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ENERGY CONSUMPTION NORMS FOR CEMENT SECTOR UNDER ENERGY CONSERVATION ACT - 2001

ENERGY CONSUMPTION NORMS FOR CEMENT SECTOR UNDER ENERGY CONSERVATION ACT - 2001. BRIEF ABOUT THE PROJECT. BACKGROUND OF THE PROJECT. CREATING AN ENVIRONMENT WITHIN CEMENT SECTOR FOR INTEGRATION OF ENERGY EFFICIENCY IN CHOICE OF TECHNOLOGY, PROCESS AND DECISION MAKING

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ENERGY CONSUMPTION NORMS FOR CEMENT SECTOR UNDER ENERGY CONSERVATION ACT - 2001

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  1. ENERGY CONSUMPTION NORMS FOR CEMENT SECTORUNDERENERGY CONSERVATION ACT - 2001

  2. BRIEF ABOUT THE PROJECT

  3. BACKGROUND OF THE PROJECT • CREATING AN ENVIRONMENT WITHIN CEMENT SECTOR FOR INTEGRATION OF ENERGY EFFICIENCY IN CHOICE OF TECHNOLOGY, PROCESS AND DECISION MAKING • ESTABLISH AND PRESCRIBE ENERGY CONSUMPTION NORMS CONSIDERING VARIOUS FACTORS : • TECHNOLOGY ADOPTED • CAPACITY OF MAJOR EQUIPMENT • RAW MATERIAL AND FUEL QUALITY • VARIETIES & GRADES OF CEMENT • EVALUATION OF ENERGY CONSUMPTION LEVELS BY BEE BASED ON ANNUAL ENERGY CONSUMPTION RETURNS BY CEMENT PLANTS, • TO DRAW ACTION PLANS AND • INITIATE POLICY DECISIONS FOR IMPROVING ENERGY EFFICIENCY

  4. OBJECTIVE OF THE PROJECT • DEVELOPMENT OF ENERGY CONSUMPTION NORMS COVERING : • KNOWLEDGE BASE • INFORMATION BASE • INTERACTION WITH CMA & OTHER EXPERTS/AGENCIES • CEMENT PLANTS & MACHINERY SUPPLIERS • BEE AND INDO-GERMAN ENERGY PROGRAMME • DESIGN OF ANNUAL REPORTING FORMAT • FOR CEMENT PLANTS TO DECLARE ANNUAL ENERGY CONSUMPTION UNDER PROVISIONS OF EC ACT 2001 • TO FACILITATE REVIEW & UPGRADATION/MODIFICATION OF NORMS DEVELOPED PERIODICALLY • ANALYSIS OF THE PERTINENT INFORMATION AND PROVIDE OUTPUTS TO BEE

  5. ACTIVITIES UNDER THE PROJECT • CATEGORISATION OF CEMENT PLANTS • FINALISATION OF CATEGORIZATION • PREPARATION OF DATA COLLECTION FORMAT • REVIEW AND COMPILATION OF DATA ON ENERGY CONSUMPTION • EVALUATION OF DATA • DEVELOPMENT OF SPECIFIC ENERGY CONSUMPTION NORMS • DESIGNING OF ANNUAL ENERGY REPORTING FORMAT

  6. PROJECT PROGRESS • FIRST MEETING OF BEE TECHNICAL COMMITTEE ON 29 JANUARY 2004 DISCUSSED THE BACKGROUND PAPER PREPARED BY NCB COVERING : • VARIOUS ASPECTS RELATING TO CATEGORIZATION • FACTORS TO BE CONSIDERED FOR VARIOUS CATEGORIES • DEVELOPMENT OF NORMS FOR EACH CATEGORY • DISCUSSIONS HELD IN CMA ENERGY TASK FORCE MEETINGS • AS PER CMA ENERGY TASK FORCE ADVICE, FORMATS FOR DATA COLLECTION AND CATEGORIZATION DISCUSSED BY A CORE GROUP OF BEE TECHNICAL COMMITTEE ON 21 JULY 2004 FOR FINALIZATION • DATA COLLECTION FORMAT SENT TO ALL CEMENT PLANTS ON 16 AUGUST 2004 • DATA RECEIVED FROM 33 PLANTS AND ANALYSED FOR PROPOSED NORMS FOR EACH CATEGORY

  7. APPROACH TOWARDS CATEGORISATION • PROCESS • TECHNOLOGY • CAPACITY OF PLANT/EQUIPMENT • TYPE OF CORE EQUIPMENT • TYPES & GRADES OF CEMENT

  8. VARIOUS SECTIONS FOR SPECIFIC ENERGY CONSUMPTION NORMS • UPTO RAW GRINDING • KILN AND COAL MILL • CEMENT MILL AND PACKING

