Cement Manufacturing Plant Energy Performance Indicator

Version 2.4, Release 5/16/2011

Introduction
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. The EPI is an energy management tool, designed to support companies and plants that seek to improve the energy efficiency of their operations. The EPI was developed as part of the EPA's voluntary ENERGY STAR program and supports benchmarking, a critical component of the comprehensive energy management approach embodied in ENERGY STAR's Guidelines for Energy Management (www.energystar.gov). 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 efficient level of performance. This score provides a relative measure of performance of the plant as compared to other plants. 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 ENERGY STAR, see www.energystar.gov/industry.

Eligible Facilities & Space Types

The Cement Manufacturing Plant Energy Performance Indicator is designed to be used to evaluate facilities that are primarily engaged 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, and therefore the scope of this tool, must be removed from any cement plant data before using as input for the EPI. Further information on this model's development is available in the Cement Manufacturing Plant EPI documentation at www.energystar.gov/EPIs.

Required Data
The following information is required in order to use the EPI. Energy Data: 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-month period of data as defined by the user, such as a calendar year or fiscal year. Production - Clinker: The total production (short tons) of clinker. Production - ASTM 1, 2, 3 and 5: The total production (short tons) of ASTM 1, 2, 3 or 5 cement. Production - ASTM 4: The total production (short tons) of ASTM 4 cement. Production - Masonry: The total production (short tons) of Masonry cement. Production - Other cement: The total production (short tons) of all other cement. Maximum daily kiln throughput: The maximum daily throughput (short tons) achieved by the plant, used to estimate annual capacity. Number of kilns: The total number of kilns in the reporting year. Labor: The total number of person hours worked at the plant. 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: A 5-digit U.S. Postal Service ZIP code used to assign the plant location. Location: General plant location is based on the ZIP code entered by user. User should confirm location matches ZIP code. Current Plant & Year: Most recent year of data for the plant the user wishes to score, or other year selected by the user for evaluation.

Reference Plant & User-defined reference plant and year for comparison purposes. Since scores for current plant and Year: reference plant are calculated independently, the choice of reference year does NOT impact current year score. The reference plant can be the same plant as the "current plant" with a different year, or a different plant. Capacity: Capacity is computed from the maximum daily kiln throughput assuming 365-day operation less an average of 38.7 days of down time (based on analysis of Portland Cement Association data). Capacity Utilization: The ratio of clinker production to total kiln capacity.

Energy Accounting

Definitions of terms used for energy accounting

Energy Data: 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 and transfers out), subject to the descriptions below. Electricity: Data for electricity includes only total electricity purchased or transferred into the plant from another facility, net of sales or transfers (see special case below for electricity generated from onsite renewables). Purchased or transferred electricity is entered into the Electricity column on the EPI worksheet. Units are in terms of site energy, i.e., in kWh or MMBtu on the basis of 3,412 Btu per kWh. Compressed Air: Account for the energy used to produce compressed air if compressed air is 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 conversion efficiencies of the external or third-party producer, and added to your plant's energy total. For example, 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.)

