the main modular-insulation targets are rotary kiln shell, preheater tower, tertiary air duct & kiln hood, clinker-cooler ducts, valves. Typical hot-surface ranges used for screening: 200–1,000 °C.

60% of cement CO2 is process calcination - NOT insulation-addressable; energy here is the fuel side only.

Indicative recoverable energy

A first-pass insulation screen suggests about 15,000 MWh/year of recoverable heat-loss reduction and about 5,000 t CO₂e/year of avoided emissions. Screening estimate scaled from installed process-heat projects and surface-temperature reduction data.

See Inzonex Modular Insulation → Run the calculator →

Screening calculation from facility class, capacity and open emissions/energy context. Engineering survey required before procurement.

Safety & the no-regret first step

Start with a thermal survey of valves, flanges, doors and bends. Removable modular insulation keeps maintenance access open while lowering exposed-surface temperature and wasted heat.

EU policy pressure on this sector

Obligation

This facility is inside the EU. For thermal equipment, insulation upgrades can support ETS exposure reduction and energy-efficiency compliance.

Sources: EU ETS, CBAM and national energy-efficiency schemes.

Frequently asked questions