Sugar Plant High Pressure On
Sugar Plant High Pressure On
Sugar Plant High Pressure On
www.avantgarde-india.com
Core Competence
Captive power plant Cogeneration plant Steam Generator design and Engineering Waste Heat Recovery systems Mini Hydro Electric power plants Combined cycle power plants Solar Thermal & Solar PV power plants Energy Audit Engineering software development Sugar plants Distillery Plants Water and Waste Water treatment plants Industrial Effluent Treatment plants Process piping Equipment design Procurement & Site supervision Third Party Inspection services Residual Life Assessment
Cogeneration Experience
Pioneered Bagasse Cogeneration in India and Commissioned the first project (18.68 MW) in November 1994 - Market Share in India about 75% Commissioned 74 Projects, including a 34.2 MW Project in Kenya, with the aggregate generation capacity of 1550 MW Implementing 38 Projects, including a 80 MW Project in Pakistan, with the aggregate generation capacity of 957 MW Completed Feasibility Reports for 62 Projects aggregating to 1150 MW
Market Share 75% Commissioned 74 Projects Implementing 38+ Projects
Under execution is 2 x 40MW units designed for bagasse and coal for JDW Sugars Limited in Pakistan
What is Co-Generation ?
It is the Co-incident generation of Thermal and Electrical energy, from the same fuel source, where both forms of energy are put to productive use.
Inhouse Consumption Electrical Power Fuel Cogeneration Plant Useful Heat Energy* Export to Grid
Molasses and Bagasse are two by products of Sugar manufacturing which could be utilized profitably
Thermal energy is needed to concentrate the sugar juice for crystallization, It is supplied by low pressure steam, typically at 2.5 bar(a) and the steam is used efficiently in multiple effect evaporators. (typically 36% steam on cane)
Electrical energy is needed for driving the mills, pumps and other machinery. (typically for all electrical drive mill 24 KW/MT of cane crushed)
The boiler steam parameters were adjusted to generate just adequate power while giving the required process steam Cogeneration under present day context is additional power generation for export to grid by adopting higher boiler steam parameters
bar
14 32 67 110 135
With low pressure boilers and steam turbine drives there was always mismatch resulting in inefficiency and use of supplementary fuels like wood or oil
The comparison was made as part of the feasibility study for a 3500 TCD Sugar Mill
No reheat
Deaerator and two stages of hp feed water heating Final feed water temperature of 210C
The difference goes up to 8.14% considering the modern super critical plants
The possible reasons Boiler outlet steam pressure of 170 bar against 110 bar
Feed Water Management Crucial while operating in sync with Sugar Mill
Maintaining the quality of return exhaust condensate from sugar mill is important. No vapor condensate will be used as boiler feed water
Permissible levels of Silica, Iron, Copper and other minerals are lower at higher pressures
Vaporous carry over of Silica increases with pressure and poses serious scaling problem in turbines Make up will be only DM water. Membrane based treatment plant preferred but could be decided based on raw water analysis
Alternate/Supplementary Fuel
The Sugar mills crush only for a limited number of days in a year and hence the bagasse availability is limited By proper sizing and optimization some bagasse could be saved in the season for the off-season operation of the power plant However year round operation of power plant will call for alternate fuels. these alternate fuels could be used as supplementary fuel in case of exigency in season Coal and Bio-mass are the major alternate fuels
Combustion Route:
Well established route, wherein the fuel is combusted in a boiler to generate steam to drive the turbine
The boiler to be designed considering the primary and alternate/supplementary fuel characteristics
Major Equipment
Boiler system generally of the travelling grate stoker fired Turbogenerator system extraction pass out type or extraction condensing type Water Treatment plant additionally makes up the losses on the return condensate
Fuel (bagasse and supplementary fuel like coal) and Ash handling systems
Distributed Control System (DCS)
Better suited technology to fire bagasse and coal or any other biomass. unfortunately comes as the lowest ranking in terms of boiler efficiency
Extraction Condensing
Part of the input steam is extracted at the desired pressure through ports in turbine. the balance steam goes to the condenser. the turbine could be designed for condensing the entire input steam.
Avant-Garde Design
135 bar(a) 545C cycle is under engineering Studies are in progress for introducing steam drying of bagasse with extraction steam from Cogeneration turbine Configuration of Cogeneration plant with reheat cycle under
Mumias, Kenya
170 TPH, 87 bar(g), 515C, Bagasse 34.2 MW
34.2 MW 28 MW
Boiler TG capacity
Gross Power Generation Crushing Season Off-Crop Power Export Crushing Season Off-Crop Project Cost Commissioning Date 14.15 MW 17.81 MW US$ 23 Million October 2008 20 MW 20 MW
Kolhapur, India
110 TPH, 110 bar(g),540C, Bagasse & Coal 20 MW
14.5 MW 17.5 MW
US$ 24 Million December 2010
Boiler TG capacity
Power Export
Crushing Season Off-Crop Project Cost Commissioning Date 20.9 MW 26.8 MW US$ 33 Million December 2009
Boiler TG capacity
Power Export
Crushing Season Off-Crop Project Cost Commissioning Date 19 MW 22 MW US$ 30 Million May 2011
AVANT-GARDE
34.2 MW Cogeneration Plant at Mumias Sugar Company, Kenya Commissioned in April 2009
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avantgarde@vsnl.com