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GB 16780-2012: PDF in English

GB 16780-2012
GB
NATIONAL STANDARD OF THE
PEOPLE’S REPUBLIC OF CHINA
ICS 27.010
F 01
Replacing GB 16780-2007
The norm of energy consumption per unit products of
cement
ISSUED ON: DECEMBER 31, 2012
IMPLEMENTED ON: OCTOBER 01, 2013
Issued by: General Administration of Quality Supervision, Inspection and
Quarantine;
Standardization Administration of the People’s Republic of China.
Table of Contents
Foreword ... 3 
1 Scope ... 5 
2 Normative references ... 5 
3 Terms and definitions ... 6 
4 Technical requirements ... 7 
5 Energy consumption statistics and calculation methods ... 9 
6 Energy saving management and measures ... 17 
Appendix A (Normative) Calculation method for the average 28-day compression
strength of clinker ... 19 
Appendix B (Informative) The norm of step-by-step energy consumption per unit
product of cement of cement enterprises ... 21 
References ... 24 
The norm of energy consumption per unit products of
cement
1 Scope
This Standard specifies the terms and definitions, technical requirements, energy
consumption statistics and calculation methods for the norm of energy consumption per
unit product of common portland cement.
This Standard applies to the calculation and assessment of energy consumption for
production enterprises of common portland cement, as well as the energy consumption
control of new projects.
2 Normative references
The following referenced documents are indispensable for the application of this
document. For dated references, only the edition cited applies to this document. For
undated references, the latest edition (including any amendment) applies to this
document.
GB 175-2007, Common portland cements
GB/T 213, Determination of calorific value of coal
GB/T 384, Determination of calorific value of petroleum products
GB/T 2589, General principles for calculation of the comprehensive energy
consumption
GB/T 12497, Three-phase induction motors economic operation
GB/T 13462, Economical operation for power transformers
GB/T 13469, Economical operation for centrifugal, mixed flow and axial flow pump
systems
GB/T 13470, Economical operation for the fan system
GB/T 17954, Economical operation of industrial boilers
GB 18613, Minimum allowable values of energy efficiency and values of efficiency
grades for motors
GB/T 19065, Economical operation for electric boiler system
GB 19153, Minimum allowable values of energy efficiency and energy efficiency
grades for displacement air compressors
GB 19761, Minimum allowable values of energy efficiency and energy efficiency
grades for fan
GB 19762, The minimum allowable values of energy efficiency and evaluating
values of energy conservation of centrifugal pump for fresh water
GB 20052, Minimum allowable values of energy efficiency and energy efficiency
grades for three-phase distribution transformers
GB/T 21372, Portland cement clinker
GB/T 23331, Energy management systems - Requirements
GB/T 24851-2010, Specification for equipping and managing of measuring
instrument of energy in building material industry
GB/T 26281, Methods for the calculation of heat balance, heat efficiency and
comprehensive energy consumption of cement rotary kiln
GB/T 26282, Measuring methods of heat balance of cement rotary kiln
GB/T 27977-2011, Test and calculation methods of electricity efficiency of cement
production
3 Terms and definitions
The following terms and definitions are applicable to this document.
3.1 The comprehensive standard coal consumption of clinker
The standard coal converted from the fuel consumption per ton of clinker produced
during the statistical period, including the fuel consumed for drying raw materials and
firing clinker.
3.2 The comparable comprehensive standard coal consumption of clinker
The standard coal consumption that is gained by correcting the comprehensive standard
coal consumption of clinker into the grade of 52.5 by the 28-day compression strength
of clinker and correcting the altitude uniformly.
3.3 The comprehensive electricity consumption of clinker
an alternative fuel is adopted by the cement enterprise, the consumption of the
alternative fuel shall be counted separately, and shall not be included in the scope of the
comprehensive standard coal consumption of clinker.
Note: For the types of waste, see the regulations in Cai Shui [2008] No. 156,
Attachment 2 of Notice on the Comprehensive Utilization of Resources and
Value-Added Tax Policies for Other Products issued by the Ministry of Finance
and the State Administration of Taxation and the regulations in Cai Shui [2009]
No. 163 Supplementary Notice on the Comprehensive Utilization of Resources
and Value-Added Tax Policies for Other Products.
