1. Biomass Cogeneration Technology in India (INDO-ASEAN Co-operation in Renewable Energy Workshop, November 5, 2012)
S C. Natu
Sr. Vice President (Power Division)
MITCON Consultancy & Engineering Services Ltd.

2. Potential & Status, Bagasse Cogeneration in Sugar Mills
All India potential, 7000 MW (650 sugar mills)
Achievements as of September 30, 2012, MW (200 projects)
Under construction, 750 MW (50 projects)
Total, 3000 MW (250 projects), 43% penetration
Private sector leading in States like UP, Tamil Nadu, Karnataka & Andhra Pradesh

3. Potential & Status, Bagasse Cogeneration in Sugar Mills (contd.)
Co-operatives leading in Maharashtra & Tamil Nadu
Own investment & BOOT models established
Conducive CERC / SERC orders, CDM, REC & power trade, the key drivers
Results of promotional measures, mainly by MNRE

4. Technology Status, Bagasse Cogeneration in Sugar Mills
Conventional rankine cycle technology
Own / saved bagasse, biomass & coal used as primary fuels, during season & off season of the sugar mills
Travel grate type boilers designed for multi-fuel operations
High pressure / temperature steam generated and expanded through back pressure or double extraction cum condensing TG set

5. Technology Status, Bagasse Cogeneration in Sugar Mills (contd.)
Medium pressure steam at 8 kg/cm2 pressure used for HP heater & process requirements
Back pressure steam at 1.5 kg/cm2 pressure used for process requirements & de-aerator
Balance steam condensed through the condenser
Power generated during season used for cogen plant auxiliaries, sugar / by-product process & balance exported to the grid

6. Technology Status, Bagasse Cogeneration in Sugar Mills (contd.)
Power generated during off season used for cogen plant auxiliaries, by-products, colony & balance exported to grid
Steam to fuel ratios range from 2.4 kg/kg to kg/kg
Steam to power ratios range from 5.2 – 5.6 kg/kw during season & 3.6 – 4.0 kg/kw during off season
PLF, 55 – 60% during season & 90% during off season

7. Technology Status, Bagasse Cogeneration in Sugar Mills (contd.)
Boiler efficiencies, 68-72% on bagasse & 80% on coal
TG efficiency of 90%
Station heat rates, 3600 – 3800 kcal/kwh
Capex, Rs crore / MW for cogen power plant & Rs. 1.0 – 1.5 crore / MW for concurrent sugar factory modernization
O&M, 3-5%

8. Technology Status, Bagasse Cogeneration in Sugar Mills (contd.)
Main packages
Boiler & auxiliaries
Turbine, generator & auxiliaries
Cooling tower or ACC
Fuel & ash handling
Electrical distribution / evacuation
Water treatment plant
Civil works

9. Technology Status, Bagasse Cogeneration in Sugar Mills (contd.)
Main packages (contd.)
Plant DCS
EOT crane
AC & ventilation system
Air compressor
DG set
Interface HP / MP / LP steam, cooling water, DM water & compressed air piping
Fire fighting

10. Technology Status, Bagasse Cogeneration in Sugar Mills (contd.)
Heat Balance Diagram – Season (20 MW Cogen Power Plant)

11. Technology Status, Bagasse Cogeneration in Sugar Mills (contd.)
Heat Balance Diagram – Off Season (20 MW Cogen Power Plant)

12. Technology Status, Bagasse Cogeneration in Sugar Mills (contd.)
Extra high pressure boiler (87 kg/cm2 pressure & 110 kg/cm2 pressure), commercialized
Matching back pressure, single / double extraction cum condensing type TG sets, commercialized
Air cooled condensers and RO type water treatment plants for overcoming water quality and availability issues, commercialized

13. Technology Status, Bagasse Cogeneration in Sugar Mills (contd.)
Plant DCS, VFDs, ACVFD drives, grid synchronization, etc. technologies, commercialized
Extended off season by utilization of cane trash & other biomass materials, getting progressively commercialized
Equipment, technology & services available indigenously

14. Potential & Status, Biomass Power in Industries (Non Bagasse)
All India potential, MW from agro waste materials (excluding sugar mills)
Potential will explode with energy plantation on waste lands for power generation
Achievements as of September 30, 2012, 1250 MW (160 projects) & under construction, 250 MW (20 projects), only 8% penetration
Conducive CERC / SERC orders, CDM, REC & power trade, the key drivers
Results of promotional measures, mainly by MNRE

