Designated Entities
- Covered under PAT Scheme
Energy Efficiency Certification Experience
Sharing
and Consulting Workshop
6th- 7th February,2013
K . K. Chakarvarti
Bureau of Energy Efficiency
New Delhi (INDIA)
Cement Sector
Indian Cement Industry
 India is the second largest cement market in the world,
accounting for about 6% of the world’s cement
production
 The cement industry uses coal and electricity as the
main sources of fuel.
 Energy cost accounts for about 40% of the total
manufacturing cost in some of the cement plants and
coal accounts for 15%–20% of the total production costs.
 The specific thermal energy consumption and electrical
energy consumption for state-of-the-art cement plants
are as low as 658 kcal/kg of clinker and 65 kWh/ton of
cement, respectively.
Indian Cement Industry (contd.)
 The specific energy consumption patterns of most of the
plants very, having wide band variation.
 This happens mainly because of plants having different
product mix based on addition of Pozzolona, Slag and
Fly Ash and different blending percentage.
 The pure cement being Ordinary Portland Cement
(OPC) and no dilution by additives, consumes the
highest energy per ton.
 The blending with additives to manufacture other
varieties reduces the Specific Energy Consumption per
ton.
Indian Cement Industry (contd.)
 Because of these complexities, it becomes extremely
difficult to come to a common model to arrive at
standardized SEC per ton.
 Considering all these situations, the conversion factors
and best possible combination and categorization have
been worked out so that no Designated Consumer may
have any grievance on the targets set out
 While setting targets , units best in the group as
reference and then worked out targets for others.
Normalization of Product Mix
Raw Material
Clinker Imported from
Other Unit
Cement Plant
Clinkering Unit
(Clinker Production)
Grinding Unit
Clinker + Gypsum+ additives* =
Cement (OPC/PPC/PSC/any
other Variety)
*(fly ash/Slag/any other unit)
Clinker Exported to
Other Unit
Cement Dispatched
Conversion of Cement Equivalent to Major grade = (Cement production of a
particular grade) X (CF* of Same grade)/(CF of Major grade)
Total Cement Production Equivalent to major grade =Production of all
grades of cement equivalent major grade + (exported clinker equivalent to
major grade Cement)**
*CF (Conversion Factor)= Clinker used for x grade/Cement Production of x grade
**Conversion of exported clinker to equivalent major grade cement = Clinker exported/CF of major grade cement
EXAMPLE- INPUT & OUTPUT FOR A TYPICAL CEMENT PLANT
Coal (Indian)
(1,03,339 Tons/yr ,GCV 3438 kcal/kg)
Coal1 (Imported)
(6246 Tons/yr, GCV 5454 kcal/kg)
CPP
(Heat Rate
3135 kcal/kWh)
3148 lakh KWh
(19.35 LAKH kWh/YR)
Furnace Oil
(669 Tons/yr, GCV 10000 kcal/kg)
HSD
(570 Tons/yr , GCV 8600 kcal/litre)
DG SET
(Heat Rate
2212 kcal/kWh)
GRID (Exported)
2.09 Lakh kWh
Crushing and
Mining
(Exported)
(25.12 LAKH kWh/YR)
Grid Electricity (53.08 Lakh KWh)
Colony, (5.1 Lakh kWh)
Coal2 (Imported)
124746 Tons/yr, GCV 6192 kcal/kg)
Pet Coke
(3316 Tons/yr, GCV 8400 kcal/kg)
Crushed Limestone
Clinkerization
(Raw Material
Processing &
Pyro-processing)
PPC
Iron Ore, Bauxite,Gypsum
Flyash, Slag, Etc
Clinker (0.06 Lakh Tons/yr)
(14.92LAKHTONNE/YR)
Grinding
(VRM and
RP &BM)
OPC
(0.08 LAKH TONNE/YR)
PSC /OTHER
(2.30 LAKH TONNE/YR)
Note: All values presented in the above diagram are average of annual energy consumption of 2007-08, 2008-09, 2009-10
Methodology for Baseline and EPIs (Summary)
 For each plant, different types of cement products and
exported clinker are converted in to equivalent major
product produced by that plant with the help of
conversion factor, reported by the concerned plant.
 Thermal Energy Input is arrived at by taking all type of
fuels into account.
