WORKSHOP ON CO2 BENCHMARKING AND MONITORING

AND CDM BENCHMARKING IN CEMENT INDUSTRY

Organised by

VDZ GTZ BEE

11 12 June 2007, New Delhi
14 15 June 2007, Mumbai.

ENERGY EFFICIENCY INITIATIVES,

ESTIMATION OF CO2 EMISSION AND
BENCHMARKING ENERGY AND
ENVIRONMENTAL PERFORMANCE IN
INDIAN CEMENT INDUSTRY
Dr. S.P. Ghosh - CMA

Top 5 Cement Producing

CountriesCement Production
(Mn.t.)
Country

2006

2005

2003

2002

2001

China

1240

1060

813.19

704.1

627.2

India

162

148

126.69

119.8

104.8

USA

100*

92.84

89.7

88.9

Japan

74*

68.9

76.3

79.5

Korea

47*

59.73

56.4

53.7

Others

876*

792.93

777.7

733.9

World Total

2305*

1954.28

1824.0

1688.0

Source : CEMB UREAU

* Data Provisonal

OUR CEMENT INDUSTRY STATUS 12-06

International Ranking

2nd

Installed Capacity*

180 mn.t

Production*

162 mn.t

No. of Plants

Large : 130

206 - Rotary : 13

Mini**

- VSK

: 193

*Projected, 2006-07
**AIMCMA - 2006
Source: CMA

Mn. TONNES

GROWTH OF INDIAN CEMENT INDUSTRY

180
160
140
120
100
80
60
40
20
0

160
142

130
98
61

45

23 20

1980

1990

2001

2006

YEAR
CAPACITY

PRODUCTION

PLANTS WITH CAPACITY OF ONE

MILLION TONNES AND ABOVE

NO. OF PLANTS

80
62

70
60
50
40
30

68

73

39

20
10
0

1995-96

2001-02

2003-04

2005-06

YEAR

CHANGING PROCESS PROFILE OF

INDIAN CEMENT INDUSTRY
1980

1960
SD
5%

DRY
1%

SD
6%

WET
61%

WET
94%

2006

1990
WET
21%

DRY
33%

SD
3%

WET
0.9%

DRY
76%

OTHERS
2.5%

SD
0.1%

DRY
96.5%

CEMENT VARIETIES
PRODUCTION IN 2006-07
Production
(Mil.Tonnes)

%age of
Total

Ordinary Portland Cement

48.64

31.25%

Portland Pozzolana Cement :

93.52

60.08%

Portland Blast Furnace Slag :

12.84

8.25%

Others and Special Cements :

0.65

0.42%

155.65

100.00%

Total:

QUANTUM JUMP IN PPC PRODUCTION:

FROM 2000 TO 2007
Year

OPC

PPC

PSC

Others

Total

%age
Increase of
PPC with
respect to
1999 - 2000

1999-2000

62.76
(66.6%)

21.3
(22.6%)

9.39
(9.97%)

0.72

94.21

2001-2002

57.68
(56.3%)

32.3
(31.5%)

11.89
(11.6%)

0.53

102.40

9%

2003-2004

53.51
(45.5%)

52.13
(44.4%)

11.26
(9.58%)

0.60

117.50

21.8%

2005-2006

55.84
(39.4%)

74.01
(52.2%)

11.37
(8.0%)

0.59

141.81

29.6%

2006-2007

48.64
(31.2%)

93.52
(60.1%)

12.89
(8.25%)

0.65

155.60

37.5%

- 22.5%

340%

36.75%

- 9.7%

65.16%

Production
Increase
in 5 Years

KEY PERFORMANCE INDICATORS

Item

Average Energy Consumption

Thermal Energy kcal/kg cl.
Electrical Energy kwh/t cem.
Best Energy Consumption
Thermal Energy kcal.kg cl.
Electrical Energy kwh/t
Capacity Utilization

Target for Performance in

Target for
Xth Plan* 2005-06 2006-07 XIth Plan #

730
95

725
95

723
82

667
68

663 (650)
63 (65)

