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 | Crusher | kWh/MT Limestone | 0.57 |
| 2 | Raw Mill – VRM | kWh/MT Raw Meal | 10.64 |
| 3 | Raw Mill – Roller Press | kWh/MT Raw Meal | 10.43 |
| 4 | Coal Mill – VRM-Pet Coke Grinding | kWh/MT Pet Coke | 33.89 |
| 5 | Coal Mill – VRM Coal Grinding | kWh/MT Coal | 21.2 |
| 6 | Six Stage Preheater - Kiln SEC | kWh/MT Clinker | 16.8 |
| 7 | Six Stage Preheater Upto Clinkersiation | kWh/MT Clinker | 41.4 |
| 8 | Thermal SEC (6 Stages) | kCal/kg Clinker | 670 |
| 9 | Five Stage Preheater- Kiln SEC | kWh/MT Clinker | 20.1 |
| 10 | Five Stage Preheater Upto Clinkersiation | kWh/MT Clinker | 45.3 |
| 11 | Thermal SEC (5 Stages) | kCal/kg Clinker | 694 |
| 12 | Cement Mill – VRM (PPC Grinding) | kWh/MT Cement | 18.8 |
| 13 | Cement Mill – VRM (OPC Grinding) | kWh/MT Cement | 22.3 |
| 14 | Cement Mill VRM (PSC Grinding) | kWh/MT Cement | 31.1 |
| 15 | Ball Mill (PPC Grinding) | kWh/MT Cement | 23.1 |
| 16 | Ball Mill + HPRG (PPC Grinding) | kWh/MT Cement | 18.58 |
| 17 | Packing Section | kWh/MT Cement | 0.7 |
| 18 | Overall SEC | kWh/MT Cement | 56.1 |