Presentation on theme: "High Pressure and efficient Boilers for Cogeneration applications"— Presentation transcript:
1High Pressure and efficient Boilers for Cogeneration applications ByB. ShuklaMD and Chief Consultant,WHITE POWERCON#2082,1stmain 4th cross Judicial Layout,GKVK PostBANGALORE
2What 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 powerFor Best Utilization of resources. To have Independency in power and steam
3The 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 ofpurchase 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 andagro 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.
6COGENERATION PLANT LAYOUT BOILERALTERNATORTURBINETOPROCESSTO PROCESSFuelAirTO POWER SUPPLYCONDENSERTO COOLING TOWERFeed waterPRDS
7Benefits of cogeneration Better Power QualityImproved Reliability and run abilityLower Energy CostsReduction CO2 in the environmentConserve Natural ResourcesSupport Grid InfrastructureFewer T&D ConstraintsDefer Costly Grid UpgradesPrice Stability
8Steps for conservation 1.Government of India enforced the energy conservation act 2001 with effect from2.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
9Mandatory 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.
10Energy Saving potential areas in sugar industries 1.Convertion from low Pressure to HPBoilers2.Steam Boilers (Reducing moisture percentagein Bagasse)3.Crushing section4.Evaporator section
11FEASIBILITY STUDY (TYPICAL STEPS) Energy auditingTechnical AnalysisInceptionImplementation PlanningFinancingOperation and maintenance
12CASE STUDIES A-IMPROVEMENT PROJECT By I-BY RETROFITTING II- -RENOVATION &TECHNOLOGICAL UPGRADATIONB-INITIATING NEW PROJECTS
13RETROFITTING Replacement of old 18/21Kgs/cm to HP >100bars boilers A-Provision of Better control system.B-Efficiency improvement by AutomationC-Reduction of unaccountable losses byproviding dust extraction systemD-Reduction of Boiler & TG down time &efficiency improvement by water & steamquality control
14Case StudiesIntroducing New HP Boiler without affecting Present Existing System
15MaxMinDiff% Saving scopeSL NO.PARTICULARSUOMActual1Cane CrushedMT7295987368386460517009167366632No. of Crop Days1731911591651883Crushing Rate/22 hours39514Crushing Rate/24 hours5Crop Day Average38576Recovery%9.519.119.7589.238.1877Bagasse Moisture50.6650.5650.1150.4188.8.131.528Steam % Cane48.7650.7148.7549.4549.749Power / Ton of CaneKWH24.6825.4625.1825.81.084.19DOWN TIME ANALYSISRs lakhs per season10No CaneHrs-Mts6.-0057-50142-15154-55204-1011Mechanical64-3559-304.-3024-55180-451814.517697.512Electrical11.-1053-554.-0024-2570-00706694.313General Cleaning97-1097-15109-25110-2551-0511051.0859.353.714Lost % on Available Hours7.0610.311.238.9611.94.8440.7Comparison of performance during various seasns from 1998 to 2002
16Plant Sanctioned Capacity Coomparison of performance with best two seasonsSL NOPARTICULARUOMMaxMin%saving scopePlant Sanctioned CapacityMT500025001Cane Crushed7295982No. of Crop Days1731592583Crushing Rate / 22 hours4162.94Crushing Rate / 24 hours4541.45Crop Day Average4217.36Recovery%9.519.7589.3577Pol in Cane11.511.61810.9638Total Losses1.8711.617a)Bagasse0.550.5410.54b)Filter Cake0.080.070.05c)Final Molasses1.271.2110.99d)Unknown Loss0.10.0490.0379Molasses % Cane4.524.4494.41510Bagasse % Cane29.5630.3231.2211Cane Preparatory Index78.1812Bagasse Moisture50.6650.1150.5213Pol % Bagasse1.861.781.7314Sugar quality ICUMSA90to13080-12015Total Available HoursHRS