15. Technology Status, Biomass Power in Industries (Non Bagasse)
Conventional rankine cycle technology, similar to bagasse cogen
Extra high pressure boiler (67 kg/cm2 pressure & 87 kg/cm2 pressure), commercialized
Variety of biomass materials established, although fuel linkage difficult
Equipment, technology & services available indigenously
Independent biomass power plant models established, yet captive power plants in industries through biomass in experimental stages

16. Key Issues for Accelerated Development
Continuation of MNRE / MoF fiscal & financial support
Rationalization of tariffs, other provisions of ERC orders & adequate hikes due to rise in capital & operating costs
Consideration capex for essential sugar mill modernization for tariff determination
Demonstration & commercialization of fuel linkage mechanisms & energy plantation models
Capacity building & information Dissemination
Technology development / demonstration, difficult biomass materials like paddy straw, mustard husk
Level playing field for CDM, REC & power trade

17. Key Areas, Co-operation with ASEAN Countries & India
Engineering / consultancy services
Technology transfer & equipment / EPC supply
O&M contracts
Financing, equity & debt
Capacity building
Information dissemination

18. MITCON, An Overview
Consultancy / engineering company, established in 1982
Central / State Government stakeholders, 59.5% of shares & Private shareholders, 40.5% shares
Profit making & IS/ISO 9001:2008 certified company
Sugar & Power, infrastructure, energy & carbon, environment, agri business, finance & market research, biotechnology, main consultancy / engineering divisions
Latest infrastructure & experienced manpower (totaling to 225, engineering about 100)
Offices in Pune, Mumbai, New Delhi, Ahmedabad, Chennai & Nagpur
MITCON Consultancy & Engineering Services Ltd.

19. Power Division, Vision & Services
To become a ‘One Stop’ service provider for decentralized Power Projects on any fuel, from concept to successful commissioning & establish at the National & International Levels
MITCON Consultancy & Engineering Services Ltd.

20. Power Division, Vision & Services (contd.)
Services (Sugar, Power & Ethanol Projects)
Pre-investment
(Feasibility study, fuel / biomass / cane survey, bankable DPR, loan syndication, lender engineering, approval services, MNRE capital grant & excise duty exemption certificates, project developer interface services, etc. )
Pre-contract Engineering
(Basic / detailed design engineering, plant layouts, specifications and drawings, EPC / packaged bid documents, bidding / bid evaluation / recommendations, pre-contract discussions, assistance in signing EPC / package contracts & manpower planning )
MITCON Consultancy & Engineering Services Ltd.

21. Power Division, Vision & Services (contd.)
Post-contract Engineering / Project Management
(Kick start meetings with vendors / EPC contractors, PERT / CPM networks, inspection / expediting, vendor drawling services and approvals, site supervision, monitoring of erection / commissioning, plant stabilization & plant MIS development)
Post-commissioning
(Witnessing PG tests, trouble shooting, plant MIS, contract to compliance reports, etc. )
MITCON Consultancy & Engineering Services Ltd.

22. Power Division, Vision & Services (contd.)
Macro Assignments & Training
Macro and Policy Studies for biomass, bagasse, natural gas, fossil fuel based industrial captive / cogen power for sugar, distillery & ethanol sectors
Organized number of regional / national / international business meets, interaction meets, workshops, seminars, training and skill up-gradation programs
MITCON Consultancy & Engineering Services Ltd.

23. Experience & Prestigious Clients
National & International experience of two decades, private, public sector & co-operative sector clients
Micro level services to over 200 sugar factories, several biomass & fossil fuel based industrial cogen / captive power projects & distilleries / ethanol plants
A dedicated team of qualified and experienced in-house staff and associate experts at various offices
State-of-the-art engineering design / drawing equipment
MITCON Consultancy & Engineering Services Ltd.

24. Experience & Prestigious Clients (contd.)
Experience (contd.)
Program partner & lead program partner of MNRE, Govt. of India
Macro level assignments and promotional work with IREDA, Winrock International India, USAID, UNDP, financial institutions & banks
International exposure & events participation
Founder member of World Alliance for Decentralized Energy (WADE) and patron member of Cogeneration Association of India (Cogen India)
MITCON Consultancy & Engineering Services Ltd.

