Beawar Main 1

M&V Report of Shree Cement Ltd.
, Beawar
Monitoring & Verification

Report
As per the requirement of PAT Cycle 2
For
Shree Cement Ltd.,
Beawar Unit
DC No.: CMT00 19RJ
Ajmer, Raj ast han
Submitted to:
Bureau of Energy Efficiency
Ministry of Power
Government of India
July 2019
Submitted By:
Energy Management Section
Mechanical & Insulating Materials Division
Electrical Research & Development Association
Vadodara, Gujarat
Electrical Research & Development Association, Vadodara 1

M&V Report of Shree Cement Ltd., Beawar



Contents
Decl ara tion ................................ ................................ ................................ ..... 3

Acknow led gem ent ................................ ................................ ........................... 4
Executiv e S umm a ry ................................ ................................ .......................... 5
Co nte nts ................................ ................................................................ ......... 6
1. Empa nel l ed A ccred ited Energ y A udi t F i rm .............................................. 11
1.1. Name of the Firm .............................................................................................................11
1.2. Registration Number of the Firm ....................................................................................11
1.3. Address .............................................................................................................................11
1.4. Undertaking......................................................................................................................11
1.5. Accredited Energy Auditor (Team Leader) .....................................................................11
1.6. About EmAEA ...................................................................................................................12
2. Des ig na ted Cons um e r ................................ ................................ ............ 14
2.1. Name ................................................................................................................................14
2.2. Sector................................................................................................................................14
2.3. PAT Registration No. ........................................................................................................14
2.4. Address .............................................................................................................................14
2.5. Energy Manager...............................................................................................................14
2.6. Authorized Signatory .......................................................................................................14
2.7. Introduction to DC ...........................................................................................................14
2.8. Recent Awards received by DC........................................................................................16
2.9. Highlights of DC ................................................................................................................16
3. Ba ckg rou nd ................................ ................................ ........................... 18
3.1. Objective...........................................................................................................................18
3.2. Purpose of Verification Report ........................................................................................19
4. Approa ch, S cope & M eth odol og y ................................ ........................... 20
4.1. Work Order.......................................................................................................................20
4.2. Period of Verification .......................................................................................................20

4.3. Composition of Team.......................................................................................................20

4.4. Activities carried out for M&V Audit ...............................................................................21
4.5. Minutes of Meeting with Plant and Verification Team ..................................................24
4.6. Checklist Prepared by EmAEA .........................................................................................24
5. Ba s eline & A s se ssm ent Yea r Scena rio ................................ ..................... 26
5.1. Plant Capacity ...........................................................................................................................26
5.2. Plant Production.......................................................................................................................27
5.3. Energy Consumption................................................................................................................29
5.4. Inclusion and Exclusion for baseline and assessment year....................................................34
6. Rep orts Su bmitted by DC ................................................................ ....... 36
6.1. Monthly, Quarterly, Yearly & EOC reports submitted by DC .........................................36
6.2. Performance on Energy Consumption & Production Process .......................................36
6.3. Production & Energy Consumption of Assessment Year ...............................................37
6.4. List & Timeline of Energy Savings Measures implemented by DC ................................38
7. Mea suring E qui pmen t & Ins trum e ntCa li br ati on ................................ ...... 43
7.1 List of major measuring equipment and calibration status ....................................................43
7.2. Measurement procedures & methods ...................................................................................45
8. Energ y S cena ri o in As ses sm ent Ye a r ................................ ...................... 46
8.1. Energy Scenario................................................................................................................46
8.2. Electrical Power Generation ............................................................................................46
8.2.1. Captive Power Plant .................................................................................................47
8.2.2. Waste Heat Recovery and Generation....................................................................47
8.3. Process Thermal Energy System & Utilization................................................................50
8.4. Share of Energy Consumption .........................................................................................50
8.5. Production........................................................................................................................53
8.6. Specific Energy Consumption ..........................................................................................53
8.7. Gate-to-Gate Analysis before Normalization .................................................................53
9. Energ y S cena ri o in a s ses sm ent yea r f or Therm al Powe r Pl an t ................. 54
10. Proces s a nd F uel Des cri pti on ................................ .............................. 55

10.1. Introduction to Process ...................................................................................................55

10.1.1 Raw Material in Cement Manufacturing.....................................................................55
10.1.2 Various Steps Involved in Cement Manufacturing .....................................................56
10.2. Process Diagram...............................................................................................................59
10.3. Addition & Deletion of Equipment compared to baseline scenario .............................60
10.4. Changes in Process flow, Plant Machinery, Technology, Product mix, etc. compared to
baseline scenario .............................................................................................................................61
10.5. Raw Material Processing..................................................................................................62
10.5.1. List of Raw Material used with quality parameters. ...............................................62
10.5.2. Conversion or Product factor to final product. .......................................................62
10.6. Fuel Handling & Utilization..............................................................................................63
10.6.1. Solid fuel handling ....................................................................................................63
10.6.2. Liquid fuel handling ..................................................................................................63
10.6.3. Gaseous fuel handling ..............................................................................................63
10.7. Fuel Analysis .....................................................................................................................64
10.7.1. Fuel Analysis procedure followed in internal labs ..................................................64
10.7.2. Frequency of Internal & External Fuel Analysis ......................................................66
10.7.3. Sample Fuel analysis report. ....................................................................................66
11. Energ y & Ma s s Ba lan ce ................................................................ ....... 67
11.1. Material Balance of Plant ................................................................................................67
11.2. Energy Balance of Plant ...................................................................................................67
12. Pro-f orma Ver if ica ti on ................................ ................................ ........ 69
12.1. Linking Errors & Calculation Errors .................................................................................69
12.2. Discrepancies in Pro-forma and Normalization sheets ..................................................69
12.3. Potential improvements to achieve more accurate reading .........................................69
12.4. Baseline Data Verification ................................................................................................70
12.4.1. Discrepancies of Data exist after verification from documents.............................70
12.4.2. List of documents verified with each parameter....................................................70
12.4.3. List of parameters verified from the baseline report. ............................................75

12.4.4. List of essential parameters not entered by the DC in the baseline as well as
assessment year that affects negative normalization ...............................................................77
12.4.5. List of parameters altered in Pro-forma from the baseline report with reason of
deviation and documentation. ...................................................................................................77
12.5. Assessment year data verification ..................................................................................78
12.5.1. List of document verified with each parameter .....................................................78
12.5.2. List of parameters arrived through calculation or formulae with the list of
document as source data. ...........................................................................................................82
12.5.3. List of parameters reported based on disaggregation of recorded data with
reviewed documents ...................................................................................................................83
12.5.4. Write-up or methodology or logic or calculation for arriving submitted data .....83
12.5.5. Data Sampling...........................................................................................................83
12.5.6. Discrepancies (if any) from the reported data and document of the sample data.
84
12.6. Pro-forma verification for Thermal Power Plant ............................................................84
12.7. SEC Quantification ...........................................................................................................85
12.7.1. Relationship with the energy saved from the energy saving projects
implemented and difference in SEC between baseline and assessment year. ........................85
12.7.2. List of energy savings projects with description in brief and photographs...........85
12.7.3. Brief description of Energy savings measures ........................................................96
13. N orma l iz a tion F a ctors ................................ ................................ ...... 143
13.1. External Factors Identified by DC for normalization ....................................................143
13.2. Additional Factors to be considered in assessment year with proper justification,
calculations and documentation for its externalities ..................................................................144
13.3. Undertaking of DC for non-availability of data for normalization factors ..................145
14. Ga te - to-ga te boun da ry di ag ra m ........................................................ 146
14.1. Energy, Product and Raw material inclusion and exclusion ........................................146
14.2. Colony, Mines, and other activities inclusion and exclusion .......................................146
14.3. Gate-to-gate boundary diagram ...................................................................................147
15. Co nclu si on s & R ecom mend ati ons ................................ ...................... 148
16. Docu me nta tio n ................................ ................................ ................ 149

16.1. Energy & Mass Balance Reports....................................................................................149

16.1.1. Quarterly, Annual & EOC Reports..........................................................................149
16.1.2. Annual Production & Material Consumption Report ...........................................150
16.1.3. Annual Energy Consumption Report .....................................................................152
16.1.4. Annual Generation, Consumption & Export Report .............................................164
16.2. Quality Reports...............................................................................................................165
16.2.1. Fuel Quality Internal Reports .................................................................................165
16.2.2. Fuel Quality External Reports ................................................................................166
16.2.3. Raw Material Quality Reports ................................................................................172
16.3. Normalization Reports ...................................................................................................173
16.3.1. Documentary Support for Normalization Factors ................................................173
16.4. Log sheets .......................................................................................................................177
16.4.1. Sample Electrical consumption data log sheet .....................................................177
16.4.2. Sample Fuel Consumption & Production data log sheet ....................................177
16.5. Calibration Certificates ..................................................................................................178
16.6. Work-orders & Job Cards for Energy Saving Measures ...............................................182
17. Annexures ................................ ........................................................ 232
17.1. Form-1 ............................................................................................................................233
17.2. Sector Specific Pro-forma with Annexures ...................................................................234
17.3. Summary Sheet ..............................................................................................................241
17.4. Copy of Form-A ..............................................................................................................243
Copy of Form-B & Undertaking ....................................................................................................244
17.5. Normalization Calculation Sheets .................................................................................246
17.6. Verification Report Acceptance letter from DC............................................................254
17.7. Declaration ...........................................................................
17.8. Work order copy ............................................................................................................255

1. Empanelled Accredited Energy Audit

Firm
1.1. Name of the Firm
ELECTRICAL RESEARCH & DEVELOPMENT ASSOCIATION (ERDA)
1.2. Registration Number of the Firm

Em-AEA 058
1.3. Address
Electrical Research & Development Association
ERDA Road,
Makarpura Industrial Estate,
Vadodara – 390010
1.4. Undertaking
ERDA hereby assures that neither the council nor the members associated
with the M&V audit have been involved in conducting Mandatory Energy
Audit at Shree Cement Ltd., Ras unit during the last four years.
1.5. Accredited Energy Auditor (Team Leader)

Mr. Bhavesh T. Vasiyani
Dy. Manager & Head, Energy Management Section
ERDA
Accredited Energy Auditor (AEA-0016)
Mobile: 7574850913
E-mail: bhavesh.vasiyani@erda.org

1.6. About EmAEA

Electrical Research and Development Association (ERDA), a not-for-profit
professional Organisation, registered under societies act and Public Trust
formed under the Charity Commissioner of Maharashtra, was promoted by
the Electrical industries and some Utilities with support from Government
of India through CSIR and grant given by the Government of Gujarat
in March 1974. ERDA was established at Vadodara on the land provided by
Gujarat government free of cost. ERDA is routinely audited by
Comptroller and Accountant General (Gujarat) for utilization of funds
sanctioned by the Government for various infrastructure and R&D projects.
ERDA’s services are provided under three business verticals namely “Testing
& Evaluation”, “Field Services”, and “R&D and Expert Services”. ERDA
operates from its state-of-the-art 25 acre head office located at Makarpura,
Vadodara and three site laboratories – ERDA (North) at Gurgaon, ERDA
(West) at Rabale & ERDA (South) at Rajahmundry to serve customers
spread across various geographical locations in India.
The Energy Management Section (EMS) of ERDA was established in the year
1995 with the objective of providing energy conservation services to the
Nation. The energy audit studies undertaken by the EMS have covered
Industries, Power Generation Utilities, Power Distribution Utilities, Fertilizer
Plants, Iron & Steel Industries, Refineries and Petrochemical Industries,
Manufacturing Industries, Chlor-Alkali Plants, Railway Workshops, Chemical
Industires, Pumping Stations, Dairies, Municipal Corporations, Commercial
Buildings, Hospitals, etc.
EMS has carried out more than 300 energy audits until now and the benefits
realized by our esteemed clients by implementing our recommendations are
quite handsome. Over the years, EMS has specialized in energy conservation
related to conventional fuels such as coal, oil & gas.

