POWER GENERATION

FROM BAGASSE
FUEL
ZAHEER UL HASSAN
Bagasse
Bagasseis the fibrous matter that Hemi-
remains aftersugarcanestalks are Cellulose
cellulose
crushedtoextracttheirjuice. 45-55%
20-25%
Bagasse is utilized as abiofueland
in the manufacture ofpulpand
buildingmaterials.
Lignin Ash
18-24% 1-4%
AS A FUEL
Bagasse is an excellent Raw
Material for power generation. It
provides a suitable and reliable
source of steam and electricity to
feed the sugar industry.

For each 10 tonnes of sugarcane

crushed, a sugar factory
produces nearly 3 tonnes of wet
bagasse.
Leaders in Bagasse Power
Generation
Brazil is the most
efficient utilizer of
this environment India
India
friendlyfuel. Indiaisalsopursuing
Brazil
Brazil tomeetitsenergy
Bagassehasashare requirementsthrough
of ~25% in energy thisfuelandhasa
mix totalproductionmore
than4000MW.
 Potential in Pakistan
Sugar industry is one of the biggest
industry in the world - 81 sugar mills

Industry crushes 30 - 40 MT sugar Potential of generating 3000

cane, yields 12 MT bagasse MW electricity
Advantages of Bagasse as Fuel

1 Bagasseisavailablealmostatnocost

2 Transmissionlossesareveryless

3 EnvironmentFriendly

4 NetemissionsofCO2arenegligible
 Calorific value
Thecalorific valueof a substance is a measure of its heating
power, which depends on the composition of the substance being
burned.

HHV LHV
OR

HHVisheatreleasedwhenfuelis LHVisdeterminedbysubtracting
combustedandproductsreturnedto heatofvaporizationofthewater
25C. fromtheHHV
Calorific Value of Bagasse

High Calorific Suitable for

Value 9600 kJ/kg use as a fuel.
1 2

Depend on Higher moisture,

moisture, content lower calorific
3 of bagasse
4 value and lesser
efficiency of fuel
How Power is generated?

Boilerforsteamgeneration

TurbineDrivenbysteam

GeneratortoproduceElectricity
BOILER
Boiler is the most important part of power
generation
Boiler needs a fuel for ignition and boiler
feed water
Heat transfer takes place through the tubes
of boiler.
For reliable and efficient operation, treatment
of boiler feed water is imperative.
Treatment of Boiler Feed Water

Producing quality steam depends on properly managed

water treatment to control steam purity, deposits and
corrosion.
Boiler performance, efficiency, and service life are direct
products of selecting and controlling feed water used in
the boiler.
Deposits and corrosion result in efficiency losses and
may result in boiler tube failures and inability to produce
steam. Deposits act as insulators and slows heat
transfer.
Impurities causing deposits

Chemicals contained in water that

influence formation of deposits in the
boilers are salts of calcium and
magnesium, which are known as
hardness salts.
Temporary hardness

Calcium and
magnesium They decompose
These are called
bicarbonates on heating,
temporary
dissolved in water releasing carbon
hardness and can
to form alkaline dioxide and forming
be removed by
solution and are a soft sludge, which
boiling.
known as Alkaline settles out
hardness
Permanent Hardness
Calcium and magnesium
sulphates, chlorides and
nitrates etc. when dissolved
in water are called non-
alkaline hardness.

These are called permanent

hardness and form hard
scales on boiler surfaces,
which are difficult to
remove.
SILICA

The presence of silica in boiler water can rise to

formation of hard silicate scales.

Silica can give rise to deposits on steam turbine

blades, after been carried over either in droplets
of water in steam, or in volatile form in steam at
higher pressures.
Internal Water Treatment
Internal water treatment is carried out by adding chemicals
to boiler and it convert the scale forming compounds to free-
flowing sludges, which can be removed by blowdown.
This method is limited to boilers, where feed water is low in
hardness salts, and when only small quantity of water is
required to be treated.
If these conditions are not applied, then high rates of
blowdown are required to dispose off the sludge. They
become uneconomical from heat and water loss
consideration.
Sodium carbonate, sodium aluminate, sodium phosphate,
sodium sulphite and compounds of vegetable or inorganic
origin are all used for water treatment.
External water Treatment
Used to remove suspended solids, dissolved
solids and dissolved gases

The external treatment process available are: ion-

exchange, demineralization and de-aeration.

