MONITORING REPORT
Version: 02
Date: 27/12/2006
ULTRATECH CEMENT LIMITED (UTCL)
Optimum utilisation of clinker by production of Pozzolana Cement at
UltraTech Cement Ltd. (UTCL),
Andhra Pradesh.
Reference No. UNFCCC 00000438
Project Location
Andhra Pradesh Cement Works
Bhogasamudram, Tadipatri
District: Anantpur, Andhra Pradesh –
515415, India
&
Arakkonam Cement Works
Chetteri village, PO Arakkonam 631003
Vellore, Tamilnadu, India
ULTRATECH CEMENT LIMITED
UltraTech Cement Limited
Bhogasamudram, Tadipatri
District: Anantpur, Andhra Pradesh –
515415, India
Tel: 91-8558-288801
Fax: 91-8558-288821/31
www.adityabirla.com2
SECTION- I: INTRODUCTION
I.1: Project Description
UltraTech Cement Limited has five integrated cement plants one among is Andhra Pradesh
Cement Works (APCW), which has as an installed capacity of 2.3 Million Tonnes per annum.
Andhra Pradesh Cement Works (APCW) is situated in Tadipatri, Andhra Pradesh. This plant
has one grinding unit installed in Arakkonam, Tamilnadu. This is a grinding unit which
produces mainly Portland Pozzolana Cement (PPC) with the clinker supplied by UltraTech
Cement Limited Tadipatri.
The project activity entails a reduction of the clinker content by producing the Portland
Pozzolana cement (PPC), thereby replacing an equivalent amount of clinker at UTCL’s
cement manufacturing units at Tadipatri, Andhra Pradesh & Arakkonam, Tamilnadu.
I.2: Current Status of the Project Activity
The project activity started in phased manner with the increasing additives percentage in the
PPC. The project is operating in a successful manner since 1st April 2000.
The project activity has been registered with UNFCCC as CDM activity1
under sectoral
scope 4 - Manufacturing Industries as per the sectoral scopes related approved
methodologies and Designated Operational Entities (DOE) (version 19 Sep 05, 15:57).The
UNFCCC reference number for the project activity is 00000438.
I.3: Baseline Methodology Adopted
TITLE: Consolidated Baseline methodology for increasing the Blend in cement
production (ACM0005 VER 02)
Reference: UNFCCC website
1
http://cdm.unfccc.int/Projects/DB/DNV-CUK1148386358.08/view.html3
Section- II: Monitoring
II.1: Monitoring Methodology
TITLE: Consolidated monitoring methodology for increasing the Blend in cement
production (ACM0005-ver02)
II.2: Monitoring Period
Monitoring period for the project activity is chosen from 01/04/2000 -31/03/2006 (Both days
included). Parameters monitored during the period and their recording frequency is given in
the ensuing paragraph. Data has been archived for verification purpose.
II.3: Monitoring Parameters
II.3.1: Data Monitored for Project Emission Calculations
ID
no
Data variable Data unit Recording
Frequency
Comments
1.1 InCao y % Daily Estimated from lab
experiment of average
daily sample.
Instrument: X-ray
Analyzer
Procedure: As per ISO
9001
1.2 OutCao y % Daily Estimated from lab
experiment of average
daily sample.
Instrument: X-ray
Analyzer
Procedure: As per ISO
9001
1.3 InMgo y % Daily Estimated from lab
experiment of average
daily sample.
Instrument: X-ray
Analyzer
Procedure: As per ISO
9001
1.4 OutMgo y % Daily Estimated from lab
experiment of average 4
ID
no
Data variable Data unit Recording
Frequency
Comments
daily sample.
Instrument: X-ray
Analyzer
Procedure: As per ISO
9001
1.5 Quantity of clinker
raw material
Kilo Tonnes Annually Measured from Silo level
(Silo rope) and
crosschecked from
physical verification.
1.6 CLNKy Kilo Tonnes of
clinker
Annually Kiln feed is measured
from weigh bridge.
Clinker quantity is
calculated from of kiln
feed to kiln feed to clinker
conversion factor.
Crosschecked from
physical verification.
1.7 FFi_y tonnes of fuel i Annually Instrument: Weigh bridge
Accuracy: +/- 2%
Calibration: As per ISO
procedure
1.8 EFFi
tCO2/tonne of
fuel i
Annually IPCC default values
Uncertainty: Low
1.9 PELE grid_CLNK,y MWh Monthly Instrument: Electrical
meter
Accuracy: +/- 1%
Calibration: Internal
procedure
1.10 EF grid_BSL tCO2/MWh Annually Calculated in the baseline
and validated by
validation DOE.
1.11 PELE sg_CLNK,y MWh Monthly Instrument: Electrical
meter
Accuracy: +/- 1%
Calibration: Internal
procedure
1.12 EF sg_y tCO2/MWh Monthly Calculated from the
quantity of fuel consumed
in power plant and the
quantity of fuel used. 5
ID
no
Data variable Data unit Recording
Frequency
Comments
1.13 ADD,y Quantity of
additives
Kilo Tonnes Monthly Instrument: Weigh bridge
Accuracy: +/- 2%
Calibration: As per ISO
procedure
1.14 PELE grid_BC,y MWh Monthly Instrument: Electrical
meter
Accuracy: +/- 1%
Calibration: Internal
procedure
1.15 PELE sg_BC,y MWh Monthly Instrument: Electrical
meter
Accuracy: +/- 1%
Calibration: Internal
procedure
1.16 PELE grid_ADD, MWh Monthly Instrument: Electrical
meter
Accuracy: +/- 1%
Calibration: Internal
procedure
1.17 PELE sg_ADD,BS L MWh Monthly Instrument: Electrical
meter
Accuracy: +/- 1%
Calibration: Internal
procedure
1.18 Fi,j,y Tones of fuel i Monthly Instrument: Weigh bridge
Accuracy: +/- 2%
Calibration: As per ISO
procedure
1.19 COEF I,j,,y tCO2/tonne of
fuel i
Annually IPCC default factors
1.20 GEN I,y MWh Annually Instrument: Electrical
meter
Accuracy: +/- 2%
Calibration: Internal
procedure
1.21 PE calcin,y tCO2/tonne of
clinker
Annually Calculated from the
formulae provided in
methodology
1.22 PE fossil_fuel,y tCO2/tonne of
clinker
Annually Calculated from the
formulae provided in 6
ID
no
Data variable Data unit Recording
Frequency
Comments
methodology
1.23 PE ele_grid_CLNK,y tCO2/tonne of
clinker
Annually Calculated from the
formulae provided in
methodology
1.24 PE ele_sg_CLNK,y tCO2/tonne of
clinker
Annually Calculated from the
formula given in
methodology
1.25 PE ele_grid_BC,y tCO2/tonne of
blended
cement
Annually Calculated from the
formula given in
methodology
1.26 PE ele_sg_BC,y tCO2/tonne of
blended
cement
Annually Calculated from the
formula given in
methodology
1.27 PE ele_grid_ADD,y tCO2/tonne of
blended
cement
Annually Calculated from the
formula given in
methodology
1.28 PE ele_sg_ADD,y tCO2/tonne of
blended
cement
Annually Calculated from the
formula given in
methodology
1.29 PE blend,y tCO2/tonne of
blended
cement
Annually Calculated from the
formula given in
methodology
II.3.2: Data Monitored for Leakage Calculations
ID
no
Data variable Data unit Recording
Frequency
Comments
3.1 Fuel consumption
for the vehicle per
kilometre
Kg of
fuel/Kilometer
Annually The actual values
recorded from
transporters.