 Electricity Purchased is converted in to equivalent
thermal energy by multiplying it with 860. Whereas the
electricity exported to grid is calculated similarly by
multiplying it with 2717 (national avg. heat rate).
 Notional energy is also imposed on imported power
 Notional Equivalent Thermal Energy for Imported
Power= Electricity purchased from Grid x (Weighted
avg. heat rate of CPP of Cement plants-860).
Methodology for Baseline and EPIs (Summary)
 Total GtG Energy Consumption is calculated by adding
the thermal inputs through all type of fuels, electricity
purchased and subtracting the power exported to grid.
 Notional Energy (equivalent thermal energy) for
Exported and Imported clinker are calculated based on
thermal and electrical SEC reported by the concerned
plant, wherein the Electrical kWh is converted into
thermal kCal by multiplying the weighted average heat
rate of the all form of electricity used in plant
 The notional energy required for exported/imported
clinker is added to the total thermal and electrical energy
consumed by the plant only to arrive at the Gate to Gate
Sp. Energy Consumption.
Perform, Achieve and Trade (PAT) Scheme
Normalization Factors (DRAFT)
The following normalization factors have been considered in consultation with the
Sectoral Expert Committee and various plants in the cement sector:
a. Equivalent major grade of cement production
The various product mixes are converted in to equivalent major grade of cement
product by the plant by using the following formulae:
i. Conversion of Ordinary Portland Cement (OPC) production equivalent to
major product
Equi va l e nt
Ma jorPr oduct 
OPC Pr oduce d(Mi l l i on
Ton) Conve rs i onfa ctorof OPC
Conve rs i on
Fa ctorof Ma jorPr oduct
[Million Ton]
ii. Conversion of Portland Pozolona (PPC) Production equivalent to major
product
Equi va l e nt
Ma jorPr oduct 
PPC Pr oduce d(Mi l l i on
Ton) Conve rs i onfa ctorof PPC
Conve rs i on
Fa ctorof Ma jorPr oduct
[Million Ton]
iii. Conversion of Portland Slag Cement (PSC)/any other variety of Cement
Production equivalent to major product
PSCora nyothe rva ri e tyCe me ntPr oduce d(Mi l l i on
Ton) Conve rs i on
fa ctorof
PSCora nyothe rva ri e ty Ce me nt
Equi va l e nt
Ma jor Pr oduct 
Conve rs i onFa ctorofMa jorPr oduct
iv. Conversion of Total Exported clinker to major product
[Million Ton]
Tota lExporte dCl i nke r(Mi l l i on
Ton)
[Million Ton]
Conve rs i on
Fa ctorof Ma jorPr oduct
where: Total Exported clinker= [Clinker Exported to other plants + clinker exported
to clinker stock over and above the opening stock,]
Equi va l e nt
Ma jorPr oduct 
v.
Conversion of Total Imported clinker to major product
Equi va l e nt
Ma jorPr oduct 
Tota lI mporte d cl i nke r(Mi l l i on
Ton)
Conve rs i on
Fa ctorof Ma jorPr oduct
[Million Ton]
where: Total Imported clinker= [Clinker Imported from other plants + clinker
Imported from clinker stock, equivalent to the quantity by which the clinker
opening stock gets reduced]
vi.
Total Equivalent major product of Cement
It can be arrived at by summing up all the different grades of cements equivalent
to major product calculated above:
Total Equivalent major product of Cement = a(i) +a( ii) +a(iii) + a( iv)
[Million Ton]
Note: S.No. a(v) is already accounted in major product
a.
Calculation for Gate to Gate Specific Energy Consumption (SEC)
i.
Total Thermal Energy Consumption (Kiln + power Generation)
Total Thermal Energy Consumptions to be calculated as:Total Thermal Energy Consumption= [{Fuel consumed (kiln+ power generation) (Million Ton) X
Gross calorific value of respective fuel (kcal/kg) X 1000}-{Electricity exported to grid (Million kWh) X
2717 (kcal/kWh)}]
[Million kcal]
where: - 2717 kcal/kWh is the National Average Gross Heat Rate of Thermal Power
Stations in the country in 2007.
Note: - 1.With reference of definition of Energy as defined in the EC-ACT 2001, if biomass is
used in the Kiln (in case of a cement plant), it does not form a part of energy and its energy
value is not to be accounted. But, if the same biomass is used in a captive power plant,
which is connected to the grid (whether exporting electricity or not), the same biomass
gets covered as energy and its energy value is to be considered.
