ENERGY CONSUMPTION NORMS FOR

CEMENT SECTOR
UNDER
ENERGY CONSERVATION ACT - 2001

METHODOLOGY ADOPTED
SETTING UP OF A TECHNICAL COMMITTEE CONSISTING OF
REPRESENTATIVES OF CEMENT INDUSTRY, NCB, CEMENT
MANUFACTURERS ASSOCIATION (CMA), GOVT. DEPTT.,
CONSULTANTS BY BUREAU OF ENERGY EFFICIENCY (BEE)
FOR GUIDANCE
CMA/CEMENT INDUSTRY
WITH THE TASK

REPS

ACTIVELY

ASSOCIATED

REGULAR INTERACTIONS BY TECHNICAL COMMITTEE AND

BEE

FACTORS CONSIDERED FOR

DEVELOPMENT OF NORMS

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

PROPOSED NORMS - 3rd CEMENT

SECTOR TASK FORCE MEETING
31 January 2005

NORMS ELECTRICAL & THERMAL ENERGY

System

Item

Electrical
Energy

Unit

Raw Mill

Cement Mill

BM/VRM
BM/VRM
VRM/RP+BM
VRM/RP+BM
VRM
VRM

BM
BM
RP+BM
RP+BM
VRM
VRM

Proposed Norm

kWh/t OPC-43
kWh/t Cement
kWh/t OPC-43
kWh/t Cement
kWh/t OPC-43
kWh/t Cement

105
97
90
80
78
73

4 St.

kcal/kg Clinker

840

5/6 St.

kcal/kg Clinker

740

Thermal Energy

VIEWS FROM TECHNICAL COMMITTEE MEMBERS

& FEEDBACK OF 12 PLANTS

Separate norms for OPC-43 and PPC

Separate norms for different % of flyash consumption
Limestone hardness to be considered
Plants using petcoke/waste products may have higher energy
consumption, weightage be given
Blaine for different grades of cement
Plants using petcoke/waste products may have higher energy
consumption, weightage be given
Total kWh/t PPC should be 85 instead of proposed 80
Increase in energy consumption due to some trials/R&D in the
plant may be given weightage through appropriate clause
Quality of flyash received from power plant (coarse or fine)

VIEWS FROM TECHNICAL COMMITTEE MEMBERS

& FEEDBACK OF 12 PLANTS (Contd.)
Separate norms for OPC-43 and PPC
Norm to vary with percent of slag/flyash used in the manufacture
of PSC/PPC
Percentage use of pozzolanic material
Residue of raw meal and fine coal
Power consumption for PSC grinding (ball mill system) be raised
to 63 kWh/t from 60 kWh/t
There should be no norms for cement mix
Norms for OPC-53 be also fixed
Suggested 110 kWh/t for plants having ball mill for raw grinding
& cement grinding
Suggested norm of 745 kcal/kg clinker instead of 740 kcal/kg
clinker for plants with 5/6 stage preheater using petcoke

PROPOSED NORMS SUBMITTED TO

BEE
July 2006
ALTERNATIVE - I
MAY BE SEEN AS A 5-YEAR ROADMAP NEEDING REVIEW THEREAFTER

NORMS ELECTRICAL ENERGY

Category

System

Item

Proposed Norm

Electrical Energy
Raw Mill

BM

Cement Mill

BM

BM

Dry Process

RP+BM
VRM/RP+BM
PG+BM

VRM

Product
OPC-43
OPC-53
PPC
PSC
OPC-43
OPC-53
PPC
PSC
OPC-43
OPC-53
PPC
PSC
OPC-43
OPC-53
PPC
PSC
OPC-43
OPC-53
PPC
PSC

Norm
kWh/tonne
95
97
80
89
91
93
77
87
88
90
74
82
90
92
77
85
86
88
74
79

106
108
93
106
102
104
90
104
99
101
87
99
101
103
89
101
97
99
86
94

NORMS - ELECTRICAL ENERGY (contd.)

Category

System

Item

Proposed Norm

Electrical Energy
Raw Mill
2
3

Cement Mill

Wet Process
Semi-Dry Process
BM

Grinding Units
(Independent)

RP+BM

VRM

Product
kWh/t Cement
kWh/t Cement
OPC-43
OPC-53
PPC
PSC
OPC-43
OPC-53
PPC
PSC
OPC-43
OPC-53
PPC
PSC

