Introduction of Cement Sector under

PAT Scheme
Sudhan Ramkumar
Bureau of Energy Efficiency
 Indian Cement Industry

 India is the second largest cement market

in the world, accounting for about 6% of
the world’s cement production
 The cement industry uses coal and
electricity as the main sources of fuel.
 Energy cost accounts for about 40% of the
total manufacturing cost in some of the
cement plants and coal accounts for 15%–
20% of the total production costs.
 Indian Cement Industry (contd.)
 The specific energy consumption patterns of
most of the plants very, having wide band
variation.
 This happens mainly because of plants having
different product mix based on addition of
Pozzolona, Slag and Fly Ash and different
blending percentage.
 The pure cement being Ordinary Portland
Cement (OPC) and no dilution by additives,
consumes the highest energy per ton.
 The blending with additives to manufacture other
varieties reduces the Specific Energy
Consumption per tonne.
 Indian Cement Industry (contd.)

 Because of these complexities, it becomes

extremely difficult to come to a common model
to arrive at standardized SEC per ton.
 Considering all these situations, the conversion
factors and best possible combination and
categorization have been worked out so that no
Designated Consumer may have any grievance
on the targets set out
 While setting targets , units best in the group as
reference and then worked out targets for
others.
 Grouping of DCs

CEMENT PLANTS
(85 DCs)

Based on Major Product

PPC (55) OPC(16) PSC (7) White OPC Wet Plant

(2)
+
(2)
Grinding(2)
+
Only clinker(1)
 DC Status In Cement Sector

 Best Thermal SEC ( EC Award 2014) : 683.6 kcal/ kg Clinker.

 Best Electrical SEC( EC Award 2014) : 67.2 kwh/ t of Cement
 Threshold Limit for DC Selection : ≥ 30000 MTOE per annum
 Total No. of identified DCs : 85
 Integrated Unit : 78
 Clinkerisation Unit : 1
 Grinding Unit : 2
 Wet Cement Plants : 2
 White Cement Plant : 2

 Baseline Energy Consumption : ~15 mMTOE by all the DCs

 Target Reduction : ~4.8%

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 Example - Input & Output for a Typical Cement Plant covered under PAT and exhibiting
the complexity involved
Coal (Indian)
(1,03,339 Tons/yr ,GCV 3438 kcal/kg)

Coal1 (Imported)
CPP 314.8 Million KWh/yr GRID (Exported)
(6246 Tons/yr, GCV 5454 kcal/kg) (Heat Rate (1.935 million kWh/YR)
3135 kcal/kWh)
Furnace Oil
(669 Tons/yr, GCV 10000 kcal/kg)
HSD Crushing and
DG SET
(570 Tons/yr , GCV 8600 kcal/litre)
(Heat Rate
Mining
2212 kcal/kWh) 0.209 Million (Exported)
kWh/ yr (2.512 million kWh/YR)
Grid Electricity (5.308 Million KWh/yr)
Colony, (0.51 Million kWh/yr)
Coal2 (Imported) Clinkerization
124746 Tons/yr, GCV 6192 kcal/kg)
Pet Coke (Raw Material Processing &
(3316 Tons/yr, GCV 8400 kcal/kg) Pyro-processing)
Crushed Limestone

Iron Ore, Bauxite,Gypsum

PPC (1.492 Million
TON/YR)
Grinding
Flyash, Slag, etc
(VRM and OPC (0.008 Million
TON/YR)
Clinker (0.006 Million Tons/yr) RP &BM)
PSC /OTHER
(0.230 Million TON/YR)
7
Note: All values presented in the above diagram are average of annual energy consumption of 2007-08, 2008-09, 2009-10
Cement Sector

8
 Summary of Energy Saving targets for Cement Sector

1) Total Energy Consumption :-15.01 Million toe

2) No. of DC's as of date :- 85
3) Total reduction for cement sector:-0.815 Million toe
4) Reduction target for DC's varying from :-

i) 3.99% to 6.87% (for PPC as major Product)

ii) 4.23% to 6.00% ( for OPC as major product)
iii)3.71% to 5.13% ( for PSC as major product)
iv) 5.01% to 5.12% (for white cement plants)
v) 4.87% to 4.88% (for Wet Cement plants)
vi) 4.10% to 5.94% ( for grinding plants)
 PAT Cycle – 1 Achievement in Cement sector
SEC Comparison (PPC)
0.25

