# How do the Bureau of Energy Efficiency Warangal rice mill reports turn husk saved into a carbon figure, and why is one dryer report's figure lower than a smaller one's?

Canonical: https://senseible.earth/answers/warangal-husk-saving-reports-carbon-per-tonne-of-husk

In five Bureau of Energy Efficiency (BEE) Warangal reports, condensate recovery for 24, 36 and 48 tonne dryers saves 140.1, 180.1 and 240.1 tonnes of husk and pays back in 1.63, 1.50 and 1.26 years. The 48 tonne summary prints a smaller carbon figure than the 24 tonne one, and it matches only part of the husk.

## The five reports side by side

- Condensate recovery, 24 tonne dryers: cost rupees (Rs) 4.12 lakh, husk saved 140.1 tonnes a year, benefit Rs 2.52 lakh, payback 1.63 years, printed carbon dioxide (CO2) cut 58.04 tonnes.
- 36 tonne dryers: Rs 4.86 lakh, 180.1 tonnes, Rs 3.24 lakh, 1.50 years, CO2 74.63 tonnes.
- 48 tonne dryers: Rs 5.43 lakh, 240.1 tonnes, Rs 4.32 lakh, 1.26 years, CO2 53.68 tonnes in the summary.
- Air pre-heater on the flue gas of a 3 tonne an hour boiler: Rs 2.80 lakh, 146.34 tonnes, Rs 2.63 lakh, 1.06 years, CO2 43.9 tonnes. On a 4 tonne an hour boiler: Rs 3.25 lakh, 193.28 tonnes, Rs 3.48 lakh, 0.93 years, CO2 65.4 tonnes.
- Husk is priced at Rs 1.80 a kilogram in every rupee line.

## Where the condensate saving comes from

Each condensate report adds two parts. For the 24 tonne dryers, flash steam saves 64.5 tonnes of husk and the hot condensate 75.6, together 140.1. For 36 tonnes it is 82.94 and 97.16, and for 48 tonnes 110.58 and 129.55. The money follows: 140.1 x Rs 1,800 is Rs 2.52 lakh. The annexures print the husk price as Rs 2 a kilogram in the 36 and 48 tonne reports, but their rupee lines use Rs 1.80. The 36 tonne cost line prints 485,536 in a column headed lakh; the summary has Rs 4.86 lakh.

## Why the biggest dryer prints the smallest carbon figure

For the 24 and 36 tonne reports the carbon figure is 0.4143 tonnes of CO2 for each tonne of husk saved (58.04 / 140.1 and 74.63 / 180.1). The 48 tonne summary prints 53.68, which is about 0.4143 times 129.55, the condensate part alone. The same report's text says the cut is about 100 tonnes, and 0.4143 times the full 240.1 tonnes is 99.5. So the summary figure is the one to doubt. The reports print no basis for the 0.4143.

The two air pre-heater reports print 43.9 and 65.4 tonnes, which is 0.30 and 0.34 tonnes for each tonne of husk. One cluster, three ratios for the same fuel. Our reading: husk is a renewable fuel, so CO2 from burning it is reported outside Scope 1, and none of these figures is a Scope 1 cut. The Vellore and Vapi reports treat biomass differently again.

## Checking the air pre-heater arithmetic

The 3 tonne boiler heat gain of 83,624 kilocalories an hour, over 12 hours and 280 days, divided by husk at 3,200 kilocalories a kilogram and boiler efficiency 0.6, gives 146.3 tonnes, which matches the report. The 4 tonne report works the same way: 110,447 kilocalories an hour gives 193.3 tonnes.

## The 48 tonne condensate report, rebuilt

- Husk saved: flash steam 110.58 + condensate 129.55 = 240.13 tonnes
- Money: 199,030 + 233,189 = Rs 4,32,219 (printed Rs 4,32,236). Payback: 5.43 / 4.32 = 1.26 years
- Carbon at 0.4143: on the full husk 240.1 x 0.4143 = 99.5 tonnes; on the condensate part alone 129.55 x 0.4143 = 53.67 tonnes, which is the summary's 53.68 to rounding

All inputs are the report's own figures except the 0.4143 ratio, which is our arithmetic on the 24 and 36 tonne reports.

## What Senseible does here

Senseible reads fuel invoices and electricity bills into monthly records, so the electricity bills and fuel invoices you upload give a year of use before a change to compare against. Condensate and flue gas temperatures come from your own readings, which you add.

- [Warangal rice mills: electricity per tonne](https://senseible.earth/answers/warangal-rice-mill-cluster-electricity)
- [Biomass or waste fuel in a boiler: Scope 1](https://senseible.earth/answers/biomass-or-waste-fuel-in-boiler-scope-1)
- [Vellore rice mill upgrades: carbon counted or nil](https://senseible.earth/answers/vellore-rice-mill-upgrades-biomass-carbon-counted-or-nil)
- [Green loan readiness check](https://senseible.earth/green-loan-check)

Sources: [BEE, Detailed project report: condensate recovery system, 24 tonne dryers, Warangal rice milling cluster (SAMEEEKSHA)](https://sameeeksha.org/pdf/dpr/Warangal_rice_milling_cluster/Condesate_recovery_system_in_24_tpb_dryers_Warangal.pdf), [BEE, Detailed project report: condensate recovery system, 36 tonne dryers, Warangal rice milling cluster (SAMEEEKSHA)](https://sameeeksha.org/pdf/dpr/Warangal_rice_milling_cluster/Condensate_recovery_system_in_36_tpb_dryers_Warangal.pdf), [BEE, Detailed project report: condensate recovery system, 48 tonne dryers, Warangal rice milling cluster (SAMEEEKSHA)](https://sameeeksha.org/pdf/dpr/Warangal_rice_milling_cluster/Condensate_recovery_system_in_48_tpb_dryers_Warangal.pdf), [BEE, Detailed project report: waste heat recovery, 3 tonne an hour boiler, Warangal rice milling cluster (SAMEEEKSHA)](https://sameeeksha.org/pdf/dpr/Warangal_rice_milling_cluster/Waste_heat_recovery_system_in_3_tph_boiler_Warangal.pdf), [BEE, Detailed project report: waste heat recovery, 4 tonne an hour boiler, Warangal rice milling cluster (SAMEEEKSHA)](https://sameeeksha.org/pdf/dpr/Warangal_rice_milling_cluster/Waste_heat_recovery_system_in_4_tph_boiler_Warangal.pdf)

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