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High Pressure and efficient Boilers for Cogeneration applications By B. Shukla MD and Chief Consultant, WHITE POWERCON #2082,1stmain 4 th cross Judicial.

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Presentation on theme: "High Pressure and efficient Boilers for Cogeneration applications By B. Shukla MD and Chief Consultant, WHITE POWERCON #2082,1stmain 4 th cross Judicial."— Presentation transcript:

1 High Pressure and efficient Boilers for Cogeneration applications By B. Shukla MD and Chief Consultant, WHITE POWERCON #2082,1stmain 4 th 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 BOILER ALTERNATOR TURBINE TO PROCESS TO PROCESS Fuel Air TO POWER SUPPLY CONDENSER TO COOLING TOWER COGENERATION PLANT LAYOUT Feed water PRDS

7 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 Benefits of cogeneration

8 Steps for conservation 1.Government of India enforced the energy conservation act 2001 with effect from 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 MaxMinDiff % Saving scope SL NO.PARTICULARS UOMActual 1Cane Crushed MT No. of Crop Days Crushing Rate/22 hours MT Crushing Rate/24 hours MT Crop Day Average MT Recovery % Bagasse Moisture % Steam % Cane % Power / Ton of Cane KWH DOWN TIME ANALYSIS Rs lakhs per season 10No Cane Hrs-Mts Mechanical Hrs-Mts Electrical Hrs-Mts General Cleaning Hrs-Mts Lost % on Available Hours% Comparison of performance during various seasns from 1998 to 2002

16 SL NO PARTICULAR UOM MaxMin%saving scope Plant Sanctioned CapacityMT Cane CrushedMT No. of Crop Days Crushing Rate / 22 hoursMT Crushing Rate / 24 hoursMT Crop Day AverageMT Recovery % Pol in Cane% Total Losses% a)Bagasse% b)Filter Cake% c)Final Molasses% d)Unknown Loss% Molasses % Cane% Bagasse % Cane% Cane Preparatory Index% Bagasse Moisture% Pol % Bagasse% Sugar quality ICUMSA%90to Total Available HoursHRS Coomparison of performance with best two seasons

17 16Down Time HoursHRS Imbibition% Fiber% Milling Loss Reduced Mill Extraction% Reduced B.House Extraction% Steam % Cane% Power / Ton of CaneKWH Rs lakhs/seaso n 23Peak Period Recovery% DOWN TIME ANALYSIS 24No Cane HRS Mechanical HRS Electrical HRS General Cleaning HRS Others HRS Lost % on Avaible Hours % Process Stock-Brown Sugar Qtls 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 (MONTH WISE) SL NOSL NO PARTICULARS UOMDEC.02JAN.03FEB.03MAR.03APL.03MAY.03JUNE.03TOTALMaxMin %savi ng 1Cane CrushedMT Recovery % Sugar ProductionQtls Season Days-Crop DayDays Season Days-Crushing DayDays Total Available HoursHRs Total Working HoursHRs Stoppage HoursHRs a)Want of CaneHRs b)Engineering(Mech&Elec)HRs

19 c)Proces s HRs d)General CleaningHRs e)Others HRs Down Time % Available% Crushing Rate / 22 hoursMTs Crushing Rate / 24 hoursMTs Crop Day AverageMTs Crushing Day AverageMTs Pol % Cane% Total Losses% a)Final Molasses% b)Bagasse% c)Filter Cake% d)Unknown% Reduced Mill Extraction% Reduced BH. Extraction% Pol % Bagasse% Bagasse % Cane% Final Molasses Purity% Molasses % Cane% Steam % Cane% Power per Ton of CaneUnits Remarks: Saving of power in terms of money will be Rs lakhs 5.00/KWH

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

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 – Kcal/kg. Thermal efficiency of KPC boiler = η th = (Net heat value * Total Steam generation) / (CV of the bagasse * total bagasse consumption) η th = (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 – 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 * efficiency of Topping TG set = 13.8 * 125*10 3 * 0.9 = 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 = η th = (Net heat value * Total Steam generation) / (Net GCV * total fuel consumption) = (702.7 * ) * 100 / (2542 * 56213) η th = 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 = * 500 = Rs. 2,57,815 = 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 = Kcal/kg (from steam table) (at 515º C and 105 kg/cm 2 ) 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


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