Cement/ electricity · heat · proof
The kiln stays.
Everything around it moves.
One provider for green electricity, recovered heat and the data that proves both — from the quarry to the bag.
About ₹5.63 a unit across the year with solar and wind, against ₹6.93 from the grid.
Heat for drying and hot water from recovered heat and heat pumps; the kiln stays on fuel.
An energy assessment on your bills and metering, then one business case for electricity and heat.
Why nowElectricity is a top-three cost · Carbon Credit Trading Scheme · CBAM · Waste heat already paid for · Green procurement · Disclosure
Illustrative reference plant; your figures come from your own tariff, fuel and load.
Quarry to bag/ where we intervene
Quarry to bag.
Eleven levers, none inside the kiln.
Limestone is crushed and stacked, raw meal is preheated and burnt, clinker is cooled, ground with gypsum, fly ash or slag, stored and packed. jouleWise acts at eleven points — electrical, thermal recovery and data, never inside the kiln chemistry.
Green sourcing
Intrastate and ISTS solar and wind contracted through open access for a flat 24×7 load — the largest single lever in cement.
ElectricityConnectivity and metering
Open access approvals, connection agreement and ABT metering at the 132 or 220 kV incomer.
ElectricitySolar on plant land
Ground-mounted and rooftop solar on land the plant already owns, sized from measured load.
ElectricityBattery storage
LFP storage to shave peaks, ride through grid events and firm the solar block.
ElectricityWaste heat recovery electricity
Preheater and cooler heat to WHRS electricity — benchmarked, then run and metered against actual kiln operation.
HeatCooler heat to drying
Cooler vent air and kiln gases routed to raw, coal and slag mill drying before any fuel is burnt for it.
HeatHeat pumps where heat is low grade
Colony, canteen and workshop hot water and low-temperature drying air — the slice of cement heat a heat pump can actually serve.
HeatMill scheduling against price
Grinding is the plant's flexible load. ergOS moves mills into the cheapest, greenest blocks within silo and despatch limits.
Data · ergOSergOS control
15-minute metering of every mill, fan, drive and WHRS train; forecasting, scheduling and trading.
Data · ergOSPer-tonne disclosure
kWh and kg CO₂ per tonne of cement, EPD inputs, BRSR Core-format and customer disclosures from esgOS.
ESG · esgOSQuarry and logistics
Limestone, fuel, fly ash and slag movement for Scope 3 and the emission-intensity baseline.
ESG · esgOSIllustrative plant. Actual intervention map built site by site in the baseline.
Electricity/ plan · implement · meter · orchestrate
Low-cost
green electricity.
A cement plant is a heavy, flat, round-the-clock load with one large flexible block: grinding. We size the green portfolio to the flat load — and move the mills into the solar hours.
Hover the profile to read any 15-minute block
No heat pumps in the picture: cement's flexible load is grinding. The mills are the hatched block, moved into the solar hours within silo and despatch limits; the kiln runs flat underneath.
Plan
Meter-data due diligence: bills, load survey, rooftop and captive parameters. Solar, wind, hybrid, BESS and exchange electricity optimised together, capex or opex, with each state's ToD, banking and open access charges in the landed-cost model.
Implement
RfP over a 25-year horizon, developer evaluation, reverse auction, PPA and shareholder agreements (26% SPV equity for captive status), open access approvals and connection agreement.
Meter and log
ABT meters at injection and drawal points — main and check meters on CTs and PTs of the required accuracy class — plus data loggers on every incomer, heat pump, steam, fuel and water line. Installed, tested, sealed and linked to the SLDC and to ergOS.
Orchestrate
ergOS forecasts 96 blocks, schedules with the SLDC, trades DAM, GDAM, RTM and GTAM, manages banking and battery health — and now dispatches heat pumps and thermal storage against price.
Heat/ what moves, what stays
Recover first.
Then electrify.
Cement is the exception in this stack. The kiln, precalciner and raw-mill dryers sit far above any heat pump and stay fuel-fired. The levers are recovering the heat the plant already makes — to electricity through WHRS and to drying — and using heat pumps only where the heat is genuinely low grade.
Heat sources we reuse
Clinker-cooler vent air, preheater exhaust, compressor and grinding-circuit heat — a cement plant makes far more heat than it can use.
Recovery before replacement
In cement the first question is never which heat pump. It is whether the heat already leaving the cooler and preheater is being used — for electricity through WHRS and for drying — before anything new is bought.
Sized from metered heat
Portable heat meters log flow and temperature on candidate processes for two to four weeks before anything is sized.
Economics/ illustrative
Low-cost electricity
drives low-cost heat.
What one kWh of useful process heat costs, and what it emits, depending on where the heat comes from. The heat pump cuts cost on any electricity; green electricity is what cuts the carbon.
Illustrative only, not an offer. Assumptions: PNG 10.4 kWh/SCM, 1.95 kg CO₂/SCM; HSD 10.0 kWh/L, 2.68 kg CO₂/L; grid 0.716 kg CO₂/kWh (CEA baseline order of magnitude); green electricity treated as zero-emission on a market basis with green attributes retired. Heat pump COP 3.5 reflects hot water near 60 °C for colony, canteen and workshop, and low-temperature drying air; COP falls as delivery temperature rises. Tariffs, fuel prices and COP vary by site and are replaced with metered values in the baseline. Coal: ₹8,000/t, 4,000 kcal/kg (4.65 kWh/kg), 1.7 kg CO₂/kg, 75% efficiency. Pet coke: ₹14,000/t, 8,000 kcal/kg (9.3 kWh/kg), 3.3 kg CO₂/kg, shown for reference only — kiln and precalciner heat is not addressable by heat pumps, so the comparison applies to the plant's low-temperature heat.