PPC Sub-Sector
0.2 Descriptions BY AY % Change Remarks
Thermal SEC 788 764 -2.97 3% reduction in Thermal SEC
0.15 Electrical SEC 64.31 63.28 -1.60 1.6% reduction in Electrical SEC
Electrical SEC Cement 34.74 34.49 -0.72
Unormalised SEC 0.0845 0.0801 -5.26
0.1
Normalised SEC 0.0771

0.05

0
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47

Assessment year Baseline year

SEC Comparison (OPC)

2500

2000 OPC Sub-Sector

Descriptions BY AY % Change Remarks
1500
Thermal SEC 792 769 -2.82 3% reduction in Thermal SEC
Electrical SEC 60.57 58.62 -3.22 3% reduction in Electrical SEC
1000
Electrical SEC Cement 34.17 33.25 -2.70 2.7% reduction in Electrical SEC
500 Unormalised SEC 0.0983 0.0893 -9.08
Normalised SEC 0.0869
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
12
Assessment year Baseline Year
 PAT Cycle – I Achievement

SEC Comparison (White Cement)

0.35 White Cement Sub-Sector
0.3 Descriptions BY AY % Change Remarks
0.25 Thermal SEC 1070 1044 -2.41 2.4% reduction in Thermal SEC
0.2 Electrical SEC 70.87 69.16 -2.42 2.4% reduction in Electrical SEC
0.15
Electrical SEC Cement 44.42 42.86 -3.53 3.5% reduction in Electrical SEC
Unormalised SEC 0.1471 0.1491 1.31
0.1
Normalised SEC 0.1439
0.05
0
1 2

Assessment year Baseline Year

SEC Comparison ( PPC Cement)

2500

2000 PSC Sub-Sector

Descriptions BY AY % Change Remarks
1500
Thermal SEC 796 772 -2.98 3% reduction in Thermal SEC
Electrical SEC 76.49 65.79 -14.00 14% reduction in Electrical SEC
1000
Electrical SEC Cement 49.16 43.73 -11.05 11% reduction in Electrical SEC
500 Unormalised SEC 0.0802 0.0758 -5.45
Normalised SEC 0.0737
0
1 2 3 4 5 6
13
Assessment Year Baseline year
 PAT Cycle – I Achievement

0.04
0.3
0.035
0.25
0.03
0.2 0.025
0.15 Baseline year 0.02 Baseline year

0.1 Assessment year 0.015 Assessment year

0.01
0.05
0.005
0
0
1 2
1 2

Grinding Sub-Sector
Wet Cement Sub-Sector
%
Descriptions BY AY % Change Remarks Descriptions BY AY Change Remarks
Thermal SEC 1140 1074 -5.80 5.8% reduction in Thermal SEC Thermal SEC 0 0 0.00
Electrical SEC 0.00 0.00 0.00
Electrical SEC 82.50 89.80 8.85 8.85% increment in Electrical SEC
Electrical SEC
Electrical SEC Cement 43.74 40.58 -7.22 7% reduction in Electrical SEC Cement 38.45 37.70 -1.97 2% reduction in Electrical SEC

Unormalised SEC 0.1242 0.1160 -6.61 Unormalised SEC 0.0172 0.0139 -19.23

Normalised SEC 0.1101 Normalised SEC 0.0150

14
Indian average Vs Global

20 kWh/ton

15
 PAT Cycle – II

No. of Annual Energy Share Apportioned Energy

S.No Sectors Identified Consumption Consumption Reduction For PAT
DCs (Million toe) (%) Cycle-1 (Million toe)

Power
1 (Thermal) 154 120.16 52.99% 3.13
2 Iron & Steel 71 40.44 17.83% 2.14
3 Cement 111 21.43 9.45% 1.1
4 Aluminium 12 10.66 4.70% 0.57
5 Fertilizer 37 8.25 3.64% 0.446
6 Paper & Pulp 29 2.68 1.18% 0.15
7 Textile 99 1.48 0.65% 0.087
8 Chlor- Alkali 24 1.77 0.78% 0.101
9 Refinery 18 18.5 8.16% 1.1
Electricity
10 Distribution 44
Companies
11 Railway 22 1.39 0.61% 0.033
Total 621 226.76 8.869
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 PAT Cycle II Target

 Total No. of identified DCs : 111

 Integrated Unit : 101
 Clinkerisation Unit : 3
 Grinding Unit : 3
 Wet Cement Plants : 2
 White Cement Plant : 2

 Baseline Energy Consumption : ~21mMTOE by all the DCs

 Target Reduction : ~1.1%

17
Thank You

Sudhan Ramkumar
Bureau of Energy Efficiency

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