nccbm1

ENERGY CONSUMPTION NORMS FOR CEMENT SECTORUNDERENERGY CONSERVATION ACT - 2001: 

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

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BRIEF ABOUT THE PROJECT

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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

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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 OBJECTIVE OF THE PROJECT

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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 ACTIVITIES UNDER THE PROJECT

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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

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

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

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FREQUENCY DISTRIBUTION OF PLANTS BASED ON SPECIFIC ENERGY CONSUMPTION

FREQUENCY DISTRIBUTION OF DRY PLANTSTHERMAL ENERGY: 

FREQUENCY DISTRIBUTION OF DRY PLANTS THERMAL ENERGY DATA OF 30 DRY PROCESS PLANTS

FREQUENCY DISTRIBUTION OF DRY PLANTSELECTRICAL ENERGY: 

FREQUENCY DISTRIBUTION OF DRY PLANTS ELECTRICAL ENERGY DATA OF 30 DRY PROCESS PLANTS

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PROPOSED NORM (THERMAL)

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

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

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PROPOSED NORMS (ELECTRICAL) OVERALL PLANT

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

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

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

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

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

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

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PROPOSED NORM (ELECTRICAL) UPTO RAW MILL

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

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

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

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PROPOSED NORM (ELECTRICAL) KILN AND COAL MILL

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

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

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PROPOSED NORM (ELECTRICAL) CEMENT MILL AND PACKING

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

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

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

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

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

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

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

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

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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 VIEWS FROM TECHNICAL COMMITTEE MEMBERS