2. Clinker opening and closing stock has now been incorporated in the form -1,
which automatically generates the summary sheet once the data is filled in Form1. The
surplus closing clinker stock in 2009-10, with respect to clinker opening stock in base
year (2007-08), has been considered for normalization as exported clinker. Similarly,
the reduction in stock from the baseline has been considered as imported clinker and
accordingly, it has been normalized as per the approved methodology.
ii.
Energy forImported Electricity Consumption
Total energy for imported Electricity Consumption is to be calculated as:Total energy for Imported Electricity=[{(Total Imported Electricity from grid
(Million kWh) X 860(kcal/kWh)}]
[Million kcal]
iii. Notional/ Normalization energy for Imported electricity from Grid
Notional Energy for imported electricity= [{Imported Electricity (Million kWh)
x (3208 - 860) (kcal/kWh)}]
[Million kcal]
where: 3208 kcal/kWh is the weighted average heat rate of captive power plants in
all DCs in cement sector.
iv. Notional/ Normalization energy for grinding of exported Clinker
It is calculated by using following formula:
Notional Energy =[{Total Exported clinker to major product (Million ton) X
Electrical SEC of cement grinding (kWh/ton of cement)
X Weighted Average Heat Rate (kcal/kWh)}]
[Million kcal]
where: -Weighted Average Heat rate (kcal/kWh) = [{Imported Electricity (Million
kWh) X 3208 (kcal/kWh)} + {DG generation (Million kWh) x DG heat rate
(kcal/kWh)} + {Captive Power Plant Generation (Million kWh) x Captive Power
plant heat rate(kcal/kWh)}] / [Imported Electricity (Million kWh) +DG generation
(Million kWh)+Captive power plant generation (Million kWh)]
v.
Notional/ Normalization energy for clinkerization of imported Clinker
It is calculated by using following formula:
Notional Energy = Total Clinker imported (Million ton) x [(Thermal SEC of
Clinkerization, kcal/kg clinker x 1000) +{Electrical SEC of
Clinkerization (kWh/ton of clinker) x Weighted Average Heat
Rate (kcal/kWh)}]
[Million kcal]
vi. Gate to Gate (GtG) Energy Consumption
GtG Energy Consumption =b(i) +b(ii) +b(iii) +b(iv)+b(v)
[Million kcal]
vii. Gate to Gate (GtG) Specific Energy Consumption
Gate to Gate (GtG) Energy Consumption (Million kcal)
GtG SEC =
Total Equivalent of Major Product of Cement (Million ton) X 1000
[ kcal/kg of equivalent cement]
Estimation of Gate to Gate (GtG) SEC
GtG SEC (kcal/kg major product cement)
Total GtG Energy Consumption with normalisation (kcal)
= --------------------------------------------Production of Equivalent Major Grade of Cement (kg)
Grouping of DCs
CEMENT PLANTS
(85 DCs)
Based on Major Product
PPC (55)
OPC(16)
PSC (7)
White OPC
(2)
+
Grinding(2)
+
Only clinker(1)
Wet Plant
(2)
DRAFT
ENERGY CONSUMPTION RANGE IN INDIAN CEMENT PLANTS (85 DC’s) (2007-10)
Products/Process
(No. of Plants)
(Major Product)
PPC
(55 Plants)
OPC
(16 Plants)
PSC
(7 Plants)
White Cement
(2 Plants)
Wet Cement
Plants
(2 Plants)
Grinding Units
(2 Plants)
Only
Clinkerization (1
Plant)
Thermal Energy
Consumption
(kcal/kg of clinker)
Electric Energy
Consumption
(kWh/Tonne
equivalent cement)
Normalized Energy
Consumption gtg
(kcal/kg equivalent
cement)
Minimum Maximum Minimum Maximum Minimum Maximum
Total Energy %
Consumption Share of
of SubSubSector
Sector
(toe)
658
1074.02
64.18
110.24
712.31
727.33
1000.94
75.67
143.48
964.66
1368.43
3295349.387
21.95%
701.02
1207.71
71.03
119.69
700.39
968.17
932008.497
6.21%
1093.72
1279.66
108.93
119.81
1452.23
1484.65
105566.281
0.70%
1026.67
1415.07
79.75
113.86
1241.4
1244.56
152403.633
1.02%
38.78
40.38
138.73
201.05
88211.169
0.59%
143790.367
0.96%


869.33
87.47
1227.1 10292843.975
(%)
1257.22
68.57%
Total 15010173.309 100.00%
Apportionment of Sub-Sector Target of Energy Saving in Cement Sector
(Data pertains to 85 plants as DC)
S.No.