E MS Carri es m and at ory PAT E n ergy Au di t , M&V Au di t f or PAT

cyc le, Proc ess Au dit , Heat and Ma ss bal anc e ca lcu l ati on , T he rmal
In sul at ion Au di t, Ill um in at ion Su rvey, et c.

2. Designated Consumer
2.1. Name
Sh ree C em ent L t d., Beaw ar Un i t
2.2. Sector
Ce men t - PPC
2.3. PAT Registration No.

CMT 00 1 9R J
2.4. Address
Ban agu r Na gar, Beaw a r, Ajme r, R ajast h an - 3 90 0 45
2.5. Energy Manager

Sh ri Sanja y Si ng h , Sr.Man ager
2.6. Authorized Signatory

Sh ri P .N.Ch h ang an i, Wh ol e Ti me Direc to r
Sh ree C em ent L t d.,
Ban agu r Na gar, Beaw a r,
Ajm er, Rajas th an - 3 90 0 45
2.7. Introduction to DC
Shree Cement Limited is an India-based cement manufacturing company.
The Company is engaged in the manufacturing of cement and power
generation. The Company operates business through two segments, which
include Cement and Power. The Company markets its cement products
under Shree Ultra Red Oxide, Bangur Cement and Rockstrong Cement

brands. The Company has a power generation capacity of over 499

megawatts and waste heat recovery power plants of 126 megawatts
capacity. The Company’s power plant and waste heat recovery units are
located at Beawar, Ras & Raipur. The Plant Cement Capacity and Location is
mentioned in table below:
Clinker Capacity Cement Capacity

Location
mTPA mTPA
Beawar 3.27 4.55
Ras 15 8.8
Raipur 5.2 3.0
Kodla - 4.0
Khushkhera - 4.5
Suratgarh - 2.0
Roorkee - 2.0
Jaipur - 2.0
Panipat - 1.5
Aurangabad - 9.0
Bulandshar - 3.0
Total 23.47 43.76
The power profile of Shree group is:
Location Total Generation Capacity (MW)

Beawar (TP) 344
Ras (TP) 136
Raipur (TP) 19
Beawar Ras & Raipur (GP) 126
Total 625
Abour Beawar Unit:
Shree Cement Beawar is an integrated cement manufacturing plant located

in Beawar, Rajasthan. The plant has two cement production units. Plant also
possesses Flue gas de-sulphurisation unit, CPP and Waste heat recovery unit
as well. The plant is producing PPC as the major product.

2.8. Recent Awards received by DC

Constant endeavor of the designated consumer for reducing the specific
energy consumption per MT of equivalent cement production, reducing the
carbon footprint of the plant, improving the process of the unit and
addressing the environmental concerns has been recognized at various
portal, leading to the DC and its various units receiving the following awards
recently:
Performance, Achieve and Trade Award by Bureau of Energy Efficiency

2017.
Rajasthan Energy Conservation Award 2017 by Department of Energy,

Government of Rajasthan
Best Quality Excellence Award 2015-16 & 2016-17 by NCCBM
Best Improvement in Thermal Energy Performance Award 2015-16 by

NCCBM
2.9. Highlights of DC
1. SCL has been ranked 2nd best company in carbon related metrics in a
report released by CDP – analyzing world 12 largest cement
companies collectively worth $ 120 billion.
2. Lowest specific water consumption in the plant
3. Highest 5-star rating by International Benchmarking firm

Whitehopleman, UK. This is the first time that any cement factory in
the world has attained 5 star status in the Whitehopleman star ranking
system during the 18 years of Whitehopleman independent cement
factory benchmarking

4. 5 Star rating for Beawar limestone mines for sustainable development

formulated by Indian Bureau of Mines, Ministry of Mines, Government
of India

3. Background
Energy conservation is an optimal operational practice, which improves the

efficiency of the equipment and process associated with both supply side and
demand side i.e. at the user end.
Perform Achieve and Trade (PAT), a flagship initiative under National Mission
for Enhanced Energy Efficiency (NMEEE), is a regulatory intervention for
reduction of specific energy consumption, with an associated market based
mechanism through which additional energy savings can be quantified and
traded as ESCerts.
Perform, Achieve & Trade (PAT) is a market based mechanism to make

improvements in energy efficiency in energy-intensive large industries and
to make facilities more cost – effective by certification of energy saving that
can be traded.
Cement sector is one of the 11 notified energy intensive sectors under which
a total of 111 plants are participating in this program. These plants have
been mandated to reduce their Specific Energy Consumption (SEC) from
baseline year of 2014-2015.
3.1. Objective
The monitoring and verification (M&V) system is very significant part of PAT
Scheme of Bureau of Energy Efficiency.
Independent evaluation of each and every activity carried out by designated

consumer to reduce its specific energy consumption, needs to be verified.

The objective of this M&V process is to ensure:
1. The data provided in Form-1 and Pro-Forma are free from any material
or energy omissions, mis-interpretations, mis-representations, etc.
and other errors.
2. The energy performance declared by the DC is accurate by considering

various normalization other relevant factors as defined by the PAT
rules.
3. There is consistency, transparency and traceability of the data.
3.2. Purpose of Verification Report

This verification report serves purpose to provide the details of sources of
verification of various data provided in Form – 1; as well as the data that are
verified which are required for the fulfillment of PAT Cycle II.
This report also serves the purpose of verification of calculations of

normalization carried out for the quantity of Es-certs that can be possibly
awarded subject to the fulfillment of the norms of PAT Cycle II
This report also verifies the measured data and the validity of the measured
data, basis on which the quantity of Es-certs has been calculated and the
qualification of the DC to avail the Es-certs.

4. Approach, Scope & Methodology
This section contains the details of the scope, approach and methodology
involved in carrying out the M&V Audit of Shree Cement Ltd., Beawar Unit
4.1. Work Order

Shree Cement Ltd., Beawar unit has expressed the desire to carry out M&V
audit for PAT Cycle-II of energy consumption data and submission of
relevant reports and documents to BEE in accordance with PAT rules.
A c opy of t h e w ork o rder i ssu ed b y Sh ree Cem en t Lt d. , Be awar

U ni t is att ac hed in pa rt 17 .9
4.2. Period of Verification

The M&V audit was carried out from 24th June, 2019 to 29th June, 2019.
4.3. Composition of Team

Following team members of Electrical Research & Development Association
have been involved in M&V Audit.
The team structure is as follows:
EM/EA
Sr. Team
Name Registration Qualifications Experience
No. Role
Number
B.E. (Electrical Engineering)
Bhavesh Team M. Tech. (Energy
1. AEA-0016 14 Years
Vasiyani Lead Management)
Accredit ed Energy Auditor
Sector
2. J. K. Jain B.Sc. (Chemistry) 35 Years
Expert
Diploma (Cement
Technology)
Arunesh Team
3. AEA-0288 B.E. (Chemical Engineering) 12 Years
Dwivedi Member
M. Tech (Energy
Management)

Accredit ed Energy Auditor

Kuldeep Team B.E. (Electrical Engineering)
4. EA-29539 6 Years
Ruparelia Member Certified Energy Auditor
4.4. Activities carried out for M&V Audit

The schedule of the activities carried out during M&V process is as follows:

M an -
S teps Des cr ipt ion T a sk s
hou rs
Methodology Description 08
Presentation by DC 08
1 Kick-off Meeting Plant Visit 08
Collection of Data 08
Finalization of Audit Dates 01
Data Sorting 04
Data Analysis 04
2 Back Office Work
Preparing Checklist 04
Preparing the list of documents required 04

Physical Verification of Data from respective
04
documents
Document Verifying Data with log books 08

3
Verification
Verifying bills of materials and energy 08
Verification of Calibration Certificates 08
Understanding Process Plant 10
4 Plant Visit Validation of Data from DCS Value 10
Verification of EnCon Activities 10

Validation of Dat a in various Forms with TOP and
08
other documents
Validation of Calculations carried for various data 06
5 Data Validation Verification of Normalization data 06
Validation of Baseline data 06
Verification of Form-1 data 06
Validation of ES-Certs 08
Conclusion of Audit 04
6 Closing Meeting
Discussion of further actions 04
Presentation 08
Total Man-hours 163

4.5. Minutes of Meeting with Plant and

Verification Team
The copy of minutes of meeting between plant and verification team is
attached below:
4.6. Checklist Prepared by EmAEA

The PAT M&V guidelines issued by BEE are used as a check list for PAT M&V
audit. In addition, verification report format provided by BEE is also referred
to meet the requirements for conducting audit and colleting the data from
DC industries.
Th e d et ail ed li st of t he d ocu m ent s verifi ed is as fol low s:
Sr. No. Resource List
1. Plant Process description
2. Design specification documents
3. Environment concern to operate reports
4. ERP Data for Production
5. ERP Data for Energy Generation
6. Internal Test reports for energy efficiency
7. Daily Production reports
8. Internal Lab report s for fuel and mat erial testing
9. External Lab reports for fuel testing
10. Fuel Receipt and inventory reports
11. Calibration Certificates of various measuring instruments
12. Baseline Report/M&V Report for previous PAT Cycle
13. Mandatory Energy Audit Report of PAT Cycle-2
14. P.O. of ENCON activities implemented
15. Logbooks related to various process
16. Plant DCS Dat a
17. Monthly reports submitted to BEE

18. Quart erly reports submit ted to BEE
19. Annual reports submitted to BEE
20. End of Cycle report submitted to BEE
21. Form 2, Form 3, Form 4 of MEA
22. Form 1
23. Form A
24. Sector specific Pro-forma
25. Normalization related document s
26. Form B

5. Baseline & Assessment Year Scenario
5.1. Plant Capacity

The plant capacity was increased from the baseline year (2014-15) to the
assessment year (2018-19). The Environmental clearance for the expansion
of the capacity under the provisions of EIA Notification 2006. The activities
were listed at Sl. No. 3(b), ‘Cement Plants’ under category ‘A’ of the
Schedule of EIA Notification 2006 and apprised by at central level.
The clearance were received on 14th May, 2018 via letter F(CPM)/ Ajmer
(Masuda)/ 1 (1)/ 2010-2011/ 889-891 from Rajasthan State Pollution
Control Board Head Office (CPM) for power plant, the letter F(Tech)/Ajmer
(Beawar)/ 4 (1) /2008-2009 6873-6875 dated 31st October, 2017 for Unit 1
and the letter F (CPM)/ Ajmer (Mansuda)/ 1(1)/ 2010-2011/ 6975-6977
dated 3 rd November, 2017 for Unit 2.
The detail of the expanded projects is as follows:
Project Capacity
Upgraded Capacity
as per Baseline Consent to operate
during Assessment
Data of Year granted by RSPCB
Year 2018-19
2014-15
Clinker
Production 7050 4000 + 5500
(TPD)
Cement
Production 7200 6000 + 7200
(TPD)
Waste Heat
Recovery
21 78
Generation
(MW)
Thermal Power
NA 300 NA
Plant (TPP)
Captive Power
44 44 MW + 3 MW
Plant
TABLE 5.1INSTALLED CAPACITY OF PLANT IN BASELINE & ASSESSMENT YEARS

