Standards related to:

GB 16780-2012GB 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.

...