1. High Pressure and efficient Boilers for Cogeneration applicationsBy
B. Shukla
MD and Chief Consultant,
WHITE POWERCON
#2082,1stmain 4th cross Judicial Layout,
GKVK Post
BANGALORE

2. What is CO-GENERATION?
This is a combined / integrated System of production of Electrical power and useful heat by sequential use of energy from a common fuel source generally bagasse).
To generate surplus power
For Best Utilization of resources
. To have Independency in power and steam

3. The Major advantage of Co- Gen power is ;-
A-Most techno- commercial viable Projects with short pay back.
B-Cost of power production is very cheap compare to that of
purchase power.
C-Dependability and reliability with quality of power.
D-Quick return on investments.
E-Restore ecological imbalance.
F-Ability to use Bio-Mass and organic matters like wood, grass and
agro wastes and also municipal wastes.
G-Availability of power between Nov. to May when Hydel power availability less.
H-provides ecmomical and timeluy solution of Power problems.

4. CO-GENERATION in SUGAR MILLS

5. How Cogeneration Saves Energy

6. COGENERATION PLANT LAYOUT
BOILER
ALTERNATOR
TURBINE TO
PROCESS
TO PROCESS
Fuel
Air
TO POWER SUPPLY
CONDENSER
TO COOLING TOWER
Feed water
PRDS

7. Benefits of cogeneration
Better Power Quality
Improved Reliability and run ability
Lower Energy Costs
Reduction CO2 in the environment
Conserve Natural Resources
Support Grid Infrastructure
Fewer T&D Constraints
Defer Costly Grid Upgrades
Price Stability

8. Steps for conservation
1.Government of India enforced the energy conservation act 2001 with effect from
2.The initial phase of 5 years would be implementation of the act .
3.The act provides mainly for efficient use of energy and its conservation.
4.Industry using

9. Mandatory Requirement of Act
Those unit having connected load of 5000 KWh are called as ‘ Designated Energy Consumer’.
As per the act it is mandatory for all designated Energy Consumers to get Energy Audit conducted by an Accredited Energy Auditor. And to designate or appoint an Energy Manager.

10. Energy Saving potential areas in sugar industries
1.Convertion from low Pressure to HP
Boilers
2.Steam Boilers (Reducing moisture percentage
in Bagasse)
3.Crushing section
4.Evaporator section

11. FEASIBILITY STUDY (TYPICAL STEPS)
Energy auditing
Technical Analysis
Inception
Implementation Planning
Financing
Operation and maintenance

12. CASE STUDIES A-IMPROVEMENT PROJECT By I-BY RETROFITTING
II- -RENOVATION &TECHNOLOGICAL UPGRADATION
B-INITIATING NEW PROJECTS

13. RETROFITTING Replacement of old 18/21Kgs/cm to HP >100bars boilers
A-Provision of Better control system.
B-Efficiency improvement by Automation
C-Reduction of unaccountable losses by
providing dust extraction system
D-Reduction of Boiler & TG down time &
efficiency improvement by water & steam
quality control

14. Case Studies
Introducing New HP Boiler without affecting Present Existing System

15.
Max
Min
Diff
% Saving scope
SL NO.
PARTICULARS
UOM
Actual 1
Cane Crushed MT
729598
736838
646051
700916
736663 2
No. of Crop Days
173
191
159
165
188 3
Crushing Rate/22 hours
3951 4
Crushing Rate/24 hours 5
Crop Day Average
3857 6
Recovery %
9.51
9.11
9.758
9.23
8.187 7
Bagasse Moisture
50.66
50.56
50.11
50.4
51.3
1.19
2.32 8
Steam % Cane
48.76
50.71
48.75
49.45
49.74 9
Power / Ton of Cane
KWH
24.68
25.46
25.18
25.8
1.08
4.19
DOWN TIME ANALYSIS
Rs lakhs per season 10
No Cane
Hrs-Mts
6.-00
57-50
142-15
154-55
204-10 11
Mechanical
64-35
59-30
4.-30
24-55
180-45
181
4.5
176
97.5 12
Electrical
11.-10
53-55
4.-00
24-25
70-00 70 66
94.3 13
General Cleaning
97-10
97-15
109-25
110-25
51-05
110
51.08
59.3
53.7 14
Lost % on Available Hours
7.06
10.3
11.23
8.96
11.9
4.84
40.7
Comparison of performance during various seasns from 1998 to 2002