85%

Quality ISO 9000

Environment ISO 14001
OHSAS 18000
Emission Compliance

700
75

95%
110 Plants
80 Plants
20 Plants
All Plants

* Report of the Working Group on Cement Industry X Five Year Plan (2002-03 to 2007-08)
# Report of the Working Group on Cement Industry XI Five Year Plan (2007-08 to 2011-12)

Figures in ( ) Pertain to Japanese Cement Industry

10

QUANTUM OF ENERGY INPUTS

TO INDIAN CEMENT INDUSTRY
COAL CONSUMPTION

: 22 MILLION T/YEAR

POWER CONSUMPTION : 14 BILLION UNITS/YEAR

TOTAL ENERGY BILL

: RS 95 BILLION kWH/ YR

CAPTIVE POWER GENERATION

DIESEL

1108 MW

THERMAL

716 MW

WIND ENERGY

80 MW

TOTAL

1904 MW

11

ENERGY CONSUMPTION PROFILE

(DRY PROCESS PLANTS - WTD. AVG.)
900 876

THERMAL
ENERGY
KCAL/KG CL.

850

816 815

800

801
780 779
771

763 750

750

742 734
729 723

700

663

650
600

120

ELECTRICAL
ENERGY
KWH/T CEMENT

857 846

91 92 93 94 95 96 97 98 99 '00 '01 '02 '03 '04 '05

120 122

BEST IN INDIA
117
111 112 110
104 105

100

650

102

BEST IN WORLD

97
91

89

84 83

82

80
63

60

91 92 93 94 95 96 97 98 99 '00 '01 '02 '03 '04 '05

65

12

TREND OF ELECTRICAL ENERGY CONSUMPTION IN INDIAN CEMENT

INDUSTRY
VRMs & 3000 TPD KILNS

140

LOW PR. PREHEATER & EXPERT

SYSTEMS

130
120
110

1200 TPD 4-ST SP KILNS

PC KILNS
ROLLER PRESS & HIGH EFFICIENCY
SEPERATORS

DRY PROCESS KILNS

100
HIGH EFFICIENCY FANS, MECHANICAL
CONVEYORS

90
80
1960

1965

1970

1975

1980

1985

1990

1995

2000

2005

YEAR
KWH/T CEMENT

13

TREND OF THERMAL ENERGY CONSUMPTION IN INDIAN

CEMENT INDUSTRY
1700

1200 TPD 4-ST SP KILNS

1500

PC KILNS

DRY PROCESS KILNS

WET TO DRY CONVERSION

1300

5-STAGE PC KILNS

1100

6 STAGE PC KILNS & MULTI-CHANNEL

BURNERS

900
700
1960

HIGH EFFICIENCY COOLERS

1965

1970

1975

1980

1985

1990

1995

2000

2005

YEAR
KCAL/KG CL.

14

Process wise Cement Energy

Consumption Pattern in India
2006
Specific Heat
Consumption
(kcal/kg of clinker)

Process

Wet

Specific Power
Consumption
(kWh/tonne of
cement)

1300

115

900

110

4 State pre heater

Precalcinator

800

105

5 stage pre-heater,
precalcinator

750

88

665 *

68 *

Semi dry
Dry process

6 stage pre-heater, twinsteam, precalcinator, pyro

step coller

Sources : CMA, NCB

* Best Achieved

15

CMA Benchmarking Exercise

Improve

productivity

Reduce

Energy Consumption

Increase

profitability

16

CMA Benchmarking Exercise

Contd..

Compares your plant with similar others

Benchmark today includes 75 plants on
quarterly basis and 100 plants on annual
basis comprising

130 crushers
116 raw mills
125 coal mills
112 kilns
209 cement kilns
17

CMA Benchmarking Exercise

Contd..

It regularly tracks and reports to participating

plants their individual performance with
respect to the Average and Best
Performer in respective affinity groups.