3.2 Distance between
the source of
additive and project
activity plant
Km Per Trip The sources of fly ash are
fixed and distances are
taken from actual truck
transport.
3.3 Quantity of additive
carried in one trip
per vehicle
Tonnes of
addtive/
vehicle
Per Trip Instrument: Weigh bridge
Accuracy: +/- 2%
Calibration: As per ISO
procedure
3.4 Emission factor for
transport fuel
Kg CO2/Kg of
fuel
Annually IPCC values are used. 7
3.5 Electricity
consumption for
conveyor system for
additives
MWh Monthly Not applicable
3.6 Grid electricity
emission factor
tonnes of
CO2/MWh
Annually Not applicable
3.7 Tonnes of additives
in year y / total
additional additives
used in year
Tonnes of fly
ash
Annually The flyash availability
records.
II.3.3: Quality Assurance (QA)/ Quality Control (QC) Plan
Quality assurance/quality control plan was made as per ISO guidelines. Monitoring was done
with necessary equipments on intervals mentioned in the methodology adopted for the project
activity. The calibration of monitoring equipment is being maintained as per the ISO
requirement and the same is being done regularly. All monitoring parameters being recorded
and the same being verified by the responsible authorities mentioned in procedure.
II. 3.4: Environmental Management Plan
In general, the environmental monitoring activities (like stack emissions, ambient air quality
for Suspended Particulate Matter etc.,) is carried out in the plant as per the guidelines
provided by Pollution Control Board (PCB). The compliance report of environmental
condition of the plant is submitted monthly to PCB and environmental statement of the plant
is submitted to PCB on annual basis. 8
Section-III: GHG Emission Reduction
Emission reduction achieved during monitoring period covered in the report has been
presented in the following table.
Formula for emission reduction calculation
2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 Total
3652 16891 30890 28105 14174 10892 104603
ERy = { [BEBC,y – PEBC,y] * BCy + Ly } * (1 – αy)Appendix-1
Baseline Emissions
Parameter Unit 1999-00
Baseline Emissions of CO2 per tonne of clinker in the project activity (tCO2/tonne clinker)-BE clinker
Baseline Emissions per tonne of clinker due to calcinations of calcium carbonate and magnesium carbonate (tCO2/tonne clinker)- BE calcin
Quantity of raw mix Tonnes 3315746
Quantity of clinker produced Tonnes 2200230
CaO content (%) of raw mix % 0
MgO content (%) of raw mix % 0
CaO content (%) of Clinker % 64.59
MgO content (%) of Clinker % 0.918
Baseline Emissions from the calcinations of
limestone(tCO2/tonne clinker) BE calcin tCO2/tclinker 0.51706
Baseline Emissions per tonne of clinker due to combustion of fossil fuels for clinker production (tCO2/tonne clinker)-BE fossil_fuel
Quantity of coal consumed-FF_,BSL Tonnes 281056.20
Net calorific value of coal Fuel(IPCC) TJ/KiloTonnes 24.41
Carbon Emission factor of coal(IPCC) tCO2/TJ 96.07
Emission factor of coal - EFF
tCO2/Ton of
fuel 2.34
Baseline Emissions per tonne of clinker due to combustion of
fossil fuels for clinker production-BE fossil_fuel
tCO2/tclinker 0.299499
Baseline grid electricity emissions for clinker production per tonnne of clinker- BE ele_grid_CLNK -(tCO2/tonne clinker)
Baseline grid electricity for clinker production -
BELEgrid_CLNK MWh 5554.46
Baseline grid emission Factor for state grid - EFgrid_BSL tCO2/MWh 0.8345
Baseline grid electricity emissions for clinker production
per tonnne of clinker BE ele_grid_CLNK
tCO2/tonne
clinker 0.002107
Baseline APGPCL electricity for clinker production -
BELEapgpcl_CLNK MWh 49321.43 10
Baseline APGPCL emission Factor - EFapgpcl_BSL tCO2/MWh 0.583
Baseline APGPCL electricity emissions for clinker
production per tonnne of clinker BE ele_apgpcl_CLNK
tCO2/tonne
clinker 0.013069
Baseline Emissions from Self generated electricity for clinker production per tonne of clinker -BE ele_sg_CLNK-(tCO2/tonne clinker)
Baseline generation of Electricity by DG sets for clinker
production -BELEsg_CLNK_DG MWh 81597.35
DG set Emission Factor in year y - EFsg_DG_BSL tCO2/MWh 0.64
Self generated electricity emissions for clinker
production per tonnne of clinker BE ele_sg_CLNK,y
tCO2/tonne of
clinker 0.023735
Baseline Emissions of CO2 per tonne of clinker in
the project activity (tCO2/tonne clinker)-BE clinker
tCO2/tonne of
clinker 0.855465
Baseline Electricity Emissions for BC grinding and preparation of additives (tCO2/tonne BC)-BE ele_ADD_BC
Annual production of BC in base year -BCBSL
kilotonnes of
BC 194.238
Baseline grid electricity emissions for BC grinding in BE ele_grid_BC -(tCO2/tonne of BC)
Baseline Grid Electricity for grinding BC -BELEgrid_BC MWh 228.43
Baseline Grid Emission Factor for state grid -
EFgrid_BSL tCO2/MWh 0.8345
Baseline Grid electricity emissions for BC grinding
(tCO2/tonne of BC) BE ele_grid_BC
tCO2/tonne of
BC 0.000981389
Baseline APGPCL Electricity for grinding BC -
BELEapgpcl_BC MWh 2055.82
Baseline APGPCL Emission Factor for apgpcl grid -
