energy consumption norms

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ENERGY CONSUMPTION NORMS FOR

CEMENT SECTOR

UNDERENERGY CONSERVATION ACT - 2001



METHODOLOGY ADOPTED

SETTING UP OF A TECHNICAL COMMITTEE CONSISTING OF

REPRESENTATIVES OF CEMENT INDUSTRY, NCB, CEMENTMANUFACTURERS’ ASSOCIATION (CMA), GOVT. DEPTT.,CONSULTANTS BY BUREAU OF ENERGY EFFICIENCY (BEE)FOR GUIDANCE

CMA/CEMENT INDUSTRY REPS’ ACTIVELY ASSOCIATED WITH THE TASK

REGULAR INTERACTIONS BY TECHNICAL COMMITTEE AND

BEE



FACTORS CONSIDERED FOR

DEVELOPMENT OF NORMS

PROCESS

TECHNOLOGY

CAPACITY OF PLANT/EQUIPMENT

TYPE OF CORE EQUIPMENT

TYPES & GRADES OF CEMENT



PROPOSED NORMS - 3rd CEMENT

SECTOR TASK FORCE MEETING

31 January 2005



NORMS – ELECTRICAL & THERMAL ENERGY

Item Unit Proposed Norm

Raw Mill Cement Mill

BM/VRM BM kWh/t OPC-43 105

BM/VRM BM kWh/t Cement 97

VRM/RP+BM RP+BM kWh/t OPC-43 90VRM/RP+BM RP+BM kWh/t Cement 80

VRM VRM kWh/t OPC-43 78

VRM VRM kWh/t Cement 73

4 St. kcal/kg Clinker 840

5/6 St. kcal/kg Clinker 740

1

2

System

Electrical

Energy

Thermal Energy



VIEWS FROM TECHNICAL COMMITTEE MEMBERS

& FEEDBACK OF 12 PLANTS

Separate norms for OPC-43 and PPC

Separate norms for different % of flyash consumption

Limestone hardness to be considered

Plants using petcoke/waste products may have higher energy

consumption, weightage be given

Blaine for different grades of cement

Plants using petcoke/waste products may have higher energyconsumption, weightage be given

Total kWh/t PPC should be 85 instead of proposed 80

Increase in energy consumption due to some trials/R&D in the

plant may be given weightage through appropriate clause

Quality of flyash received from power plant (coarse or fine)



VIEWS FROM TECHNICAL COMMITTEE MEMBERS

& FEEDBACK OF 12 PLANTS (Contd.)

Separate norms for OPC-43 and PPC

Norm to vary with percent of slag/flyash used in the manufacture

of PSC/PPC

Percentage use of pozzolanic material

Residue of raw meal and fine coal

Power consumption for PSC grinding (ball mill system) be raised

to 63 kWh/t from 60 kWh/t There should be no norms for cement mix

Norms for OPC-53 be also fixed

Suggested 110 kWh/t for plants having ball mil l for raw grinding

& cement grinding

Suggested norm of 745 kcal/kg clinker instead of 740 kcal/kg

clinker for plants with 5/6 stage preheater using petcoke



PROPOSED NORMS SUBMITTED TO

BEE

July 2006

ALTERNATIVE - I

MAY BE SEEN AS A 5-YEAR ROADMAP NEEDING REVIEW THEREAFTER



NORMS – ELECTRICAL ENERGY

Cate- Item

orElectrical Ener

Raw Mill Cement Mill Product

OPC-43 95 - 106OPC-53 97 - 108

PPC 80 - 93PSC 89 - 106

OPC-43 91 - 102OPC-53 93 - 104

PPC 77 - 90PSC 87 - 104

OPC-43 88 - 99OPC-53 90 - 101

PPC 74 - 87PSC 82 - 99

OPC-43 90 - 101OPC-53 92 - 103PPC 77 - 89PSC 85 - 101

OPC-43 86 - 97OPC-53 88 - 99

PPC 74 - 86PSC 79 - 94

kWh/tonne

1

BM

BM

RP+BM

BM

System Proposed Norm

Norm

VRM/RP+BM

PG+BM

VRM

Dry Process



NORMS - ELECTRICAL ENERGY (contd.)

