EPI Tool Cement

7/28/2019 EPI Tool Cement

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Introduction

Energy Data:

Production - Clinker:

Production - ASTM 1, 2, 3 and 5:

Production - ASTM 4:

Production - Masonry:

Production - Other cement:

Maximum daily kiln throughput:

Number of kilns:

Labor:

All data values must be inserted in the white boxes on the EPI tab. Definitions are given below.

Definitions of Terms

Plant Characteristics Definitions of terms used in the plant characteristics section

ZIP Code:

Location:

Current Plant & Year:

General plant location is based on the ZIP code entered by user. User should confirm locationmatches ZIP code.

Most recent year of data for the plant the user wishes to score, or other year selected by the userfor evaluation.

The total production (short tons) of clinker.

A 5-digit U.S. Postal Service ZIP code used to assign the plant location.

The total production (short tons) of ASTM 1, 2, 3 or 5 cement.

The total production (short tons) of ASTM 4 cement.

The total production (short tons) of Masonry cement.

The total production (short tons) of all other cement.

The maximum daily throughput (short tons) achieved by the plant, used to estimate annualcapacity.

The total number of kilns in the reporting year.

The total number of person hours worked at the plant.

Manufacturing plants that score a 75 or higher using this EPI are eligible to earn ENERGY STAR certification from the U.S.Environmental Protection Agency as recognition for superior performance. For more information on earning the ENERGYSTAR, see www.energystar.gov/industry.

Eligible Facilities & Space TypesThe Cement Manufacturing Plant Energy Performance Indicator is designed to be used to evaluate facilities that are primarengaged in manufacturing cement via the onsite production of clinker and finish grinding portland, natural, masonry,pozzolanic, and other hydraulic cements. Energy data for operations that are outside the scope of this definition, andtherefore the scope of this tool, must be removed from any cement plant data before using as input for the EPI. Furtherinformation on this model's development is available in the Cement Manufacturing Plant EPI documentation atwww.energystar.gov/EPIs.

Required DataThe following information is required in order to use the EPI.

Annual energy purchases or transfers for the "current" year (and optionally for a "reference" year,defined by user) for each energy source and fuel type. Annual is defined as a continuous 12-montperiod of data as defined by the user, such as a calendar year or fiscal year.

Cement Manufacturing Plant

Energy Performance IndicatorVersion 2.4, Release 5/16/2011

The ENERGY STAR Cement Manufacturing Plant Energy Performance Indicator (EPI) enables plants to compare their

energy performance to similar plants operating in the United States.

This EPI normalizes for differences between plants using the plant characteristics described below.

The EPI produces an Energy Performance Score on a scale from 1 to 100, with a score of 100 reflecting the most efficientlevel of performance. This score provides a relative measure of performance of the plant as compared to other plants.

The EPI is an energy management tool, designed to support companies and plants that seek to improve the energyefficiency of their operations. The EPI was developed as part of the EPA's voluntary ENERGY STAR program and supportbenchmarking, a critical component of the comprehensive energy management approach embodied in ENERGY STAR'sGuidelines for Energy Management (www.energystar.gov ).


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Reference Plant &

Year:

Capacity:

Capacity Utilization:

Energy Accounting

Energy Data:

Electricity:

Non-Electric Energy Use:

All energy inputs must be metered or otherwise verifiable (e.g., utility bills, delivery receipts).Energy values are entered as net values (i.e., purchases and transfers in minus sales andtransfers out), subject to the descr iptions below.

Electricity from Onsite Renewables: Include the electricity consumed from onsite renewablegeneration (e.g., solar PV, wind, small hydro) in your total energy consumption (Other columnYou must convert the total kWh of electricity consumed from onsite renewable generation to Bby multiplying by the thermal conversion factor for electricity (3,412 Btu/kWh). Enter that Btu into the Other column on the EPI worksheet. Excess electricity from onsite renewable generathat is sold or transferred offsite is not accounted for in the EPI. All electricity purchases ortransfers into the plant are entered in the Electricity column on the EPI worksheet, as specifieabove.

The EPI recognizes the efficiency benefits of onsite generation by applying the site thermalconversion factor of 3,412 Btu/kWh rather than the higher value that is used for grid-sourcedelectricity.

Electricity from All Other Onsite Generation: Do not include the electricity consumed from other onsite generation (e.g., CHP, diesel generators) in your total energy consumption. Wheelectricity is generated onsite from these other sources, include the fuel that is purchased ortransferred into the plant to operate other onsite generation, but do not include the electricitygenerated by those systems.

Electricity from onsite generation that is sold or transferred offsite must be subtracted from thepurchased electricity to represent "net of sales or transfer." Enter your electricity purchases nsales and transfers in the Electricity column.

