High Pressure and efficient Boilers for

Cogeneration applications

By
B. Shukla
MD and Chief Consultant,
WHITE POWERCON
#2082,1stmain 4th cross Judicial Layout,
GKVK Post
BANGALORE-560065

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

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.

CO-GENERATION in SUGAR MILLS

How Cogeneration Saves Energy

COGENERATION PLANT LAYOUT

TO
POWER
SUPPLY
Feed water

BOILER

Fuel

Air

TURBINE

ALTERNATOR

PRDS

TO
PROCESS
CONDENSER

TO PROCESS

TO COOLING
TOWER

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

Steps for conservation

1.Government of India enforced the
energy conservation act 2001 with effect
from 1.3.2002.
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

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.

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

FEASIBILITY STUDY (TYPICAL STEPS)

Energy auditing
Technical Analysis
Inception
Implementation Planning
Financing
Operation and maintenance

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

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

Case Studies
Introducing New HP Boiler without affecting
Present Existing System

Comparison of performance during various seasns from 1998 to 2002

SL
NO
.

PARTICULARS

UOM

Cane Crushed

MT

No. of Crop Days

Crushing Rate/22 hours

2002-03

2001-02

2000-01

1999-00

1998-99

Actual

Actual

Actual

Actual

Actual

729598

736838

646051

700916

736663

173

191

159

165

188

MT

4162.95

3951

4194.98

4385.11

4230.29

Crushing Rate/24 hours

MT

4541.39

4311.12

4576.34

4783.32

4614.77

Crop Day Average

MT

4217.33

3857

4063.22

4247.98

3918.42

Recovery

9.51

9.11

9.758

9.23

8.187

Bagasse Moisture

50.66

50.56

50.11

50.4

51.3

Steam % Cane

48.76

50.71

48.75

49.45

49.74

Power / Ton of Cane

KWH

24.68

25.46

25.18

Max

Min

%
Saving
scope

Diff

51.3

50.11

1.19

2.32

25.8

24.68

1.08

4.19
Rs
51.57
lakhs
per
season

DOWN TIME ANALYSIS

10

No Cane

Hrs-Mts

6.-00

57-50

142-15

154-55

204-10

11

Mechanical

Hrs-Mts

64-35

59-30

4.-30

24-55

180-45

181

4.5

176

97.5

12

Electrical

Hrs-Mts

11.-10

53-55

4.-00

24-25

70-00

70

66

94.3

13

General Cleaning

Hrs-Mts

97-10

97-15

109-25

110-25

51-05

110

51.08

59.3

53.7

14

Lost % on Available Hours

11.9

7.06

4.84

40.7

7.06

10.3

11.23

8.96

11.9

Coomparison of performance with best two seasons

SL
NO

PARTICULAR

Plant Sanctioned Capacity

UOM

2002-03

2000-01

1994-95

Max

MT

5000

5000

2500

MT

729598

646051.4

721475.5

173

159

258

Cane Crushed

No. of Crop Days

Crushing Rate / 22 hours

MT

4162.9

4149.982

2819.806

Crushing Rate / 24 hours

MT

4541.4

4576.344

3076.152

Crop Day Average

MT

4217.3

4063.216

2796.416

Recovery

9.51

9.758

9.357

Pol in Cane

11.5

11.618

10.963

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

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

4148-39

3816-33

6173-40

Min

%saving scope

16

Down Time Hours

HRS

17

Imbibition% Fiber

18

Milling Loss

19

Reduced Mill Extraction

20
21

292-55

428-25

544-45

259.14

293.58

295.62

4.12

3.78

3.69

95.73

96.02

95.89

Reduced B.House Extraction

91.27

91.66

93.43

Steam % Cane

48.76

48.75

47.41

22

Power / Ton of Cane

KWH

23

Peak Period Recovery

24.68

25.18

9.68

9.923

48.76

47.41

2.77
Rs 21.62
lakhs/seaso
n

9.83

DOWN TIME ANALYSIS

24

No Cane

HRS

6.-00

142-15

54-15

25

Mechanical

HRS

64-35

4.-30

152-15

26

Electrical

HRS

11.-10

4.-00

5.-30

27

General Cleaning

HRS

97-10

109-25

28

Others

HRS

112-10

167-50

29

Lost % on Avaible Hours

7.06

11.23

8.82

30

Process Stock-Brown Sugar

Qtls

2325

1477.49

694.65

Remarks:Possible saving of running hours =128 hours

Possible increased in crushing of cane per season= 24220 MT/season

64.58

4.5

93

164-00

109.416

97.16

11.2

168-45

167.83

112.166

33.17

341.8

213.8

128 hours

ANALYSIS OF PERFORMANCE FOR THE SEASON 2002-2003(MONTH WISE)

S
L
N
O

PARTICULARS

UOM

Cane Crushed

MT

Recovery

DEC.02

JAN.03

FEB.03

MAR.03

APL.03

MAY.03

JUNE.03

TOTAL

48558.3

128742

134980

140288

127097

128072.4

21860

729598

8.05

8.84

10.06

10.66

10.14

8.75

6.68

9.61

Sugar Production

Qtls

3100

113875

13227.5

14747

13123.3

114975

25397

696220

Season Days-Crop Day

Days

14

31

28

31

30

31

173

Season Days-Crushing Day

Days

14

27

27

31

29

31

167

Total Available Hours

HRs

332-36

744-00

672-00

744-00

720-00

744-00

192-03

4148-39

Total Working Hours

HRs

330-51

641-40

636-35

705-45

676-15

692-10

172-28

3855-44

Stoppage Hours

HRs

1.-45

102-20

35-25

38-15

43-45

51-50

19-35

292-55

a)Want of Cane

HRs

0-00

6.-00

0-00

0-00

0-00

0-00

0-00

6.-00

b)Engineering(Mech&Elec)