EFapgpcl_BSL tCO2/MWh 0.583
Baseline APGPCL electricity emissions for BC grinding
(tCO2/tonne of BC) BE ele_apgpcl_BC
tCO2/tonne of
BC 0.006170488
Baseline self generated electricity emissions for BC grinding BE ele_sg_BC
Baseline generation of Electricity by DG sets for BC
grinding -BELEsg_DG_BC MWh 3426.3611
Baseline Self generated electricity emissions for BC
grinding (tCO2/tonne of BC) BE ele_sg_BC
tCO2/tonne of
BC 0.0112896
Baseline Grid electricity emissions for additive preparation BE ele_grid_ADD
Baseline grid electricity emissions for additive
preparation BE ele_grid_ADD
tCO2/tonne of
BC 0
Baseline emissions from Self generated electricity additive preparation BE ele_sg_ADD
Emissions from Self generated electricity additive
preparation BE ele_sg_ADD
tCO2 / tonne of
BC 0
Baseline electricity Emissions for BC grinding and
preparation of additives BE ele_ADD_BC
tCO2 / tonne of
BC
0.018441512
Project Emissions
Parameter Unit 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06
Emissions of CO2 per tonne of clinker in the project activity plant (tCO2/tonne clinker)-PE clinker,y
Emissions per tonne of clinker due to calcinations of calcium carbonate and magnesium carbonate in year y (tCO2/tonne clinker)- PE calcin,y
Quantity of raw mix consumption Tonnes 3247974 2710865 3553619 3316163 3339869 3470369
Quantity of clinker produced Tonnes 2140235 1786310 2356155 2200070 2215800 2304560
CaO content (%) of raw mix % 0 0 0 0 0 0
MgO content (%) of raw mix % 0 0 0 0 0 0
CaO content (%) of Clinker % 64.44 64.02 63.99 63.58 63.18 63.49
MgO content (%) of Clinker % 0.93 0.78 0.94 0.97 0.97 0.96
Emissions from the calcinations of limestone(tCO2/tonne
clinker) PE calcin,y tCO2/tclinker 0.51601 0.51107 0.51259 0.50970 0.50656 0.50888
Emissions per tonne of clinker due to combustion of fossil fuels for clinker production in year y (tCO2/tonne clinker)-PE fossil_fuel,y
Quantity of coal consumed-FF_,y Tonnes 280424.11 261332.68 356262.31 328680.03 325768.28 350140.99
Net calorific value of coal Fuel(IPCC) TJ/KiloTonnes 24.31 21.88 20.44 20.19 22.06 20.48
Carbon Emission factor of coal(IPCC) tCO2/TJ 96.07 96.07 96.07 96.07 96.07 96.07
Emission factor of coal - EFF
tCO2/Ton of
fuel 2.34 2.10 1.96 1.94 2.12 1.97
Emissions per tonne of clinker due to combustion of fossil
fuels for clinker production-PE fossil_fuel,y tCO2/tclinker 0.306022 0.307453 0.296910 0.289752 0.311515 0.298891
Grid electricity emissions for clinker production per tonnne of clinker in year y - PE ele_grid_CLNK, y (tCO2/tonne clinker)
Grid Electricity for clinker production in year y -
PELEgrid_CLNK,y MWh 4270.71 8651.93 9302.03 30856.86 65019.96 91809.37
Grid Emission Factor in year y- EFgrid_y tCO2/MWh 0.8345 0.8345 0.8345 0.8345 0.8345 0.8345
Grid electricity emissions for clinker production per tonnne
of clinker PE ele_grid_CLNK,y
tCO2/tonne
clinker 0.001665 0.004042 0.003295 0.011704 0.024487 0.033245
APGPCL Electricity for clinker production in year y -
PELEapgpcl_CLNK,y MWh 85675.45 64344.61 78845.51 47401.09 51302.40 43998.35
APGPCL Emission Factor in year y- EFapgpcl_y tCO2/MWh 0.583 0.583 0.583 0.583 0.583 0.583 13
APGPCL electricity emissions for clinker production per
tonnne of clinker PE ele_apgpcl_CLNK,y
tCO2/tonne
clinker 0.023338 0.021000 0.019509 0.012561 0.013498 0.011131
Emissions from self generated electricity per tonne of clinker production in year y -PE ele_sg_CLNK,y-(tCO2/tonne clinker)
Generation of Electricity by DG sets for clinker production in
year y-PELEsg_CLNK_DG,y MWh 48976.50 45793.07 46624.53 42635.90 5546.64 0.00
DG set Emission Factor in year y - EFsg_DG_y tCO2/MWh 0.67 0.65 0.65 0.64 0.65 0.65
Self generated electricity emissions for clinker production per
tonnne of clinker PE ele_sg_CLNK,y
tCO2/tonne of
clinker 0.015239 0.016576 0.012887 0.012486 0.001625 0.000000
Emissions of CO2 per tonne of clinker in the project activity in
year y (tCO2/tonne clinker)-PE clinker,y
tCO2/tonne of
clinker 0.862274 0.860146 0.845187 0.836198 0.857680 0.852147
Electricity Emissions for BC grinding and preparation of additives in year y (tCO2/tonne BC)-PE ele_ADD_BC,y
Annual production of BC in year y -BCy kilotonnes of BC 487.46748 875.3367 956.88085 716.8872 662.3782 748.31003
Grid electricity emissions for BC grinding in a year y PE ele_grid_BC,y -(tCO2/tonne of BC)
Southern Grid Electricity for grinding BC in year y -
PELEapgrid_BC,y (AP) MWh 396.63 950.13 683.18 871.39 1473.06 2679.02
Southern Grid Emission Factor in year y- EFapgrid_y (AP) tCO2/MWh 0.8345 0.8345 0.8345 0.8345 0.8345 0.8345
Regional grid electricity emissions for BC grinding in year y
(tCO2/tonne of BC) PE ele_apgrid_BC,y
tCO2/tonne of
BC 0.000679 0.000906 0.000596 0.001014 0.001856 0.002988
APGPCL Electricity for grinding BC in year y -
PELEapgpcl_BC,y MWh 7956.77 7066.18 5790.73 1338.59 1162.28 1283.88
APGPCL Emission Factor in year y- EFapgpcl_y tCO2/MWh 0.583 0.583 0.583 0.583 0.583 0.583
