Investigating energy consumption drivers and reduction measures in intensive manufacturing sectors

Improving energy efficiency in energy-intensive industries is essential for reducing environmental impact and ensuring long-term competitiveness. This study analyses energy use in the most energy-intensive processes across the cement, ceramics, glass, and steel sectors using a structured methodology that combines process mapping, benchmarking against best practices, and systems analysis of energy-influencing factors. Energy drivers were categorised into energy inputs, material inputs, equipment, operations, and environmental conditions, with causal loop diagrams (CLDs) used to visualise their interdependencies. Benchmarking revealed that while the adoption of best practices has improved efficiency, substantial gaps remain, particularly in thermal management, material optimisation, and process control. Cross-sectoral insights reveal shared challenges related to high-temperature processes and heat losses, with the largest efficiency gains linked to improved thermal management, combustion control, and equipment upgrades. However, some decarbonisation pathways can increase process-level energy input in the short to medium term, introducing trade-offs between emissions reduction and energy performance. This study provides a practical framework for evaluating industrial energy use, highlighting the need for integrated strategies that align energy efficiency with decarbonisation goals. It offers a foundation for future research and policy development to support sustainable process innovation in high-energy sectors.