energy consumption norms
TRANSCRIPT
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ENERGY CONSUMPTION NORMS FOR
CEMENT SECTOR
UNDERENERGY CONSERVATION ACT - 2001
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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
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FACTORS CONSIDERED FOR
DEVELOPMENT OF NORMS
PROCESS
TECHNOLOGY
CAPACITY OF PLANT/EQUIPMENT
TYPE OF CORE EQUIPMENT
TYPES & GRADES OF CEMENT
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PROPOSED NORMS - 3rd CEMENT
SECTOR TASK FORCE MEETING
31 January 2005
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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
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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)
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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
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PROPOSED NORMS SUBMITTED TO
BEE
July 2006
ALTERNATIVE - I
MAY BE SEEN AS A 5-YEAR ROADMAP NEEDING REVIEW THEREAFTER
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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
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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
System Proposed Norm
Norm
BM
RP+BM
VRM
Grinding Units
(Independent)
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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
System Proposed Norm
Norm
1
kcal/k clinker
Dry Process
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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
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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
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PROPOSED NORMS - 4th CEMENT
SECTOR TASK FORCE MEETING
October 2006
ALTERNATIVE - II
MAY BE SEEN AS A 3-YEAR ROADMAP NEEDING REVIEW THEREAFTER
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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)
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NORMS – ELECTRICAL ENERGY
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
System Proposed Norm
BM
BM
1
BM
RP/PG+BM
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NORMS – THERMAL ENERGY
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
System Proposed Norm
Dry Process
NORMS SUPPLEMENTARY NOTES
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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
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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
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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
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NORMS PROPOSED BY CMA
ALTERNATIVE - III
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NORMS – ELECTRICAL ENERGY
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
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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
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PROPOSED NORMS
Based on % Improvement
ALTERNATIVE - IV
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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
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ADVANTAGES
EASY TO FOLLOW AND MONITOR
DISADVANTAGES
PERCENTAGE REDUCTION MAY BE DIFFICULT TO ACHIEVE DUETO VARIOUS CONSTRAINTS OF TECHNOLOGY, LAYOUT,
FINANCE, MARKET FORCES ETC.