Cate- Item

orElectrical Ener

Raw Mill Cement Mill Product

2 Wet Process kWh/t Cement 100 - 1083 Semi-Dr Process kWh/t Cement 100 - 108

OPC-43 36 - 38OPC-53 38 - 40

PPC 37 - 40

PSC 63 - 68OPC-43 33 - 35OPC-53 35 - 37

PPC 34 - 37PSC 58 - 63

OPC-43 31 - 33OPC-53 33 - 35

PPC 34 - 36PSC 55 - 58

kWh/tonne

4


Norm

BM

RP+BM

VRM

Grinding Units

(Independent)



NORMS – THERMAL ENERGY

Cate- Item

orThermal Ener

Product

4 Sta e PH with Grate Cooler Clinker 810 - 8604 Sta e PC with Grate Cooler Clinker 790 - 840

5/6 Sta e PC with Grate Cooler Clinker 720 - 7705/6 Sta e PC Old Plants ** Clinker 780 - 830Kilns with Planetar Cooler Clinker 850 - 900

2 Wet Process Clinker 1250 - 1400

3 Semi-Dry Process Clinker 900 - 1000


Norm

1

kcal/k clinker

Dry Process



NORMS – SUPPLEMENTARY NOTES

(Alternative – I)

1 Range of Norms has been formulated considering the material characteristics/product fineness and conversion factors (% additives)

2 BM - Ball Mill; RP - Roller Press(Efficient); PG - Pregrinder/HRC(1st Generation)/VRM (Gravity Discharge);

VRM - Vertical Roller Mill; PH - Preheater Kiln; PC - Precalciner Kiln

3 Energy consumption figures are yearly average values for reference year

4 Energy consumption in Workshop, Plant & Colony Lighting is excluded from overall energy consumption

5 Thermal energy consumption figures to be on NCV basis for the fuel

6 ** Plants commissioned before 1980 and retrofitted 5/6 Stage Preheater later

7 For plants producing more than one variety of cement, the norms to be worked out based on actual product mix for reference year

8 Similarly, for plants having a mix of technologies, the norms to be derived on weighted capacities for reference year

9 Energy consumption in mining & haulage of material upto plant may not be considered keeping in view the different modes

of transport/conveying and varying distances involved

10 Energy consumption for special cements (other than OPC, PPC, PSC) has not been considered. In case any plant is producing

substantial quantity of special cements, separate norms may be formulated for individual cases

11 Plants with capacity upto 1200 tpd may be given weightage of 5% in thermal energy norm and 10% in electrical energy normover and above the proposed norms in their respective categories

12 Plants using alternate fuels may be given weightage as under in the proposed norms :

a) 10-30% Alternate Fuel - 2% on both Thermal & Electrical Energy Norm

b) > 30% Alternate Fuel - 3% on both Thermal & Electrical Energy Norm



VIEWS FROM TECHNICAL COMMITTEE

MEMBERS & INDUSTRY

RAW MEAL TO CLINKER CONVERSION FACTOR CONSIDERED

(1.45-1.50) NEEDS REVIEW (REVISED TO 1.60)

PERCENTAGE FLYASH ADDITION MAY BE REVIEWED FOR PPC

5-STAGE PH WITHOUT PC MAY BE ADDED AS SEPARATECATEGORY

4-STAGE PC WITH GRATE COOLER (OLD PLANTS) MAY BE

CLUBBED WITH 5/6 STAGE PC OLD PLANTS



PROPOSED NORMS - 4th CEMENT

SECTOR TASK FORCE MEETING

October 2006

ALTERNATIVE - II

MAY BE SEEN AS A 3-YEAR ROADMAP NEEDING REVIEW THEREAFTER



REVISED PROPOSED NORMS

HIGHLIGHTS OF MODIFICATIONS

SIMPLIFIED WITH LESSER CATEGORIES OF PLANTS

CONVERSION FACTORS REVISED, AS DISCUSSED IN

TECHNICAL COMMITTEE MEETING OF 26 JULY 2006

ONLY UPPER VALUES PRESCRIBED INSTEAD OF RANGES

THERMAL ENERGY NORMS REVISED CONSIDERING CMADATA MADE AVAILABLE TO NCB ON 04 OCT. 2006

METHODOLOGY FOR FINAL INTERPRETATION OF NORMS,

PLANT-WISE (COMPUTING IN TERMS OF GJoules/T CEMENT)




Cate- Item

goryNorm

Raw Mill Cement Mill Product kWh/tonne

OPC-43 109OPC-53 111

PPC 99

PSC 108

OPC-43 104

OPC-53 106

PPC 95

PSC 105

OPC-43 103

OPC-53 105PPC 94

PSC 102

OPC-43 99

OPC-53 101PPC 91

PSC 95

Dry Process

VRM/RP+BM

VRM


BM

BM

1

BM

RP/PG+BM




Cate- Item

gory

NormProduct kcal/kg cl.

