The Morbi manual lists carbon dioxide savings for 17 projects: can I add them up into a cluster total?

No. The 16 lines with a figure add to 975,504 tonnes of carbon dioxide a year (line 6 has none), but the manual says units must implement one of three agitator measures, and the gas turbine and gas engine lines replace the same spray dryer fuel. It does not say whether a line is for one unit or the cluster.

The table

Section 3.6 of the manual, headed Environmental benefits, gives a reduction in carbon dioxide in tonnes a year for each technology picked for a detailed project report. Seventeen lines, in tonnes:

• 1. Variable frequency drive on ball mills and blungers: 53,682
• 2. Variable frequency drive on agitator motors: 8,890
• 3. Efficient motors on agitators: 10,637
• 4. On and off timer on agitators: 17,443
• 5. Kiln and other hot surface insulation: 58,749
• 6. Power factor panel: not applicable
• 7. Solar preheating of spray dryer slurry: 75,940
• 8. Kiln exhaust recuperator, tile kilns: 189,539
• 9. Variable frequency drive on press hydraulic motors: 67,069
• 10. Briquette fired hot air generator: 62,500
• 11. Gas turbine with exhaust to the spray dryer: 210,750
• 12. Gas engine with exhaust to the spray dryer: 200,000
• 13. Efficient motors on the polishing line: 7,367
• 14. Light kiln cars, sanitary ware tunnel kiln: 3,866
• 15. Recuperator, sanitary ware tunnel kiln: 1,599
• 16. Cooling zone hot air as combustion air, tunnel kiln: 1,713
• 17. Final cooling hot air to preheat input, tunnel kiln: 5,760

The sum, and the three counts

The 16 lines that carry a figure add to 975,504 tonnes (line 6, the power factor panel, has none). The manual counts its projects three ways: 16 measures in its list of findings (section 4.1.1), 15 numbered technologies short-listed for project reports (section 4.1.5, with the three agitator measures as one item), and 17 lines here. The press drive is in the last two counts and not in the first, so the counts do not describe exactly the same set.

Why you cannot add them

1. Agitators. Lines 2, 3 and 4 are three ways to save the same agitator electricity. The manual says units must implement one of the technology, whichever is comfortable to them. At most one counts, so at most 17,443 of the 36,970 on these three lines.
2. Gas turbine and gas engine. Lines 11 and 12 both make power, both put their exhaust in the spray dryer in place of its fuel, and both are listed for vitrified tile. A unit fits one for the same dryer. That is my reading; the manual does not say they are exclusive.
3. Same gas saved more than once. Insulation, solar slurry preheating, the recuperator, the briquette hot air generator and the turbine or engine all cut the same kiln and dryer gas. If a unit does several, each one saves less than it would alone. That is my reading.
4. One agitator measure and one prime mover, taking the larger of each, gives 975,504 less 8,890 less 10,637 less 200,000 = 755,977. That is still an upper bound, because of the overlap in the third point.

The basis is not printed

The table does not say whether a line is for one unit, for every unit, or for some share of them. It does not say which emission factor was used. The project reports show it is not simply one unit: the polishing motor report gives 402 tonnes for one unit and says there are about 25 vitrified tile units, while the table prints 7,367, which is 18 units' worth. The recuperator report gives 142 tonnes for one unit, and the table prints 189,539, which is about 1,335 units' worth, more than the cluster's 479 units. So the table's recuperator line cannot be that project repeated across every unit. I cannot tell what it assumes.

What to quote

• For a unit, the project report's per-unit tonnes, redone at the grid factor of the year you report. Today that is 0.675 kilograms of carbon dioxide for each kilowatt hour for financial year (FY) 2025-26.
• For the cluster, do not add the table. Say the manual gives a figure for each project and does not give a total.
• Never present any of these as a credit you can sell. The reports speak of extra income through carbon credit as a possibility; it needs a method and an independent check.

The sums

• The 16 lines with a figure (line 6 has none): 975,504 tonnes
• Agitator lines 2 + 3 + 4: 8,890 + 10,637 + 17,443 = 36,970; keep only the largest, 17,443
• Turbine 210,750 and engine 200,000: keep one
• With one agitator measure and the larger prime mover: 975,504 less 8,890 less 10,637 less 200,000 = 755,977 tonnes, an upper bound
• Polishing: 7,367 / 402 = 18.3 units' worth; recuperator: 189,539 / 142 = 1,335 units' worth

Tonnes are as printed in the manual and the project reports, at the factors those reports used, which they do not state. Today's grid factor is lower than the older one the polishing report seems to have used.

What Senseible does here

Senseible reads fuel invoices and electricity bills into monthly records, so a unit's own gas, oil and power lines are on file to set beside the report's figures. It does not measure a kiln or replace an audit.

• Morbi reports ranked by payback
• Roller kiln waste heat recovery
• Vitrified tile polishing line saving
• Green loan readiness check

Sources: BEE, Manual on Energy Conservation Measures in Ceramic Industry, Morbi cluster (SAMEEEKSHA), BEE, Detailed project report: energy conservation in polishing section, Morbi (SAMEEEKSHA), BEE, Detailed project report: waste heat recovery in roller kiln, Morbi (SAMEEEKSHA)

Last reviewed 2026-11-07. Section 3.6 and sections 4.1.1, 4.1.5 are from the April 2010 Bureau of Energy Efficiency (BEE) manual; per-unit tonnes are from the polishing and roller kiln project reports (sections 3.4.2). The manual's tonnes use factors it does not print.