5.1.1.2 Statistical scope of standard coal consumption in the comprehensive energy
consumption of cement
The fuel quantity consumed in the whole cement production process, from the time
when raw material enters the production factory to the time when cement leaves the
factory, including the fuel consumed for drying raw materials and cement mixtures and
firing clinker. If an alternative fuel is adopted by the cement enterprise, the consumption
of the alternative fuel shall be counted separately, and shall not be included in the scope
of the comprehensive energy consumption of cement.
5.1.2 Statistical scope of electricity consumption
5.1.2.1 Statistical scope of the comprehensive electricity consumption of clinker
The electric quantity consumed in the whole clinker production process, from the time
when raw material enters the production factory to the time when cement clinker leaves
the factory, excluding the electricity consumed in the construction of infrastructure,
technical innovation and other projects. When waste is used as an alternative fuel or an
alternative raw material, the electricity consumed for waste disposal shall be counted
separately and shall not be included in the scope of the comprehensive electricity
consumption of clinker.
5.1.2.2 Statistical scope of the comprehensive electricity consumption of cement
The electric quantity consumed in the whole cement production process, from the time
when raw material enters the production factory to the time when cement leaves the
factory, excluding the electricity consumed in the construction of infrastructure,
technical innovation and other projects. When waste is used as an alternative raw
material, an alternative fuel, or a cement mixture, the electricity consumed for waste
disposal shall be counted separately and shall not be included in the comprehensive
electricity consumption of cement.
5.1.2.3 Statistical scope of the comprehensive electricity consumption of cement
grinding enterprises
The electric quantity consumed in the whole cement production process, from the time
when cement clinker, gypsum and admixtures enter the production factory to the time
when the cement leaves the factory.
5.2 Statistical method
5.2.1 Statistical method of fuels
During the statistical period, cement enterprises regularly count the amount of raw coal
used for drying raw fuel materials, cement mixtures and firing clinker, as well as the
amount of oil or gas used for ignition. When waste is used as an alternative raw material,
the amount of fuel consumed for drying waste shall be counted separately. When waste
is used as a cement mixture, the amount of fuel consumed for drying shall also be
counted separately. At the same time, the low calorific value of the as-received
corresponding to the consumed fuel shall be counted.
When the waste gas from the firing system is used for power generation in a waste heat
power station, the power generation of the waste heat power station and the self-
consumption power of the waste heat power station shall be counted. When the exhaust
gas of the firing system is used for waste heat utilization other than raw material and
fuel drying, the waste heat utilization inlet and outlet heat and the heat dissipation loss
of the waste heat utilization system shall be checked regularly. Refer to the provisions
of GB/T 26282 and GB/T 26281 for detection and calculation.
5.2.2 Statistical method of electricity consumption
Cement production enterprises regularly make statistics based on the electricity
recorded by the electric meters in the process of raw material preparation, fuel
preparation, clinker firing and cement grinding. When waste is used as an alternative
raw material, an alternative fuel, or a cement mixture, the electricity consumed for
waste disposal shall be counted separately. The electricity consumption test can be
carried out according to the method specified in GB/T 27977-2011.
5.3 Calculation methods
5.3.1 The comparable comprehensive standard coal consumption of clinker
5.3.1.1 The comprehensive standard coal consumption of clinker
The comprehensive standard coal consumption of clinker shall be calculated according
to Formula (1):
Where:
5.3.4 The comparable comprehensive electricity consumption of cement
5.3.4.1 The comprehensive electricity consumption of cement
The comprehensive electricity consumption of cement shall be calculated according to
Formula (9):
Where:
QS – the comprehensive electricity consumption of cement, in kilowatt-hours per ton
(kW·h/t);
qfm – the electricity consumption during the cement grinding and packaging process
within the statistical period, in kilowatt-hours (kW·h);
pcl – clinker consumption during the statistical period, in tons (t);
qm – the average electricity consumption per ton of mixture pretreatment during the
statistical period, in kilowatt-hours per ton (kW·h/t);
pm – consumption of mixtures during the statistical period, in tons (t);
qg – the average electricity consumption per ton of gypsum during the statistical period,
in kilowatt-hours per ton (kW·h/t);
pg – gypsum consumption during the statistical period, in tons (t);
qfz – auxiliary electricity consumption that shall be apportioned during the statistical
period, in kilowatt-hours (kW·h);
PC – total output of cement during the statistical period, in tons (t).