It is necessary to remove suspended solids and

colours because they may foul the resins
subsequently used in the subsequent treatment
sections.
Pre-Treatment
Methodsofpre-treatmentincludesimplesedimentationinsettling
tanksorsettlinginclarifierswiththeaidofflocculantsandcoagulants.
Water Treatment

Thefirststageoftreatmentistoremovehardnesssaltsandthen
possiblynon-hardnesssalts.Removalofhardnesssaltsiscalled
SofteningwhileremovaloftotalsaltsiscalledDemineralization
ION-EXCHANGE Method

Inion-exchangeprocess,thehardnessisremovedasthewaterpasses
throughsyntheticresinsandwithouttheformationofanyprecipitate.
Thesimplesttypeisbaseexchangeinwhichcalciumandmagnesium
ionsareexchangedforsodiumions.
Aftersaturationregenerationisdonewithsodiumchloride.
De-Mineralization
Demineralizationisthecompleteremovalofallsalts.Thisisachieved
byusingacationresin,whichexchangesthecationsintheraw
waterwithhydrogenions,producinghydrochloric,sulphuricand
carbonicacid.
Carbonicacidisremovedindegassingtowerinwhichairisblown
throughtheacidwater.Followingthis,thewaterpassesthroughan
anionresinwhichexchangesanionswiththemineralacid(e.g.
sulphuricacid)andformswater.
Contd.

Followingthis,thewaterpassesthroughananionresinwhich
exchangesanionswiththemineralacid(e.g.sulphuricacid)andforms
water.
Regenerationofcationsandanionsisnecessaryatintervalsusing,
typically,mineralacidandcausticsodarespectively.Thecomplete
removalofsilicacanbeachievedbycorrectchoiceofanionresin
De-Aeration
InDe-Aeration,dissolvedgasessuchasoxygenandcarbondioxideare
expelledbypre-heatingthefeedwaterbeforeitenterstheboiler.
Allnaturalwaterscontaindissolvedgasesinsolution.Certaingases,
suchascarbondioxideandoxygen,greatlyincreasecorrosion.When
heatedinboilersystems,carbondioxide(CO2)andoxygen(O2)are
releasedasgasesandcombinewithwater(H2O)toformcarbonic
acid,(H2CO3).
 Carbonicacidcorrodesmetalreducingthelifeofequipmentand
piping.Italsodissolvesiron(Fe)whichwhenreturnedtotheboiler
precipitatesandcausesscalingontheboilerandtubes.
Thisscalenotonlycontributestoreducingthelifeoftheequipment
butalsoincreasestheamountofenergyneededtoachieveheat
transfer
Chemical De-Aeration

After Mechanical de-aeration by heating the feed water,

dissolved gases are reduced to very low
levels(0.005mg/ltr).
Even trace amounts of oxygen may cause corrosion
damage to a system.
Consequently, good operating practice requires removal
of that trace oxygen with a chemical oxygen scavenger
such as sodium sulfite or hydrazine.
 Hydrazinereactswithoxygentoformnitrogenandwater.
Itisinvariablyusedinhighpressuresboilerswhenlowboilerwater
solidsarenecessary,asitdoesnotincreasetheTDSoftheboiler
water.
Recommended feed-water limits
Factor Upto 20kg/cm2 21-39kg/cm2 40-59kg/cm2
Total iron(max)ppm 0.05 0.02 0.01
Total 0.01 0.01 0.01
copper(max)ppm
Total silica(max)ppm 1 0.3 0.1
Oxygen(max)ppm 0,02 0.02 0.01
ph 8.8-9.2 8.8-9.2 8.2-9.2
Hydrazine ppm
Hardness ppm 1 0.5
Efficiency of boiler
Efficiency of a boiler is mainly thermal and combustion
efficiency.

Boiler efficiency =(steam value per hour: kg)*(H2-

H1)*100
(Fuel consumption per hr: kg)*(Fuel
cal.value:kcl/kg)

H1 = enthalpy of steam (kcal/kg)

H2 = enthalpy of feed water (kcal/kg)
 Generally,theefficiencyofboilerliesin80-88%.
Theremaining10-12%arelosses.
Losses in Boiler

Blow down losses

ON-OFF LOSSES
Convection losses
Radiation losses
 Turbine
A'TURBINE'isamachinewhichisusedasadriverforother
machines-Generators,pumps,compressors...Etc.
AturbineoperationdependsontheKineticenergycontainedin
flowingfluidswhichisthenconvertedintoMechanicalenergy.
ThisMechanicalenergyisthenconvertedintoElectrical,Heat
(Thermal)orPressureenergyasrequired.
Aturbinetherefore,isusedinthesamewayasaDieselengine,Petrol
engineorElectricmotor,todriveothermachines.Modernturbinescan
producethousandsofHorse-powerofenergy.
Steam Turbine
Insteamturbines,thethermalandpressureenergycontainedin
superheated,highpressuresteamisusedtodrivetheshaftofthe
turbine.
Steamturbinesaregenerallyusedwherethereisaplentifulsupplyof
water.
Thewatermustfirstbetreatedtoremoveimpuritieswhichwillcause
problemsintheturbine.-Chlorides,othersalts,Oxygenandsolid
particles.Thisisdonetopreventcorrosion,erosionandscaledeposits
inthesystem.
Contd.