An affinity Group for any particular major

equipment or auxiliary includes the same type
of equipment, providing thereby a comparison
between the likes only.
18

AFFINITY GROUP DEFINITIONS FOR

DIFFERENT EQUIPMENTS
Classification

Codes

Crushers

Jaw
Roll
Impact
Hammer
Hammer Impactor
Hybrid
Others

CR1
CR2
CR3
CR4
CR5
CR6
CR7

Raw Mills

Ball Mill
Ball Mill with high efficiency classifier
Hybrid Mills (Roll Press + Ball Mill)
Vertical Roller Mill

RM1
RM2
RM3
RM4

19

AFFINITY GROUP DEFINITIONS FOR

DIFFERENT EQUIPMENTS
Classification

Codes

Coal Mills

Ball Mill upto 30 tph

Ball Mill with 30 + tph
VRM
Other Systems

CLM1
CLM2
CLM3
CLM4

Kilns
Wet Process upto, 1000 TPD
Semi Dry Process, upto 1000 TPD

KL1
KL2

Long Dry Kilns with

Upto, 1000 TPD
1000 1500 TPD
1500 2000 TPD

KL3
KL4
KL5

20

AFFINITY GROUP DEFINITIONS FOR

DIFFERENT EQUIPMENTS
Classification

Codes

Dry Kilns with

2000 2500 TPD, Pre-Heater
2000 2500 TPD, With PH and PC
2500 3000 TPD, With 4 Stage PH & PC
2500 3000 TPD, With 5 6 Stage PH & PC
3000 3500 TPD, With 4 Stage PH & PC
3000 3500 TPD, With 5 6 Stage PH & PC
3500 4500 TPD
4500 6000 TPD
6000 8000 TPD

KL6
KL7
KL8
KL9
KL10
KL11
KL 12
KL13
KL14

21

AFFINITY GROUP DEFINITIONS FOR

DIFFERENT EQUIPMENTS
Classification

Codes

Cement Mills

Ball Mill upto 30 TPH

Ball Mill upto 30 50 TPH
Ball Mill upto 50 100 TPH
Ball Mill upto 100 150 TPH
Ball Mill upto 150 200 TPH
Ball Mill upto 200 + TPH
Ball Mill with High Efficiency Classifier
Vertical Roller Mill
Hybrid (Roll Press + Ball Mill)

CM1
CM2
CM3
CM4
CM5
CM6
CM7
CM8
CM9

22

PARTICIPANTS CEMENT PLANTS

Vasavadatta Cement - Sedam

Kanoria Cement - Bagalkot

Mangalam Cement Unit-I Morak

Dalmia Cement (Bharat) Ltd.-Dalmiapuram

Mangalam Cement Unit-II Morak

Birla Cement Works - Chittorgarh

Century Cement - Baikunth

Chittor Cement Works - Chittorgarh

Binani Cement Ltd. - Binanigram

Chettinad Cement (Puliyur Cement Works)

Mysore Cement Ltd. - Ammasandra

Chettinad Cement (Karikkali Cement Works)

India Cement - Sankarnagar

Zuari Cement - Yerranguntla

Aditya Cement Adityapuram (Grasim Group)

Guj Ambuja Himachal (Ambuja Group)

Rajashree Cement Malkhed (Grasim Group)

Guj Ambuja - Bhatinda* (Ambuja Group)

Grasim Cement South (Grasim Group)

Guj Ambuja - Ropar* (Ambuja Group)

Grasim Cement- Raipur (Grasim Group)

Guj Ambuja - Rabriyawas (Ambuja Group)

Birla Super - Solapur* (Grasim Group)

Maratha Cement - Chandrapur (Ambuja Group)

Birla Plus - Bhatinda* (Grasim Group)

Gujarat Ambuja - Eastern (Ambuja Group)

Shree Digvijay Cement Sikka (Grasim Group)

Ambuja Cement-Kodinar (Ambuja Group)

Vikram Cement Khor (Grasim Group)

Gajambuja Cement-Kodinar (Ambuja Group)

