Which Bureau of Energy Efficiency Jodhpur pet coke storage report fits my lime unit, the large one or the medium one?

Two Bureau of Energy Efficiency (BEE) Jodhpur reports price covered pet coke storage at rupees (Rs) 2.4 lakh for a 12,000 tonne a year unit and Rs 1.5 lakh for 7,500 tonnes. Each saves 1% of the fuel bill and prints a payback of 1.6 years, the same ratio at two sizes.

The two reports side by side

• Large unit, 12,000 to 15,000 tonnes of quicklime a year: Rs 2.4 lakh in Table 4.1 and a saving of Rs 1.5 lakh a year. The live page on large-unit pet coke storage loss works through that case, so this page does not repeat its figures.
• Medium unit, about 7,500 tonnes: 1.25 + 0.125 + 0.125 = Rs 1.5 lakh. Saving Rs 0.95 lakh. Payback 1.6 years in the text, which is the 19 months of Table 4.2 (about 19.2 months). Net present value (NPV) Rs 1.03 lakh, internal rate of return (IRR) 36%, return on investment (ROI) 161%.
• Both put pet coke at Rs 7,000 a tonne, call for a hard floor and brick or concrete bays, and say in section 4.5 that 4 to 5 weeks of process break down are needed, while their downtime section says none is required.

Where the 1% comes from

Both reports use a pet coke cost of Rs 1,280 for each tonne of quicklime. 12,000 x 1,280 x 1% = Rs 1.536 lakh, printed as 1.5. 7,500 x 1,280 x 1% = Rs 0.96 lakh, printed as 0.95. At Rs 7,000 a tonne, Rs 1,280 is about 0.183 tonnes of pet coke for each tonne of quicklime (my division), so 1% of the fuel is about 22 and 14 tonnes a year.

The reports do not agree on how much is lost today. The text of the large report says units lose about 2 to 3%, put at Rs 4.0 lakh a year. Annexure 1 of both uses 1.5%: Rs 2.304 lakh at 12,000 tonnes, Rs 1.44 lakh at 7,500 and Rs 0.768 lakh at 4,000. The saving booked is 1%, about two thirds of the 1.5% line.

Printed figures that do not tie

• Size bands overlap. The large report says 12,000 to 15,000 tonnes a year. The medium report's Table 3.1 prints 5,000 to 12,000, and its text says about 7,500. A 12,000 tonne unit fits both; the annexure of each uses 12,000 as its large example.
• The medium report's Table 4.1 totals Rs 1.5 lakh and its section 4.2 funds it as Rs 0.375 lakh equity and Rs 1.125 lakh loan. Its Annexure 4 starts from Rs 1.80 lakh, with Rs 0.45 lakh equity and Rs 1.35 lakh debt. 1.8 / 0.95 is 1.9 years, not 1.6.
• Annexure 1 of both says a kiln uses 0.2 tonnes of pet coke for each tonne of quicklime, at Rs 1.44 for each kilogram of quicklime (Rs 1,440 a tonne of quicklime). That nearly agrees with 0.2 x Rs 7,000 = Rs 1,400, while the tables use Rs 1,280.
• Executive summary tables: the large report prints project cost 2.0, which is the material line only, against Rs 2.4 lakh in total. The medium report prints the saving as 10.95, where the body says 0.95.
• The large report's sensitivity table moves the saving by about 7% either way: Rs 1.4, 1.5 and 1.6 lakh, with IRR of 31, 36 and 40%. The medium report moves it by about 5%: 0.9, 0.95 and 1.0.

Before you order

• Weigh the pet coke that comes in and the pet coke that goes to the kiln for a month. The gap is your loss. The reports assume 1.5%.
• Pick the report by your own tonnes of pet coke, not the label. At 0.183 tonnes a tonne, a 12,000 tonne unit burns about 2,200 tonnes a year.
• Ask the builder what the bays cost per square metre at today's rates. Both reports print one lump sum.

The medium report, rebuilt from its own inputs

• Fuel bill: 7,500 tonnes x Rs 1,280 = Rs 96.0 lakh a year
• 1% saved: Rs 0.96 lakh, printed as 0.95. The 1.5% loss line is Rs 1.44 lakh
• Table 4.1 cost Rs 1.5 lakh / Rs 0.95 lakh = 1.58 years, about 19 months, as printed
• My reading with Annexure 4's Rs 1.80 lakh: 1.80 / 0.95 = 1.9 years, about 23 months

Figures are the report's own, at the report year's prices; the last line is my division of its annexure.

What Senseible does here

Senseible reads fuel invoices and electricity bills into monthly records, so the pet coke bought each month is on file, to set against the pet coke you weigh into the kiln. It does not weigh a stockpile. The green loan check shows what a lender asks for.

• Green loan readiness check
• Pet coke storage loss at a lime kiln
• Lime kiln insulation and pet coke saving
• Jodhpur lime kiln units and pet coke carbon

Sources: BEE, Detailed project report: improved handling and storage of pet coke, large units, Jodhpur limestone cluster (SAMEEEKSHA), BEE, Detailed project report: improved handling and storage of pet coke, medium units, Jodhpur limestone cluster (SAMEEEKSHA)

Last reviewed 2026-11-05. Report figures are from BEE's Small and Medium Enterprises (SME) programme project reports of 2011; costs, pet coke price and paybacks are at the report year's prices. Check today's pet coke price and a current quote before you rely on the payback.