Superheatedsteamisusedtoruntheturbinesassaturatedsteamcan
causeerosionofbladesofturbineduetowaterdroplets.
Steamcomingfromboilerissaturatedsteamandisfutherheatedina
super-heater.
Working of steam turbine

Inanyturbine,therotorismountedonashaftandconsistsofthe
'Sails'or'Paddles'whichwecallas'Blades.
Thebladesarefittedintoawheelatanangleandarecalled'Rotor
Blades'.Thewheelisthenmountedontotheshaft.
Inordertogetthesteamtopasstotherotorblades,weneedameans
ofdirectingthesteamontotheblades.Thepieceofequipmentused
forthisiscalledaNOZZLE.
Contd.

Asthesteamleavesanozzle,itspressuredecreasesandits
'VELOCITY'increases.
Thishighvelocitysteamjetisdirectedattherotorbladesand,asin
thepin-wheel,therotorandshaftbeginstorotate.
Asmoreandmoresteamisreleasedontotheblades,thespeedof
rotationincreases.
Types of Steam Turbines
Thereare2typesofturbines.
1)Condensingturbines
2)Backpressureturbines
Back Pressure turbine
Foranysteamturbinetooperate,apressuredifferencemustexist
betweenthesteamsupplyandtheexhaust.Wheretheexhauststeamis
aboveatmosphericpressure,theturbineisclassedasaBackPressure
Turbine'or'Non-CondensingTurbine'.
Condensing turbine
Inacondensingsteamturbine,themaximumamountofenergyis
extractedfromthesteam.Thisisachievedbypassingtheexhaust
steamintoacondenser(calledaSurfaceCondenser).
Thesteamiscondensedbysurfacecontactwithbundlesoftubes
throughwhichcoolingwaterispassing.
Asthesteamcondenses,itsvolume,onchangingtowater,decreases
byabout1800times.Thisgreatdecreaseinvolumecausesavacuum
toforminthecondenser.
Contd.
Duetothis,thepressuredropacrosstheturbineandthereforethe
turbinepowerismaximised.Thesteamcondensate(water)islevel
controlledinthecondenserandpumpedbacktothesteamgeneration
plant.
However,althoughthewaterforthesteamgenerationispurifiedand
treated,thesteamwillstillcontainsomeNon-condensibles.
Thesewillbuildupinthesurfacecondenserandgraduallydestroythe
vacuum,therebydecreasingtheP.D.acrosstheturbineandthus
decreasingitsefficiencyandpower.
Contd.
Inordertomaintainthevacuum,thenon-condensiblesmustbe
removedfromthesurfacecondenser.Thisiscarriedoutbyasystemof
STEAMEJECTORS'andEjectorCondensers'whichpullthegases
fromthesurfacecondenserandejectthemtotheatmosphere.
How to make Bagasse Power
plant Cost effective

Low Bagasse Moisture.

01pointreductioninbagassemoistureimprovesboilerefficiencyby
about0.6point.
ConventionalBagassedryerorconcentrationofdistilleryspentwash
couldbeconsideredtotrapthedissipatedenergythroughboilers
stakes.
Low Boiler Flue Gas Temperature
Boilerefficiencyincreasesbyabout01pointforevery15Creduction
instackgastemperature.
Economizercanbeinstalledtoreducethefluegastemperature.
Feed Water Temperature
10Criseinfeedwatertemperatureincreasesboilerefficiencyby1%
RiseinDeaeratortemperatureaswellasofcondensatecanhelpto
increasefeedwatertemperature.
Scaling of Boiler.
AScaleof01mmthicknessincreasesfuelconsumptionby03%in
boilerfiring.
Properchemicaldozing,basedonfeedandboilerwateranalysishelp
toreducescalingfrominsideboilertubes.Ifnecessarychemical
cleaningcouldbeadopted.
High Pressure Boiler
Boilerefficiencyrises10%afterinstallingboilerof65Bargat500C
insteadof25Barg300C.
High Pressure steam
Steamconsumptioncanbereducedto4kg/kWhfrom6kg/kWhon
condensingmodeofturbineusingsteampressure65bargat500C
insteadof25bargat300C.
Boiler blow down heat recovery
Heatofblow-downwatercanbeextractedbyplacingaexchangerinits
path.Recoveredenergycanbeusedforboilerfeedwaterheating,hence
2to5%energysavingcanbeachieved.