5.2. Plant Production

The production data for Baseline year and Assessment year is as follows:
S. Baseline Assessment
Particulars Unit
No Year Year
(2014-2015) (2018-2019)
1 Production Capacity (Clinker) Tonne 2573250 3270000
2 Production Capacity (Cement) Tonne 2625000 4550000
3 Total Clinker Production Tonne 1976086 2092205
4 Total Cement Production(All varieties) Tonne 2107898 1735802
5 Capa city Utilization (Clinker) % 76.79 63.98
6 Capacity Utilization (Cement ) % 80.30 38.15
7 OPC Production Tonne 611915 631252
8 PPC Production Tonne 1495983 1104550
9 PSC Production Tonne 0 0
10 Composite Cement Production Tonne 0 0
11 Clinker Exported Tonne 1012069 818945.03
12 Clinker Imported Tonne 539229 0
13 Clinker Fact or for OPC Fraction 0.890 0.883
14 Clinker Fact or for PPC Fraction 0.605 0.5786
TABLE 5.2 PRODUCTION IN BASELINE & ASSESSMENT YEAR
The production data can be represented graphically as:
C HART 5.1. P RODUCTION DURING BASELINE AND ASSESSMENT YEAR AT SHREE CEMENT
LTD., BEAWAR UNIT

The share of PPC production to total production in Assessment Year is as

follows:
C HART 5.2. SHARE OF PPC PRODUCTION DURING ASSESSMENT YEAR AT SHREE CEMENT
LTD., BEAWAR UNIT

5.3. Energy Consumption

The energy consumption by DC during baseline year and assessment year
for PAT Cycle 2 is as follows:
Baseline Assessment
S. No Particulars Unit
Year Year
1 Electricity Consumption
1.1 Total Electricity Purchased from grid/ Other Lakh kWh 724.46093 0
2 Through Captive Power Plant (Grid Connected)
2.1 Installed Capacity MW 44 44
2.2 Annual Gross Unit generation Lakh kWh 1827.45497 713.26367
2.3 Auxiliary Power Consumption % 6.81 7.647
3 Through Waste Heat Recovery
3.1 WHR Installed Capacity MW 21 21
3.2 Annual Generation Lakh kWh 955.76341 943.69536
4 Power from dedicated Line
4.1 Power Wheeled through dedicated line MW 0 0
4.2 Annual Wheeled Electricity Lakh kWh 22.62095 612.43
5 Total
5.1 Total Own Generation of Electricity Lakh kWh 2805.84 2270.48
5.2 Electricity Exported to Grid/others Lakh kWh 1337.19914 252.15064
5.3 Electricity Supplied to Colony/others Lakh kWh 26.10668 59.3501
Electricity Supplied to Grid/Colony/others
5.4 Lakh kWh 1337.19914 311.50074
from CPP
5.5 Total Aux Power Consumption of CPP % 6.81 7.65
Equivalent Thermal Energy supplied to
5.6 Million kcal 363317.0063 84634.75106
grid/others
5.7 Total Electricity Consumed Lakh kWh 2166.99444 1958.97887
T ABLE 5.3 ELECTRICAL E NERGY G ENERATION & C ONSUMPTION DURING BASELINE &
ASSESSMENT Y EAR

Sl. Assessment
Particulars Unit Baseline Year
No Year
1. Pet coke
1.1 Average Gross calorific kcal/ kg 7707 0
1.2 Quantity used Tonne 42783 0
1.3 Energy Used Million kcal 329723.333 0
2. Coal(Imported)
2.1 Average Gross calorific value kcal/ kg 6856 7055.08
2.2 Quantity used Tonne 36553 31838
2.3 Thermal Energy Used Million kcal 250590.585 224619.63
4. Waste Generation From CPP( AFBC/CFBC Boiler)
4.1 Average Gross calorific value kcal/ kg 0 0
4.2 Total Quantity Consumed Tonne 0 0
4.3 Thermal Energy from Waste in Power Plant Million kcal 0 0
5. Liquid Waste: Tire Oil
5.1 Gross calorific value kcal/ kg 0 0
5.2 Average Density kg/lt r 0 0
5.3 Quantity used (DG Set) kilo Liter 0 0
5.4 Quantity used (CPP) kilo Liter 0 0
5.5 Thermal Energy Used (DG Set) Million kcal 0 0
5.6 Thermal Energy Used (CPP) Million kcal 0 0
6 Total Thermal Energy Used Million kcal 580313.918 224619.63
8. Heat Rate
8.1 Gross Heat Rate of DG Set kcal/kWh 0 0
8.2 Gross Heat Rate of CPP (St eam Turbine) kcal/kWh 3175.530601 3149.180863
8.4 Weighted Heat Rate kcal/kwh 3181.179575 2989.161898
T ABLE 5.4 FUEL CONSUMPTION FOR POWER GENERATION IN CPP DURING B ASELINE &
ASSESSMENT Y EAR

S. Assessment
Particulars Unit Baseline Year
No Year
1. Pet coke
1.1 Average Gross calorific value (Kiln) kcal/ kg 7883 7690.07
1.2 Quantity used for process (Pyro) Tonne 161244 198390
1.3 Thermal Energy Used in Process Million kcal 1271054.126 1525633.536
2. Coal(Imported)
2.1 Average Gross calorific value (Kiln) kcal/ kg 0 0
2.2 Quantity used for process Tonne 0 0
2.3 Thermal Energy Used in Process Million kcal 0 0
3. Coal 4 (Other Solid Fuel)
3.1 Average Gross calorific value (Kiln) kcal/ kg 0 0
3.2 Quantity used for process Tonne 0 0
3.3 Thermal Energy Used in Process Million kcal 0 0
4. Bio mass or Other purchased Renewable solid fuels: bagasse, rice husk, etc.
4.1 Average Gross calorific value as fired kcal/ kg 6394.11
4.2 Quantity used for process heating Tonne 43699.4 0
4.3 Thermal Energy Used in Process Million kcal 279418.8751 0
5. Solid Waste: rubber Tires chips, Municipal Solid wast e etc.
5.1 Average Gross calorific value as fired kcal/ kg 5854 0
5.2 Quantity used for process heating Tonne 64.7 0
6. High Speed Diesel (HSD)
6.1 Gross calorific value kcal/ltr 9783 0
6.2 Quantity used for process heating kilo Liter 4.185 0
7. Liquid Wast e : Tire Oil
7.1 Gross calorific value kcal/ltr 10200 10200
7.2 Quantity used for process kilo Liter 181 279.26
8. Liquefied Petroleum Gas (LPG)
8.1 Gross calorific value kcal/kg 12500 12500
8.2 Quantity used for process heating Million kg 0.00044595 0.002565
8.3 Total LPG Consumption as fuel Million kg 0.00044595 0.002565

9. Total Thermal Energy Used in Process Million kcal 1271100.642 1525665.598

TABLE 5.5 FUEL CONSUMPTION IN PROCESS DURING BASELINE & ASSESSMENT YEAR
Baseline Assessment
S. No Performance Indicators Unit
Year Year
1. Thermal SEC kcal/kg Clinker 785 729.2
2. Electrical SEC (up to Clinkerization) kWh/Tonne Clinker 57.6 57.7
3. Electrical SEC (Cement Grinding) kWh/Tonne Cement 33.57 34.73
4. Additional Electrical Energy Consumed Lakh kWh 10.94
5. Additional Thermal Energy Consumed Million kcal 279418.8751
TABLE 5.6 FUEL P ERFORMANCE I NDICATORS DURING B ASELINE & ASSESSMENT YEAR
The Comparison of Electrical & Thermal Specific Energy Consumption for

Clinkerization process and Electrical Energy Consumption for Cement
grinding process can be represented in the chart as:
C HART 5.3 S PECIFIC T HERMAL & ELECTRICAL ENERGY C ONSUMPTION FOR CLINKERIZATION
PROCESS IN B ASELINE & ASSESSMENT YEARS

CHART 5.4 SPECIFIC ENERGY C ONSUMPTION FOR C EMENT GRINDING PROCESS IN

BASELINE & ASSESSMENT Y EARS
From the above data and curves, it is clear that the specific energy
consumption in Clinkerization process has been increased nominally.
The gate to gate energy comparison between baseline year & assessment
year is as follows:
Baseline Assessment
S.
Gate to Gate SEC Unit Year Year
No.
(2014-15) (2018-19)
Gate to Gat e kcal/kg of equivalent
1 561.79 569.51
Specific Energy Consumpt ion Cement
Gate to Gat e toe/tonne of equivalent
2 0.0562 0.0570
Specific Energy Consumpt ion Cement
TABLE 5.7 GATE TO GATE SPECIFIC E NERGY C ONSUMPTION DURING BASELINE YEAR &
ASSESSMENT Y EAR
The gate-to-gate specific energy consumption during baseline year and

assessment year can be represented as:

C HART 5.4 G ATE TO G ATE SPECIFIC ENERGY CONSUMPTION FOR DC IN BASELINE &
ASSESSMENT YEARS
5.4. Inclusion and Exclusion for baseline and

assessment year.
To comply the environmental norms following changes were carried in the
plant.
Instead of existing ESP in Raw mill in Kiln 2, Bag house was installed. Hence,
the existing ID fans of 710 kW were to be replaced by Raw mill Bag House
Fans of 1000 kW.
Sr Date of
Equipment Name Section
No Commissioning
1 Installation of Bag House in place of Raw Mill ESP Kiln 2 27-June-2016
2 Stopped Utilization of Alternative Fuel Pyro 2015 Onwards
TABLE 5.8 INSTALLATION OF NEW EQUIPMENT DUE TO MANDATORY ENVIRONMENTAL
NORMS
As per the guidelines of Bureau of Energy Efficiency, earlier Carbon Powder

which was in baseline year considered as alternative fuel, is not considered

as alternative fuel anymore. Hence, the DC has stopped consuming carbon

powder anymore.
After stopping usage of Carbon powder as an alternative fuel, the DC

required Normalization of 279418 Million kcal/ Annum
The change in energy consumption due to inclusion of these equipment is as

follows:
Base Line Assessmen

Year 2014- t Year Difference
Equipme
Sl. 15 2018-19 Electricity
nt Serial Sectio
No Equipment Name Electricity Electricity Consumpti
No n
. Consumpti Consumpti on (lakh
on (lakh on (lakh kWh)
kWh) kWh)
Bag House Raw Mill
1 229 FN 1 Kiln 2 30.02 40.96 10.94
Kiln 2
TABLE 5.9 ADDITIONAL E NERGY CONSUMPTION DUE TO INSTALLATION OF NEW EQUIPMENT

DUE TO MANDATORY ENERGY NORMS
Unit Equipment Name Equipment Section Date of Electrical Electrical Running Running
Serial No Commissioning Rated Rated Load Load
Capacity Capacity 2014-15 2018-19
2014-15 2018-19
Date kW kW kW kW
Raw Mill 2 Bag House

710 1000 383 703
1 Fan 229 FN 1 Kiln 2 27.06.2016

6. Reports Submitted by DC
6.1. Monthly, Quarterly, Yearly & EOC reports

submitted by DC
The DC has submitted Yearly reports to Bureau of Energy Efficiency as form-
1. They are attached as Annexure 17.1
6.2. Performance on Energy Consumption &

Production Process
From the Form -1 submitted by DC in during various monitoring years as
well as assessment year and base line year, the performance of production
and energy consumption is as follows:
Baseline Year Assessment Year

Parameters
(2014-15) (2018-19)
Total Cement Production (MT) 2107898 1735802
Total Normalized Energy Consumption (TOE) 233638.9 168615.82
Total Equivalent Product (lakh MT) 41.59 34.58

GTG Sp. Energy Consumption without
0.0562 0.0570
Normalization (TOE/Tonne)
The specific energy consumption has been increased from 0.0562

TOE/Tonne of equivalent product to 0.0570 TOE/Tonne of equivalent
product, if no normalization is considered.