Electricity from Onsite Renewables: Include the electricity consumed from onsite renewable generation (e.g., solar PV, wind, small hydro) in your total energy consumption ( Other column). You must convert the total kWh of electricity consumed from onsite renewable generation to Btus by multiplying by the thermal conversion factor for electricity (3,412 Btu/kWh). Enter that Btu value into the Other column on the EPI worksheet. Excess electricity from onsite renewable generation that is sold or transferred offsite is not accounted for in the EPI. All electricity purchases or transfers into the plant are entered in the Electricity column on the EPI worksheet, as specified above. The EPI recognizes the efficiency benefits of onsite generation by applying the site thermal conversion factor of 3,412 Btu/kWh rather than the higher value that is used for grid-sourced electricity. Electricity from All Other Onsite Generation: Do not include the electricity consumed from all other onsite generation (e.g., CHP, diesel generators) in your total energy consumption. When electricity is generated onsite from these other sources, include the fuel that is purchased or transferred into the plant to operate other onsite generation, but do not include the electricity generated by those systems. Electricity from onsite generation that is sold or transferred offsite must be subtracted from the total purchased electricity to represent "net of sales or transfer." Enter your electricity purchases net of sales and transfers in the Electricity column. Non-Electric Energy Use: Include all other forms of energy purchased or transferred (natural gas, oil, coal, etc.), net of sales or transfers. This EPI includes a field for waste-derived fuels (e.g., tires). For fuels not defined in the EPI, use the Other column. Steam: Account for the energy used to produce steam if steam is transferred in from an external or third-party site whose energy does not appear in your plant's energy total. The Btu for producing steam is calculated using actual boiler conversion efficiencies of the external or third-party producer, and added to your plant's energy total (i.e., the Btu value of the fuel used to make the steam). 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.)

Recovered Energy: Do not include energy recovered from the production process (e.g., waste heat, process byproducts) in the energy accounting of the EPI. The EPIs underlying statistical model recognizes that plants have an opportunity to recover or self-produce a portion of the energy they require, and is adjusted based on plant characteristics and purchased energy inputs to the EPI.

Annual Cost: Total annual energy cost for each fuel type in current year dollars. Input of cost data is optional and does not impact the Energy Performance Score. This feature is provided for your convenience and use.

Results

Definitions of terms used in the results section

Energy Performance Score: The Energy Performance Score is a percentile ranking for your plant normalized for the plant characteristics listed above. Purchased Source Energy (MMBtu): The sum of direct fossil fuel consumption and electricity, with electricity converted from kWh to Btu using the national average power plant conversion (11,396 Btu/kWh). For more information on source energy definitions, see www.energystar.gov. Purchased Site Energy (MMBtu): The sum of direct fossil fuel consumption and electricity, with electricity converted from kWh to Btu using the thermal conversion factor for electricity (3,412 Btu/kWh). Energy Intensity The source energy use per total production of clinker for the current, reference, average and (Source MMBtu/Short Ton of Clinker): efficient plant. The first two ratios are directly based on input data, and the latter two are the projected normalized values for an efficient and average plant (see below) relative to the current plant performance. 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

Statement of Energy Performance: The workbook tab labeled Statement of Energy Performance (SEP) contains a printable form that is used only when submitting an application for ENERGY STAR plant certification. The results from the EPI will be automatically populated in the appropriate fields in the SEP form. For further information on earning the ENERGY STAR, see http://www.energystar.gov/index.cfm?c=industry.bus_industry_plants_apply. Facility Performance Report: The workbook tab labeled Facility Performance Report provides a printable form that can be used to summarize the results from the EPI. This report is intended to be used by plants or companies for their own internal records.

About The EPI

This ENERGY STAR Plant EPI was developed by the US EPA in collaboration with companies participating in the ENERGY STAR Industry Focus and with technical support from Duke University and ICF International. The EPI is based upon confidential plant-level information. Technical documentation on the design of the EPI is available at www.energystar.gov/EPIs. This EPI will be updated periodically and revised by the US EPA as part of the ENERGY STAR Industry Focus. For more information on the Industry Focus, visit www.energystar.gov/industry or contact energystrategy@energystar.gov. The research for this model was conducted with the cooperation of the Portland Cement Association (PCA). All data provided by PCA are protected by a Non-Disclosure Agreement with Duke University. Research results are those of the author, Gale Boyd (gale.boyd@duke.edu), and do not necessarily reflect opinions of the PCA. The research has been prepared to insure that no confidential data are revealed in this spreadsheet or other documentation.