Sub Sector
NO. OF DCs
Target Energy Reduction
for PAT Cycle-1
Avg. Energy Consumption
Mkcal
Million toe
%
Million toe
toe
1
PPC
55
102928440
10.293
68.57%
0.559 558865.489
2
OPC
16
32953494
3.295
21.95%
0.179 178925.965
3
PSC
7
9320085
0.932
6.21%
0.051
50604.807
4
White
2
1055663
0.106
0.70%
0.006
5731.880
5
Wet
2
1524036
0.152
1.02%
0.008
8274.985
6
Grinding
2
882112
0.088
0.59%
0.005
4789.558
7
Clinkerization
1
1437904
0.144
0.96%
0.008
7807.315
Total
85
150101733
15.010
100.00%
0.815 815000.000
Summary Sheet of Designated Consumer Cement Plant
Details of information regarding Gate to Gate SEC, Target SEC and Target Energy saving for PAT Cycle-1
1
2
Name of the Unit
The Sector to which unit falls
3
Complete Postal address of Plant
ABC Plant
Cement Sector
India
4
Details of Production
Basis/Calculation
Total Clinker Production
Annual Production
Total Combined Cement
b
Production
Annual Production
c
Production of OPC
Annual Production
d
Production of PPC
Annual Production
e
Production of PSC
Annual Production
f
Clinker Exported
Annual
g
Clinker Imported
Annual
h
Clinker Stock
(Closing Clinker stock in 2010- Opening Clinker Stock in 2007)/3
i
Total Clinker Exported
(Clinker Exported + Clinker exported to clinker stock)
j
Total Clinker Imported
(Clinker imported + Clinker Imported from clinker stock)
5
Conversion Factors (CF) for Clinker to various Cement grades
a
Clinker to OPC
Clinker used for OPC Production/OPC Produced
b
Clinker to PPC
Clinker used for PPC Production/PPC Produced
c
Clinker to PSC
Clinker used for PSC Production/PSC Produced
Total Thermal Energy
6
[Fuel Consumed (Lakh Tonne) X CGV of Fuel (Kcal/Kg)] X 100
Consumption
{(Electricity Generated through CPP+Electricity generation through DG Set +
Total Electricity consumed within Electricity generation through WHR+ Electricity Purchased from Grid) 7
the plant
Electricity exported to Grid}
Unit
Lakh Tonne
Average of Period (2007-10)
11.02
Lakh Tonne
Lakh Tonne
Lakh Tonne
Lakh Tonne
Lakh Tonne
Lakh Tonne
Lakh Tonne
Lakh Tonne
Lakh Tonne
unit
Fraction
Fraction
Fraction
13.64
2.65
10.99
0.00
0.33
0.09
0.19
0.52
0.09
Million kcal
1523498.01
Lakh kWh
1278.73
Lakh kWh
Lakh kWh
183.70
59.46
Million kcal
unit
1523140.41
Average of Period (2007-10)
Lakh Tonne
3.52
Lakh Tonne
10.99
Lakh Tonne
0.00
Lakh Tonne
0.71
Lakh Tonne
0.12
Annual
Lakh Tonne
unit
kCal/kg Clinker
15.22
Average of Period (2007-10)
952.33
Annual
kWh/Tonne Clinker
67.04
Annual
kWh/Tonne Cement
32.33
a
8
9
Electricity Purchased from Grid
Electricity Exported to Grid
Total Energy Consumed
(Thermal+Electrical)
10
11
Average of year 2007-08, 2008-09 and 2009-10
Average of year 2007-08, 2008-09 and 2009-10
[Total Thermal Energy (Million kcal)+{(Total Electricity purchased from
grid (Lakh kWh) X 860)-Electricity exported (Lakh kWh) X National Heat
Rate 2717 kcal/kWh}/10]
Equivalent major grade cement Production
OPC Production equivalent to
major product
PPC Production equivalent to
b
major product
PSC/any other verity Cement
Production equivalent to major
c
product
Total Exported clinker to major
d
product
Total Imported Clinker to major
e
product
Total Equivalent major product of
f
Cement
12
Performance Indicators
a
Thermal SEC