6.3. Production & Energy Consumption of

Assessment Year
The production and energy consumption of Assessment year is already been

discussed in Chapter 5.

7. Measuring Equipment &

InstrumentCalibration
7.1 List of major measuring equipment and

calibration status
Major measurements required for the analysis of the performance of the
plant are as follows:
Other measurements that does not affect gate-to-gate specific energy

consumption is as follows:

Th e c ali bration of al l el ect ri cal an d m ech an ica l eq ui pm en t i s

carri ed out at in t erval of eve ry t wo years.
Th e c ali bration c erti fi cat es are at tac hed i n Appe nd ix.

7.2. Measurement procedures & methods

Standard measurement principles are applied for measurement of energy
and mass flow. The stocks are recorded every day for recording
consumption and production of materials. Electrical measurements are
recorded in digital format in control system. The data can be downloaded as
and when required. The interval of recording depends upon the requirement
of user.

8. Energy Scenario in Assessment Year
8.1. Energy Scenario

The energy scenario in assessment year can be described in the following
table.
Particulars Unit Value

Energy Details
Total Thermal Energy Consumption Million kcal 1921936.91
Total Electricity consumed within the plant Lakh kWh 1958.98
Electricity Purchased from Grid Lakh kWh 0
Electricity Exported to Grid/Colony/Others from CPP Lakh kWh 311.5
Total Energy Consumed (Thermal + Elect rical) Million kcal 1815717.06
Performance Indicators
Thermal SEC kcal/kg Clinker 729
Electrical SEC (up to Clinkerization) kWh/Tonne Clinker 57.7
Electrical SEC (Cement Grinding) kWh/Tonne Cement 34.7
8.2. Electrical Power Generation

Electrical power generation in Beawar unit is done in two ways:
1. By firing conventional fuels along with alternate fuels to generate energy

to produce steam in boiler that runs turbine which inturn rotates Generator
to generate electrical energy.
This is done in Captive Power Plant (CPP)
2. Steam is produced using waste heat of flue gases in Waste heat recovery
boilers. The steam, thus generated rotates turbine which inturn rotates
Generator to generate electrical energy.
This is done in Green Power Plant (GPP).

8.2.1. Captive Power Plant

The energy scenario of captive power plant is as follows:
Own Generation
Through DG sets
Grid Connected Yes/No Yes
Installed Capacity MW 4.8
Annual Gross Unit Generation Lakh kWh 0
Designed Gross Heat Rate kcal/kWh 0
Running Hours Hrs 0
Through Steam turbine/ generator

STG 1
Grid Connect ed Yes/No Yes
Installed Capacity MW 44
Annual Gross Unit generation Lakh kWh 713.26367
Auxiliary Power Consumption % 7.647
Design Gross Heat Rate kcal/ kWh 2698.9
The gross heat rate is calculated as the ratio of gross energy generated to
the total energy consumed for a particular year. The gross heat rate of the
unit is 3149.180863 kcal/kWh, while the weighted heat rate is 2989.161898
kcal/kWh which considers the effect of the electrical energy generated by
WHRB discussed in next topic.
8.2.2. Waste Heat Recovery and Generation

In the cement manufacturing unit pyro-processing/clinkerization is one of
the most energy intensive process. Clinkerization process takes place at
about 1400-1450 º C, hence flue gases generated during the clinkerization
process contains very high amount of thermal energy. Earlier the waste
gases of clinkerization process (exit gases of the Pre-heater and Clinker
cooler) were wasted to the atmosphere. The pre heater exit gases were sent
to the Gas Conditioning Tower (GCT) and a part of the pre heater waste
gases is being sent to the raw mill and coal mill for pre heating. From the
GCT the exit gases were wasted in the atmosphere, exit gases of clinker

cooler were sent to an Electrostatic Precipitator (ESP) and wasted in the

atmosphere. In order to utilize the waste heat, SCL has installed capacity of
21 MW Waste Heat Recovery based power generation unit.
The technology used for the Waste heat recovery is utilizing the waste heat
of the waste /exit gases of PH and AQC to generate electricity. The
schematic diagram of the WHR system with before and after scenario is
given figure 8.1 and 8.2.
P re -P roj ect S ce nar io Flo w sheet
Flue gas ses from P re-heater

1
P reheater
Hot gas
K iln feed
GC T
K iln Cooler
4
E S P F an
COOLER ESP
Clinker
from K i ln 3
Flue gass es to P H fan To CM as Clinker Cooler
a fil ler
PH
To RM /Coal 2
M ill /Main ESP
S . no. Des c ription

1 P H ex it
2 P H fan inlet
3 A QC inlet
4 CV fan inlet
Figure 8.1 Pre WHRB

Figure 8.2 Post WHRB Installation
The energy generated in GPP is as follows:
Particulars Unit Assessment Year

Through Waste Heat Recovery
WHR Installed Capacity MW 21
Annual Generation Lakh kWh 943.69536
Total Energy Generated, Consumed & Export
Total Own Generation of Electricity Lakh kWh 2770.48
Electricity Exported to Grid/others Lakh kWh 252.15064
Electricity Supplied to Colony/others Lakh kWh 59.3501
Electricity Supplied to Grid/Colony/others from CPP Lakh kWh 311.50074
Total Aux Power Consumption of CPP % 7.64
Equivalent Thermal Energy supplied to grid/others Million kcal 84634.75106
Total Electricity Consumed Lakh kWh 1958.97887

8.3. Process Thermal Energy System &

Utilization
Th e t h erm al e nerg y u ti li zed i n proc ess i n form of vario us fu el fo r
vari ous app li cati on is di scu ssed in ch apt er 5 .
8.4. Share of Energy Consumption

The total energy used in the plant in the previous year is as follows:

Total Thermal Energy Used in CPP Million kcal 224619.63
Total Thermal Energy Used in Process Million kcal 1525633.536
Weighted Heat Rate of Plant kcal/kWh 2989.161898
Total Electricity Consumed in Plant
Million kcal 585584.28
(Process)
The percentage share of the energy in process is as follows:
C HA RT 8 .1 S HA RE OF E NER GY C ON SUMPTION IN P ROCESS
The percentage share of thermal energy used in power plant and fuel is as
follows:

C HA RT 8 .1 S HA RE OF T HER MAL E NER GY C ON SUMPTION IN P ROCESS & CP P
The share of energy from various fuel is as follows:

Energy from Pet coke in Process Million kcal 1525633.54
Energy from Coal in Process Million kcal 0
Energy from Coal in Power Plant Million kcal 224619.63
Energy from Solid Waste in Process Million kcal 0
Energy from Liquid Waste in Process Million kcal 2649.042
Energy from Liquid Waste in Power Plant Million kcal 0
Energy from LPG in Process Million kcal 32.06
Total Energy in Process Million kcal 1525665.598
Total Thermal Energy in Power Plant Million kcal 224619.63
* E NER GY F RO M W AS TE IS NO T CONSID ERED IN TOTAL THERMAL ENERGY .

8.5. Production
Th e p rod uct i on det ai ls are al read y d isc uss ed i n Ch apt er 5 .
8.6. Specific Energy Consumption

The specific energy consumption for clinker as intermediate product and for
cement as final product is as follows:
a Thermal SEC for Clinker kcal/kg Clinker 729

b Electrical SEC (up to Clinkerization) kWh/Tonne Clinker 57.7
c Electrical SEC (Cement Grinding) kWh/Tonne Cement 34.7
8.7. Gate-to-Gate Analysis before Normalization

The gate-to-gate analysis before normalization is as follows:
Not ional Energy Required for grinding of

a Million kCal 153689.02
exported Clinker
Not ional Energy Required for clinkerization
b Million kCal 0
of imported Clinker
c Not ional Energy for Purchased Power Million kCal 0
d Gate to Gat e Energy Consumption Million kCal 1969406.08
kcal/kg of equivalent
e Gate to Gat e Specific Energy Consumption 569.51
Cement
toe/tonne of equivalent
f Gate to Gat e Specific Energy Consumption 0.0570
Cement

9. Energy Scenario in assessment year for

Thermal Power Plant
The plant does not have any thermal power plant, other than Captive plant.

10. Process and Fuel Description
10.1. Introduction to Process

Cement is a material which is highly compatible to the earth's eco-system
and most adaptable to sustainable development. Cement is a fine powder
which sets after a few hours when mixed with water, and then hardens into
a solid, strong material. Cement is mainly used to bind fine sand and coarse
aggregates together in concrete. Cement is a hydraulic binder, i.e. it
hardens when water is added to cement powder. Joseph Aspdin, a Leeds
Builder and bricklayer had invented the Portland cement in 1824. In this
process, Aspdin mixed and ground hard limestone and finely divided clay
into the form of slurry and calcined it in a furnace similar to a lime kiln, till
carbon di oxide was expelled. The mixture so calcined was then ground to a
fine powder & was used as Portland cement. The name Portland was given
owing to the resemblance of this hardened cement paste to the natural
stone available at a place called Portland in England.
In India Portland cement was first manufactured in 1904 near

Madras,(Chennai) by South India Industries Limited and later developed by
The Indian Cement company limited in 1914.
10.1.1 Ra w Mat erial in Ce men t Ma nufa ct uring

1) Limestone :- Contains predominantly calcium carbonate (CaCO3) and to
use in cement manufacture, it should have 42-43% lime (CaO) minimum. In
cement manufacture it is prime raw material and its usage would be 90-
93%.
(2) Clay :- It contains more of silica (SiO2) and its usage should be 2 to 3%
in cement manufacture.
(3) Bauxite :-It contains alumina (Al2O3) and it's usage should be 2 to 3%
in cement manufacture.
(4) Iron Ore :- It contains mainly iron oxide (Fe2O3) and it's usage should
be 1 to 2% in cement manufacture.
The raw materials mix composition would be 90-93% limestone, 2-3% clay,
2-3% Bauxite, 1-2% Iron ore in cement making.
Fuel :- Coal is used for burning the raw mix in powdered form. Normally
both imported and indigenous coal are used, coal is being imported from
mainly South Africa, Australia etc. because of low ash content.
Pet coke is also used as fuel while manufacturing of cement.
10.1.2 V ar ious St ep s Involv ed in Cem ent Ma nufa cturing

The various steps involved in cement manufacturing are as follows:
1) Mining of limestone
2) Raw material preparation / raw mix preparation:
a) Crushing
b) Homogenization
c) Proportioning of raw materials
d) Grinding
e) Storing and Blending
3) Burning of raw mix
4) Clinker grinding along with gypsum
a) Grinding
b) Storing
c) Packing

RAW MATERIAL PREPARATION:
The prime raw material limestone after blasting in mines is broken into big
boulders. Then it is transported by dumpers to limestone crusher where it is
crushed to 15 to 20mm size.
STACKING/RECLAIMING:
After crushing, the crushed limestone is piled longitudinally by an equipment

called stacker / reclaimer. The stacker deposits limestone longitudinally in
the form of a pile. The pile is normally 250 to 300 m long and 8-10 m high.
The reclaimer cuts the pile vertically, simultaneously from top to bottom to
ensure homogenization of limestone.
The crushed limestone from pile is transported through belt conveyor to

hopper. Similarly, other raw materials like clay, bauxite, iron ore etc. are
also transported by belt conveyor from storage yard to respective hoppers.
All raw materials are proportioned in requisite quantity through weigh
feeders. The proportioned raw materials are transported by belt conveyor to
Raw Mill for grinding into powder form. After grinding, the powdered raw
mix, is stored in a raw meal-silo where blending takes place. Blending is
done by injecting compressed air. This powdered material (Raw mix) is fed
to the kiln for burning and Coal also requires homogenization as it contains
different ash.
BURNING:
The powdered raw mix is fed into 4 to 6 stage preheater from top by air
pressure. The hot gases from kiln enters preheater from bottom. The
powdered raw mix slides down through cyclones and comes in contact with
hot air which travels from top to bottom. In preheater the temperature of
raw mix rises to 900ºC to 1000ºC and nearly 90% Calcination (removal of
CO 2 from CaCO3) takes place before entering the kiln.

