# Why do the Bureau of Energy Efficiency Jodhpur gasifier reports cost the same 62.7 lakh rupees for a 15 and a 30 tonne a day lime kiln but save 25 and 49 lakh?

Canonical: https://senseible.earth/answers/jodhpur-lime-kiln-gasifier-15-and-30-tpd-reports

Two Bureau of Energy Efficiency (BEE) Jodhpur reports price a producer gas kiln upgrade at the same rupees (Rs) 62.7 lakh for 15 and 30 tonne a day (tpd) lime kilns, and book savings of Rs 25 and Rs 49 lakh a year. The tables print 27 and 14 months, and the 30 tpd summary repeats the 15 tpd figures.

## The two reports side by side

- 15 tpd kiln, production printed as 4,500 a year (the text says kilograms (kg); I read it as tonnes, which is 15 tpd for 300 days): Table 4.1 is equipment Rs 57.0 lakh + erection 2.85 + miscellaneous 2.85 = Rs 62.7 lakh. Saving Rs 25.0 lakh a year. Text payback 2.5 years, Table 4.2 27 months.
- 30 tpd kiln, 9,000 a year, read the same way: the same Rs 62.7 lakh. Saving Rs 49.0 lakh. Text payback 16 months, Table 4.2 14 months.
- Both compare a pet coke kiln at 1,530 to 1,650 kilocalories (kcal) a kilogram and 180 kg of pet coke per tonne with a coal fired gasifier kiln at 1,100 to 1,200 kcal and 220 kg of bituminous coal per tonne. They cost pet coke at Rs 9 a kg and coal at Rs 5.5.

## Why the same cost, and what the savings include

The savings follow production, 4,500 and 9,000 tonnes: Rs 25.0 lakh over 4,500 is about Rs 556 a tonne and Rs 49.0 lakh over 9,000 is about Rs 544. The project cost does not follow it, so the bigger kiln pays back in about half the time.

Section 3.1.1 of each report counts fuel only, Rs 350 to 400 a tonne, and prints Rs 16.85 and Rs 33.00 lakh. Section 3.2 books Rs 525 to 750 a tonne, which adds a credit for product lost today. The table prices that loss at 5 to 10% of a Rs 3,500 tonne, Rs 175 to 350, and sets it to nil for the gasifier. So Rs 25 and Rs 49 lakh are fuel plus lower wastage. The reports print no measured wastage.

The report also prints the fuel saving as per kilogram where it means per tonne.

## Printed figures that do not tie

- 15 tpd, payback: Rs 62.7 lakh / Rs 25.0 lakh is 2.5 years, which is 30 months. The text prints 2.5 years and the executive summary table prints 30 months, both correct, while Table 4.2 prints 27.
- 15 tpd, returns: the text gives an internal rate of return (IRR) of 97%, but 97 is the ROI (return on investment) figure in Table 4.2, not a separate IRR. Table 4.2 gives an IRR of 10.8%, which is the figure in the sensitivity table, and the executive summary table prints IRR 11, net present value (NPV) 1.18 and ROI 97. The NPV is Rs 1.185 lakh at 12%. An IRR of 10.8% is below 12%, so the text's 97% IRR and the table's IRR cannot both hold.
- 15 tpd, sensitivity: with savings 5% lower, Rs 23.75 lakh, the NPV turns negative at minus Rs 2.33 lakh and the IRR is 8.42%.
- 30 tpd, executive summary: its table is a copy of the 15 tpd one. It prints project cost Rs 62.7 lakh, saving Rs 25.0 lakh, IRR 11, NPV 1.18, ROI 97 and payback 30 months, under the project name 'Replacement of Old and Inefficient motors', against Rs 49.0 lakh and 14 months in its body. So the 30 tpd report prints 30, 16 and 14 months.
- 30 tpd, payback: 62.7 / 49.0 is 1.28 years, about 15 months; the text prints 16 and the table 14. NPV Rs 68.65 lakh and IRR 51.72%, and a 5% lower saving still gives NPV of Rs 61.76 lakh.
- Pet coke is priced at Rs 9 a kg here and at Rs 7 a kg in the Jodhpur insulation and storage reports of the same year.

## Before you order

- Weigh your own pet coke tonnes per tonne of quicklime. The report's 180 kg is a benchmark, not your kiln.
- Measure product lost today, and ask the supplier to commit to the kcal figure. For a 15 tpd kiln the loss credit is a large part of the case.
- Get a quote that states fuel handling, ash and the producer gas cleaning, which the reports leave to a single lump sum.

## The 15 tpd report, fuel and wastage split

- Pet coke: 180 kg x Rs 9 = Rs 1,620 a tonne. Coal: 220 kg x Rs 5.5 = Rs 1,210. Difference Rs 410, against Rs 350 to 400 printed
- Fuel part as printed: 4,500 tonnes x about Rs 375 = Rs 16.85 lakh. Whole saving printed: Rs 25.0 lakh
- My reading: the other Rs 8.15 lakh is the lower product loss, about Rs 181 a tonne
- Rs 62.7 lakh / Rs 25.0 lakh = 2.5 years. On fuel alone, 62.7 / 16.85 = about 3.7 years

Printed lines are the report's own. The last two are an example of my own reading of its figures.

## What Senseible does here

Senseible reads fuel invoices and electricity bills into monthly records, so the pet coke bought each month is on file. Quicklime made is not read from bills, so keep your own production log. It does not measure kiln wastage. The green loan check shows what a lender asks for.

- [Green loan readiness check](https://senseible.earth/green-loan-check)
- [Producer gas kiln energy per kg in Jodhpur](https://senseible.earth/answers/jodhpur-lime-kiln-producer-gas-energy-per-kg)
- [Jodhpur kiln insulation reports compared](https://senseible.earth/answers/jodhpur-kiln-insulation-15-30-50-tpd-reports-compared)
- [Jodhpur lime kiln units and pet coke carbon](https://senseible.earth/answers/jodhpur-lime-kiln-units-petcoke-carbon)

Sources: [BEE, Detailed project report: gasifier for 15 tpd kilns, Jodhpur limestone cluster (SAMEEEKSHA)](https://sameeeksha.org/pdf/dpr/Jodhpur_lime_kiln_cluster/02_Energy_cost_saving_by_installing_gasifier_for_kilns15tpd_Jodhpur_cluster.pdf), [BEE, Detailed project report: gasifier for 30 tpd kilns, Jodhpur limestone cluster (SAMEEEKSHA)](https://sameeeksha.org/pdf/dpr/Jodhpur_lime_kiln_cluster/03_Energy_cost_reduction_by_installling_gasifier_for_kilns_30tpd_Jodhpur_cluster.pdf)

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