Norm
kWh/tonne
100
100
36
38
37
63
33
35
34
58
31
33
34
55

108
108
38
40
40
68
35
37
37
63
33
35
36
58

NORMS THERMAL ENERGY

Category

Item

System

Proposed Norm

Thermal Energy

Dry Process

2
3

Wet Process
Semi-Dry Process

4 Stage PH with Grate Cooler

4 Stage PC with Grate Cooler
5/6 Stage PC with Grate Cooler
5/6 Stage PC (Old Plants)**
Kilns with Planetary Cooler

Product

Norm
kcal/kg clinker

Clinker
Clinker
Clinker
Clinker
Clinker
Clinker
Clinker

810
790
720
780
850
1250
900

860
840
770
830
900
1400
1000

NORMS SUPPLEMENTARY NOTES

(Alternative I)
1
2
3
4
5
6
7
8
9
10
11

Range of Norms has been formulated considering the material characteristics/product fineness and conversion factors (% additives)
BM - Ball Mill; RP - Roller Press(Efficient); PG - Pregrinder/HRC(1st Generation)/VRM (Gravity Discharge);
VRM - Vertical Roller Mill; PH - Preheater Kiln; PC - Precalciner Kiln
Energy consumption figures are yearly average values for reference year
Energy consumption in Workshop, Plant & Colony Lighting is excluded from overall energy consumption
Thermal energy consumption figures to be on NCV basis for the fuel
** Plants commissioned before 1980 and retrofitted 5/6 Stage Preheater later
For plants producing more than one variety of cement, the norms to be worked out based on actual product mix for reference year
Similarly, for plants having a mix of technologies, the norms to be derived on weighted capacities for reference year
Energy consumption in mining & haulage of material upto plant may not be considered keeping in view the different modes
of transport/conveying and varying distances involved
Energy consumption for special cements (other than OPC, PPC, PSC) has not been considered. In case any plant is producing
substantial quantity of special cements, separate norms may be formulated for individual cases
Plants with capacity upto 1200 tpd may be given weightage of 5% in thermal energy norm and 10% in electrical energy norm
over and above the proposed norms in their respective categories

12

Plants using alternate fuels may be given weightage as under in the proposed norms :
a) 10-30% Alternate Fuel - 2% on both Thermal & Electrical Energy Norm
b) > 30% Alternate Fuel - 3% on both Thermal & Electrical Energy Norm

VIEWS FROM TECHNICAL COMMITTEE

MEMBERS & INDUSTRY
RAW MEAL TO CLINKER CONVERSION FACTOR CONSIDERED
(1.45-1.50) NEEDS REVIEW (REVISED TO 1.60)
PERCENTAGE FLYASH ADDITION MAY BE REVIEWED FOR PPC
5-STAGE PH WITHOUT PC MAY BE ADDED AS SEPARATE
CATEGORY
4-STAGE PC WITH GRATE COOLER (OLD PLANTS) MAY BE
CLUBBED WITH 5/6 STAGE PC OLD PLANTS

PROPOSED NORMS - 4th CEMENT

SECTOR TASK FORCE MEETING
October 2006
ALTERNATIVE - II
MAY BE SEEN AS A 3-YEAR ROADMAP NEEDING REVIEW THEREAFTER

REVISED PROPOSED NORMS

HIGHLIGHTS OF MODIFICATIONS

SIMPLIFIED WITH LESSER CATEGORIES OF PLANTS

CONVERSION FACTORS REVISED, AS DISCUSSED IN
TECHNICAL COMMITTEE MEETING OF 26 JULY 2006
ONLY UPPER VALUES PRESCRIBED INSTEAD OF RANGES
THERMAL ENERGY NORMS REVISED CONSIDERING CMA
DATA MADE AVAILABLE TO NCB ON 04 OCT. 2006
METHODOLOGY FOR FINAL INTERPRETATION OF NORMS,
PLANT-WISE (COMPUTING IN TERMS OF GJoules/T CEMENT)

NORMS ELECTRICAL ENERGY

Category

System

Item

Raw Mill

BM

Proposed Norm

Cement Mill

BM

BM
1

Dry Process
VRM/RP+BM

RP/PG+BM

VRM

Product

Norm
kWh/tonne

OPC-43
OPC-53
PPC
PSC
OPC-43
OPC-53
PPC
PSC
OPC-43
OPC-53
PPC
PSC
OPC-43
OPC-53
PPC
PSC

109
111
99
108
104
106
95
105
103
105
94
102
99
101
91
95

NORMS - ELECTRICAL ENERGY (contd.)