APGPCL electricity emissions for BC grinding in year y
(tCO2/tonne of BC) PE ele_apgpcl_BC,y
tCO2/tonne of
BC 0.009516 0.004706 0.003528 0.001089 0.001023 0.001000
Southern Grid Electricity for grinding BC in year y -
PELEtngrid_BC,y (TN) MWh 3527.92 9965.88 1567.60 3138.83 1703.34 5089.03
Southern Grid Emission Factor in year y- EFtngrid_y (TN) tCO2/MWh 0.8345 0.8345 0.8345 0.8345 0.8345 0.8345
Regional grid electricity emissions for BC grinding in year y
(tCO2/tonne of BC) PE ele_tngrid_BC,y
tCO2/tonne of
BC 0.006 0.010 0.001 0.004 0.002 0.006
Emissions from self generated electricity for BC grinding in year y PE ele_sg_BC,y
Generation of Electricity by DG sets for BC grinding in year
y-PELEsg_BC,y MWh 4548.50 11400.52 19026.47 15899.47 16322.76 15084.75
Self generated electricity emissions for BC grinding in year y
(tCO2/tonne of BC) PE ele_sg_BC,y tCO2/tonne of BC 0.006214 0.008422 0.012949 0.014289 0.015994 0.013084 14
Grid electricity emissions for additive preparation in year y PE ele_grid_ADD,y
Grid electricity emissions for additive preparation in year y
PE ele_grid_ADD,y
tCO2/tonne of
BC 0.00 0.00 0.00 0.00 0.00 0.00
Emissions from Self generated electricity additive preparation in year y PE ele_sg_ADD,y
Emissions from Self generated electricity additive preparation in
year y PE ele_sg_ADD,y
tCO2 / tonne of
BC 0 0 0 0 0 0
Electricity Emissions for BC grinding and preparation
of additives in year y PE ele_ADD_BC,y
tCO2 / tonne of
BC 0.022448 0.023535 0.018440 0.020046 0.021019 0.022747 15
Leakages
Parameter Unit 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06
Quantity of Flyash procured from
Rayalseema Thermal power
plant (APCW)
Tonnes
36551 48643 57392 20730 22776 23180
Quantity of Flyash procured from
North chennai thermal power
station (APCW)
Tonnes
5555 4349 14 0 351 1069
Quantity of Flyash procured from
TCP limited (APCW)
Tonnes
0 1147 0 0 0 0
Quantity of Flyash procured from
Vijayawada Thermal power plant
(APCW)
Tonnes
6224 3552 3164 0 0 0
Quantity of Flyash procured from
Nellore Thermal power plant
(APCW)
Tonnes
6508 7478 9619 0 0 0
Quantity of Flyash procured from
Jindal (APCW)
Tonnes
29824 18505 2618 0 0 0
Quantity of Flyash procured from
Raichur Thermal power plant
(APCW)
Tonnes
2483 1975 0 0 0 0
Quantity of Flyash procured from
Rayalseema Thermal power
plant (ARCW)
Tonnes
0 0 37 80 16 68
Quantity of Flyash procured from
North chennai thermal power
station (ARCW)
Tonnes
5854 69450 135090 139756 122001 33002
Quantity of Flyash procured from
Veetech (ARCW)
Tonnes
0 0 0 0 0 106096
Quantity of Flyash procured from
TCP limited (ARCW)
Tonnes
1941 26063 0 0 0 016
Total quantity of Fly ash
procured Tonnes 94940 181163 207934 160566 145143 163416
Fuel consumption for the Vehicle
per kilometre-TFcons
kg of fuel/ kilometre
0.4545 0.4545 0.4545 0.4545 0.4545 0.4545
Distance between the source of
additive(Rayalseema thermal
power plant)and the project
activity plant-Dadd_source (APCW)
kilometre 110 110 110 110 110 110
Distance between the source of
additive(North chennai thermal
power station)and the project
activity plant-Dadd_source (APCW)
kilometre 425 425 425 425 425 425
Distance between the source of
additive(TCP limited) and the
project activity plant-Dadd_source
(APCW)
kilometers 425 425 425 425 425 425
Distance between the source of
additive(Vijayawada thermal
power plant)and the project
activity plant-Dadd_source (APCW)
kilometre 480 480 480 480 480 480
Distance between the source of
additive(Nellore thermal power
plant)and the project activity
plant-Dadd_source (APCW)
kilometre 265 265 265 265 265 265
Distance between the source of
additive(Jindal)and the project
activity plant-Dadd_source (APCW)
kilometre 171 171 171 171 171 171 17
Distance between the source of
additive(Raichur thermal power
plant)and the project activity
plant-Dadd_source (APCW)
kilometre 325 325 325 325 325 325
Distance between the source of
additive(Rayalseema thermal
power plant)and the project
activity plant-Dadd_source (ARCW)
kilometre 284 284 284 284 284 284
Distance between the source of
additive(North chennai thermal
power station)and the project
activity plant-Dadd_source (ARCW)
kilometre 124 124 124 124 124 124
Distance between the source of
additive Veetech-Dadd_source
(ARCW)
kilometre 124 124 124 124 124 124
Distance between the source of
additive TCP limitedDadd_source
(ARCW)
kilometre 136 136 136 136 136 136
Net calorific value of Diesel
Fuel(IPCC) TJ/KiloTonnes 43.33 43.33 43.33 43.33 43.33 43.33
Carbon Emission factor of
Diesel fuel (IPCC) tCO2/TJ 74.07 74.07 74.07 74.07 74.07 74.07
Emission factor for transport
fuel(Diesel)-TEF
kg CO2/ kg of fuel 3.21 3.21 3.21 3.21 3.21 3.21
Electricity consumption for the
conveyor system for additivesELEconveyor_ADD
MWh 0.00 0.00 0.00 0.00 0.00 0.00
Version: 02
Date: 27/12/2006
ULTRATECH CEMENT LIMITED (UTCL)
Optimum utilisation of clinker by production of Pozzolana Cement at
UltraTech Cement Ltd. (UTCL),
Andhra Pradesh.