Recovered Energy: Do not include energy recovered from the production process (e.g., wastheat, process byproducts) in the energy accounting of the EPI. The EPIs underlying statistica

model recognizes that plants have an opportunity to recover or self-produce a portion of the ethey require, and is adjusted based on plant characteristics and purchased energy inputs to thEPI.

Steam: Account for the energy used to produce steam if steam is transferred in from an exteor third-party site whose energy does not appear in your plant's energy total. The Btu for prodsteam is calculated using actual boiler conversion efficiencies of the external or third-partyproducer, and added to your plant's energy total (i.e., the Btu value of the fuel used to make thsteam). For example,

10 million lbs steam (per year) x 1128 Btu/lb @ 150 psig / 85% boiler efficiency =

13,271 MMBtu natural gas (before adjusting for steam distribution losses)(Example for illustration only. Your factors and method will vary.)

100 SCFM compressed air x 0.2 kW/SCFM x 4800 hours (per year) = 96,000 kWh(SCFM is Standard Cubic Feet of air per Minute)

(Example for illustration only. Your factors and method will vary.)

Definitions of terms used for energy accounting

Data for electricity includes only total electric ity purchased or transferred into the plant from anfacility, net of sales or transfers (see special case below for electricity generated from onsiterenewables). Purchased or transferred electricity is entered into the Electricity column on theworksheet. Units are in terms of site energy, i.e., in kWh or MMBtu on the basis of 3,412 Btu kWh.

Compressed Air: Account for the energy used to produce compressed air if compressed air transferred in from an external or third-party site whose energy does not appear in your plant's

energy total. The kWh for producing compressed air is calculated using actual conversionefficiencies of the external or third-party producer, and added to your plant's energy total. Forexample,

Include all other forms of energy purchased or transferred (natural gas, oil, coal, etc.), net of sor transfers. This EPI includes a field for waste-derived fuels (e.g., tires). For fuels not definedthe EPI, use the Other column.

User-defined reference plant and year for comparison purposes. Since scores for current planreference plant are calculated independently, the choice of reference year does NOT impactcurrent year score. The reference plant can be the same plant as the "current plant" with a diffyear, or a different plant.

Capacity is computed from the maximum daily kiln throughput assuming 365-day operation leaverage of 38.7 days of down time (based on analysis of Portland Cement Association data).

The ratio of clinker production to total kiln capacity.


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Annual Cost:

Results

Energy Performance Score:

Purchased Source Energy (MMBtu):

Purchased Site Energy (MMBtu):

Efficient Plant: Defined at the values associated with a plant operating at the 75th percentile.

Average Plant: Defined at the values associated with a plant operating at the 50th percentile.

Report Tabs

Statement of Energy Performance:

Facility Performance Report:

About The EPI

The sum of direct fossil fuel consumption and electricity, with electricity converted from kWh to using the thermal conversion factor for electricity (3,412 Btu/kWh).

Energy Intensity

(Source MMBtu/Short Ton of Clinker):

The source energy use per total production of clinker for the current, reference, average andefficient plant. The first two ratios are directly based on input data, and the latter two are theprojected normalized values for an efficient and average plant (see below) relative to the currenplant performance.

The workbook tab labeled Statement of Energy Performance (SEP) contains a printable form thused only when submitting an application for ENERGY STAR plant certification. The results frothe EPI will be automatically populated in the appropriate fields in the SEP form. For furtherinformation on earning the ENERGY STAR, seehttp://www.energystar.gov/index.cfm?c=industry.bus_industry_plants_apply.

The workbook tab labeled Facility Performance Report provides a printable form that can be usto summarize the results from the EPI. This report is intended to be used by plants or companfor their own internal records.

The Energy Performance Score is a percentile ranking for your plant normalized for the plantcharacteristics listed above.

Total annual energy cost for each fuel type in current year dollars. Input of cost data is optioand does not impact the Energy Performance Score. This feature is provided for your

convenience and use.

This ENERGY STAR Plant EPI was developed by the US EPA in collaboration with companies participating in the ENERSTAR Industry Focus and with technical support from Duke University and ICF International. The EPI is based uponconfidential plant-level information. Technical documentation on the design of the EPI is available atwww.energystar.gov/EPIs . This EPI will be updated periodically and revised by the US EPA as part of the ENERGY STAIndustry Focus. For more information on the Industry Focus, visit www.energystar.gov/industry or [email protected].

The research for this model was conducted with the cooperation of the Portland Cement Association (PCA). All dataprovided by PCA are protected by a Non-Disclosure Agreement with Duke University. Research results are those of theauthor, Gale Boyd ([email protected]), and do not necessarily reflect opinions of the PCA. The research has beenprepared to insure that no confidential data are revealed in this spreadsheet or other documentation.