  9. FREQUENCY DISTRIBUTION OF PLANTS BASED ON SPECIFIC ENERGY CONSUMPTION

  10. FREQUENCY DISTRIBUTION OF DRY PLANTSTHERMAL ENERGY DATA OF 30 DRY PROCESS PLANTS

  11. FREQUENCY DISTRIBUTION OF DRY PLANTSELECTRICAL ENERGY DATA OF 30 DRY PROCESS PLANTS

  12. PROPOSED NORM(THERMAL)

  13. THERMAL ENERGY 4 STAGE PH (KCAL/KG CLINKER) DATA FROM 8 PLANTS

  14. THERMAL ENERGY 5/6 STAGE PH (KCAL/KG CLINKER) DATA FROM 22 PLANTS

  15. PROPOSED NORMS (ELECTRICAL)OVERALL PLANT

  16. OVERALL PLANT RAW MILL : BALL MILL / VRM CEMENT MILL : BALL MILL (kWh/T OPC 43) DATA FROM 19 PLANTS

  17. OVERALL PLANT RAW MILL : BALL MILL / VRM CEMENT MILL : BALL MILL (kWh/T CEMENT) DATA FROM 18 PLANTS

  18. OVERALL PLANT RAW MILL : VRM / ROLLER PRESS + BALL MILL CEMENT MILL : ROLLER PRESS + BALL MILL (kWh/T OPC 43) DATA FROM 7 PLANTS

  19. OVERALL PLANT RAW MILL : VRM / ROLLER PRESS + BALL MILL CEMENT MILL : ROLLER PRESS + BALL MILL (kWh/T CEMENT) DATA FROM 8 PLANTS

  20. OVERALL PLANT RAW MILL : VRM CEMENT MILL : VRM (kWh/T OPC 43) DATA FROM 2 PLANTS

  21. OVERALL PLANT RAW MILL : VRM CEMENT MILL : VRM (kWh/T CEMENT) DATA FROM 3 PLANTS

  22. PROPOSED NORM(ELECTRICAL)UPTO RAW MILL

  23. UPTO RAW MILL BALL MILL (kWh/T MATERIAL) DATA FROM 13 PLANTS

  24. UPTO RAW MILL ROLLER PRESS & BALL MILL (kWh/T MATERIAL) DATA FROM 1 PLANT

  25. UPTO RAW MILL VERTICAL ROLLER MILL (kWh/T MATERIAL) DATA FROM 16 PLANTS

  26. PROPOSED NORM(ELECTRICAL)KILN AND COAL MILL

  27. KILN & COAL MILL 4 STAGE PH (kWh/T CLINKER) DATA FROM 8 PLANTS

  28. KILN & COAL MILL 5/6 STAGE PH (kWh/T CLINKER) DATA FROM 22 PLANTS

  29. PROPOSED NORM(ELECTRICAL)CEMENT MILL AND PACKING

  30. CEMENT MILL BALL MILL (kWh/T OPC 43) DATA FROM 17 PLANTS

  31. CEMENT MILL ROLLER PRESS & BALL MILL (kWh/T OPC 43) DATA FROM 7 PLANTS

  32. CEMENT MILL VERTICAL ROLLER MILL (kWh/T OPC 43) DATA FROM 1 PLANT

  33. CEMENT MILL BALL MILL (kWh/T PPC) DATA FROM 9 PLANTS

  34. CEMENT MILL ROLLER PRESS & BALL MILL (kWh/T PPC) DATA FROM 6 PLANTS

  35. CEMENT MILL VERTICAL ROLLER MILL (kWh/T PPC) DATA FROM 2 PLANTS

  36. CEMENT MILL BALL MILL (kWh/T PSC) DATA FROM 2 PLANTS

  37. CEMENT MILL ROLLER PRESS & BALL MILL (kWh/T PSC) DATA FROM 1 PLANT

  38. VIEWS FROM TECHNICAL COMMITTEE MEMBERS • 5/6 STAGE PREHEATER KILNS : • NORM TO BE 800 KCAL/KG CL (OLD KILNS WITH CONVENTIONAL CYCLONES AND COOLER CANNOT OPERATE AT 740 KCAL/KG CL) • PSC GRINDING : • FOR BALL MILL, NORM TO BE 63 KWH/T CEMENT INSTEAD OF 60 KWH/T CEMENT • SEPARATE NORMS BE SPECIFIED DEPENDING ON SLAG PERCENTAGE BEING ADDED • BALL MILL WITH ROLLER PRESS FOR CEMENT : • ANOTHER CATEGORY TO BE INTRODUCED FOR FIRST GENERATION INEFFICIENT PRE-GRINDERS WITH BALL MILL; NORM TO BE 35 INSTEAD OF 28 KWH/T OPC-43. OVERALL NORM IN SUCH CASE TO BE 92 INSTEAD OF 90 KWH/T OPC-43 • CEMENT MILL (CONVERTED FROM RAW MILL) : • SEPARATE NORM TO BE 42 KWH/T OPC-43

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