Powdered raw mix enters the kiln at one end and the burner is situated at
the opposite end. The rotary kiln rotates at the speed of 1 to 3 revolution
per minute (RPM). The raw mix in the kiln melts first into liquid form and
then transforms into nodules due to the effect of the rotation of the kiln.
There are two zones inside the kiln, namely calcining zone and burning zone.
The zone where raw mix enters into the kiln is called calcining zone. Where
temperature would be 950-1000ºC. Burning zone starts after this zone
where temperature would be 1350-1450ºC.
The hot clinker from kiln discharge is cooled very quickly/ quenched in air
with the help of efficient coolers. The temperature of clinker is brought to
80-90ºC from 1350ºC. Fast cooling is very essential to get good quality
clinker. If cooling is not quick, the compound stability in clinker will be
adversely affected resulting in lower strength of cement after grinding.
Clinker from clinker silo is transported to clinker hopper by belt conveyor.

Similarly, gypsum, fly ash or any other additive are transported to their
respective hoppers by belt conveyors.
CEMENT GRINDING:
The proportioning of clinker, gypsum and fly ash is done by electronic weigh
feeders. In modern plants, clinker and gypsum are pre-crushed in a Roller
press and subsequently fed into ball mill for fine grinding. The installation of
roller press technology is very beneficial in terms of both quality and energy
conservation. The cement produced from roller press is showing better
particle size distribution in cement (and hence good strength development)
and consumes less power.
The resultant product is called cement and stored in a Multi compartment

silo. This avoids intermixing of products.

PACKING OF CEMENT:
Cement is packed in HDPE bags having capacity of 50 kg. Electronically

controlled, High efficiency rotary packers are used for Packing. Packers are
highly precise with tolerance of +/- 0.5%. It displays the weight of each bag
before discharge. It ensures the weight of packed bag is 50kg. Electronic
balances are installed for random cross check of packed bags. The packed
bags are loaded into trucks / Railway Wagons.
TRANSPORTATION OF CEMENT: Cement is transferred to various locations

as per the market requirement and stored in godowns or the distribution
points, this is distributed through trucks and by rail or by cement Bulkers
from the plant.
10.2. Process Diagram

Im age cou rte sy: En cycl op edi a Bri tan n ica
10.3. Addition & Deletion of Equipment

compared to baseline scenario
To comply the environmental norms following changes were carried in the
plant.
Instead of existing ESPs, Bag house were installed for Unit 2. Hence, the
existing ID fans of 710 kW was replaced by Raw mill Bag House Fans of
1000 kW.
Sr Date of
Equipment Name Section
No Commissioning
1 Raw Mill Bag house fan U-2 27 July 2016
TABLE 10.1 INSTALLATION OF NEW EQUIPMENT DUE TO MANDATORY ENVIRONMENTAL
NORMS
The change in energy consumption due to inclusion of these equipment is as

follows:
Base Line Assessmen

Year 2014- t Year Difference
Equipme
Sl. 15 2018-19 Electricity
nt Serial Sectio
No Equipment Name Electricity Electricity Consumpti
No n
. Consumpti Consumpti on (lakh
on (lakh on (lakh kWh)
kWh) kWh)
Bag House Raw Mill
1 229 FN 1 Kiln 2 30.02 40.96 10.94
Kiln 2
TABLE 10.2 ADDITIONAL E NERGY CONSUMPTION DUE TO INSTALLATION OF NEW

EQUIPMENT DUE TO MANDATORY ENERGY NORMS

10.4. Changes in Process flow, Plant Machinery,

Technology, Product mix, etc. compared to
baseline scenario
As per the guidelines of Bureau of Energy Efficiency, earlier Carbon Powder
which was in baseline year considered as alternative fuel, is not considered
as alternative fuel anymore. Hence, the DC has stopped consuming carbon
powder anymore.
Else, there is no change in process flow, plant machinery technology,

product mix, etc. compared to baseline scenario.

10.5. Raw Material Processing

10.5.1. List of Raw Material used with quality
parameters.
The plant uses various raw materials in cement manufacturing mainly Lime
store, Gypsum, slag and fly ash. The raw materials are tested for various
quality parameters before use as given in table 28. The various Quality
Parameters Analysis Test Results for assessment year for lime stone, slag,
Gypsum and fly ash are given as Other Document 16.2.3
Quality Parameters
Quality Parameters
S.No. Raw Material Used Analysis Results
Tested
given in Annexures
SiO2; Al2O3; Fe2O3; CaO;
MgO; SO3; Na2O; K2O; Cl;
1 Lime Stone CaCO3; MgCO3 (as
percentage) and LSF; SM;
AM
SiO2; Al2O3; Fe2O3; CaO;
2 Slag MgO; Gain; SM (as
Percentage)
SO3; I.R.; Purity; SM; Cl (as Document 16.2.3
3 Gypsum
percentage)
SiO2+Al2O3+Fe2O3; SiO2;
MgO; SO3; Alkali as Na2O;
LOI; Blaine; % Particles
retained on 45 micron sieve;
4 Fly Ash
Lime Reactivity; % Ratio
Strength OPC to PPC; Auto
Clave Exp.; Chloride (as
percentage)
10.5.2. Conversion or Product factor to final product.

The Conversion Factors (CF) for Clinker to various Cement grades used in
the assessment year is given below in table:
Conversion Factors (CF) for Clinker t o various Cement grades Value

a Clinker to OPC 0.883
b Clinker to PPC 0.5786

10.6. Fuel Handling & Utilization.
10.6.1. Solid fuel handling

Co al a nd pet c oke c ome s b y w ag ons an d g oe s to w agon t i ppl er.
Th rou gh th e ti pp ler fu el go es ho ppers a nd t h en t o bel t co nve yors.
From t he b elt con vey in g sy ste m fu el goes in t o tw o h op pers . O ne
h opp er d edi cat ed for Sh ree p ow er w hi le oth er ho ppe r de di cat ed to
cem en t pl ant . Th e coa l h an dli ng syst em is sh ow n bel ow :
10.6.2. Liquid fuel handling

L iq ui d fu el as Ti re o il, coal t ar, a nd ot he r li qu id w aste is h andl ed
an d s to red a s f uel barre ls.
10.6.3. Gaseous fuel handling

LPG cylinders are being used as gaseous fuels for minor constructions and
other heating works.

10.7. Fuel Analysis

10.7.1. Fuel Analysis procedure followed in internal labs
The fuel sampling method is described below and fuel testing procedure
followed by the plant internal laboratory is given in table 10.5.
Fuel Sampling Method of receipt Petcoke & Coal:
A. From Wagon Tippler / Unloader:
When Wagon/ truck is unloaded at Wagon tippler / unloader collect sample

from belt, with the help of scoop after interval of 3 to 5 minutes.
B. From Yard:
When truck is unloaded in yard, during unloading & after unloading

collect sample with the help of scoop from the surface of each heap & inside
the heap from 8 to 10 points.
C. Day Average sample (Partywise):
a) Total quantity collected f r o m e a c h W a g o n / truck must be

minimum 8 to 10kgs.
b) Sieve the collected sample of 10 wagons/ trucks from each party from
12.5mm sieve &
c) Crush the sample bigger than 12.5mm in crusher or manually &

maintain 12.5mm size & mix it with 12.5mm screened sample.
d) Mix all collected samples of 10wagons/ trucks properly in a tray/

or on MS plate,
e) Reduce the quantity by coning & quartering / by Riffle sample

divider,
f) Reduce the quantity upto 4kg.,

g) Take 2kgs of sample, this will be your party wise day average
sample for total moisture.
h) Sieve the remaining 2kgs. sample from 3.35mm sieve &
i) Crush the sample bigger than 3.35mm in crusher or manually &

maintain 3.35mm size & mix it with 3.35mm screened sample.
j) Mix all collected samples properly in a tray/ or on MS plate,
k) Reduce the quantity by coning & quartering / by Riffle sample

divider,
l) Reduce the quantity up to 500gms.
m) Take 100gms. sample & pulverize it so that all sample must pass
212micron,
n) This will be your party wise day average sample for proximate
analysis.
Material: COAL/PET COKE

Sample
S.No.
Collected from Frequency Preparation
1 Auto Sampler As per received 1) 50-60 Kg as received sample, collected
rake, composite from each coal rake
2 Belt sample of 10 2) 30 Kg sample collected form 10 wagons
wagon Mix all collected samples properly on MS
3 Trucks Composite plate, reduce the quantity by coning &
sample of 5 quartering up to 3kg
truck (A) Moisture Sample (Size-12.5 mm, Qty.-1
Kg.)
4 Yard
(B) Quality Sample (Size -3.35 mm, Qty.-500
gm) ground Quality sample in pulverizer and
Testing procedure
Sieve Analysis
All sample passed from following IS sieves for sieve analysis and weight. 1)40mm
2)25mm 3)20mm 3)10mm 4)6.5mm 5)2.8mm 6)1mm
1.Total moisture
Weight 250 (w1) gm sample of 12.5mm size in a tray put it in oven (108
dryness for 4-6 hours but t ill constant weight (w2)

% Moisture= ((w2-w1)*100)/weight of sample

2) %IM (Inherrent moisture)
Weight approx. 1 gm sample in a crucible and put it in air oven for 1.5 hour but till constant
weight at 108 C±2 C , cool it in desicator and weigh it (W2).
%IM= (W1-W2)/weight of sample)*100
Where W1= weight of crucible+sample
3)%VM (Volatile matters)
Weight approx. 1 gram sample in a VM crucible with lid and put it in furnace for 7 minut es
(In absesnce of oxigen) at 900 C±10 C , cool it in desicator and weigh it (W2).
%VM=((W1-W2)/weight of sample)*100))-IM
where W1= weight of crucible with lid + sample
4)%ASH
Weight approx. 1 gm sample in a ASH crucible and put it in furnace for 30 minutes at 500 C
and further 30 to 60 minutes but till constant weight at 815 C±10 C cool it in desicator and
weigh it (W2).
%IM= (W1-W2)/weight of sample)*100
Where W1= weight of crucible+Ash
5)%FC (Fixed carbon)

Fixed carbon is arrived at after deducting from 100 the sum of moisture,ash and volatile
matter contents as percent.
%FC=100- (IM+ASH+VM)
6)Gross calorific value (Kcal/Kg.)