Madras Cement -Alathiyur

Gujarat Sidhee Cement Veraval

Shree Cement Ltd., Unit I (Shree)

ACC Mancherial (ACC)

Shree Cement Ltd., Unit II (Shree)

KCP Macherla

Manikgarh Cement - Gadchandur

CCI Tandur

23

Maihar Cement Unit-I Saralanagar

Tamil Nadu CementCorp.-Ariyalur

Maihar Cement Unit-II Saralanagar

Damodhar Cement & Slag Ltd.-Madhukunda*

Birla Vikas Cement - Satna

India Cement - Sankari

Satna Cement Works - Satna

Birla Corp. Ltd. - Raebareli*

Lakshmi Cement - Banas

India Cements Ltd. - Dalavoi

India Cement Vishnupuram

Kesoram Cement - Basant Nagar

ACC - Kymore Cement Work (ACC)

Ambuja Cement Eastern - Sankrail* (Ambuja Group)

Shriram Cement Works - Kota

Indorama Cement Ltd.*

Madras Cement-Ramasamyraja Nagar

Ultra tech CemCo A.P Cement Works

Diamond Cements - Jhansi*

ACC Tikaria Cement Works* (ACC)

Orient Cement - Devapur

ACC Chanda Cement Works (ACC)

Priyadarshini Cement Ltd.-Nalgonda

ACC Madukkarai Cement Works(ACC)

Birla Corp-Durgapur Cement Works*

J.K.Cement- Nimbahera

ACC Chaibasa Cement Works (AC)

Narmada Cement Co. Ratnagiri

J.K.Cement- Mangrol

Narmada Cement Company Magdalla

ACC - Gagal

Ultratech Jharasguda

Narmada Cement Co. Ltd. Jafarabad UltraTech

UltraTech Cement Arakkonam

UltraTech CemCo- Awarpur

UltraTech Hirmi

OCL India Ltd.-Rajgangpur

Gujrat Cement Works

24

Indicators which are being used in affinity

group report
1) Electric energy consumption Crushing (Kwh per
ton of limestone)
2) Electric energy consumption Raw Mill (Kwh per
ton of raw mix)
3) Electric energy consumption Kiln (Kwh per ton
of clinker)
4) Electric energy consumption Cement Mill (Kwh
per ton of OPC 43 equivalent)
5) Electric energy consumption Coal Mill (Kwh per
ton of coal)
6) Thermal Energy consumption (burning) Kiln &
Cooler (Kcal per kg of clinker)

25

Indicators which are being used in

Environment report
Conventional Air Pollution
SPM Released -- Cement Mill (mg/Nm3)
SPM Released -- Clinker Cooler (mg/Nm3)
SPM Released -- Coal Mill (mg/Nm3)
SPM Released -- Kiln (mg/Nm3)
Ambient Quality
SPM Concentration-Average Value (mg/Nm3)

26

TEXT BASED REPORTS SAMPLE

1) QUATERLY PERFORMANCE REPORT AFFINITY WISE
Energy Consumption AFFINITY WISE
Equipment

Affinity
Group

Rating of
Performance

ELECTRICAL ENERGY (Kwh per ton of material)

PLANT XX

QUARTER II YEAR 2006

Equipment
Your
Avg
Value

Affinity Group Values

Best
Coeff of
Variation

(%)
1

CRUSHER

CR3 AVERAGE

1.34

1.36

0.43

32.70

RAW MILL - I

RM1 ABOVE AVERAGE

17.38

21.16

8.50

17.69

RAW MILL - II

RM1 ABOVE AVERAGE

17.06

21.16

8.50

17.69

KILN - I

KL4

AVERAGE

27.73

28.43

20.63

13.77

KILN - II

KL4

AVERAGE

27.34

28.43

20.63

13.77

CEMENT MILL I CM2

22.88
12.38

ABOVE AVERAGE

28.18

32.33

CEMENT MILL II CM2

22.88
12.38

ABOVE AVERAGE

28.00

32.33

CEMENT MILL III CM2

22.88
12.38

BELOW AVERAGE

40.02

32.33

THERMAL ENERGY FOR BURNING(KCal per kg of clinker)