1716Down Time HoursHRS292-55428-25544-4517Imbibition% Fiber%259.14293.58295.6218Milling Loss4.123.783.6919Reduced Mill Extraction95.7396.0295.8920Reduced B.House Extraction91.2791.6693.4321Steam % Cane48.7648.7547.412.7722Power / Ton of CaneKWH24.6825.18Rs lakhs/season23Peak Period Recovery9.689.9239.83DOWN TIME ANALYSIS24No Cane6.-00142-1554-1525Mechanical64-354.-30152-1564.584.59326Electrical11.-104.-005.-3027General Cleaning97-10109-25164-0097.1611.228Others112-10167-50168-45167.8333.1729Lost % on Avaible Hours7.0611.238.8230Process Stock-Brown SugarQtls2325694.65341.8213.8 128 hoursRemarks:Possible saving of running hours =128 hoursPossible increased in crushing of cane per season= MT/season
18ANALYSIS OF PERFORMANCE FOR THE SEASON 2002-2003(MONTH WISE) SL NOPARTICULARSUOMDEC.02JAN.03FEB.03MAR.03APL.03MAY.03JUNE.03TOTALMaxMin%saving1Cane CrushedMT128742134980140288127097218607295982Recovery%8.058.8410.0610.6610.148.756.689.613Sugar ProductionQtls310011387514747114975253976962204Season Days-Crop DayDays1431283081735Season Days-Crushing Day27291676Total Available HoursHRs332-36744-00672-00720-00192-037Total Working Hours330-51641-40636-35705-45676-15692-10172-28Stoppage Hours1.-45102-2035-2538-1543-4551-5019-35292-55a)Want of Cane0-006.-00b)Engineering(Mech&Elec)5.-005.-5520-4512.-4021-3510.-2075-45
19c)ProcessHRs0-000-500-301.-20d)General Cleaning41-4026-1529-1597-10e)Others1.-4548-503.-1517-001.-5030.159.-15112-109Down Time % Available%0.5313.755.275.146.086.9710.-207.0610Crushing Rate / 22 hoursMTs3228.944142504.211Crushing Rate / 24 hours4815.347712731.812Crop Day Average41532732.513Crushing Day Average4768.214Pol % Cane9.84410.65611.94712.62712.1411.0259.1111.515Total Losses1.81.8281.8981.9932.012.2842.4432a)Final Molasses1.131.1431.2181.3061.311.3691.451.27b)Bagasse0.5210.5430.540.5450.560.570.60.55c)Filter Cake0.080.0810.0830.0840.0870.105d)Unknown0.0690.0620.0570.0580.060.2630.2880.116Reduced Mill Extraction94.7995.3195.8896.1296.0295.6494.4895.7317Reduced BH. Extraction91.6691.4991.3991.1591.1991.1490.4691.2718Pol % Bagasse1.891.881.861.851.841.919Bagasse % Cane27.5328.8229.0629.4230.1930.7531.6329.5620Final Molasses Purity29.630.4530.9931.7131.5131.5534.1531.3521Molasses % Cane4.264.174.374.614.664.854.934.5222Steam % Cane49.4747.6947.6248.3747.9648.1870.9148.7623Power per Ton of CaneUnits23.6123.2724.6925.1325.5734.324.6332.2Remarks: Saving of power in terms of money will be Rs lakhs 5.00/KWH
23BY Technological Up gradation A-Replacement of old low pressure Boilers to High pressure to get the benefitsimproved cycle efficiency.B-Providing Topping up TG Set to optimize expenses on Electrical system.C-Better environments by ProvidingEmission monitoring.
24Acquire Best Available Technology in New Projects A-Select Most modern and reliableequipmentsB-Design Tailor make System.C-Select Flexible System for Betterutilization of resources and Better economy.
26Actual 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
27Then 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.
28Thermal 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%
29Expected 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 croreNet gain in power = 2.79 crore Net gain in fuel save = 2.57 crore Then total gain = = 5.36 crore
30Heat 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 tphFor maximum efficiency steam required for cane/hr = 100/0.80 = 125 tph
31The 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 andmunicipal wastes.G-Availability of power between Nov. to May when Hydel power availabilityless.Continue---H-provides ecmomical and timeluy solution of Power problems.
32STEPS FOOR SAVINGS!-Saving of Bagasse by adopting high technology HP Boilers2-Reduction of moisture in bagasse 50 to 45% by improving Milling Technique.3-Reduction in Process steam consumptions in evaporator and Prime moversBLTFF evaporators4- Reduction in live s team consumption by using multi stage reaction Turbines.5- Reduction in over consumptions of power TCH using new technique ofVariable drives and high efficient auxiliaries.6-improve crushing rate by having quality power