The sum of direct fossil fuel consumption and electricity, with electricity converted from kWh to using the national average power plant conversion (11,396 Btu/kWh). For more information onsource energy definitions, see www.energystar.gov.

Statement of Energy Performance & Facility Performance Report

Definitions of terms used in the results section


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Plant CharacteristicsCurrent Plant Refe

Enter Name E

2010

ZIP Code: Maximum daily kiln throughput 1 short tons

Location: ZIP Code Error Total clinker produced 1 short tons

Annual capacity 326 short tons

Capacity utilization 0% percent

ASTM 1, 2, 3 and 5 produced 1 short tons

ASTM 4 produced short tons

Masonry produced short tons

Other cement produced short tonsNumber of kilns 1 number

Labor 1 hours

Energy ConsumptionElectricity Gas Distillate Oil Residual Oil Coal Wa

Select units

Annual Cost ($)* E

Annual Cost ($)* E* Entering cost data is optional and does not impact the computation of the Energy Performan

Results

Energy Performance Score (EPS)

Annual Energy Cost ($/year)

Total Cement Shipped (Short Tons)

Energy Cost/Total Clinker ($/Short Ton)

Purchased Source Energy (MMBtu)

Purchased Site Energy (MMBtu)

Average Plant

1 1

Energy Performance Indicator

Year

375.78

Cement Manufacturing Plant

Version 2.4, Release 5/16/2011

97

Your Reference PlantYour Current Plant

97 50

Enter Name 2010 Enter Name 2010

Enter Name (2010) Enter Name (2008)

1.00

1 1

1.00

376

Energy Intensity(Source MMBtu/Short Ton of Clinker)

1

1

Enter Name 2008

3761

Annual Purchases & Transfers

Annual Purchases & Transfers

2008

Enter Name

2010

Enter Name

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0 100000 200000 300000 400000 500000 600000 0 100000 200000 300000 400000 500

EPS = EPS = 97


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OMB No. 2060-0347

STATEMENT OF ENERGY PERFORMANCE

Enter Name

For 12-month period ending: Enter Month/Day/Year

Facility Address Owner's Address Corporate Energy Manager Contact

Enter Name Owner's Name Contact NameStreet Address Street Address Email AddressAddress 2 Address 2 Phone NumberZIP Code Error City, State0 ZIP

Energy PerformanceScore: 97

GHG Savings (Kg CO2e) 19,938

Energy Savings (MMBtu) 375

Professional Verification

Professional Engineer NameAddressAddress 2City, State ZIPPhone Number:License Number:Licensing State:

EPI Verification

NOTE:

For US EPA Use Only:

4. Estimates of energy and CO2 emissions savings are provided to illustrate the difference between the

benchmarked plant's energy use and estimated CO 2 emissions as compared to "an average plant" that is defined

as having an energy performance score at the 50th percentile.

The fuel mix used to estimate emissions data for the average plant is the same as for the benchmarked plant.

These estimates are provided to assist plants with communicating their energy and environmental achievements.

3. An energy performance score of 75 is the minimum required score to be considered eligible for the ENERGYSTAR.

2. All energy performance scores and supporting data must first be verified by the US EPA or a US EPA-

designated EPI reviewer if supporting data is considered to be proprietary before submitting applications for the

ENERGY STAR.

Cement Manufacturing Plant Energy

Performance Indicator

Professional Engineer Stamp

Based on the conditions observed at the time of

my visit to this facility, I certify that the

information used in this tool to generate the

energy performance score represented on this

statement is accurate.

1. Applications for certification of plant energy performance to the US EPA must be made within 4 months of Period

Ending date. Award of the ENERGY STAR is not final until approved by the US EPA.

EPI attached for EPA review.

EPI contains proprietary informationand has been sent to thedesignated reviewer.


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Facility Performance Report

Enter Name

For 12-month period ending: Enter Month/Day/Year

Facility Address Owner's Address Corporate Energy Manager Contact

Enter Name Owner's Name Contact NameStreet Address Street Address Email AddressAddress 2 Address 2 Phone NumberZIP Code Error City, State0 ZIP

Facility Energy and Production

Maximum daily kiln throughput 1 short tons

Total clinker produced 1 short tonsAnnual capacity 326 short tonsCapacity utilization 0% percentASTM 1, 2, 3 and 5 produced 1 short tonsASTM 4 produced 0 short tonsMasonry produced 0 short tonsOther cement produced 0 short tonsNumber of kilns 1 number

Labor 1 hoursPurchased Source Energy (MMBtu) 1Purchased Site Energy (MMBtu) 1

Cement Manufacturing Plant Energy Performance IndicatorEnergy Performance Score: 97

NOTES:

Type notes on facility energy performance here

Documents

EPI Tool Cement