The calorific value of a sample is determined by combustion of the sample in controlled
environment.The heat released is proportional to the calorific value of the substance.
Weq=Water Equivalent
7) Ultimate analysis (C,H,N,S determination)

Ultimate analysis is being done by CHNS analyzer (Leco CHN 628S)
10.7.2. Frequency of Internal & External Fuel Analysis

The fuel analysis is done for finding GCV (As received basis) on daily routine
basis through proximate analysis. Ultimate analysis is done on quarterly
basis through external labs as per the guidelines of Bureau of energy
efficiency.
10.7.3. Sample Fuel analysis report.

Sample fuel analysis report is attached in part 16.2.1 and 16.2.2

11. Energy & Mass Balance
Th e e nerg y an d ma ss b alan ce of t h e pl an t for as sessm en t year is

as foll ow s:
11.1. Material Balance of Plant

Th e m at erial bal an ce o f cem en t plan t is as f oll ow s:
Material Consumption Production
Material Mass (MT) Material Mass (MT)
Limestone & Other additives 30318 Net Cement Produced 1735802
Gypsum 157484
Fly Ash 351439
Clinker Used 1196561
Import ed Clinker 0
Total 1735802 Total 1735802
11.2. Energy Balance of Plant

Th e e nerg y b alan ce of t h e pl an t i s as foll ow s:
Energy from Pet coke in Process Million kcal 1525633.54
Energy from Coal in Process Million kcal 0
Energy from Coal in Power Plant Million kcal 224619.63
Energy from Solid Waste in Process Million kcal 0
Energy from Liquid Waste in Process Million kcal 2649.042
Energy from Liquid Waste in Power Plant Million kcal 0
Energy from LPG in Process Million kcal 32.06
Total Energy in Process Million kcal 1525665.598
Total Thermal Energy in Power Plant Million kcal 224619.63

Total Thermal Energy Used in CPP Million kcal 224619.63
Total Thermal Energy Used in Process Million kcal 1525633.536

Weighted Heat Rate of Plant kcal/kWh 2989.161898

Total Electricity Consumed in Plant
Million kcal 585584.28
(Process)

Through Waste Heat Recovery
WHR Installed Capacity MW 21
Annual Generation Lakh kWh 943.69536
Total Energy Generated, Consumed & Export
Total Own Generation of Electricity Lakh kWh 2770.48
Electricity Exported to Grid/others Lakh kWh 252.15064
Electricity Supplied to Colony/others Lakh kWh 59.3501
Electricity Supplied t o Grid/Colony/others from CPP Lakh kWh 311.50074
Total Aux Power Consumption of CPP % 7.64
Equivalent Thermal Energy supplied to grid/others Million kcal 84634.75106

12. Pro-forma Verification
12.1. Linking Errors & Calculation Errors

No linking and calculation errors were found in Pro-forma
12.2. Discrepancies in Pro-forma and

Normalization sheets
No d isc repan ci es w ere obse rved in pro -fo rma an d n orm ali zat io n
sh eet s
12.3. Potential improvements to achieve more

accurate reading
Since, the fly ash which is waste is re-used in Cement / power plant has
been not accounted separately in previous assessment year, and has been
continued in base line year. The energy is accounted twice.
Since, the energy is calculated twice during present baseline year, the same
has been followed for the present assessment year for apple to apple
comparison.
However, this methodology (twice accounting) does not have any major
impact on GTG value.
This should be rectified for the next baseline year, as the pro-forma was
updated after the present baseline year.

12.4. Baseline Data Verification

12.4.1. Discrepancies of Data exist after verification from
documents
No discrepancies were found after verification of documents.
12.4.2. List of documents verified with each parameter.

Foll ow in g i s t h e li st of d ocu me nt s ve rifi ed wi th eac h p aram et ers:
Source of
S. No Particulars/Parameters
Data/Document Verified
A Production and capacity utilization details
Design Specification
A1 Production Capacity (Clinker)
Document
A2 Production Capacity (Cement)
Document
A3 Total Clinker Production ERP/Production documents
A4 Total Cement Production(All varities) ERP/Production documents
A5 Opening Clinker St ock ERP/Production documents
A6 Closing Clinker Stock ERP/Production documents
A7 Opening Cement Stock ERP/Production documents
A8 Closing Cement Stock ERP/Production documents
A11 OPC Production ERP/Production documents
A12 PPC production ERP/Production documents
A13 PSC/any other Cement Production NA
A14 Clinker Exported ERP/Production documents
A15 Clinker Imported ERP/Production documents
A16 Quantity of Fly Ash used Daily Production Report
A17 Quantity of Gypsum Used Daily Production Report
A18 Quantity of Slag Used NA
A19 Quantity of any other Additive used Daily Production Report
A20 Clinker Fact or for OPC Daily log sheet, DPR
A21 Clinker Fact or for PPC Daily log sheet, DPR
A22 Clinker Fact or for PSC/others NA
Not e: Please do not keep the cell A1-A19 blank
B Kiln Start /Stop
(i)a Kiln-1 Production DPR

(i)b Kiln-1 Operating Thermal SEC DPR, Lab Report

(i)c Kiln-1 Operating Electrical SEC DPR , Power per Tonn
(i)d Kiln-1 Running Hours DPR
(i)e Kiln-1 Hot to Hot start (Internal & External) DPR
(i)f Kiln-1 Hot to Cold stop due to external factor DPR
(i)g Kiln-1 Hot to Cold stop due to external factor DPR
Kiln-1 Hot to Cold stop due to external factor
(i)h DPR
(Electrical Energy Consumption)
(i)i Kiln-1 Cold to Hot start due to external factors DPR
(i)j Kiln-1 Cold to Hot start due to external factors DPR
Kiln-1 Cold to Hot st art due to external factors
(i)k DPR
(i)l Kiln-1 Cold to Hot start due to internal factors DPR
(ii)a Kiln-2 Production DPR
(ii)b Kiln-2 Operating Thermal SEC DPR, Lab Report
(ii)c Kiln-2 Operating Electrical SEC DPR , Power per Tonn
(ii)d Kiln-2 Running Hours DPR
(ii)e Kiln-2 Hot to Hot start (Internal & External) DPR
(ii)f Kiln-2 Hot to Cold stop due to external factor DPR
(ii)g Kiln-2 Hot to Cold stop due to external factor DPR
(ii)h DPR
(ii)i Kiln-2 Cold to Hot start due to external factors DPR
(ii)j Kiln-2 Cold to Hot start due to external factors DPR
Kiln-2 Cold to Hot start due to ext ernal fact ors
(ii)k DPR
(ii)l Kiln-2 Cold to Hot start due to internal factors DPR
For Additional Kiln data, DC neeed yto submit the
Not e:
information in separte excel sheet as per above format
C Electricity Consumption
Electricity through Grid / Other (Including colony and
C.1
others)
(i) Purchased Electricity from grid (SEB) Meter Reading
C.2.2 Through Steam turbine/ generator
C.2.2.1 STG 1
(ii) Installed Capacity OEM, lett er of intent
(iii) Annual Gross Unit generation DGR , Meter Records
(iv) Auxiliary Power Consumption DGR , Meter Records
(v) Design Gross Heat Rate OEM, lett er of intent
C.2.2.2 STG2

(ii) Installed Capacity Letter of Intent

C.2.2.6 STG
C.2.4 Through Wast e Heat Recovery

(i) WHR Installed Capacity Calibration Certificate
(ii) Annual Generation DGR
Average running hrs,
(iii) WHR Running Hours
source DGR
C.3 Total Own Generation of Electricity

C.4 Electricity Exported to Grid/others Meter Reading
C.5 Electricity Supplied to Colony/others Meter Reading
D Solid Fuel Consumption
D.2 Petcoke
Fuel receipt & consumption
(i) Landed Cost of fuel (Last purchase)
inventory
Internal Lab Report, Test
(ii) Average Gross calorific value (Power generat ion)
Certificate
(iii) Average Gross calorific value (Kiln)
Certificate
(iv) Quantity purchased
inventory
(v) Average Moisture in Fuel Internal Lab Report
(vi) Quantity used for power generation Daily Generation Report
(vii) Quantity used for process (Pyro) Daily Production Report
D.3 Coal(Imported)
inventory
Certificate
Certificate
inventory


(vii) Quantity used for process Daily Production Report
D.8 Coal 4 (Other Solid Fuel)
inventory
Certificate
Certificate
inventory
Bio mass or Other purchased Renewable solid fuels (pl. specify) baggase, rice husk,
D.9
etc.
inventory
(ii) Average Gross calorific value as fired
Certificate
(iii) Quantity purchased
inventory
(iv) Average Moisture in Fuel Internal Lab Report
(v) Quantity used power generation
(vi) Quantity used for process heating Daily Production Report
Solid Waste (pl. specify and refer CPCB guidelines, enclosed) rubber tyres chips,
D.10
Municipal Solid waste etc.
inventory
Certificate
inventory
E.4 High Speed Diesel (HSD)

(ii) Gross calorific value Standard Values
(iv) Average Density Standard Values
Stores , Monthwise Deisel
(viii) Quantity used for process heating
& Tyre
E.6 Liquid Wast e (pl. specify and refer CPCB guidelines, enclosed)


(v) Quantity used for power generation (DG Set)
Stores , Monthwise Diesel
(vi) Quantity used for power generation (CPP)
& Tyre
(vii) Quantity used for process
& Tyre
F Gaseous Fuel
F.2 Liquefied Petroleum Gas (LPG)
(ii) Gross calorific value Standards (Same as BY)
Same as BY(used for
(v) Quantity used for process heating
Construction)
I Performance Indicators
I.1 Thermal SEC DPR, lab report, process
I.2 Electrical SEC (up to Clinkerization) DPR, Production report
I.3 Electrical SEC (Cement Grinding) DPR, Production report
M Documentation for Normalisation
Capacity Utilizat ion-Document Available for
(i) BY data not available
Normalisation
Fuel Quality in CPP-Document Available for Consolidat ed Fuel quality
(ii)
Normalisation data is not available
Petcoke Utilization in Kiln-Document Available for
(iii) DPR, lab reports
Normalisation
individual turbine running
(iv) CPP PLF- Document Available for Normalisation
hours not available
(v) Power Mix-Document Available for Normalisation DGR for CPP, WHR
(vi) Product Mix-Document Available for Normalisation Production Report

12.4.3. List of parameters verified from the baseline

report.
The following parameters were verified by previous cycle assessment year
report and PAT notification details for verification of baseline data.
S. No Particulars Unit
Annual Installed
A1 Production Capacity (Clinker) Tonne
Capacity
Annual Installed
A2 Production Capacity (Cement) Tonne
Capacity
A3 Total Clinker Production Annual Tonne
A4 Total Cement Production(All varieties) Annual Tonne
A5 Opening Clinker St ock Annual Tonne
A6 Closing Clinker Stock Annual Tonne
A7 Opening Cement Stock Annual Tonne
A8 Closing Cement Stock Annual Tonne
A9 Capacity Utilization (Clinker) A3x100/A1 %
A10 Capacity Utilization (Cement ) A4x100/A2 %
A11 OPC Production Annual Tonne
A12 PPC Production Annual Tonne
A13 PSC/any other Cement Production Annual Tonne
A14 Clinker Exported Annual Tonne
A15 Clinker Imported Annual Tonne
B Details of Other Additives Used
B1 Quantity of Fly Ash used Annual Tonne
B2 Quantity of Gypsum Used Annual Tonne
B3 Quantity of Slag Used Annual Tonne
B4 Quantity of any other Additive used Annual Tonne
C Conversion Factors (CF) for Clinker to various Cement grades
C1 Clinker Fact or for OPC Annual Fraction
C2 Clinker Fact or for PPC Annual Fraction
C3 Clinker Fact or for PSC Annual Fraction
D Performance Indicators
D1 Thermal SEC kCal/kg Clinker