27

2) QUATERLY PERFORMANCE REPORT PLANT LEVEL

QUATERLY REPORT FOR PERFORMANCE INDICATORS
PLANT XX QUARTER YY YEAR YYYY
Description

Your
Performance

Your Plant Avg of Best

Value Group Values

Conventional Air Pollution

1 SPM Released -- Cement Mill (mg/Nm3)

BELOW AVERAGE

71.00 62.36

11.69

2 SPM Released -- Clinker Cooler (mg/Nm3)

BELOW AVERAGE

74.00 67.90

18.30

3 SPM Released -- Coal Mill (mg/Nm3)

AVERAGE

61.00 58.14

17.20

4 SPM Released -- Kiln (mg/Nm3)

ABOVE AVERAGE

40.00 76.77

14.00

ABOVE AVERAGE

0.11

Ambient Quality
5 SPM Concentration-Average Value (mg/Nm3)

0.18

0.06

28

GRAPHICAL REPORTS
1.) PERFORMANCE OF CEMENT MILL IN ITS AFFINITY GROUP

AFFINITY GROUP DESCRIPTION : BALL MILL, 50-100 TPH

(CM3)

Electrical Energy in Kwh/ton of OPC43

equ.

29

GRAPHICAL REPORTS
2.) PERFORMANCE OF CEMENT MILL OF A PLANT OVER FOUR
QUARTERS

Affinity Group Description : HYBRID (Roll Press + Ball Mill) (CM9)

Kwh/ton of OPC 43 equ.

28

24

20

16
Qtr 1

Qtr 2

Qtr 3

Qtr 4

30

GRAPHICAL REPORTS
4.) PERFORMANCE OF ALL THE CEMENT MILL OF A PLANT OVER
FOUR QUARTERS.

Energy Consumption-Cement Mills Plant-XX F.Y. 2004-05

Kwh/ton of OPC 43 equivalent

38

36

34

32

30

Qtr 1
Cement Mill I

Qtr 2
Cement Mill II

Cement Mill III

Qtr 3
Cement Mill IV

Qtr 4
Cement Mill V

31

GRAPHICAL REPORTS
1) PERFORMANCE OF CEMENT MILL WITH THE AVG & BEST
OF ITS PEER GROUP OVER ANY TIME PERIOD.

32

2) COMPARITIVE ANALYSIS OF EQUIPMENT (CEMENT MILL)

INDIVIDUAL PLANTS

BEST

AVERAGE

ACTUAL

33

One Plant All Parameters

34

35

PROPOSED ENERGY CONSUMPTION

NORMS SUGGESTED BY CMA & NCB
Item

System

Thermal Energy
(Unit K.Cal/Kg.
Clinker measures
As NCV)

Proposed Norms

1. Wet Process
2. Semi-Dry Process
3. Dry Process Kiln < 1000 TPD

< 1400

4. Dry Process, Kiln 1000 to 2000 TPD Capacity

< 875

< 1000

5. Kiln with 2000 to 3500 TPD Capacity on Commissioning

a)
b)
6. a)
b)

Plants Commissioned before 1989

< 850
Plants Commissioned after 1989, or Old Plants with Major
Modification after 1989 initial Capacity less than 3500 TPD < 820
Kiln above 3500 TPD Capacity Commissioned Pre 2000
Kiln above 3500 TPD Capacity Commissioned Post 2000

All Capacities mean Original Installed Capacity.