16. Plant Sanctioned Capacity
Coomparison of performance with best two seasons
SL NO
PARTICULAR
UOM
Max
Min
%saving scope
Plant Sanctioned Capacity MT
5000
2500 1
Cane Crushed
729598 2
No. of Crop Days
173
159
258 3
Crushing Rate / 22 hours
4162.9 4
Crushing Rate / 24 hours
4541.4 5
Crop Day Average
4217.3 6
Recovery %
9.51
9.758
9.357 7
Pol in Cane
11.5
11.618
10.963 8
Total Losses
1.871
1.617
a)Bagasse
0.55
0.541
0.54
b)Filter Cake
0.08
0.07
0.05
c)Final Molasses
1.27
1.211
0.99
d)Unknown Loss
0.1
0.049
0.037 9
Molasses % Cane
4.52
4.449
4.415 10
Bagasse % Cane
29.56
30.32
31.22 11
Cane Preparatory Index
78.18 12
Bagasse Moisture
50.66
50.11
50.52 13
Pol % Bagasse
1.86
1.78
1.73 14
Sugar quality ICUMSA
90to130
80-120 15
Total Available Hours
HRS

17. 16
Down Time Hours
HRS
292-55
428-25
544-45 17
Imbibition% Fiber %
259.14
293.58
295.62 18
Milling Loss
4.12
3.78
3.69 19
Reduced Mill Extraction
95.73
96.02
95.89 20
Reduced B.House Extraction
91.27
91.66
93.43 21
Steam % Cane
48.76
48.75
47.41
2.77 22
Power / Ton of Cane
KWH
24.68
25.18
Rs lakhs/season 23
Peak Period Recovery
9.68
9.923
9.83
DOWN TIME ANALYSIS 24
No Cane
6.-00
142-15
54-15 25
Mechanical
64-35
4.-30
152-15
64.58
4.5 93 26
Electrical
11.-10
4.-00
5.-30 27
General Cleaning
97-10
109-25
164-00
97.16
11.2 28
Others
112-10
167-50
168-45
167.83
33.17 29
Lost % on Avaible Hours
7.06
11.23
8.82 30
Process Stock-Brown Sugar
Qtls
2325
694.65
341.8
213.8
 128 hours
Remarks:Possible saving of running hours =128 hours
Possible increased in crushing of cane per season= MT/season

18. ANALYSIS OF PERFORMANCE FOR THE SEASON 2002-2003(MONTH WISE)
SL NO
PARTICULARS
UOM
DEC.02
JAN.03
FEB.03
MAR.03
APL.03
MAY.03
JUNE.03
TOTAL
Max
Min
%saving 1
Cane Crushed MT
128742
134980
140288
127097
21860
729598 2
Recovery %
8.05
8.84
10.06
10.66
10.14
8.75
6.68
9.61 3
Sugar Production
Qtls
3100
113875
14747
114975
25397
696220 4
Season Days-Crop Day
Days 14 31 28 30 8
173 5
Season Days-Crushing Day 27 29
167 6
Total Available Hours
HRs
332-36
744-00
672-00
720-00
192-03 7
Total Working Hours
330-51
641-40
636-35
705-45
676-15
692-10
172-28
Stoppage Hours
1.-45
102-20
35-25
38-15
43-45
51-50
19-35
292-55
a)Want of Cane
0-00
6.-00
b)Engineering(Mech&Elec)
5.-00
5.-55
20-45
12.-40
21-35
10.-20
75-45

19. c)Process
HRs
0-00
0-50
0-30
1.-20
d)General Cleaning
41-40
26-15
29-15
97-10
e)Others
1.-45
48-50
3.-15
17-00
1.-50
30.15
9.-15
112-10 9
Down Time % Available %
0.53
13.75
5.27
5.14
6.08
6.97
10.-20
7.06 10
Crushing Rate / 22 hours
MTs
3228.9
4414
2504.2 11
Crushing Rate / 24 hours
4815.3
4771
2731.8 12
Crop Day Average
4153
2732.5 13
Crushing Day Average
4768.2 14
Pol % Cane
9.844
10.656
11.947
12.627
12.14
11.025
9.11
11.5 15
Total Losses
1.8
1.828
1.898
1.993
2.01
2.284
2.443 2
a)Final Molasses
1.13
1.143
1.218
1.306
1.31
1.369
1.45
1.27
b)Bagasse
0.521
0.543
0.54
0.545
0.56
0.57
0.6
0.55
c)Filter Cake
0.08
0.081
0.083
0.084
0.087
0.105
d)Unknown
0.069
0.062
0.057
0.058
0.06
0.263
0.288
0.1 16
Reduced Mill Extraction
94.79
95.31
95.88
96.12
96.02
95.64
94.48
95.73 17
Reduced BH. Extraction
91.66
91.49
91.39
91.15
91.19
91.14
90.46
91.27 18
Pol % Bagasse
1.89
1.88
1.86
1.85
1.84
1.9 19
Bagasse % Cane
27.53
28.82
29.06
29.42
30.19
30.75
31.63
29.56 20
Final Molasses Purity
29.6
30.45
30.99
31.71
31.51
31.55
34.15
31.35 21
Molasses % Cane
4.26
4.17
4.37
4.61
4.66
4.85
4.93
4.52 22
Steam % Cane
49.47
47.69
47.62
48.37
47.96
48.18
70.91
48.76 23
Power per Ton of Cane
Units
23.61
23.27
24.69
25.13
25.57
34.3
24.63
32.2
Remarks: Saving of power in terms of money will be Rs lakhs 5.00/KWH

23. BY Technological Up gradation
A-Replacement of old low pressure Boilers to High pressure to get the benefits
improved cycle efficiency.
B-Providing Topping up TG Set to optimize expenses on Electrical system.
C-Better environments by Providing
Emission monitoring.