Reference No. UNFCCC 00000438
Project Location
Andhra Pradesh Cement Works
Bhogasamudram, Tadipatri
District: Anantpur, Andhra Pradesh –
515415, India
&
Arakkonam Cement Works
Chetteri village, PO Arakkonam 631003
Vellore, Tamilnadu, India
ULTRATECH CEMENT LIMITED
UltraTech Cement Limited
Bhogasamudram, Tadipatri
District: Anantpur, Andhra Pradesh –
515415, India
Tel: 91-8558-288801
Fax: 91-8558-288821/31
www.adityabirla.com2
SECTION- I: INTRODUCTION
I.1: Project Description
UltraTech Cement Limited has five integrated cement plants one among is Andhra Pradesh
Cement Works (APCW), which has as an installed capacity of 2.3 Million Tonnes per annum.
Andhra Pradesh Cement Works (APCW) is situated in Tadipatri, Andhra Pradesh. This plant
has one grinding unit installed in Arakkonam, Tamilnadu. This is a grinding unit which
produces mainly Portland Pozzolana Cement (PPC) with the clinker supplied by UltraTech
Cement Limited Tadipatri.
The project activity entails a reduction of the clinker content by producing the Portland
Pozzolana cement (PPC), thereby replacing an equivalent amount of clinker at UTCL’s
cement manufacturing units at Tadipatri, Andhra Pradesh & Arakkonam, Tamilnadu.
I.2: Current Status of the Project Activity
The project activity started in phased manner with the increasing additives percentage in the
PPC. The project is operating in a successful manner since 1st April 2000.
The project activity has been registered with UNFCCC as CDM activity1
under sectoral
scope 4 - Manufacturing Industries as per the sectoral scopes related approved
methodologies and Designated Operational Entities (DOE) (version 19 Sep 05, 15:57).The
UNFCCC reference number for the project activity is 00000438.
I.3: Baseline Methodology Adopted
TITLE: Consolidated Baseline methodology for increasing the Blend in cement
production (ACM0005 VER 02)
Reference: UNFCCC website
1
http://cdm.unfccc.int/Projects/DB/DNV-CUK1148386358.08/view.html3
Section- II: Monitoring
II.1: Monitoring Methodology
TITLE: Consolidated monitoring methodology for increasing the Blend in cement
production (ACM0005-ver02)
II.2: Monitoring Period
Monitoring period for the project activity is chosen from 01/04/2000 -31/03/2006 (Both days
included). Parameters monitored during the period and their recording frequency is given in
the ensuing paragraph. Data has been archived for verification purpose.
II.3: Monitoring Parameters
II.3.1: Data Monitored for Project Emission Calculations
ID
no
Data variable Data unit Recording
Frequency
Comments
1.1 InCao y % Daily Estimated from lab
experiment of average
daily sample.
Instrument: X-ray
Analyzer
Procedure: As per ISO
9001
1.2 OutCao y % Daily Estimated from lab
experiment of average
daily sample.
Instrument: X-ray
Analyzer
Procedure: As per ISO
9001
1.3 InMgo y % Daily Estimated from lab
experiment of average
daily sample.
Instrument: X-ray
Analyzer
Procedure: As per ISO
9001
1.4 OutMgo y % Daily Estimated from lab
experiment of average 4
ID
no
Data variable Data unit Recording
Frequency
Comments
daily sample.
Instrument: X-ray
Analyzer
Procedure: As per ISO
9001
1.5 Quantity of clinker
raw material
Kilo Tonnes Annually Measured from Silo level
(Silo rope) and
crosschecked from
physical verification.
1.6 CLNKy Kilo Tonnes of
clinker
Annually Kiln feed is measured
from weigh bridge.
Clinker quantity is
calculated from of kiln
feed to kiln feed to clinker
conversion factor.
Crosschecked from
physical verification.
1.7 FFi_y tonnes of fuel i Annually Instrument: Weigh bridge
Accuracy: +/- 2%
Calibration: As per ISO
procedure
1.8 EFFi
tCO2/tonne of
fuel i
Annually IPCC default values
Uncertainty: Low
1.9 PELE grid_CLNK,y MWh Monthly Instrument: Electrical
meter
Accuracy: +/- 1%
Calibration: Internal
procedure
1.10 EF grid_BSL tCO2/MWh Annually Calculated in the baseline
and validated by
validation DOE.
1.11 PELE sg_CLNK,y MWh Monthly Instrument: Electrical
meter
Accuracy: +/- 1%
Calibration: Internal
procedure
1.12 EF sg_y tCO2/MWh Monthly Calculated from the
quantity of fuel consumed
in power plant and the
quantity of fuel used. 5
ID
no
Data variable Data unit Recording
Frequency
Comments
1.13 ADD,y Quantity of
additives
Kilo Tonnes Monthly Instrument: Weigh bridge
Accuracy: +/- 2%
Calibration: As per ISO
procedure
1.14 PELE grid_BC,y MWh Monthly Instrument: Electrical
meter
Accuracy: +/- 1%
Calibration: Internal
procedure
1.15 PELE sg_BC,y MWh Monthly Instrument: Electrical
meter
Accuracy: +/- 1%
Calibration: Internal
procedure
1.16 PELE grid_ADD, MWh Monthly Instrument: Electrical
meter
Accuracy: +/- 1%
Calibration: Internal
procedure
1.17 PELE sg_ADD,BS L MWh Monthly Instrument: Electrical
meter
Accuracy: +/- 1%
Calibration: Internal
procedure
1.18 Fi,j,y Tones of fuel i Monthly Instrument: Weigh bridge
Accuracy: +/- 2%
Calibration: As per ISO
procedure
1.19 COEF I,j,,y tCO2/tonne of
fuel i
Annually IPCC default factors
1.20 GEN I,y MWh Annually Instrument: Electrical
meter
Accuracy: +/- 2%
Calibration: Internal
procedure
1.21 PE calcin,y tCO2/tonne of
clinker
Annually Calculated from the
formulae provided in
methodology
1.22 PE fossil_fuel,y tCO2/tonne of
clinker
Annually Calculated from the
formulae provided in 6
ID
no
Data variable Data unit Recording
Frequency
Comments
methodology
1.23 PE ele_grid_CLNK,y tCO2/tonne of
clinker
Annually Calculated from the
formulae provided in
methodology
1.24 PE ele_sg_CLNK,y tCO2/tonne of
clinker
Annually Calculated from the
formula given in
methodology
1.25 PE ele_grid_BC,y tCO2/tonne of
blended
cement
Annually Calculated from the
formula given in
methodology
1.26 PE ele_sg_BC,y tCO2/tonne of
blended
cement
Annually Calculated from the
formula given in
methodology
1.27 PE ele_grid_ADD,y tCO2/tonne of
blended
cement
Annually Calculated from the
formula given in
methodology
1.28 PE ele_sg_ADD,y tCO2/tonne of
blended
cement
Annually Calculated from the
formula given in
methodology
1.29 PE blend,y tCO2/tonne of
blended
cement
Annually Calculated from the
formula given in
methodology
II.3.2: Data Monitored for Leakage Calculations
ID
no
Data variable Data unit Recording
Frequency
Comments
3.1 Fuel consumption
for the vehicle per
kilometre
Kg of
fuel/Kilometer
Annually The actual values
recorded from
transporters.
