Steam Turbines and Cogeneration

Cyrus Engineer
Director

D. P. Roy
Executive Director
Cut Costs
?

How

?
 Return on Investment
• Fixed Deposit 8%

• Property in Gurgaon ! 70%

• Power thru Cogeneration 80%

Plus Depreciation Benefits of 80%
CO-GENERATION 160%
Why is Co-Generation so Attractive?
As the word CO-GEN goes, it signifies two Separate
Generations,
co-existing at the same time.

Steam is a basic need of the Process industry.

Generating it at Higher pressure adds just 5 to 20% on the Fuel
Costs, but Premium Energy (Power) is produced.

5000 Kcal of Coal costs Rs 4.50

5000 Kcal of Electricity costs Rs.26.00

A common misnomer is that energy is being produced.

Cogeneration does not produce energy, it merely converts Heat
to Electrical energy. Therefore, higher the Energy (Superheat)
within the steam, more the power.
NEED FOR CO-GENERATION
• GRID POWER (SEB) COST HAS GONE UP.
• UNCERTAIN AND UNRELIABLE POWER
AVAILABILITY.
• HEAVY DEMAND CHARGES PAYMENT INSPITE OF
LOAD SHEDDING.
• HIGH MAINTAINANCE AND RUNNING COSTS OF
D.G. SETS.
• HEAVY COMPETITION IN INDUSTRY LEADING TO
LOWER REALISATIONS AND PROFITABILITY
• HELPS CONSERVE OUR ENVIROMENT
 ESSENTIAL REQUIREMENTS
FOR CO-GENERATION
• PROCESS STEAM PRESSURE
• THE PROCESS STEAM PRESSURE (BACK PRESSURE) DETERMINES THE
EFFECTIVENESS OF COGEN.
• LOWER THE PRESSURE REQUIREMENT, HIGHER THE POWER GENERATION, BETTER
IS THE PAYBACK.

• PROCESS STEAM DEMAND

• THE PROCESS STEAM REQUIREMENT DETERMINES THE EFFECTIVENESS OF COGEN.
• HIGHER THE REQUIREMENT, BETTER IS THE PAYBACK.

• POWER REQUIREMENT IN PLANT

• THE POWER DEMAND WILL DETERMINE THE FOLLOWING :-
• BOILER PRESSURE
• TYPE OF POWER GENERATOR
 TURBO GENSET SELECTION
FACTORS
• TURBINE SELECTION FACTORS
• STEAM FLOW – MAX, AVERAGE AND DESIGN
• BACK PRESSURE
• POWER OUTPUT ACHIEVABLE

• POWER GENERATOR SELECTION FACTORS

• STEAM FLOW FLUCTUATIONS
• POWER LOAD FLUCTUATIONS

• TURBINE EFFICIENCY
• SPECIFIC STEAM TO POWER RATIO
• TURNDOWN RATIO
 SELECTION OF
GENERATION MODE
STAND ALONE
ISLAND SYSTEM
IDEAL SYSTEM WHERE STEAM AND POWER
LOADS ARE CONSTANT. POWER SPURTS
FLUCTUATION MAY NEED STEAM VENTING.
THE SYSTEM IS SUITABLE WHERE POWER
REQUIRED IS LESS THAN OR EQUAL TO
COGENERATED POWER
WILL OPERATE EVEN WHEN POWER FROM
SEB FAILS
SYNCHRONISED
GENERATION
THE ONLY SUCCESSFUL SYSTEM ON
FLUCTUATION STEAM AND POWER LOADS
WHENEVER POWER DEMAND FAR
EXCEEDS COGEN POSSIBILITY
NEEDS SYNCHRONISATION FROM SEB OR
D.G. SET TO OPERATE. TRIPS WHEN GRID
POWER FAILS.
 VARIATION OF POWER OUTPUT
WITH CHANGE IN BACK PRESSURE
TECHNICAL BACK BACK BACK
PARAMETERS PRESSURE PRESSURE PRESSURE
3 Kg/cm2 (g) 4 Kg/cm2 (g) 5 Kg/cm2 (g)

