Which printed figures can you trust in the Bureau of Energy Efficiency (BEE) Odisha raw material preheating reports for 50, 100 and 200 tonne a day (TPD) sponge iron kilns?

BEE's Odisha reports preheat kiln feed with flue gas, saving 8,251, 14,145 and 30,647 tonnes of coal a year for 50, 100 and 200 tonne a day kilns. Each prints costs, coal baselines and paybacks that differ between summary, text and annexure, so check which figure you rely on.

The three reports on the annexure basis

• 50 TPD: 12,000 normal cubic metres an hour of flue gas, cooled from 900 to 300 degrees Celsius (C), carries 2,946,828 kilocalories an hour. At 3,000 kilocalories a kilogram of coal that is 982 kilograms an hour. 24 hours x 350 days gives 8,251 tonnes (982.28 x 8,400; the 982 shown is rounded, which is why 982 x 8,400 reads 8,249). Preheating kiln power: 1,200 kilowatt hours (kWh) a day.
• 100 TPD: 24,000 cubic metres, 5,893,655 kilocalories, 1,965 kilograms an hour. 24 hours x 300 days gives 14,145 tonnes (1,964.55 x 7,200; the 1,965 shown is rounded, which is why 1,965 x 7,200 reads 14,148). Power 1,800 kWh a day.
• 200 TPD (two kilns of 100): 48,000 cubic metres, 12,769,586 kilocalories, 4,257 kilograms an hour. 24 x 300 gives 30,647 tonnes (4,256.5 x 7,200; the 4,257 shown is rounded, which is why 4,257 x 7,200 reads 30,650). Power 2,880 kWh a day.
• Money, each at rupees (Rs) 2,500 a tonne of coal and Rs 3.30 a kWh: coal Rs 206, 354 and 766 lakh, less power Rs 14, 18 and 29 lakh, leaves Rs 192, 336 and 738 lakh a year. The flue gas flow is 240 cubic metres an hour for each tonne a day of kiln in all three.

Three project costs in each report

• The summary table prints Rs 165.00 lakh for the 50 TPD, Rs 375.10 lakh for the 100 and Rs 610.00 lakh for the 200. The annexures give Rs 182, 341 and 610 lakh. The body cost tables list the kiln itself at Rs 165, 341 and 610 lakh and add erection and commissioning (5%) and cabling and civil work (5%): Rs 181.50, 375.10 and 671.00 lakh.
• So the summary mixes bases: the 100 TPD shows the full cost, the other two show equipment only. The text paybacks use yet other figures: Rs 182 lakh for the 50 TPD, Rs 341 lakh for the 100 and Rs 610 lakh for the 200.
• The 50 TPD text also says the kiln costs Rs 110 lakh in section 4.1.1, against Rs 165 lakh in its own table.

The payback is in years, and depends on the cost you use

The summary tables print 0.9, 1.00 and 0.83 under a "Months" heading; the text says years. On the full body costs: 181.50 / 192 = 0.95 years, 375.10 / 336 = 1.12 and 671.00 / 738 = 0.91. On the printed summary costs: 0.86, 1.12 and 0.83. The 100 TPD's printed 1.00 uses its Rs 341 lakh equipment cost. Plan on the full-cost figures, since erection and cabling are real.

The coal baselines do not agree

• Table 3.1 gives the kiln's coal as 693,000, 48,000 and 96,000 tonnes a year. The first cannot be right for a 50 TPD kiln. The annexures say 90, 180 and 320 tonnes a day, which is 31,500, 54,000 and 96,000 tonnes over 350, 300 and 300 days. For comparison, our linked page on the Orissa fuel economizer report puts a 50 TPD kiln at about 18,500 tonnes of coal a year, against 31,500 here, so the two pages draw on different reports with different baselines.
• On that annexure basis the saving is 26.2%, 26.2% and 31.9% of the coal. On Table 3.1's 48,000 for the 100 TPD it is 29.5%.
• The audited units tell another story. The four 100 TPD units in Table 1.4 burn 35,503 to 40,210 tonnes a year, so 14,145 tonnes would be 35 to 40%. The 200 TPD unit burns 65,897 tonnes, and 30,647 would be about 47%. Either the savings are high or the baselines are.
• The 50 TPD text gives the saving three ways: 8,194 tonnes in section 3.1.1, 8,149 in Table 3.1 and 8,251 in the annexure, and Rs 194 lakh against Rs 192 lakh.

Carbon dioxide (CO2)

None of the three reports prints a CO2 figure. On Indian coal at 1.76 kilograms of CO2 a kilogram, the saved coal is 14,522, 24,895 and 53,939 tonnes a year, less power at the Central Electricity Authority (CEA) factor for financial year (FY) 2025-26, 0.675 kilograms a kWh: 284, 365 and 583 tonnes. That is a net of about 14,238, 24,530 and 53,356 tonnes. The coal here is rated 3,000 kilocalories a kilogram, which probably carries less carbon than India's average, so your own coal's carbon content will give a better number. Take the coal tonnes from your own ledger, not these baselines.

The 200 TPD report, rebuilt

• Heat: 12,769,586 / 3,000 = 4,256.5 kilograms of coal an hour x 24 x 300 = 30,647 tonnes (30,646.8 unrounded), printed 30,647
• Coal money: 30,647 x Rs 2,500 = Rs 766 lakh. Power: 2,880 x 300 x Rs 3.30 = Rs 28.5 lakh
• Net: Rs 738 lakh. Payback on Rs 610 lakh equipment: 0.83 years; on Rs 671 lakh in full: 0.91 years
• CO2: 30,647 x 1.76 = 53,939 tonnes less power 864,000 kWh x 0.675 = 583 tonnes

Printed lines are the reports' own at the reports' prices (2010). The CO2 lines are our arithmetic, an estimate, using Senseible's Indian coal factor and the CEA version 22.0 grid factor.

What Senseible does here

Senseible reads fuel invoices and electricity bills into monthly records, so your coal bought by month is on file to test a report's baseline against. It does not measure kiln flue gas; that comes from your own survey.

• Raw material preheating in a 100 TPD kiln
• Sponge iron kiln fuel economiser
• Sponge iron waste heat power, 2 and 4 megawatt
• Green loan readiness check

Sources: BEE, Detailed project report: raw material preheating, 50 TPD, Orissa sponge iron cluster (SAMEEEKSHA), BEE, Detailed project report: raw material preheating, 100 TPD, Orissa sponge iron cluster (SAMEEEKSHA), BEE, Detailed project report: raw material preheating, 200 TPD, Orissa sponge iron cluster (SAMEEEKSHA), Central Electricity Authority (CEA), CO2 Baseline Database for the Indian Power Sector

Last reviewed 2026-11-05. Report figures are from BEE's Small and Medium Enterprises (SME) programme project reports, with coal at Rs 2,500 a tonne and power at Rs 3.30 a kWh. Check today's prices, your own coal ledger and a current quote before you rely on any saving.