Electrical SEC (up to
b
Clinkerization)
a
c
Electrical SEC (Cement Grinding)
(OPC Produced X CF Of OPC)/CF of Major Product
(PPC Produced X CF Of PPC)/CF of Major Product
0.97
0.73
0.00
(PSC Produced X CF Of PSC)/CF of Major Product
Total Exported Clinker/CF of Major Product
Total Imported Clinker/CF of Major Product
(11a)+(11b)+(11c)+(11d)
13
Calculation for Gate to Gate SEC
Notional Energy Required for
grinding of exported Clinker
a
Notional Energy Required for
clinkerization of imported
Clinker
{Major Product of Cement of Total exported clinker (Lakh Tonne) x
Electrical SEC of cement grinding (kWh/Tonne of cement) x Weighted
average Heat Rate (kcal/kWh)}/10
d
Notional Energy for Purchased Purchesed Electricity (sr.no.8) X {Weighted average heat rate of all dcs in
Power
cement sector( 3208 kcal/kWh) - 860}/10
Gate to Gate Energy
Consumption
(10)+(13a)+(13b)+(13c)
Gate to Gate Specific Energy
Consumption
(13d)/{(11f)*100}
e
Target Estimation for PAT Cycle-1
14
a
Reduction Specific Energy
Consumption (SEC) Target
From Summary Sheet of Cement Sector
Target Specfic Energy
Consumption for PAT cycle-I
(13e) x {1- (14a)/100}
Target Energy saving for PAT
cycle-I
[{(13e) - (14b)} x (11f) x 10]
Note:Weighted average heat rate of
your plant
15
Million kCal
9143.04
Million kCal
10549.21
Million kCal
43133.82
Million kCal
1585966.48
kcal/kg equivalent
major cement
product
unit
1042.13
PAT Cycle-1
5.8378
%
b
c
Average of Period (2007-10)
[Total Clinker imported (Lakh Tonne) x {Thermal SEC of
Clinkerization kCal/kg clinker) x 1000+electrical SEC of clinkerization
(kWh/Tonne of clinker)x Weighted average Heat Rate (kcal/kWh)}/10]
b
c
unit
[{Imported Electricity (Lakh kWh) X 3208 (kcal/kWh)} + {DG generation
(lakh kWh) x DG heat rate (kcal/kWh)} +{Captive Power Plant Generation
(lakh kWh) x Captive Power plant heat rate (kcal/kWh)}] / [Imported
Electricity (Lakh kWh) +DG generation (Lakh kWh)+Captive power plant
generation (Lakh kWh)]
Note:Weighted
average heat rate of all DCs in
∑{Captive power plant generation (Lakh kWh) X Captive power plant Heat
Cement Sector
16
Rate (kcal/kWh)} / ∑ {Captive power plant generation (Lakh kWh)}
kcal/kg equivalent
major cement
product
981.29
metric ton of oil
equivalent (toe)
9258.56
kcal/kWh
3988.72
kcal/kWh
3208
Summary of Energy Saving targets for Cement Sector
1) Total Energy Consumption :-15.01 Million toe
2) No. of DC's as of date :- 85
3) Total reduction for cement sector:-0.815 Million toe
4) Reduction target for DC's varying from :-
i) 3.99% to 6.87% (for PPC as major Product)
ii) 4.23% to 6.00% ( for OPC as major product)
iii)3.71% to 5.13% ( for PSC as major product)
iv) 5.01% to 5.12% (for white cement plants)
v) 4.87% to 4.88% (for Wet Cement plants)
vi) 4.10% to 5.94% ( for grinding plants)
Iron & Steel sector
Iron & Steel sector
 Steel sector is one of the major contributors of
Energy saving targets under PAT Cycle 1.
 The total reported energy consumption of 67
designated consumers is about 25.32 million ton
of oil equivalent.
 By the end of the first PAT cycle it is expected to
reduce the energy consumption by 1.48 million
ton of oil equivalent which is around 18 % of
total energy savings target.