Turbine Input 10 TPH 10 TPH 10 TPH

conditions 33 Kg/cm2 g) 33 Kg/cm2 g) 33 Kg/cm2 g)

Process Steam 3 Kg/cm2 (g) 4 Kg/cm2 (g) 5 Kg/cm2 (g)

Pressure
(Back Pressure)
Power output 600 KW 540 KW 500 KW
from turbine
 VARIATION OF POWER OUTPUT WITH
CHANGE IN INLET STEAM CONDITIONS
TECHNICAL 6 TPH 6 TPH 6 TPH 6 TPH
PARAMETERS 9 Kg/cm2(g) 21 Kg/cm2(g) 21 Kg/cm2 (g) 33 Kg/cm2(g)

Steam 2500C Saturated 3300C 3500C

Temperature

Process Steam 3 Kg/cm2 (g) 3 Kg/cm2 (g) 3 Kg/cm2 (g) 3 Kg/cm2 (g)
Pressure
(Back Pressure)
Power output 145 KW 220 KW 300 KW 340 KW
from turbine

Quality of Dry - 1900C 7 % Wet Dry - 2100C Dry - 2100C

exhaust Steam
 VARIATION OF POWER OUTPUT WITH
CHANGE IN INLET STEAM CONDITIONS
TECHNICAL 20 TPH 20 TPH 6 TPH
PARAMETERS 32 Kg/cm2(g) 42 Kg/cm2(g) 63 Kg/cm2 (g)

Steam 3500C 4200C 4800C

Temperature

Process Steam 3 Kg/cm2 (g) 3 Kg/cm2 (g) 3 Kg/cm2 (g)

Pressure
(Back Pressure)

Power output from 1645 KW 2060 KW 2630 KW

turbine
 THUMB RULE ON BACK PRESSURE

Use Lowest Possible Back Pressure !

It saves you a lot on Installation and Fuel
costs.

When it comes to Power Produced,

Increasing Back Pressure by 1 Kg/cm2 is the
equivalent of increasing Boiler Steam
pressure by about 6 Kg/cm2
ADVANTAGES WHEN
PURCHASING FROM
COGEN PACKAGE
SUPPLIERS

1. One point source for both systems

2. Proper System integration with Process
3. One Point Guarantee and Responsibility.
4. Complete Steam piping design.
5. Electrification and Grid Synchronisation
assistance.
6. One Point for Boiler and Turbine Service.
 Case Study – Newsprint Paper Mill
Damanganga Paper Mills

• A single machine produces 140 Tons of Newsprint per day.

• A Boiler of 12 Ton at 21 Kg pressure operates on Plastic and other

wastes (With proper Flue Gas Scrubbing Plant)

• The turbine produces 9000 units on an average per day on a steam load
of 200 Tons/day.

• Back pressure is maintained at 2.5 to 3 Kg.

• Power is generated at 80 paise per unit compared to Grid power at Rs.

5.20 per unit.

• Therefore the saving is Rs.39,000 per day.

• In operation for the last 15 months, it has saved Damanganga Paper Mills
over Rs. 1.75 Crores till date.
Damanganga Paper Mill
Turbine Installation
 Case Study – Best Paper Mills, Vapi.

• A single machine produces 80 Tons of Kraft Paper per day.

• A Boiler of 12 Ton at 32 Kg pressure operates on Coal

• The turbine produces 8000 units on an average per day on a steam

load of 160 Tons/day.

• Back pressure is maintained at 2.5 to 3 Kg.

• Power is generated at 1.40 paise per unit compared to Grid power

at Rs. 5.20 per unit.

• Therefore the saving is Rs.30,000 per day.

• In operation for the last 12 months, it has saved Best Paper Mills
over Rs. One Crore till date.
 Best Paper Mill
Installation Photos
 Case Study – Textiles
Sangam Processors, Bhilwara
• The unit processes Synthetic Cloth (Suitings)

• The connected machinery includes 40 Jiggers, 11 Jet Dyeing, 3 Open

Decadising, 3 Rotary machines, 4 Drying ranges, KD, Zero-Zero, Super
Finish and Hydrolic Jigger.