Cement Manufacturing Plant Energy Performance Indicator

Version 2.4, Release 5/16/2011

Plant Characteristics
Current Plant Enter Name ZIP Code: Location: ZIP Code Error Year Maximum daily kiln throughput Total clinker produced Annual capacity Capacity utilization ASTM 1, 2, 3 and 5 produced ASTM 4 produced Masonry produced Other cement produced Number of kilns Labor 1 1 2010 1 1 326 0% 1
short tons short tons short tons percent short tons short tons short tons short tons number hours

Reference Plant Enter Name 2008 1 1 326 0% 1

1 1

Energy Consumption
Electricity Select units Enter Name 2010 Enter Name 2008 Annual Purchases & Transfers Annual Cost ($)* Annual Purchases & Transfers Annual Cost ($)* Enter cost
* Entering cost data is optional and does not impact the computation of the Energy Performance Score.

Gas

Distillate Oil

Residual Oil

Coal

Waste-derived 1 Enter cost 1

Other

Results
Your Current Plant Enter Name 2010 97 1 1 1 1.00 Your Reference Plant Enter Name 2008 97 1 1 1 1.00 Average Plant Enter Name 2010 50 1 376 376 375.78 Enter Name (2008)
100% 100%

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) Energy Intensity (Source MMBtu/Short Ton of Clinker) Enter Name (2010)

Efficient Plant Enter Name 2010 75 1 41 41 41.05

EPS = 97

90%

EPS = 97

90%
80% 70% 60% 50% 40% 30% 20% 10% 0%

80%
70% 60%

50%
40%

30%
20% 10% 0%
0 100000 200000 300000 400000 500000 600000

100000

200000

300000

400000

500000

600000

Purchased Source Energy (MMBtu)

Purchased Source Energy (MMBtu)

OMB No. 2060-0347

STATEMENT OF ENERGY PERFORMANCE Enter Name

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

Facility Address Enter Name Street Address Address 2 ZIP Code Error 0

Owner's Address Owner's Name Street Address Address 2 City, State ZIP

Corporate Energy Manager Contact Contact Name Email Address Phone Number

Cement Manufacturing Plant Energy Performance Indicator Energy Performance 97 Score: GHG Savings (Kg CO2e) Energy Savings (MMBtu) Professional Verification Professional Engineer Name Address Address 2 City, State ZIP Phone Number: License Number: Licensing State: EPI Verification 19,938 375

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.

EPI attached for EPA review.

EPI contains proprietary information and has been sent to the designated reviewer.
NOTE:

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. 2. All energy performance scores and supporting data must first be verified by the US EPA or a US EPAdesignated EPI reviewer if supporting data is considered to be proprietary before submitting applications for the ENERGY STAR. 3. An energy performance score of 75 is the minimum required score to be considered eligible for the ENERGY STAR.

4. Estimates of energy and CO2 emissions savings are provided to illustrate the difference between the benchmarked plant's energy use and estimated CO2 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.

For US EPA Use Only:

The government estimates the average time need to fill out this form is 6 hours (includes the time entering energy data, PE facility inspection, and notarizing the SEP) and welcomes suggestions for reducing this level of effort. Send comments (referencing OMB control number) to the Director, Collection Strategies Division, US EPA (2822T) 1200 Pennsylvania Ave. NW Washington, DC 20460)

Facility Performance Report Enter Name

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

Facility Address Enter Name Street Address Address 2 ZIP Code Error 0 Facility Energy and Production Maximum daily kiln throughput Total clinker produced Annual capacity Capacity utilization ASTM 1, 2, 3 and 5 produced ASTM 4 produced Masonry produced Other cement produced Number of kilns Labor Purchased Source Energy (MMBtu) Purchased Site Energy (MMBtu)

Owner's Address Owner's Name Street Address Address 2 City, State ZIP

Corporate Energy Manager Contact Contact Name Email Address Phone Number

1 1 326 0% 1 0 0 0 1 1 1 1

short tons short tons short tons percent short tons short tons short tons short tons number hours

Cement Manufacturing Plant Energy Performance Indicator Energy Performance Score: 97 NOTES: Type notes on facility energy performance here