Specific Energy Consumption and
Targets- Iron & Steel
•
Fertilizer Sector
Fertilizer Sector
• There are 29 large size fertilizer units, manufacturing a wide range
of nitrogenous and phosphatic /complex fertilizers.
Fertilizer Plants
 Natural Gas ,
 Naphtha & LSHS (Fuel ,feed )
 Urea (Product )
 Ammonia (Product )
 These plants consume energy to the tune of 13 Million MTOE. The
industrial units belonging to this sector have taken conscious and
concerted measures to lower their energy consumption in order to
be competitive while maintaining profitability given the rising fuel and
feedstock prices.
 Energy savings of 0.478 million ton of oil equivalent /year is
expected to be achieved, which is 7.15 % of total national energy
saving targets assessed under PAT.
Specific Energy Consumption and TargetsFertilizers
Thermal Power Stations
Thermal Power Plants
 Total No of DCs = 144
 Threshold limit to be DC = 30,000 tons of oil equivalent
(TOE) per annum
 Specific energy consumption (net heat rate) varies
from 1774 kcal/kWh to 5134 kcal/kWh for these 144
designated consumers.
 Total Target Set = 3.1 million ton of oil equivalent
Thermal Power Plant Groups under PAT Scheme
Thermal Power Plants
[DC :144 Nos]
Coal/Lignite
[97]
Gas [40]
Diesel [7]
Target Setting in TPPs
• Net Design Heat Rate
Net Design Heat Rate= Gross Design Heat Rate
1- APC% operative
• Net Operative Heat Rate
Net operative Heat Rate = Gross operative Heat Rate
1- APC% operative
Target Setting in TPPs
• Heat Rate Deviation (%)
Heat Rate Deviation (%) = (Operating Heat Rate – Design Heat Rate) x 100
Design Heat Rate
• Heat Rate Deviation
Heat Rate Deviation = (Operating Heat Rate – Design Heat
Rate)
Target Setting for Reduction of NHR
Deviation in Net Station Heat
Rate from Design Net Heat Rate
Reduction Target for Deviation in
Net Station Heat Rate (%)
Up to 5 %
10 %
More than 5% and Up to 10 %
17 %
More than 10% and Up to 20%
21 %
More Than 20 %
24 %
Net Heat Rate = Gross Heat Rate / (1- APC%)
Parameter
Plant-1
Plant-2
Gross HR(GHR)
2500 Kcal/Kwh
2500 Kcal/Kwh
APC
8%
10%
Net HR (NHR)
2717(= 2500/0.92)
Kcal/Kwh
2777(=2500/0.90)
KCal/Kwh
Parameter to be Considered for Target Setting
•
•
•
•
•
Annual Generation (MUs) & PLF(%)
Design Gross Station Heat Rate (kCal/kWh)
Annual Operating Gross Station Heat Rate (kCal/kWh)
Annual Operating Auxiliary Power Consumption (%)
Quality of Coal i.e.
Average GCV (kCal/Kg) & Ash Content(%)
Or
Average GCV of Gas used
• Annual Quantity of Coal Consumed in Tonnes (SCM of Gas in case of Gas
Plants)
• Annual Quantity of Secondary Oil Consumed in Tonnes
Example - 1
S. No.
Parameters
Unit
Value
1
Installed Capacity
MW
420
2
Annual Gross Gen.
MU
2050
3
Annual Net Gen.
MU
1850
4
Annual PLF
%
56
5
Annual Average Operative Heat Rate
kCal/kWh
2650
6
Average APC
%
10
7
Statioan Design Heat Rate
kCal/kWh
2450
8
Net Operative Heat Rate
kCal/kWh
2936
9
Net Design Heat Rate
kCal/kWh
2715
10
Deviation from Design Net Heat Rate
11
% Deviation
12
Target Reduction
14
Target Net Heat Rate
15
Reduction Target in TOE
kCal/kWh
222
%
8
17% of Deviation (222)
38
kCal/kWh
2899
toe
6971
Example - 2
S. No.
Parameters
Unit
Value
1
Installed Capacity
MW
1260
2
Annual Gross Gen.
MU
9938
3
Annual Net Gen.