D2 Electrical SEC (up to Clinkerization) kWh/Tonne Clinker

kWh/Tonne
D3
Electrical SEC (Cement Grinding) Cement
E Details of Electricity Consumption
E1 Electricity from Grid / Other
(i) Total Units Annual Lakh kWh
(ii) Purchased / Billed Units Annual Lakh kWh
(iii) Wind Energy (through Wheeling) Annual Lakh kWh
(iv) CPP of Sister Plant (through Wheeling) Annual Lakh kWh
(v) Plant Connected Load Annual kW
(vi) Cont ract demand with utilit y kVA
(vii) Plant Run Hours Kiln hours
(viii) Plant Run Hours CPP hours
E.2 Own Generation
E2.1 Through DG sets
Gross Unit
(i) Annual generation Lakh kWh
Generation
(ii) Avg. Gross Heat rate of DG Set kCal/kWh
E.2.2 Through Steam turbine/ generator
(i) Annual Gross Unit generation Lakh kWh
(ii) Average Gross Heat Rate kCal/ kWh
(iii) uxilliary Power Consumption %
(vi) Plant Load Factor (PLF) %
E.3 Weighted Average Heat Rate of plant kcal/kWh
E.4 Total Generation of Electricity Lakh kWh
E.5 Electricity Supplied to Grid/ot hers Lakh kWh
Equivalent Thermal Energy supplied to
E.6 Million kCal
grid/others
E.7 Total Electricity Consumed Lakh kWh
F GCV of Fuels
F.1 GCV of Imported Coal (Process Heating) used for kiln kCal/kg
F.2 GCV of Imported Coal (Power Generation) used for CPP kCal/kg
F.3 GCV of Indian Coal kCal/kg
F.4 GCV of Petcoke kCal/kg
F.5 GCV of Liquid Fuel kCal/kg
Total Thermal Energy Input through all
G Million kCal
Fuels

12.4.4. List of essential parameters not entered by the

DC in the baseline as well as assessment year
that affects negative normalization
Since, the fly ash which is waste is re-used in Cement / power plant has
been not accounted separately in previous assessment year, and has been
continued in base line year. The energy is accounted twice.
Since, the energy is calculated twice during present baseline year, the same
has been followed for the present assessment year for apple to apple
comparison.
However, this methodology (twice accounting) does not have any major
impact on GTG value.
This should be rectified for the next baseline year, as the pro-forma was
updated after the present baseline year.
12.4.5. List of parameters altered in Pro-forma from the

baseline report with reason of deviation and
documentation.
No parameter was altered in pro-froma from baseline year.

12.5. Assessment year data verification

12.5.1. List of document verified with each parameter
Foll ow in g d ocu m ent s we re veri fie d for each pa ram ete rs:
Source of
S. No Particulars/Parameters
Data/Document Verified
A1 Production Capacity (Clinker)
Document
A2 Production Capacity (Cement)
Document
A3 Total Clinker Production ERP/Production documents
A4 Tot al Cement Production(All varities) ERP/Production documents
A5 Opening Clinker St ock ERP/Production documents
A6 Closing Clinker Stock ERP/Production documents
A7 Opening Cement Stock ERP/Production documents
A8 Closing Cement Stock ERP/Production documents
A11 OPC Production ERP/Production documents
A12 PPC production ERP/Production documents
A13 PSC/any other Cement Production NA
A14 Clinker Exported ERP/Production documents
A15 Clinker Imported ERP/Production documents
A16 Quantity of Fly Ash used Daily Production Report
A17 Quantity of Gypsum Used Daily Production Report
A18 Quantity of Slag Used NA
A19 Quantity of any other Additive used Daily Production Report
A20 Clinker Fact or for OPC Daily log sheet, DPR
A21 Clinker Fact or for PPC Daily log sheet, DPR
A22 Clinker Fact or for PSC/others NA
Not e: Please do not keep the cell A1-A19 blank
B Kiln Start /Stop
(i)a Kiln-1 Production DPR
(i)b Kiln-1 Operating Thermal SEC DPR, Lab Report
(i)c Kiln-1 Operating Electrical SEC DPR , Power per Tonn
(i)d Kiln-1 Running Hours DPR
(i)e Kiln-1 Hot to Hot start (Internal & External) DPR

(i)f Kiln-1 Hot to Cold stop due to external factor DPR

(i)g Kiln-1 Hot to Cold stop due to external factor DPR
(i)h DPR
(i)i Kiln-1 Cold to Hot start due to external factors DPR
(i)j Kiln-1 Cold to Hot start due to external factors DPR
(i)k DPR
(i)l Kiln-1 Cold to Hot start due to internal factors DPR
(ii)a Kiln-2 Production DPR
(ii)b Kiln-2 Operating Thermal SEC DPR, Lab Report
(ii)c Kiln-2 Operating Electrical SEC DPR , Power per Tonn
(ii)d Kiln-2 Running Hours DPR
(ii)e Kiln-2 Hot to Hot start (Int ernal & External) DPR
(ii)f Kiln-2 Hot to Cold stop due to external factor DPR
(ii)g Kiln-2 Hot to Cold stop due to external factor DPR
(ii)h DPR
(ii)i Kiln-2 Cold t o Hot start due to external factors DPR
(ii)j Kiln-2 Cold to Hot start due to external factors DPR
(ii)k DPR
(ii)l Kiln-2 Cold to Hot start due to internal factors DPR
For Additional Kiln data, DC neeed yto submit the

Not e:
information in separte excel sheet as per above format
C Electricity Consumption
Electricity through Grid / Other (Including colony and
C.1
others)
(i) Purchased Electricity from grid (SEB) Meter Reading
C.2.2 Through Steam turbine/ generator
C.2.2.1 STG 1
(ii) Installed Capacity OEM, lett er of intent
C.2.2.2 STG2

C.2.2.6 STG
C.2.4 Through Wast e Heat Recovery

(i) WHR Installed Capacity Calibration Certificate
(ii) Annual Generation DGR
Average running hrs,
(iii) WHR Running Hours
source DGR
C.3 Total Own Generation of Electricity

C.4 Electricity Exported to Grid/others Meter Reading
C.5 Electricity Supplied to Colony/others Meter Reading
D Solid Fuel Consumption
D.2 Petcoke
inventory
Certificate
Certificate
inventory
(vii) Quantity used for process (Pyro) Daily Production Report
D.3 Coal(Imported)
inventory
Certificate
Certificate
inventory

D.8 Coal 4 (Other Solid Fuel)

inventory
Certificate
Certificate
inventory
Bio mass or Other purchased Renewable solid fuels (pl. specify) baggase, rice husk,
D.9
etc.
inventory
Certificate
inventory
Solid Waste (pl. specify and refer CPCB guidelines, enclosed) rubber tyres chips,
D.10
Municipal Solid waste etc.
inventory
Certificate
inventory
E.4 High Speed Diesel (HSD)

Stores , Monthwise Deisel
(viii) Quantity used for process heating
& Tyre
E.6 Liquid Wast e (pl. specify and refer CPCB guidelines, enclosed)

(v) Quantity used for power generation (DG Set)

(vi) Quantity used for power generation (CPP)
& Tyre
(vii) Quantity used for process
& Tyre
F Gaseous Fuel
F.2 Liquefied Petroleum Gas (LPG)
(ii) Gross calorific value Standards (Same as BY)
Same as BY(used for
(v) Quantity used for process heating
Construction)
I Performance Indicators
I.1 Thermal SEC DPR, lab report, process
I.2 Electrical SEC (up to Clinkerization) DPR, Production report
I.3 Electrical SEC (Cement Grinding) DPR, Production report
M Documentation for Normalisation
Capacity Utilizat ion-Document Available for
(i) BY data not available
Normalisation
Fuel Quality in CPP-Document Available for Consolidat ed Fuel quality
(ii)
Normalisation data is not available
Petcoke Utilization in Kiln-Document Available for
(iii) DPR, lab reports
Normalisation
individual turbine running
(iv) CPP PLF- Document Available for Normalisation
hours not available
(v) Power Mix-Document Available for Normalisation DGR for CPP, WHR
(vi) Product Mix-Document Available for Normalisation Production Report
12.5.2. List of parameters arrived through calculation or

formulae with the list of document as source
data.
Following parameters were calculated through formula:
Parameter arrived through

S.No Document as source of data
calculation/formulae
1 STG Auxiliary Power Consumption DGR , Meter Records
2 STG Gross Heat Rate OEM, lett er of intent
3 Clinker Fact or for OPC Daily log sheet, DPR
4 Clinker Fact or for PPC Daily log sheet, DPR
5 Kiln- Operating Thermal SEC DPR, Lab Report
6 Kiln -Operating Electrical SEC DPR , Power per Tonn
7 Fuel Average Gross calorific value
Certificate

8 Thermal SEC DPR, lab report, process

9 Electrical SEC (up to Clinkerization) DPR, Production report
10 Electrical SEC (Cement Grinding) DPR, Production report
12.5.3. List of parameters reported based on

disaggregation of recorded data with reviewed
documents
Not Ap pli cab le
12.5.4. Write-up or methodology or logic or calculation

for arriving submitted data
Not Ap pl ica ble
12.5.5. Data Sampling

Following data were reviewed:
1) Monthly data were reviewed for production and consumption for the
analysis.
2) Daily calorific heat data was verified.
3) Daily log sheet for electrical data was verified and tallied with monthly
data.

S.No. Sample Data Document Primary Source

Daily Production
1 OPC Production (Annual) ERP Data
Reports
Daily Production
2 PPC Production (Annual) ERP Data
Reports
Daily Production
3 Quantity of Fly Ash used (Annual) ERP Data
Reports
Quantity of Gypsum Used Daily Production
4 ERP Data
(Annual) Reports
Daily Production
5 Quantity of Slag Used (Annual) ERP Data
Reports
Daily Production
6 Kiln-5 Production Daily Production Reports
Reports
7 Purchased Electricity Electricity Bill Meter Readings
Annual Gross Unit generation
8 Daily Generation Report Meter Records
from Steam Turbine
Fuel receipt & Fuel Purchase
9 Petcoke-Quantity Purchased
consumption inventory records
Fuel receipt & Fuel Purchase
10 Coal-Quantity Purchased
consumption inventory records
Petcoke-Average Gross calorific Monthly summarized Daily Internal Lab
11
value (Power generation) Internal Lab Report Records
Coal-Average Gross calorific value Monthly summarized Daily Internal Lab
12
(Power generation) Internal Lab Report Records
12.5.6. Discrepancies (if any) from the reported data and

document of the sample data.
No d isc repan ci es w ere obse rved
12.6. Pro-forma verification for Thermal Power

Plant
Not ap pl icab le

12.7. SEC Quantification

12.7.1. Relationship with the energy saved from the
energy saving projects implemented and
difference in SEC between baseline and
assessment year.
Baseline Assessment
Specific Energy Consumption Unit
Year Year
Gate to Gat e Specific Energy kcal/kg of

1 561.79 569.51
Consumption equivalent Cement
Normalized Gate to Gat e Specific kcal/kg of