< 800
< 770

36

PROPOSED ENERGY CONSUMPTION

NORMS SUGGESTED BY CMA & NCB
Item
Power

System
1. Integrated Plants

(Kwh/Tonne
Cement)

a)
b)
c)
d)

OPC - 43
OPC 53
PPC
PSC

< 110
< 112
< 100
< 108

2. Grinding Unit
a)
b)
c)
d)

OPC - 43
OPC 53
PPC
PSC

< 110
< 112
< 100
< 108

Power Consumption for Pozzolana Cement (PPC) and Slag Cement

(PSC) depends upon the percentage of fly ash or slag used and varies
widely for the same plant. Grinding units should not have separate
Norms. The energy (power) consumption should be linked to that of
the sources clinker. The power consumption values for each Grinding
unit should be computed on the basis of power consumption up to
clinkerisation of the mother unit from which the clinker is sourced, plus
the value for cement grinding, and be equated with the power
consumption for the integrated plant.

37

Proposal to BEE for Energy Conservation Norms

Voluntary Reduction for Power Consumption
OPC 43

OPC 53

PPC

PSC

Range
(Kwh/Tonne)

Annual
Reduction

Range
(Kwh/Tonne)

Annual
Reduction

Range
(Kwh/Tonne)

Annual
Reduction

Range
(Kwh/Tonne)

Annual
Reduction

< 85

0.00%

< 87

0.00%

< 77

0.00%

< 80

85 90

0.25%

87 92

0.25%

77 82

0.25%

80 85

0.25%

90 100

0.50%

92 100

0.50%

82 90

0.50%

85 95

0.50%

100 109

0.75%

100 111

0.75%

90 99

0.75%

95 106

0.75%

> 109

> 1.00%

> 111

> 1.00%

> 99

> 1.00%

> 106

> 1.00%

VOLUNTARY REDUCTION* FOR HEAT CONSUMPTION

1. Annual Reduction to be monitored only at the

end of the block period.

Range, K.Cal/Kg.

Voluntary Annual
Reduction

< 725

0.00%

2. Block period may be considered as 3 years.

725 750

0.25%

750 780

0.50%

3. Base Year 2006-2007 Figures may be

considered.

780 820

0.75%

> 825

1.00%

4. Hence, Terminal Year for the Block period =

2009-2010.

38

GHG Emission from Cement

Manufacture
Cement

manufactured generates one

major GHG CO2
One tonne of cement produces 0.6 to
1.0 tonne of CO2
The sources of CO2 emission are
Calcination

: 45 - 50%
Fuel Combustion
: 40 - 45%
Power used/ generation : 10 - 20%
39

ESTIMATION OF CO2 EMISSION OVER

DECADES - INDIAN CEMENT
INDUSTRY
YEAR

IPCC

CMA

NCL

1990

20933

20933

20851

1994

29510

29461

29305

2000

47317

46742

46774

IPCC :interGov-l Panel on Climate Change

CMA :Cement Manuf. Association,India
NCL :National Chemical Laboratories,India
40

ESTIMATES OF GHG EMISSION

DIFFERENT AGENCIES TALLY WELL

ITEM YEAR
CO2 1994
SO2

1994

IPCC
29,512
19

CMA
29,463

NCL
29,307

18.6

41

SIGNIFICANT GHG EMISSION

REDUCTION
YEAR CEMENT PRODN GHG EMISSION
RATIO
Cement:
GHG

1990
44.87 mln.t
1.20

53.84 mln.t

1996
64.54 mln. t
1.19

77.02 mln. t

2000
94.21 mln. t
0.97
2003

117.45 mln. t

91.82 mln. t
101.55 mln. t 42

FUTURE TARGETS FOR

GHG
REDUCTION
Area of
Future Use
Likely GHG Reduction
Improvement

% (2015)

(%)

Blended Cements

75-80

22-24

CNG as Fuel

20

8-9

Waste Derived Fuel 20

8-9

Non-Conventl Energy 8

2-3

(Wind,Hydro)

Energy Efficient
10
8-10
Plant/Machinery ____________________________
TOTAL 48-55

43

Carbon
Carbon Sequestration
Sequestration
About 20 millions Trees
Planted in last 2 decades
Around Plants - Carbon Sink