PH Plants with Grate Cooler Clinker 870

PC Plants commissioned before 1989 Clinker 840

PC Plants commissioned before 1989, upgraded Clinker 800

PC Plants commissioned after 1989 Clinker 770Kilns with Planetary Cooler & < 1000 tpd plants Clinker 900

2 Wet Process Clinker 1400

3 Semi-Dry Process Clinker 1000

1


Dry Process

NORMS SUPPLEMENTARY NOTES



NORMS – SUPPLEMENTARY NOTES

(Alternative – II)

1 Energy consumption in Workshop, Plant & Colony Lighting isexcluded from overall energy consumption.

2 For plants producing more than one variety of cement, the norms to

be worked out based on actual product mix.

3 Similarly, for plants having a mix of technologies, the norms to be

derived on weighted capacit ies.

4 Energy consumption in mining & haulage of material upto plant may

not be considered keeping in view the different modes oftransport/conveying and varying distances involved.

5 Energy consumption for special cements (other than OPC, PPC, PSC)

has not been considered. In case any plant is producing substantial

quantity of special cements, separate norms may be formulated forindividual cases.

6 Plants using alternate fuels may be given weightage as under in the

proposed norms :

10-30% Alternate Fuel - 2% on both Thermal & Electrical Energy Norm

> 30% Alternate Fuel - 3% on both Thermal & Electrical Energy Norm



NORMS – PROPOSED INTERPRETATION

IN TERMS OF GJ/T Cement

IF A PLANT MEETS EITHER THERMAL OR ELECTRICAL NORM, BUT

DOES NOT MEET THE OTHER, THEN ITS PERFORMANCE MAY BE

EVALUATED THROUGH TOTAL GJOULES/T CEMENT :

GJ/T CEMENT =

[ (KCAL/KG CLINKER X 4.18 X CLINKER : CEMENT RATIO) + (KWH/TCEMENT X 3.6)] / 1000



EXPECTED DRAWBACKS DURING MONITORING

MAY HAVE TO BE REVIEWED EVERY 3 YEARS RESULTING IN

OTHER MODALITIES INCLUDING FRESH NOTIFICATIONS ETC.

DIFFICULTIES MAY BE ENCOUNTERED WITH STATE LEVEL

IMPLEMENTING AGENCIES DURING MONITORING ON THE

INTERPRETATION OF SOME OF THE CLAUSES/CONCESSIONS &WEIGHTAGES



NORMS PROPOSED BY CMA

ALTERNATIVE - III




PRODUCT KWH/T

OPC 53 112

PPC 100

OPC 43 110

PSC 106

NOTE: NO SEPARATE NORMS FOR INDEPENDENT GRINDING UNITS; TO

BE CLUBBED WITH PARENT CLINKER UNIT

NORMS THERMAL ENERGY




CATEGORY KCAL/KGCLINKER

SEMI-DRY PROCESS 1050

DRY PROCESS, KILN < 1000 TPD 1000

DRY PROCESS, KILN 1000 TO 2000 TPD 925

DRY PROCESS, KILN 2000 TO 3500 TPD

PLANTS INSTALLED BEFORE 1989

PLANTS COMMISSIONED BEFORE 1989, BUT

PARTLY UPGRADED AFTER 1989

NEW PLANTS COMMISSIONED AFTER

1989/OLD PLANTS WITH MAJOR

MODIFICATION

875

825

800

DRY PROCESS, KILN > 3500 TPD 770

WET PROCESS 1350



PROPOSED NORMS

Based on % Improvement

ALTERNATIVE - IV



NORMS – BASED ON % IMPROVEMENT

THE CONCEPT TO BE APPLICABLE FOR EACH PLANT

INDIVIDUALLY

THE BASE LEVEL CONSUMPTION TO BE THE AVERAGE OF

PREVIOUS TWO YEARS OF THE PLANT

PERCENTAGE IMPROVEMENT TARGET TO BE ACHIEVED IN

FOUR YEARS AS PER FOLLOWING CATEGORIES :

CATEGORY ELECTRICAL (KWH/T

CEMENT)

THERMAL (KCAL/KG CL.)

RANGE %

IMPROVEMENT

RANGE %

IMPROVEMENTI Upto 75 0.25 Upto 720 0.25

II 76 – 85 0.50 720 – 770 0.50

III 86 – 100 0.75 771 – 825 0.75

IV > 100 1.00 > 825 1.00



ADVANTAGES

EASY TO FOLLOW AND MONITOR

DISADVANTAGES

PERCENTAGE REDUCTION MAY BE DIFFICULT TO ACHIEVE DUETO VARIOUS CONSTRAINTS OF TECHNOLOGY, LAYOUT,

FINANCE, MARKET FORCES ETC.

energy consumption norms

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