2 561.79 487.601
Energy Consumpt ion equivalent Cement
12.7.2. List of energy savings projects with description in

brief and photographs
Following energy saving projects were implemented from baseline years to

assessment years

12.7.3. Brief description of Energy savings measures
Following are modification done in Pyro & Cooler section which reduces heat
consumption by 46 kcal/kg clk.
Feed box diameter of cyclone 5-6 is enlarged and position changed,

resulting in decrease in free lime and better calcined material to kiln,
also results in better heat transfer and thus reduces gas outlet
temperature by 10°C it will reduce heat consumption.
Top triplet cyclones are insulated with 5 mm ceramic paper to reduce

radiation losses which also results in heat consumption saving.
Installation of MVD in Kiln string fan of unit 2.
False air reduction in preheater and cooler section also contributed in

reduction of heat consumption.
Installation of Schenck firing system in both kiln and calciner coal

firing system in place of FK pump resulting in less coal flushing and
uniform coal distribution resulting in saving in terms of coal.
Replacement of Cold air fan-8 by hot air fan in Unit 2.
Replacement of AQC-II outlet damper by Shut-off type damper in Unit

2
Primary air reduction by increase in flame momentum thus reduces

heat consumption.
Installation of Cassette plates in place of conventional old grate plates

in clinker cooler and also replaced old step grate plate (slot size 3mm)
by new step grate plate (slot size 7 mm) at 2 nd step in clinker cooler
and also installed horse shoe in step grate side for better cooler
recuperation efficiency which increases from 50% to 55 % thus results
in specific energy savings. False reduction in AQC and cooler ESP

circuit by 20 % by arresting leakage points and also closing cooler

stack damper which results in more air to HAR and increase in HAR
temperature accounting for savings in terms of heat consumption.
Conducted CFD of HAR duct.
Kiln inlet seal replacement from pneumatic seal to graphite seal

resulting in reduction of heat consumption.
Following tables indicates the savings in heat consumption-
Replacement Of Fan-8 in hot air recirculation
Stack flow After Installation of

Parameters Unit
FN-8 flow at stack
O
Temp. C 112 111
I/L Pres. mmwg -7 -5
Duct Dia. M 4.45 4.45
AREA M2 15.55 15.55
DENSITY kg/Nm3 1.29 1.29
DENSITY Kg/m3 0.86 0.87
D.P mmwg 0.25 0.06
Pitot Tube Const. CP 0.87 0.87
VEL. m/sec 2.08 1.04
FLOW m3/sec 32.35 16.15

3
m /hr 116446.34 58141.54
Nm3/hr 77833.75 38971.51
Nm3/Kg-clk 0.41 0.20
Net flow used after fan-8 Nm3/Kg-clk 0.203

installation
Heat Kcal/hr Kcal/hr 2702388 1341010
Net Heat saving @ 4600 TPD Kcal/Kg-clk 7.10

Schenck firing system in place of FK pump to stop coal flushing& reduce heat consumption
With Existing FK pump

With New system
Parameters Unit
for transport of coal
Average data
CV of coal Kcal/kg-coal 7500 7500
Clinker TPD 4600 4600
Running Hrs hrs 24 24
% coal fired
% 10 9.9
(kiln+calciner)
Net estimated coal
TPD 4.60
savings
Heat savings kCal/kg Clk. 7.50
Estimation of savings Kcal/kg clk after installation of Shut-off type damper in AQC-II outlet
duct
After
Parameters Unit Before
Suction at fan I/L MMwg -440 -380

Across ESP false air
increase Nm3/Kg-Clk 0.12 0
O
Temperature at stack C 113 45
Damper opening of
stack % 12 0
Net Saving Kcal/kg clk 4.23

Estimation of savings Kcal/kg clk after increasing Cooler recuperation efficiency
Parameters Unit Before After
Clinker Production TPD 4586 4586
Running Hrs hrs 24.0 24

o
TAD Temp C 830 860
o
Secondary Temp C 1110 1140
Cooler Efficiency % 50 56
Kcal/kg
Net Saving 10
clk
Not e-Cooler Grate plates were changed with cassette type plate results in less heat
consumption and better cooler efficiency with better heat transfer, results in increase in
tertiary and secondary temperature
Estimation of savings Kcal/kg clk after reducing primary air in kiln
With high primary After low primary air

Parameters Unit
air
Primary air % 15 7
Specific Kiln Comb Air Nm3/kg-clk 0.32

0.32
requirement
Primary air Nm3/kg-clk 0.05 0.02
O
Temperature C 60 60
Heat Kcal/kg-clk 0.89 0.41
O2% at kiln inlet oxygen % 5 2
Volume at kiln inlet Nm3/Kg Clk 0.34 0.33

O
Temp C 1050 1050
Pressure mmwg -35 -35
Heat Kcal/kg-clk 119 115
Net Heat Saving Kcal/kg-clk 4

Installation of 5 mm ceramic paper in triplet cyclone U2
Cyclone surface area 534 m2
After
Particular Unit Before
Surface Area M2 534 534
Emissivity Kiln shell 0.95 .95
Wind Velocity m/sec 2 2
ambient temp °C 35 35
Cyclone Surface t emp °C 130 95
Radiation heat loss Kcal/hr/m2 563099 285426
Convection heat loss Kcal/hr/m2 305301 166054
Kcal/hr/m2 868400 451480

Total Heart loss
Kcal/kg clk 4.54 2.36
Kcal/kg clk 2.18

Net Saving
Rs Lacs/annum 39.85
Monetary saving
Cost of ceramic paper Rs.(Lacs) 11.3

Kiln inlet seal replacement by graphite seal Unit-2
Parameters Unit Value
Kiln diameter Meter 4.4
Running Hrs hrs 24
O
False air temp C 30
Thickness of seal gap mm 13
Pressure at kiln inlet chamber mmwg 30
DP across kiln inlet mmwg 30
Specific heat of air kcal/ oC 0.24
Air density at 30 oC kg/m3 1.1
Average leak surface temp. m2 0.18
Heat savings through seal gap kcal/sec 113
Heat savings through seal gap kcal/day 9722299
Heat savings through seal gap kcal/kg clk 2.0
5K & 6K modification in cyclone feed box entry in Unit-2
Particular UOM Before After
Total combustion volume Nm3/kg clinker 1.6 1.6
PH Outlet temperature °C 315 305
Heat loss Kcal/kg clinker 82.47 79.85
Savings Kcal/kg clinker 2.6

Installation of MVD in KS fan U2
Flow Nm3/kg clinker 0.78 0.72
Temperature °C 300 300
Heat loss Kcal/kg clinker 84 79
On conservative basis 2-3 kcal/ kg clinker can be saved
Implementation of CFD study for HAR duct in Unit-2
Flow in cooler Kg/hr 380000 415000
Running Hrs hrs 24.0 24
TAD Temp °C 750-780 820-850
Secondary Temp °C 1000-1020 1050-1100
Net Saving achieved Kcal/kg clk 3
Installation of upgraded optima fuzzy logic control system for Unit-2
Particular UOM values
Nm3/kg clk 1.65

Flow before
Flow after modification Nm3/kg clk 1.6
Reduction in flow Nm3/kg clk 0.05
temperature of outlet gases °C 310
Heat saving achieved kcal/kg clinker 2.81

En ergy sav ing me as ures in G PP & CP P
1 . E nerg y sa vin gs by i n creased st eam g ene rati on by

rep lace men t o f Wa st e he at rec overy Boi l ers i n AQ C-1 an d
PH- 1 of Un it 1
Du e to in st all at ion o f n ew b oil er, st eam ge nera ti on in crea sed

resu l ti ng t o t he i n crease in ele ct ri cal po wer.
With old boilers With New boilers

6 stage (3-12 6 stage (16-22
Sr.
Particulars Unit May, 2017) Aug, 2018)
No.
AQC-1 PH-1 AQC-1 PH-1
Flue Gas Inlet 0
1 C 532 287 439 301
Temperature
Flue Gas Outlet 0
2 C 92 208 142 155
Temperature
3 dp across boiler mmW C 123 310 63 48
4 HP Steam Generation TPH 9.5 7.0 18.7 10.8
5 HP Steam Pressure kg/cm2 23 27 17
6 HP Steam Temperature kg/cm2 397 260 391
7 LP Steam Generation TPH 2.7 -- NA 6.6

Total Unit 1 equivalent
8 TPH 17.9 32.8
steam generation
9 SSC kg/kWh 6.7 5.7
10 Power Gen MW 2.66 5.81
13 Specific P Gen kWh/MT 16.6 43.9
14 Gain kWh/MT 27.3
15 Gain in P Generation MW 3.1
16 Gain in P Generation kWh/annum 24877755
17 Monetary Gain Lakh Rs/annum 871
18 Investment Lakh Rs 3009
19 Simple Payback Years 3.5
Th e b ase dat a a re as fol lows:






2 . Mod ifi cat io n of Du ct an d in st all ati on o f ded u ste r i n AQC -2

Boi le r an d h enc e, redu ct io n of dp across t h e elem en t s and
red uct i on of e nerg y co nsu m pt io n b y coo ler ESP fan .


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M&V Report of Shree Cement Ltd.

Monitoring & Verification

Electrical Research & Development Association, Vadodara 1

Electrical Research & Development Association, Vadodara 3

Electrical Research & Development Association, Vadodara 4

Electrical Research & Development Association, Vadodara 5

Decl ara tion ................................ ................................ ................................ ..... 3

Electrical Research & Development Association, Vadodara 6

4.3. Composition of Team.......................................................................................................20

Electrical Research & Development Association, Vadodara 7

10.1. Introduction to Process ...................................................................................................55

Electrical Research & Development Association, Vadodara 8

Electrical Research & Development Association, Vadodara 9

16.1. Energy & Mass Balance Reports....................................................................................149

Electrical Research & Development Association, Vadodara 10

1. Empanelled Accredited Energy Audit

1.2. Registration Number of the Firm

1.5. Accredited Energy Auditor (Team Leader)

Electrical Research & Development Association, Vadodara 11

1.6. About EmAEA

Electrical Research & Development Association, Vadodara 12

E MS Carri es m and at ory PAT E n ergy Au di t , M&V Au di t f or PAT

Electrical Research & Development Association, Vadodara 13

2.3. PAT Registration No.

2.5. Energy Manager

2.6. Authorized Signatory

Electrical Research & Development Association, Vadodara 14

brands. The Company has a power generation capacity of over 499

Clinker Capacity Cement Capacity

The power profile of Shree group is:

Location Total Generation Capacity (MW)

Abour Beawar Unit:

Shree Cement Beawar is an integrated cement manufacturing plant located

Electrical Research & Development Association, Vadodara 15

2.8. Recent Awards received by DC

Performance, Achieve and Trade Award by Bureau of Energy Efficiency

Rajasthan Energy Conservation Award 2017 by Department of Energy,

Best Quality Excellence Award 2015-16 & 2016-17 by NCCBM

Best Improvement in Thermal Energy Performance Award 2015-16 by

2. Lowest specific water consumption in the plant

3. Highest 5-star rating by International Benchmarking firm

Electrical Research & Development Association, Vadodara 16

4. 5 Star rating for Beawar limestone mines for sustainable development

Electrical Research & Development Association, Vadodara 17

Energy conservation is an optimal operational practice, which improves the

Perform, Achieve & Trade (PAT) is a market based mechanism to make

Independent evaluation of each and every activity carried out by designated

Electrical Research & Development Association, Vadodara 18

The objective of this M&V process is to ensure:

2. The energy performance declared by the DC is accurate by considering

3. There is consistency, transparency and traceability of the data.

3.2. Purpose of Verification Report

This report also serves the purpose of verification of calculations of

Electrical Research & Development Association, Vadodara 19

4. Approach, Scope & Methodology

4.1. Work Order

A c opy of t h e w ork o rder i ssu ed b y Sh ree Cem en t Lt d. , Be awar

4.2. Period of Verification