25. Experience & Prestigious Clients (contd.)
International
Pure Diet Mocambique Limitada, Mozambique
Sugar Corporation of Uganda Ltd., Uganda
Alliance Tire Co. Ltd., Israel
Delta Energy Inc, UK
Sindicatum Carbon Capital, Singapore
Charter Oak Energy, Renova Engineering PC & Nitash Inc, USA
NUCON Energy Corporation, USA
Ratnala, Behl & Co., USA
Entech Energy Consultants Ltd., UK
UNDP-GEF
USAID
Winrock International India
Swiss Development Corporation
MITCON Consultancy & Engineering Services Ltd.

26. Experience & Prestigious Clients (contd.)
Coverage
Sectoral
Power
Biomass
Sugar
Chemical
Steel
Ethanol
Paper
Rice Mills
Infrastructure
Waste Heat Recovery
Geographic
Maharashtra
Tamil Nadu
Bihar
UP / Uttarakhand
Karnataka
Andhra Pradesh
Goa
Gujarat
Madhya Pradesh
Punjab
Rajasthan
MITCON Consultancy & Engineering Services Ltd.

27. Experience & Prestigious Clients (contd.)
Coverage
Services
(End of Pipe, Concept to Commissioning)
Pre-investment
Engineering
Project Management
Macro Assignments
Events / Training
Fuel Types
Biomass
Bagasse
Coal
Natural gas
Waste heat recovery
Size Range
1 MW to 600 MW
MITCON Consultancy & Engineering Services Ltd.

28. Key Achievements Micro Level
Establishment in private, public, co-operative & other sectors, across India at the national level
Fuel assessment / DPRs / TEV studies / appraisals / loan syndication / lender engineering for public, private & co-operative sector clients & banks / FIs
Owner Engineering / Consultancy Services for biomass power, bagasse cogen along with concurrent sugar factory modernization / expansion & coal fired power plants
MITCON Consultancy & Engineering Services Ltd.

29. Key Achievements (contd.)
Micro Level (contd.)
EPC consultancy services for TANGEDCO / Govt. of TN, 12 cogen power plants along with concurrent sugar factory modernization projects (installed capacity 183 MW), in advance stages of construction & expected to commission in Sept – Dec, 2012)
EPC consultancy services for HPCL Bio Fuels Ltd., integrated sugar expansion / modernization (3500 TCD), cogen power plants (20 MW) & ethanol plants (60 KLPD) at Lauriya & Sugauli in Bihar
MITCON Consultancy & Engineering Services Ltd.

30. Key Achievements (contd.)
Micro Level (contd.)
Consultant to Urjankur Trust for Shri Datta SSKL & Shri Tatyasaheb Kore Warana SSKL, DPR preparation & EPC consultancy for concurrent sugar factory modernization projects
Appointment as LIE by PNB, 2X600 MW imported coal based power plant of ITPCL at Cuddalore, Tamil Nadu
Project developer interface, consultancy & engineering services for BOOT projects for IREL, BPCL & DCM
Pre-investment & engineering services for existing / new sugar plants & ethanol plants
MITCON Consultancy & Engineering Services Ltd.

31. Key Achievements (contd.)
Micro Level (contd.)
Engineering services for first 67 Kg/cm2 pressure bagasse cogen power plant (Mula SSKL, 2006), first 87 Kg/cm2 pressure (YM Krishna SSKL, 2010) & first 110 Kg/cm2 pressure (Shankar SSKL, 2011) in Maharashtra
Engineering services for biomass, bagasse, coal based power plants, 412 MW commissioned capacity (31 projects) & 470 MW under erection (18 projects)
Approved TEV consultants & lender engineers for large no. of banks & financial institutions
MITCON Consultancy & Engineering Services Ltd.

32. Key Achievements (contd.)
Macro Level
All India Bagasse Cogen Study for IREDA, New Delhi
Program Partner & Lead Program Partner of MNRE
Member Secretary, Cogen India & Vice Chairman, WADE
Cane Cogen Handbook of USAID / WII (Partner)
Assessment, Strategy & Action Plan for Non Sugar Cogen Market Development Initiative for USAID / Nexant
Guidelines for Captive Cogen – A handbook for Govt. of Maharashtra, Department of Energy
UNDP-GEF-MNRE project, Removal of Barriers to Biomass Power Generation in India
Renewable Energy Certificates
MITCON Consultancy & Engineering Services Ltd.

33. Contact Details
S. C. Natu Sr. Vice President (Power Division) MITCON Consultancy & Engineering Services Ltd. 1st Floor, Kubera Chambers Shivajinagar, Pune Tel : (020) / 3309, (D), Fax : (020)
MITCON Consultancy & Engineering Services Ltd.

34. Thank You