• The turbine produces 7000 units on an average per day on a steam load
of 1,35,000 Kg/day.

• Back pressure is maintained at 2.5 to 3 Kg.

• The Boiler consumes 41 Tons of Lignite or 24 Tons of imported Coal per

day.

• Power is generated at Rs. 1.50 per unit. Therefore the saving is

Rs.21,000 per day.

• In operation for the last 16 months, it has saved Sangam Processors

over a Rs. One Crore till date.
Sangam Processors, Bhilwara
Installation Photos
 Case Study – Calcium Carbonate
Sagar Lime Chem, Saharanpur
• There are 6 Drying Cylinders which consume steam at 2 Kg pressure.

• There is no electrical connection with the Grid.

• The entire power load of 300 Amps is met by the steam turbine.

• The turbine produces 4500 units on an average per day on a steam load
of 72 Tons/day.

• Back pressure is maintained at 2 to 2.5 Kg.

• Power is generated at Rs. 1.50 per unit.

• Therefore the saving on Grid Power is Rs.15,000 per day or Rs. 50

Lacs per year.

• In UP there is very poor availability of Power and most units operate DG

Sets, where power generation cost Rs. 10 per unit. In such case the
savings would be Rs. 38000 per day or Rs. 1.3 Crores per year.

• The additional investment for cogeneration was just 50 Lacs!

Sagar Lime Chem, Saharanpur
Installation Photos
 Case Study – Rice Mill
Giriraj Rice Mill, Burdwan
The plant processes 200 Tons of Paddy per day.

IBL modified the Plant to suit the Cogen system.

There is no electrical connection with the Grid.

Power load of 380 KW is met by the Back Pressure Steam turbine.
A 500 KW condensing Turbine meets the requirement of the Cold Store.

The Back pressure turbine produces 8500 units on an average per day on a
steam load of 190 Tons/day. Back Pressure Turbine Power is generated at
80 paise per unit.

The condensing Turbine Produces 8000 units at Rs. 3.50 per Unit

The average cost of Power is just Rs 2.10 per unit.

Therefore the saving on Grid Power is Rs.40,000 per day or Rs. 120 Lacs
per year.

The additional investment for Turbo Generation was Rs. 190 Lacs
Giriraj Rice Mill, Burdwan
Installation Photos
 Unique Low Pressure Application
Cochin Kagaz, Kerala
Cochin Kagaz was
operating a 10 Ton Husk
fired Boiler at 10 Kg/cm2
pressure.

IBL installed a Superheater

and Back Pressure
Turbine.

Power now generated – 200 KWH (4.8 MW per day)

Steam Inlet pressure to turbine 9 Kg/cm2
Investment Rs. 50 Lacs, Savings – Rs. 40 lacs / year
Turbine is in operation for last 3 years.
 How Power Generation cost is calculated
CO GEN SYSTEM 32 KG LOW PRESS SYS
Process Steam Requirement 7500 Kg/hr 7500 Kg/hr
Process Steam Pressure 3.5 Kg/cm2 10.5 Kg/cm2
Cost of Equipment 17000000 Rs. 8500000 Rs.
ECONOMICS OF CO GENERATION
Fuel Consumption with Coal 5000 Kcal/kg 1207 Kg/hr 1085 Kg/hr
Extra Fuel Consumption for Power Generation 123 Kg/hr
Cost of Fuel per Kg 3.50 Rs/Kg
Additional Fuel Cost 429 Rs/hr
Additional Fuel Cost per Day 10295 Rs/day
Power Generated at 7.5 TPH Load 420 KW
Extra power for Cogen Boiler 30 KW
Power available to Plant 390 KW
Power Produced Per Day 9360 KW/Day
Basic Cost of Power due to Fuel Only 1.10 Rs/Unit
Cost Of SEB Power 4.50 Rs/Unit
Savings in power per unit 3.40 Rs./unit
Savings in power per day 31825 Rs/day
Savings in Power Generated per month 954746 Rs/month
Savings in Power Generated per year 11138707 Rs/year
DIFFERENTIAL COST OF COGEN
PROJECT 8500000 Rs.
Interest Cost @ 12% per day 2795 per day
Interest Cost @ 12% per unit 0.30 Rs./unit
Final Power Cost 1.40 Rs./unit
Payback Period 1 year
 About
• IB Turbo was incubated by Industrial Boilers Ltd. to
cater to the requirement of Small Steam Turbines in
2001.

