There are significant opportunities in most of the cement plants to improve their energy efficiency as the gap between the best performing plant and
the other plants is still large (difference of 10-12 kWh/MT cement and 50-80 kcal/kg clinker).
This Benchmarking tool will help cement plants to understand the extent of difference in their performance as compared to the best performing
plants, as well as the root cause for the differences.
The best-operating values and the outcome of the benchmarking study are as follows
| BENCHMARKING NUMBERS | |||
|---|---|---|---|
| Sr. No. | Section | Unit | Value |
| 1 | Emission Intensity | Kg CO2/MT Cement | 285 |
| 2 | SEC Upto Clinkerisation | kWh/MT Clinker | 42.1 |
| 3 | SEC Grinding + Packing | kWh/MT Cement | 18.62 |
| 4 | Overall SEC | Kg CO2/MT Cement | 56.1 |
| 5 | SP. Heat Consumption | kCal/Kg Clinker | 67.5 |
| 6 | Clinker Factor | 0.55 | |
| 7 | Renewable Energy | % of overall Electrical Energy | 24 |
| 8 | Average power generation through WHR | kWh/MT Clinker | 32 |
| 9 | Alternate Fuel ( Thermal Substitution Rate ) % | % | 35 |
| 10 | No. Of Preheater Stages | 6 | |
| 11 | Share of CPP ,Grid,WHR and RE in Overall Power Consumption | CPP : GRID : WHR : RE | 23 : 31 : 21 : 18 |
| 12 | Major Product | - | PSC |