3.2 Distance between
the source of
additive and project
activity plant
Km Per Trip The sources of fly ash are
fixed and distances are
taken from actual truck
transport.
3.3 Quantity of additive
carried in one trip
per vehicle
Tonnes of
addtive/
vehicle
Per Trip Instrument: Weigh bridge
Accuracy: +/- 2%
Calibration: As per ISO
procedure
3.4 Emission factor for
transport fuel
Kg CO2/Kg of
fuel
Annually IPCC values are used. 7
3.5 Electricity
consumption for
conveyor system for
additives
MWh Monthly Not applicable
3.6 Grid electricity
emission factor
tonnes of
CO2/MWh
Annually Not applicable
3.7 Tonnes of additives
in year y / total
additional additives
used in year
Tonnes of fly
ash
Annually The flyash availability
records.
II.3.3: Quality Assurance (QA)/ Quality Control (QC) Plan
Quality assurance/quality control plan was made as per ISO guidelines. Monitoring was done
with necessary equipments on intervals mentioned in the methodology adopted for the project
activity. The calibration of monitoring equipment is being maintained as per the ISO
requirement and the same is being done regularly. All monitoring parameters being recorded
and the same being verified by the responsible authorities mentioned in procedure.
II. 3.4: Environmental Management Plan
In general, the environmental monitoring activities (like stack emissions, ambient air quality
for Suspended Particulate Matter etc.,) is carried out in the plant as per the guidelines
provided by Pollution Control Board (PCB). The compliance report of environmental
condition of the plant is submitted monthly to PCB and environmental statement of the plant
is submitted to PCB on annual basis. 8
Section-III: GHG Emission Reduction
Emission reduction achieved during monitoring period covered in the report has been
presented in the following table.
Formula for emission reduction calculation
2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 Total
3652 16891 30890 28105 14174 10892 104603
ERy = { [BEBC,y – PEBC,y] * BCy + Ly } * (1 – αy)Appendix-1
Baseline Emissions
Parameter Unit 1999-00
Baseline Emissions of CO2 per tonne of clinker in the project activity (tCO2/tonne clinker)-BE clinker
Baseline Emissions per tonne of clinker due to calcinations of calcium carbonate and magnesium carbonate (tCO2/tonne clinker)- BE calcin
Quantity of raw mix Tonnes 3315746
Quantity of clinker produced Tonnes 2200230
CaO content (%) of raw mix % 0
MgO content (%) of raw mix % 0
CaO content (%) of Clinker % 64.59
MgO content (%) of Clinker % 0.918
Baseline Emissions from the calcinations of
limestone(tCO2/tonne clinker) BE calcin tCO2/tclinker 0.51706
Baseline Emissions per tonne of clinker due to combustion of fossil fuels for clinker production (tCO2/tonne clinker)-BE fossil_fuel
Quantity of coal consumed-FF_,BSL Tonnes 281056.20
Net calorific value of coal Fuel(IPCC) TJ/KiloTonnes 24.41
Carbon Emission factor of coal(IPCC) tCO2/TJ 96.07
Emission factor of coal - EFF
tCO2/Ton of
fuel 2.34
Baseline Emissions per tonne of clinker due to combustion of
fossil fuels for clinker production-BE fossil_fuel
tCO2/tclinker 0.299499
Baseline grid electricity emissions for clinker production per tonnne of clinker- BE ele_grid_CLNK -(tCO2/tonne clinker)
Baseline grid electricity for clinker production -
BELEgrid_CLNK MWh 5554.46
Baseline grid emission Factor for state grid - EFgrid_BSL tCO2/MWh 0.8345
Baseline grid electricity emissions for clinker production
per tonnne of clinker BE ele_grid_CLNK
tCO2/tonne
clinker 0.002107
Baseline APGPCL electricity for clinker production -
BELEapgpcl_CLNK MWh 49321.43 10
Baseline APGPCL emission Factor - EFapgpcl_BSL tCO2/MWh 0.583
Baseline APGPCL electricity emissions for clinker
production per tonnne of clinker BE ele_apgpcl_CLNK
tCO2/tonne
clinker 0.013069
Baseline Emissions from Self generated electricity for clinker production per tonne of clinker -BE ele_sg_CLNK-(tCO2/tonne clinker)
Baseline generation of Electricity by DG sets for clinker
production -BELEsg_CLNK_DG MWh 81597.35
DG set Emission Factor in year y - EFsg_DG_BSL tCO2/MWh 0.64
Self generated electricity emissions for clinker
production per tonnne of clinker BE ele_sg_CLNK,y
tCO2/tonne of
clinker 0.023735
Baseline Emissions of CO2 per tonne of clinker in
the project activity (tCO2/tonne clinker)-BE clinker
tCO2/tonne of
clinker 0.855465
Baseline Electricity Emissions for BC grinding and preparation of additives (tCO2/tonne BC)-BE ele_ADD_BC
Annual production of BC in base year -BCBSL
kilotonnes of
BC 194.238
Baseline grid electricity emissions for BC grinding in BE ele_grid_BC -(tCO2/tonne of BC)
Baseline Grid Electricity for grinding BC -BELEgrid_BC MWh 228.43
Baseline Grid Emission Factor for state grid -
EFgrid_BSL tCO2/MWh 0.8345
Baseline Grid electricity emissions for BC grinding
(tCO2/tonne of BC) BE ele_grid_BC
tCO2/tonne of
BC 0.000981389
Baseline APGPCL Electricity for grinding BC -