HRs

0-00

5.-00

5.-55

20-45

12.-40

21-35

10.-20

75-45

Max

Min

%savi
ng

c)Proces
s

HRs

0-00

0-50

0-00

0-30

0-00

0-00

0-00

1.-20

d)General Cleaning

HRs

0-00

41-40

26-15

0-00

29-15

0-00

0-00

97-10

e)Others

HRs

1.-45

48-50

3.-15

17-00

1.-50

30.15

9.-15

112-10

Down Time % Available

10.-20

10

Crushing Rate / 22 hours

11

0.53

13.75

5.27

5.14

6.08

6.97

MTs

3228.9

4414

4664.88

4373.12

4134.77

4617.712

2504.2

4162.95

Crushing Rate / 24 hours

MTs

3522.43

4815.3

5088.96

4771

4510.66

5037.504

2731.8

4541.39

12

Crop Day Average

MTs

3468.45

4153

4820.73

4525.41

4236.57

4131.368

2732.5

4217.33

13

Crushing Day Average

MTs

3468.45

4768.2

4999.27

4525.41

4382.66

4131.368

2732.5

4368.85

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

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

0.08

0.087

0.105

0.08

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

1.84

1.9

1.86

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

23.61

23.27

24.69

25.13

25.57

34.3

24.63

Remarks: Saving of power in terms of money will be Rs 77.15 lakhs /month. @Rs 5.00/KWH

7.06

34.3

23.27

32.2

% Recovery during 2002-03

12

Recovery

10
8
6
4

8.05

8.84

Dec

Jan

10.06 10.65 10.14

8.75

2
0

Feb

Mar Apl

May Jun

6.68

%bagasse moisture

%bagasse moisture
35
30
25
20
15
10
5
0

27.53

Dec

28.82 29.06

Jan

Feb

29.42

30.19

Mar

Apl

30.75 31.63

May

Dec Jan Feb Mar Apl May Jun

Jun

Column 7
29
28.6
28.2
27.8
27.4

power consumed per ton of cane

power consumption per ton of cane

crushed
40
35
30
25
20
15
10

34.3
23.61 23.61 23.27 24.69 25.13 25.57

5
0
Dec

Jan

Feb

Mar

Apl

May

Jun

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.

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.

Comparison
Prevailing System
TBW Boiler
70 TPH, 67ata & 485C

Proposed System

KCP Boiler
70 TPH, 43.4ata &
400C

SIEMENS Turbine

GEC Turbine

Multi fuel Boiler

105ata, 525 C, 88%

GEC Turbine

SIEMENS Turbine

C
C
11 KV BUS

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 400C)
Then net heat value of KPC boiler 767 105 662 Kcal/kg.

Thermal efficiency of KPC boiler = th = (Net heat value * Total Steam generation) / (CV of
the bagasse * total bagasse consumption)
th = (662 * 122759) / (2277 * 61672)
= 57.99% 58% ( against 69% of design)

Heat value of TBW boiler = 807.7 Kcal/kg (From steam table)

(at 67 ata and 485C)
Then net heat value of TBW boiler 807.7 105 702.7 Kcal/kg
GCV of coal = (CV of coal * total coal consumption) / Total fuel consumption
= (5500 * 4622) / 56213 = 452.22 Kcal/kg
GCV of Bagasse = (CV of bagasse * total bagasse consumption) / Total fuel consumption
= (2277 * 51591) / 56213 = 2089.77 Kcal/kg
Then net GCV = 452.22 + 2089.77 = 2542 Kcal/kg

Then net heat gain = heat gain * steam required for cane * efficiency of Topping TG set
= 13.8 * 125*103 * 0.9
= 1552.5 Kcal/kg
Total power generation = 1552.5/860 = 1.8 MW
Transfer rate = 1800 * 24 * 330 * 1.96 = 2.79 crore.

Thermal efficiency of TBW boiler = th = (Net heat value * Total Steam generation) /
(Net GCV * total fuel consumption)
= (702.7 * 129399) * 100 / (2542 * 56213)
th = 63% (against 71.75% of design)

Average thermal efficiency of KPC & TBW boiler = (58+63) / 2 = 60.5%

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 02-03
= 729598 * 0.3 * 0.235
= Rs. 51436.65
Then total saving of bagasse = 51437 * 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 = 2.79+2.57 = 5.36 crore

Heat value of AFBC boiler = 821.5 Kcal/kg (from steam table)

(at 515 C and 105 kg/cm2)
Then net heat gain = 821.5 807.7
= 13.8 Kcal/kg

From data
Budgeted crane crushed/year = 775000 M.T
Actual crane crushed/year = 72598.401 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)
= (775000 * 0.48) / (170*24)
= 91.176 tph
100 tph
For maximum efficiency
steam required for cane/hr = 100/0.80 = 125 tph

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.

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