• IB Turbo started manufacturing turbines in 2002.

• Today, IBT Turbines are in operation in all parts of

India as well as in Singapore, Thailand and Vietnam
 IB Turbo Range of Steam Turbines
Model BT – 4 & BT - 6

• Type Back Pressure Single Stage.

• Operating range 100 to 800 KW
• Inlet Pressure 8.5 Kg/cm2 to 37 Kg/cm2
• Inlet Steam temp. range Saturated at 99% Dryness to 3800C
• Back Pressure 1.1 Ata to 5 Kg/cm2
• Power Outputs available
Induction Generation
Alternator Based Synchronised Generation
Alternator Based Stand Alone

• Status 100 Turbines in Operation

 Model MBT – 6
• Type Bleed + Back PressureTurbine
• Operating range 1 to 3 MW
• Inlet Pressure 33 Kg/cm2 to 63 Kg/cm2
• Inlet Steam temp. Superheated 300 - 4800C
• Back Pressure Upto 9 Kg/cm2
 Model BCT – 6
• Type Bleed + Condensing Turbine
• Operating range 1 to 3 MW
• Inlet Pressure 8.5 Kg/cm2 to 63 Kg/cm2
• Inlet Steam temp. Superheated 300 - 4500C
• Back Pressure 1.1 Ata to 9 Kg/cm2
• Power Outputs available Alternator Based Stand Alone
Alternator Based Grid Parallel
Induction Generator with BT- 4 Turbine
BT- 6 Turbine with Alternator (600 KW)
Ashoka Distillery, Hatim
 AGROPAK-TD
The Power Generation
High Pressure FBC Boiler

• Built-in Superheater
• Choice of Fuel Feeding Systems
- In Bed for Coal, Lignite, Saw Dust.
- Over Bed for Rice Husk.
• Bio Gas Compatible.
• Microprocessor Controlled Fuel Feeder
• Water cooled, Suvega Tube Waterwall.
• Packaged Concept, Minimum welding at
Installation site. No Expansion of tubes
• Steady Steam Pressure and Temperature for
critical turbine applications.
• Loaded with high efficiency drum internals.
 BI-DRUM
The Power Generation
High Pressure FBC Boiler

• High Efficiency Boiler.

• Built-in Superheater
• Choice of Fuel Feeding Systems
- In Bed for Coal, Lignite, Saw Dust.
- Over Bed for Rice Husk.
• Bio Gas Compatible.
• Microprocessor Controlled Fuel Feeder
• Loaded with high efficiency drum internals.
 Essentials for selection of Boiler fuels
Fuels appropriate for
Cogeneration in Indian Context
• Round the year availability
• Low Cost of Fuel Coal
• Ease of Operation Lignite

• Less Pollution Bagasse

Saw Dust
• Less Labour Requirement
Rice Husk
• Low Power Consumption
Natural Gas
Agro Residues
Industrial wastes
 How much does it cost to
Generate Power ?
Thru Back Pressure Turbine
• Between Rs. 0.80 per unit to Rs. 1.50 per unit.

Thru Condensing Turbine

• Between Rs. 3.00 per unit to Rs. 4.50 per unit.

Thru Bleed + Condensing Turbine

• Between Rs. 2.50 per unit to Rs. 4.00 per unit.
Successful Industrial Applications
Synchronised Generation
• Paper
• Textiles
• Food Processing
• Breweries
• Malt

Stand Alone Generation

• Distilleries
• Rice
• Calcium Carbonate
• Solvent extraction
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