BELEapgpcl_BC MWh 2055.82
Baseline APGPCL Emission Factor for apgpcl grid -
EFapgpcl_BSL tCO2/MWh 0.583
Baseline APGPCL electricity emissions for BC grinding
(tCO2/tonne of BC) BE ele_apgpcl_BC
tCO2/tonne of
BC 0.006170488
Baseline self generated electricity emissions for BC grinding BE ele_sg_BC
Baseline generation of Electricity by DG sets for BC
grinding -BELEsg_DG_BC MWh 3426.3611
Baseline Self generated electricity emissions for BC
grinding (tCO2/tonne of BC) BE ele_sg_BC
tCO2/tonne of
BC 0.0112896
Baseline Grid electricity emissions for additive preparation BE ele_grid_ADD
Baseline grid electricity emissions for additive
preparation BE ele_grid_ADD
tCO2/tonne of
BC 0
Baseline emissions from Self generated electricity additive preparation BE ele_sg_ADD
Emissions from Self generated electricity additive
preparation BE ele_sg_ADD
tCO2 / tonne of
BC 0
Baseline electricity Emissions for BC grinding and
preparation of additives BE ele_ADD_BC
tCO2 / tonne of
BC
0.018441512
Project Emissions
Parameter Unit 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06
Emissions of CO2 per tonne of clinker in the project activity plant (tCO2/tonne clinker)-PE clinker,y
Emissions per tonne of clinker due to calcinations of calcium carbonate and magnesium carbonate in year y (tCO2/tonne clinker)- PE calcin,y
Quantity of raw mix consumption Tonnes 3247974 2710865 3553619 3316163 3339869 3470369
Quantity of clinker produced Tonnes 2140235 1786310 2356155 2200070 2215800 2304560
CaO content (%) of raw mix % 0 0 0 0 0 0
MgO content (%) of raw mix % 0 0 0 0 0 0
CaO content (%) of Clinker % 64.44 64.02 63.99 63.58 63.18 63.49
MgO content (%) of Clinker % 0.93 0.78 0.94 0.97 0.97 0.96
Emissions from the calcinations of limestone(tCO2/tonne
clinker) PE calcin,y tCO2/tclinker 0.51601 0.51107 0.51259 0.50970 0.50656 0.50888
Emissions per tonne of clinker due to combustion of fossil fuels for clinker production in year y (tCO2/tonne clinker)-PE fossil_fuel,y
Quantity of coal consumed-FF_,y Tonnes 280424.11 261332.68 356262.31 328680.03 325768.28 350140.99
Net calorific value of coal Fuel(IPCC) TJ/KiloTonnes 24.31 21.88 20.44 20.19 22.06 20.48
Carbon Emission factor of coal(IPCC) tCO2/TJ 96.07 96.07 96.07 96.07 96.07 96.07
Emission factor of coal - EFF
tCO2/Ton of
fuel 2.34 2.10 1.96 1.94 2.12 1.97
Emissions per tonne of clinker due to combustion of fossil
fuels for clinker production-PE fossil_fuel,y tCO2/tclinker 0.306022 0.307453 0.296910 0.289752 0.311515 0.298891
Grid electricity emissions for clinker production per tonnne of clinker in year y - PE ele_grid_CLNK, y (tCO2/tonne clinker)
Grid Electricity for clinker production in year y -
PELEgrid_CLNK,y MWh 4270.71 8651.93 9302.03 30856.86 65019.96 91809.37
Grid Emission Factor in year y- EFgrid_y tCO2/MWh 0.8345 0.8345 0.8345 0.8345 0.8345 0.8345
Grid electricity emissions for clinker production per tonnne
of clinker PE ele_grid_CLNK,y
tCO2/tonne
clinker 0.001665 0.004042 0.003295 0.011704 0.024487 0.033245
APGPCL Electricity for clinker production in year y -
PELEapgpcl_CLNK,y MWh 85675.45 64344.61 78845.51 47401.09 51302.40 43998.35
APGPCL Emission Factor in year y- EFapgpcl_y tCO2/MWh 0.583 0.583 0.583 0.583 0.583 0.583 13
APGPCL electricity emissions for clinker production per
tonnne of clinker PE ele_apgpcl_CLNK,y
tCO2/tonne
clinker 0.023338 0.021000 0.019509 0.012561 0.013498 0.011131
Emissions from self generated electricity per tonne of clinker production in year y -PE ele_sg_CLNK,y-(tCO2/tonne clinker)
Generation of Electricity by DG sets for clinker production in
year y-PELEsg_CLNK_DG,y MWh 48976.50 45793.07 46624.53 42635.90 5546.64 0.00
DG set Emission Factor in year y - EFsg_DG_y tCO2/MWh 0.67 0.65 0.65 0.64 0.65 0.65
Self generated electricity emissions for clinker production per
tonnne of clinker PE ele_sg_CLNK,y
tCO2/tonne of
clinker 0.015239 0.016576 0.012887 0.012486 0.001625 0.000000
Emissions of CO2 per tonne of clinker in the project activity in
year y (tCO2/tonne clinker)-PE clinker,y
tCO2/tonne of
clinker 0.862274 0.860146 0.845187 0.836198 0.857680 0.852147
Electricity Emissions for BC grinding and preparation of additives in year y (tCO2/tonne BC)-PE ele_ADD_BC,y
Annual production of BC in year y -BCy kilotonnes of BC 487.46748 875.3367 956.88085 716.8872 662.3782 748.31003
Grid electricity emissions for BC grinding in a year y PE ele_grid_BC,y -(tCO2/tonne of BC)
Southern Grid Electricity for grinding BC in year y -
PELEapgrid_BC,y (AP) MWh 396.63 950.13 683.18 871.39 1473.06 2679.02
Southern Grid Emission Factor in year y- EFapgrid_y (AP) tCO2/MWh 0.8345 0.8345 0.8345 0.8345 0.8345 0.8345
Regional grid electricity emissions for BC grinding in year y
(tCO2/tonne of BC) PE ele_apgrid_BC,y
tCO2/tonne of
BC 0.000679 0.000906 0.000596 0.001014 0.001856 0.002988
APGPCL Electricity for grinding BC in year y -
PELEapgpcl_BC,y MWh 7956.77 7066.18 5790.73 1338.59 1162.28 1283.88