Roadmap/ from baseline to proof
Baseline.
Electricity. Heat.
Proof.
BaselineWeeks 1–4
Bills, load survey, fuel and steam records, portable heat metering on candidate processes, ESG data map.
RoadmapWeeks 4–8
RE-100 electricity plan, waste-heat and WHRS review, a mill-scheduling model, and the ESG and emission-intensity data map — in one business case.
Meter and logWeeks 6–12
ABT metering at the incomer and data loggers on electricity, heat, fuel and water lines — the measured base every later step is sized, settled and reported on.
Electricity live~3 months after roadmap
Open access contracted and approved; rooftop solar and BESS where they fit; every source orchestrated against demand on ergOS.
Heat livePilot, then scale
Waste heat first — WHRS optimisation and cooler heat into drying — then heat pumps on colony, workshop and low-temperature drying air.
Operate and discloseEvery block · every year
ergOS runs electricity and heat; esgOS publishes BRSR Core-format, CBAM, CDP and customer disclosures with an audit trail.
We can fund it. You choose how. Each lever — electricity or heat — can be bought four ways, and the two levers can be bought differently.
Timelines indicative; confirmed after the baseline and dependent on state approvals and equipment lead times.
Questions/ asked most often
Before you
commit anything.
Does it replace my boiler?
What if electricity is expensive?
What does the site need?
Is it proven?
In short/ Cement
The Cement playbook is jouleWise's typical engineering approach for cement plants: the kiln stays. everything around it moves.
One provider for green electricity, recovered heat and the data that proves both — from the quarry to the bag. For a cement producer, the levers that remain are electrical, thermal recovery and data — and all three are now scored by regulators and buyers. Six pressures point at the same metered data. Cement is the exception in this stack. The kiln, precalciner and raw-mill dryers sit far above any heat pump and stay fuel-fired. The levers are recovering the heat the plant already makes — to electricity through WHRS and to drying — and using heat pumps only where the heat is genuinely low grade.
What to take away
- Heat duties and temperatures: Colony, canteen and workshop 40–60 °C (heat pump); Low-moisture additive drying 50–90 °C (heat pump); Coal and pet-coke mill drying 60–100 °C (heat pump); Slag and fly-ash drying 140–200 °C (stays on fuel); Raw mill drying 150–200 °C (stays on fuel); Precalciner 850–900 °C (stays on fuel); Kiln burning zone 1450–1450 °C (stays on fuel).
- PNG-fired boiler: ₹6.22 per kWh of useful heat, 0.221 kg CO₂/kWh-th
- Diesel (HSD) boiler: ₹10.59 per kWh of useful heat, 0.315 kg CO₂/kWh-th
- Coal-fired boiler: ₹2.29 per kWh of useful heat, 0.487 kg CO₂/kWh-th
- Pet-coke fired kiln fuel: ₹2.01 per kWh of useful heat, 0.473 kg CO₂/kWh-th
- Heat pump on DISCOM electricity: ₹2.43 per kWh of useful heat, 0.205 kg CO₂/kWh-th
- Heat pump on green open access: ₹1.57 per kWh of useful heat, 0.000 kg CO₂/kWh-th
- Heat pump in solar blocks + store: ₹1.14 per kWh of useful heat, 0.000 kg CO₂/kWh-th
- Plant areas with a lever: Grinding shifted into solar blocks, Waste heat recovery electricity, Cooler heat to drying, Open access at 132 or 220 kV, Per-tonne disclosure.
What it assumes
- Illustrative only, not an offer. Assumptions: PNG 10.4 kWh/SCM, 1.95 kg CO₂/SCM; HSD 10.0 kWh/L, 2.68 kg CO₂/L; grid 0.716 kg CO₂/kWh (CEA baseline order of magnitude); green electricity treated as zero-emission on a market basis with green attributes retired. Heat pump COP 3.5 reflects hot water near 60 °C for colony, canteen and workshop, and low-temperature drying air; COP falls as delivery temperature rises. Tariffs, fuel prices and COP vary by site and are replaced with metered values in the baseline. Coal: ₹8,000/t, 4,000 kcal/kg (4.65 kWh/kg), 1.7 kg CO₂/kg, 75% efficiency. Pet coke: ₹14,000/t, 8,000 kcal/kg (9.3 kWh/kg), 3.3 kg CO₂/kg, shown for reference only — kiln and precalciner heat is not addressable by heat pumps, so the comparison applies to the plant's low-temperature heat.
- Timelines indicative; confirmed after the baseline and dependent on state approvals and equipment lead times.
Start/ Cement
Tell us the plant.
We'll map the stack.
Send one year of electricity bills and fuel records. We return the baseline, the electricity-and-heat roadmap and the business case.
This presentation is issued for discussion purposes only. Prices, durations, heat pump performance and outcomes shown are indicative, depend on site, state, load profile, process temperatures, contracted terms, exchange prices and the regulatory orders in force, and do not constitute an offer, warranty or commitment by jouleWise. Screens and plant illustrations are illustrative. Client names are cited from jouleWise assignments. Any engagement is governed solely by definitive agreements between the parties.