Category

System

Item

Raw Mill
2

Wet Process

Semi-Dry Process

Proposed Norm

Cement Mill

BM

Grinding Units
(Independent)

RP/PG+BM

VRM

Product
kWh/t Cement
(Mix)
kWh/t Cement
(Mix)
OPC-43
OPC-53
PPC
PSC
OPC-43
OPC-53
PPC
PSC
OPC-43
OPC-53
PPC
PSC

Norm
kWh/tonne
108
108
40
42
42
70
39
41
41
67
37
39
39
65

NORMS THERMAL ENERGY

Category

Item

Dry Process

2
3

Wet Process
Semi-Dry Process

System

PH Plants with Grate Cooler

PC Plants commissioned before 1989
PC Plants commissioned before 1989, upgraded
PC Plants commissioned after 1989
Kilns with Planetary Cooler & < 1000 tpd plants

Proposed Norm

Product
Clinker
Clinker
Clinker
Clinker
Clinker
Clinker
Clinker

Norm
kcal/kg cl.
870
840
800
770
900
1400
1000

NORMS SUPPLEMENTARY NOTES

(Alternative II)
1

Energy consumption in Workshop, Plant & Colony Lighting is

excluded from overall energy consumption.

For plants producing more than one variety of cement, the norms to
be worked out based on actual product mix.

Similarly, for plants having a mix of technologies, the norms to be

derived on weighted capacities.

Energy consumption in mining & haulage of material upto plant may

not be considered keeping
in view the different modes of
transport/conveying and varying distances involved.

Energy consumption for special cements (other than OPC, PPC, PSC)
has not been considered. In case any plant is producing substantial
quantity of special cements, separate norms may be formulated for
individual cases.

Plants using alternate fuels may be given weightage as under in the

proposed norms :
10-30% Alternate Fuel - 2% on both Thermal & Electrical Energy Norm
> 30% Alternate Fuel - 3% on both Thermal & Electrical Energy Norm

NORMS PROPOSED INTERPRETATION

IN TERMS OF GJ/T Cement
IF A PLANT MEETS EITHER THERMAL OR ELECTRICAL NORM, BUT
DOES NOT MEET THE OTHER, THEN ITS PERFORMANCE MAY BE
EVALUATED THROUGH TOTAL GJOULES/T CEMENT :

GJ/T CEMENT =
[ (KCAL/KG CLINKER X 4.18 X CLINKER : CEMENT RATIO) + (KWH/T
CEMENT X 3.6)] / 1000

EXPECTED DRAWBACKS DURING MONITORING

MAY HAVE TO BE REVIEWED EVERY 3 YEARS RESULTING IN
OTHER MODALITIES INCLUDING FRESH NOTIFICATIONS ETC.
DIFFICULTIES MAY BE ENCOUNTERED WITH STATE LEVEL
IMPLEMENTING AGENCIES DURING MONITORING ON THE
INTERPRETATION OF SOME OF THE CLAUSES/CONCESSIONS &
WEIGHTAGES

NORMS PROPOSED BY CMA

ALTERNATIVE - III

NORMS ELECTRICAL ENERGY

PRODUCT

KWH/T

OPC 43

110

OPC 53

112

PPC

100

PSC

106

NOTE: NO SEPARATE NORMS FOR INDEPENDENT GRINDING UNITS; TO

BE CLUBBED WITH PARENT CLINKER UNIT

NORMS THERMAL ENERGY

CATEGORY

KCAL/KG
CLINKER

WET PROCESS

1350

SEMI-DRY PROCESS

1050

DRY PROCESS, KILN < 1000 TPD

1000

DRY PROCESS, KILN 1000 TO 2000 TPD

925

DRY PROCESS, KILN 2000 TO 3500 TPD

PLANTS INSTALLED BEFORE 1989
PLANTS COMMISSIONED BEFORE 1989, BUT
PARTLY UPGRADED AFTER 1989
NEW PLANTS COMMISSIONED AFTER
1989/OLD PLANTS WITH MAJOR
MODIFICATION
DRY PROCESS, KILN > 3500 TPD

875
825
800

770

PROPOSED NORMS
Based on % Improvement
ALTERNATIVE - IV

NORMS BASED ON % IMPROVEMENT

THE CONCEPT
INDIVIDUALLY

THE BASE LEVEL CONSUMPTION TO BE THE AVERAGE OF

PREVIOUS TWO YEARS OF THE PLANT

PERCENTAGE IMPROVEMENT TARGET TO BE ACHIEVED IN

FOUR YEARS AS PER FOLLOWING CATEGORIES :
CATEGORY

TO

BE

APPLICABLE

ELECTRICAL (KWH/T
CEMENT)

FOR

EACH

PLANT

THERMAL (KCAL/KG CL.)

RANGE

%
IMPROVEMENT

RANGE

%
IMPROVEMENT

Upto 75

0.25

Upto 720

0.25

II

76 85

0.50

720 770

0.50

III

86 100

0.75

771 825

0.75

IV

> 100

1.00

> 825

1.00

ADVANTAGES
EASY TO FOLLOW AND MONITOR

DISADVANTAGES
PERCENTAGE REDUCTION MAY BE DIFFICULT TO ACHIEVE DUE
TO VARIOUS CONSTRAINTS OF TECHNOLOGY, LAYOUT,
FINANCE, MARKET FORCES ETC.