APGPCL Emission Factor in year y- EFapgpcl_y tCO2/MWh 0.583 0.583 0.583 0.583 0.583 0.583
APGPCL electricity emissions for BC grinding in year y
(tCO2/tonne of BC) PE ele_apgpcl_BC,y
tCO2/tonne of
BC 0.009516 0.004706 0.003528 0.001089 0.001023 0.001000
Southern Grid Electricity for grinding BC in year y -
PELEtngrid_BC,y (TN) MWh 3527.92 9965.88 1567.60 3138.83 1703.34 5089.03
Southern Grid Emission Factor in year y- EFtngrid_y (TN) tCO2/MWh 0.8345 0.8345 0.8345 0.8345 0.8345 0.8345
Regional grid electricity emissions for BC grinding in year y
(tCO2/tonne of BC) PE ele_tngrid_BC,y
tCO2/tonne of
BC 0.006 0.010 0.001 0.004 0.002 0.006
Emissions from self generated electricity for BC grinding in year y PE ele_sg_BC,y
Generation of Electricity by DG sets for BC grinding in year
y-PELEsg_BC,y MWh 4548.50 11400.52 19026.47 15899.47 16322.76 15084.75
Self generated electricity emissions for BC grinding in year y
(tCO2/tonne of BC) PE ele_sg_BC,y tCO2/tonne of BC 0.006214 0.008422 0.012949 0.014289 0.015994 0.013084 14
Grid electricity emissions for additive preparation in year y PE ele_grid_ADD,y
Grid electricity emissions for additive preparation in year y
PE ele_grid_ADD,y
tCO2/tonne of
BC 0.00 0.00 0.00 0.00 0.00 0.00
Emissions from Self generated electricity additive preparation in year y PE ele_sg_ADD,y
Emissions from Self generated electricity additive preparation in
year y PE ele_sg_ADD,y
tCO2 / tonne of
BC 0 0 0 0 0 0
Electricity Emissions for BC grinding and preparation
of additives in year y PE ele_ADD_BC,y
tCO2 / tonne of
BC 0.022448 0.023535 0.018440 0.020046 0.021019 0.022747 15
Leakages
Parameter Unit 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06
Quantity of Flyash procured from
Rayalseema Thermal power
plant (APCW)
Tonnes
36551 48643 57392 20730 22776 23180
Quantity of Flyash procured from
North chennai thermal power
station (APCW)
Tonnes
5555 4349 14 0 351 1069
Quantity of Flyash procured from
TCP limited (APCW)
Tonnes
0 1147 0 0 0 0
Quantity of Flyash procured from
Vijayawada Thermal power plant
(APCW)
Tonnes
6224 3552 3164 0 0 0
Quantity of Flyash procured from
Nellore Thermal power plant
(APCW)
Tonnes
6508 7478 9619 0 0 0
Quantity of Flyash procured from
Jindal (APCW)
Tonnes
29824 18505 2618 0 0 0
Quantity of Flyash procured from
Raichur Thermal power plant
(APCW)
Tonnes
2483 1975 0 0 0 0
Quantity of Flyash procured from
Rayalseema Thermal power
plant (ARCW)
Tonnes
0 0 37 80 16 68
Quantity of Flyash procured from
North chennai thermal power
station (ARCW)
Tonnes
5854 69450 135090 139756 122001 33002
Quantity of Flyash procured from
Veetech (ARCW)
Tonnes
0 0 0 0 0 106096
Quantity of Flyash procured from
TCP limited (ARCW)
Tonnes
1941 26063 0 0 0 016
Total quantity of Fly ash
procured Tonnes 94940 181163 207934 160566 145143 163416
Fuel consumption for the Vehicle
per kilometre-TFcons
kg of fuel/ kilometre
0.4545 0.4545 0.4545 0.4545 0.4545 0.4545
Distance between the source of
additive(Rayalseema thermal
power plant)and the project
activity plant-Dadd_source (APCW)
kilometre 110 110 110 110 110 110
Distance between the source of
additive(North chennai thermal
power station)and the project
activity plant-Dadd_source (APCW)
kilometre 425 425 425 425 425 425
Distance between the source of
additive(TCP limited) and the
project activity plant-Dadd_source
(APCW)
kilometers 425 425 425 425 425 425
Distance between the source of
additive(Vijayawada thermal
power plant)and the project
activity plant-Dadd_source (APCW)
kilometre 480 480 480 480 480 480
Distance between the source of
additive(Nellore thermal power
plant)and the project activity
plant-Dadd_source (APCW)
kilometre 265 265 265 265 265 265
Distance between the source of
additive(Jindal)and the project
activity plant-Dadd_source (APCW)
kilometre 171 171 171 171 171 171 17
Distance between the source of
additive(Raichur thermal power
plant)and the project activity
plant-Dadd_source (APCW)
kilometre 325 325 325 325 325 325
Distance between the source of
additive(Rayalseema thermal
power plant)and the project
activity plant-Dadd_source (ARCW)
kilometre 284 284 284 284 284 284
Distance between the source of
additive(North chennai thermal
power station)and the project
activity plant-Dadd_source (ARCW)
kilometre 124 124 124 124 124 124
Distance between the source of
additive Veetech-Dadd_source
(ARCW)
kilometre 124 124 124 124 124 124
Distance between the source of
additive TCP limitedDadd_source
(ARCW)
kilometre 136 136 136 136 136 136
Net calorific value of Diesel
Fuel(IPCC) TJ/KiloTonnes 43.33 43.33 43.33 43.33 43.33 43.33
Carbon Emission factor of
Diesel fuel (IPCC) tCO2/TJ 74.07 74.07 74.07 74.07 74.07 74.07
Emission factor for transport
fuel(Diesel)-TEF
kg CO2/ kg of fuel 3.21 3.21 3.21 3.21 3.21 3.21
Electricity consumption for the
conveyor system for additivesELEconveyor_ADD
MWh 0.00 0.00 0.00 0.00 0.00 0.00
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