Mined out areas

converted into
lakes.
SIBERIAN Birds

CARBON SINKS GREENERY AROUND

CEMENT PLANTS

GHG PROTOCOL: SOME BACKGROUND

Convened in 1998 by WRI and WBCSD
Mission: to develop international GHG
accounting & reporting standards for business
through an inclusive & transparent multistakeholder process
Two modules: GHG Protocol Corporate
Accounting and Reporting Standard
(Corporate Standard) and GHG Protocol for
Project Accounting (Project Protocol)

46

BENEFITS OF A COMMON STANDARDS

Simplify measurement & reporting
Harmonization across international borders &
different initiatives
Improve comparability & credibility
Minimize the cost of developing a GHG
inventory
Establish a common foundation for GHG
markets.

47

CUSTOMIZATION OF INVENTORY TOOLS: INDIA INDUSTRY

FRIENDLY & CUSTOMIZED FOR INDIAN CONDITIONS

Goal: Improved consistency & accuracy in estimation of

emissions
*
Develop sector-specific Emission Quantification Tool:

Start with internationally developed tool and

methodologies: GHG Protocol (WRI/WBCSD)
*
Add India-specific fuels, emissions factors, generation mix data
*

User-friendly, streamlined
Incorporates needs & objectives of key stakeholders
Reflects Indian operating conditions, developments and
testing in India by Indian Industry.

Add conventional air pollutants

Cement Sector Tool Completed

Power Sector Tool Under Development

48

CORPORATE GHG MANAGEMENT:

STEP-BY-STEP

Secure Management support

Establish a Team
Prepare a Budget
Define Inventory Boundary
Determine Sources of Emissions
Factor in Emissions from Leased Assets
Design Efficient Data Management System
Select a Base Year
Obtain appropriate Data, ensure Data Quality
Apply Calculation Tool
Guard against Calculation Errors
Identify Emission Reduction opportunities
Decide on Target Type
Decide on Target Level
Implement Emission Reduction Activities
Publicly Report Inventory.

49

IDENTIFICATION OF GHG EMISSION

SOURCES

All forms of stationary combustion sources: kilns,

precalcinators, captive power plant (DG etc), driers
etc.
Process related emissions: GHG emissions resulting
due to process operations i.e. emission of CO2 due to
calcination of raw materials.
Emissions from mobile sources: company owned
vehicles, locos, quarry equipment etc.
Indirect emissions (import and export of electricity)
For accounting GHG emissions at plant level, all
emissions to be classified as scope (1/2/3).
50

STRUCTURE OF THE
CUSTOMIZED CEMENT TOOL

Consists of simple Excel based tool and a

guidance document to fill the worksheets
The Excel tool has independent worksheets to
calculate emisisons from various sources
Worksheets in the tool:
General Plant Information
Custom Emission Factor for Calcination
Custom Emission Factor for Fuel
Direct Process Emissions
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STRUCTURE OF THE
CUSTOMIZED CEMENT TOOL
Direct Emissions from Stationary Combustion
(kiln, pre-calcinator, DG set etc.)
Direct Emissions from Mobile Vehicle, Quarry
Equipment
Indirect Electricity Import
Indirect Clinker Imports
Summary Inventory Sheet
Reference Sheets (like Unit Conversion, Default
Emission Factors etc.)

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KEY DATA REQUIREMENT

Annual Clinker Production
Annual Fuel Consumption Data Sourcewise
Annual Electricity Purchased
Average Clinker Composition (CaO/MgO
Content), Raw Material Composition, Carbon
Content and CV of Coal
Average Dust Emissions from Kiln Stack.

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PROPOSED PARTNERSHIP WITH

CMA

Tool to be Transferred to CMA

CMA Members Adopt it on a Voluntary Basis.
Tool and Guidance to be Available on CMA, GHG
Protocol and TERI Websites
TERI to initially Provides Details to Plant Managers
of Different Cement Plants on Using Tool
Initially 2 Dissemination Workshops Regional Level
Plants start Inventorisation and Use the GHG
Inventory Tool at Plant/Corporate Level
TERI can Provide Back-up Support.

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