MU
9074
4
Annual PLF
%
90.03
5
Annual Average Operative Heat Rate
kCal/kWh
2348
6
Average APC
%
8.68
7
Statioan Design Heat Rate
kCal/kWh
2302
8
Net Operative Heat Rate
kCal/kWh
2571
9
Net Design Heat Rate
kCal/kWh
2521
10
Deviation from Design Net Heat Rate
11
% Deviation
12
Target Reduction
14
Target Net Heat Rate
15
Reduction Target in TOE
kCal/kWh
50
%
2
10 % of Deviation (50)
5
kCal/kWh
2566
toe
4578
Specific Energy Consumption and
Targets- Thermal Power Plants
Specific Energy Consumption and
Targets- Thermal Power Plants
Pulp and Paper
Pulp & Paper
 31 designated consumers from various states have been identified
 Pulp & paper sector has been categorized on the basis of their Raw
material in to three subsectors i.e. Wood based ,Agro based, and
Recycled fiber based (RCF).
 The total reported energy consumption of these designated
consumers is about 2.08 million ton of oil equivalent.
 Specific energy consumption varies from 0.202 toe/t to 0.878 toe/t
for these 31 designated consumers.
 By the end of the first PAT cycle, the energy savings of 0.119 million
ton of oil equivalent /year is expected to be achieved, which is
around 2% of total national energy saving targets assessed under
PAT.
Specific Energy Consumption and
Targets- Pulp & Paper
ACC Ltd
Cement House, 121, Maharshi Karve Road,
Mumbai-400020
BUREAU OF ENERGY EFFICIENCY
MINISTRY OF POWER, GOVERNMENT OF INDIA
Established in 1936, ACC has been a most trusted and preferred cement manufacturer in India with countrywide manufacturing and distribution network. Among the first companies in India to include
commitment to environment protection as a corporate objective, ACC has won various accolades for energy and environment friendly measures taken at its plants and mines, and has also been felicitated for
its acts of good corporate citizenship. ACC has establishments across India with 11 integrated plant s, 6 grinding units along with 37 ready mix plants.
Located in the picturesque Barmana village of Himachal Pradesh, ACC Gagal has two kilns installed. The
plant known as Gagal-I unit started in 1984 with an annual capacity of 0.56 million tons was upgraded to
4300 TPD in the year 2003 by modifying Preheater (PH) to 6 stage with separate line calciner. Gagal-II
Unit with a capacity of 1 million tons of cement was installed in 1994-95 with 4 stage PH and later was
upgraded to 4950 TPD in Year 2006.
The plant consumes about 341 million units of electricity annually which is supplied by the state grid. To
use the heat energy from the waste gases, ACC is installing a Waste Heat Recovery Boiler (WHRB)
based power generation of 7MW gross capacity. This is Steam Rankine cycle based power plant and will
have four waste heat recovery boilers (i.e., one each at the pre-heater exhaust outlet and one
each at clinker cooler exhaust outlet for production line 1 & 2) with one set of turbo generator
with its auxiliaries.
The net annual generation potential is about 44 million units which will be about 13% of present
electricity consumption. The Waste Heat Recovery Power Plant will provide a reliable supply of green
electrical energy at predictable cost, without negative impact on existing plant operations. This green
energy project in this eco sensitive region will help in reducing the CO2 foot print apart from ensuring
energy security for the plant during winter. This project has becomes viable only with PAT and CDM
benefits.
Waste Heat Recovery Power Project Benefit
Annual net electricity generation of 44 million kWh
 36575 tons of CO2 emission reduction
14035 MTOE energy saving
Helps PAT Compliance and CER earnings
Other PAT Initiatives Under Implementation
•Installation of VFDs for majority of variable HT and LT loads
•Increasing the stages of Pre-heater to reduce the waste heat
•Waste heat recovery in other plants
•Co processing of industrial wastes and other alternate fuels and raw
materials across the plants to reduce the fossil fuel consumption
•Installation of optimization software
Other ACC initiatives
BEE five star rated Corporate office
LEED-Platinum rated Control Room and residential building
Installation of Vertical roller mills instead of ball mills
Installation of mechanical conveying system
Energy Efficient lighting, pumps, compressors, fans and motors
Installation of centralized energy monitoring software
Contact person details for more information
Mr Narayanarao Kapialavai, Director-Energy and Environment, ACC Thane Complex, LBS Marg, Thane -400604 [email protected]
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