When the enterprise uses all purchased clinker to produce cement, the QCL of the
purchased clinker in Formula (9) shall be calculated as zero; when the enterprise
purchases part of the clinker to produce cement, the QCL of the purchased clinker in
Formula (9) shall be calculated as 65 kW·h/t uniformly.
When the enterprise sells part of the clinker, the sold clinker shall not be included in pcl
in Formula (9) for calculating the comprehensive electricity consumption of cement.
5.3.4.2 Cement strength grade correction factor
Calculate the cement strength grade correction factor according to Formula (10):
5.3.6 When an enterprise produces cement of two or more different strength grades
during the statistical period, it shall use the weighted average method to calculate the
comparable comprehensive electricity consumption of cement and the comparable
comprehensive energy consumption of cement based on the comparable comprehensive
electricity consumption of cement of different strength grades and the cement output.
5.3.7 When an enterprise has multiple production lines, the energy consumption shall
be calculated separately for the production lines, and the electricity consumption of the
common parts shall be allocated to each production line according to the production
capacity.
6 Energy saving management and measures
6.1 Basic management of energy saving
6.1.1 The enterprise shall establish an energy management system in accordance with
the requirements specified in GB/T 23331.
6.1.2 The enterprise shall regularly assess the amount of fuel and electricity consumed
per unit product in production, decompose and implement the assessment indicators to
each basic-level department, and establish an energy accountability system.
6.1.3 The enterprise shall establish an energy consumption statistical system as required,
establish a document file of energy consumption test data, energy consumption
calculation and assessment results, and conduct controlled management of the
documents.
6.1.4 The enterprise shall be equipped with energy measuring instruments and establish
an energy measurement management system in accordance with the requirements of
GB/T 24851-2010.
6.1.5 The enterprise shall regularly test and calculate the thermal balance and thermal
efficiency of the cement rotary kiln system according to the methods specified in GB/T
26282 and GB/T 26281 according to the operation of the production line, and test and
calculate the electric energy efficiency in the cement and clinker production process
according to the method specified in GB/T 27977-2011.
6.2 Management of energy-saving technology
6.2.1 Energy-consuming equipment
6.2.1.1 Enterprises shall make motor systems, pump systems, fan systems, power
transformers, industrial boilers, electric heating boilers and other general energy-
consuming equipment comply with the requirements of GB/T 12497, GB/T 13469,
GB/T 13470, GB/T 13462, GB/T 17954 and GB/T 19065, as well as other relevant
energy-using product economic operation standards.
Appendix A
(Normative)
Calculation method for the average 28-day compression strength of clinker
A.1 Scope
This Appendix applies to the calculation of the average 28-day compression strength of
cement clinker.
A.2 Principle of the method
Calculate according to the 28-day compression strength value of clinker obtained in
GB/T 21372 and the corresponding clinker output, and use the 28-day compression
strength index of portland cement specified in Table 3 in GB 175-2007 as the 28-day
compression strength index of cement clinker of corresponding strength grade.
A.3 Calculation of the average 28-day compression strength of clinker on a daily,
ten-day, monthly, quarterly and annual basis
A.3.1 Calculation of the average 28-day strength of clinker on a daily basis
The average 28-day strength of clinker on a daily basis can be calculated by the
weighted average method, that is, the 28-day compression strength of clinker is
multiplied by the daily output, respectively added and divided by the total output of the
kiln to obtain the average 28-day compression strength of clinker on a daily basis.
A.3.2 Average strength grade of clinker on a ten-day basis
Multiply the daily 28-day compression strength of clinker on a ten-day basis by the
daily output, add them up and divide by the total output of the kiln on that ten-day basis,
to get the average 28-day compression strength of clinker on a ten-day basis.
A.3.3 Average strength grade of clinker on a monthly basis
Multiply the daily 28-day compression strength of clinker on a month basis by the daily
output, add them up and divide by the total output of the kiln in that month, to get the
average 28-day compression strength of clinker on a monthly basis.
A.3.4 Average equivalent grade of clinker on a quarterly basis
Multiply the average 28-day strength grade of clinker in each month of the quarter by
the monthly clinker production, add them up and divide by the total clinker production
in the quarter, to get the actual quarterly average strength grade of clinker.
......
Source: Above contents are excerpted from the PDF -- translated/reviewed by: www.chinesestandard.net / Wayne Zheng et al.