24. Acquire Best Available Technology in New Projects
A-Select Most modern and reliable
equipments
B-Design Tailor make System.
C-Select Flexible System for Better
utilization of resources and Better economy.

25. Multi fuel Boiler 105ata, 525º C, 88%
Comparison
Prevailing System
Proposed System
TBW Boiler
70 TPH, 67ata & 485ºC
KCP Boiler 70 TPH, 43.4ata & 400ºC
Multi fuel Boiler 105ata, 525º C, 88%
67ata & 485ºC
Topping up TG set
42ata & 400ºC
18.6 MW, 61 tph TG
9.74 MW, 70 tph TG
SIEMENS Turbine
GEC Turbine
GEC Turbine
SIEMENS Turbine
18.6 MW, 61 tph TG C
9.74 MW, 70 tph TG C C C
11 KV BUS

26. Actual Thermal Efficiency of existing power plant on date
Heat value of KPC boiler ≈ 767 Kcal/kg (from steam table) (at 43.4 ata and 400ºC)
Then net heat value of KPC boiler ≈ 767 – 105 ≈ 662 Kcal/kg. Thermal efficiency of KPC boiler = ηth = (Net heat value * Total Steam generation) / (CV of the bagasse * total bagasse consumption) ηth = (662 * ) / (2277 * 61672) = 57.99% ≈ 58% ( against 69% of design)
Heat value of TBW boiler = Kcal/kg (From steam table) (at 67 ata and 485ºC) Then net heat value of TBW boiler ≈ – 105 ≈ Kcal/kg GCV of coal = (CV of coal * total coal consumption) / Total fuel consumption = (5500 * 4622) / = Kcal/kg GCV of Bagasse = (CV of bagasse * total bagasse consumption) / Total fuel consumption = (2277 * 51591) / = Kcal/kg Then net GCV = = 2542 Kcal/kg

27. Then net heat gain = heat gain. steam required for cane
Then net heat gain = heat gain * steam required for cane * efficiency of Topping TG set = 13.8 * 125*103 * = Kcal/kg Total power generation = /860 = 1.8 MW Transfer rate = 1800 * 24 * 330 * 1.96 = 2.79 crore.

28. Thermal efficiency of TBW boiler = ηth = (Net heat value
Thermal efficiency of TBW boiler = ηth = (Net heat value * Total Steam generation) / (Net GCV * total fuel consumption) = (702.7 * ) * 100 / (2542 * 56213) ηth = 63% (against 71.75% of design) Average thermal efficiency of KPC & TBW boiler = (58+63) / 2 = 60.5%

29. Expected direct efficiency of multifuel boiler = 84% Then fuel saving = 84 – 60.5 = 23.5% Cost of fuel saving = Actual cane crushed * % of fuel caned * % fuel save for = * 0.3 * = Rs Then total saving of bagasse = * = Rs. 2,57, = 2.57 crore
Net gain in power = 2.79 crore Net gain in fuel save = 2.57 crore Then total gain = = 5.36 crore

30. Heat value of AFBC boiler = 821
Heat value of AFBC boiler = Kcal/kg (from steam table) (at 515º C and 105 kg/cm2) Then net heat gain = – = 13.8 Kcal/kg From data Budgeted crane crushed/year = M.T Actual crane crushed/year = M.T No. of crop days = 170 days % Steam required for crane = 48% % of bagasse in cane = 30% Then steam required for cane/hr. = (budgeted cane crushed * %steam reqd. for cane) / (No. of days * 24) = ( * 0.48) / (170*24) = tph ≈ 100 tph
For maximum efficiency steam required for cane/hr = 100/0.80 = 125 tph

31. The Major advantage of Co- Gen power is ;-
A-Most techno- commercial viable Projects with short pay back.
B-Cost of power production is very cheap compare to that of purchase power.
C-Dependability and reliability with quality of power.
D-Quick return on investments.
E-Restore ecological imbalance.
F-Ability to use Bio-Mass and organic matters like wood, grass and agro and
municipal wastes.
G-Availability of power between Nov. to May when Hydel power availability
less.
Continue---
H-provides ecmomical and timeluy solution of Power problems.

32. STEPS FOOR SAVINGS
!-Saving of Bagasse by adopting high technology HP Boilers
2-Reduction of moisture in bagasse 50 to 45% by improving Milling Technique.
3-Reduction in Process steam consumptions in evaporator and Prime movers
BLTFF evaporators
4- Reduction in live s team consumption by using multi stage reaction Turbines.
5- Reduction in over consumptions of power TCH using new technique of
Variable drives and high efficient auxiliaries.
6-improve crushing rate by having quality power