ISSN

0972-0855

VOL

3 3,

JA N - M A R

2008

A QUARTERLY NEWSLETTER ON SUGAR MILL COGENERATION SPONSORED BY THE MINISTRY OF NEW AND RENEWABLE
ENERGY (MNRE), GOVERNMENT OF INDIA, PUBLISHED BY WINROCK INTERNATIONAL INDIA

Continuous Electro-Deionization (CEDI): Modern

Trends in Steam Generation for Sugar Cogeneration
By S Srivastava, Sr General Manager Intellectual Capital Building, Doshion Veolia Water Solutions
With the development of cogeneration
power plants and industries quest to be
self-reliant for power an essential
ingredient to the sugar process industry,
demineralization is an important process
for utility managers in the sugar industry.
Earlier, the process condensate, many times in excess of the
feed water deionization (DI) requirement, was the chief
reason for utility managers to ignore DI as a critical process
to the success of an integrated sugar processing complex.
Today, the significant nature of the power plant feed water
requirement has motivated utility managers to look for newer
options to meet the stringent quality requirements with
certainty.
Some Critical DI Water Parameters to be monitored by
Utility Managers
pH
Conductivity at 250C
Silica as SiO2

8.0
0.2 micro siemens/cm
0.02 ppm

With colloidal silica being a new entrant to the above list,

and the chief reason for glass-like deposits on the turbine
blades, water management became even more critical.

C O N T E N T S
Financing Update: IREDA

The EID Parry CDM Experience

Multi-fuel Boilers for Power Generation

In-Plant Training on Sugar Cogeneration

8
10

Civil Construction Issues for Bagasse

Cogeneration Plants

12

Efficient O&M of Electrical Systems

14

Please fill in
and send us the
feedback form
enclosed. Sugar
mills are
requested to also
fill in their
technical details.
Thank you.

The above challenges were adequately

addressed by water treatment engineers
by designing schemes that included
membrane barriers, typically microfiltration
and ultrafiltration (MF/UF) in combination with reverse
osmosis, to remove the bulk of dissolved impurities. For
polishing of the water to the desired quality, till date, one
had to rely on the old age technology of ion exchange resinbased plants (IX process), which require complex chemistry.
CEDI employs a combination of ion exchange resins and
membranes, and DC current to continuously deionize water
without the use of regeneration chemicals.

The principle behind ion exchange is that polymeric resin

beads have the functionality to provide either positive or
negative charges that attract and remove certain contaminant
ions from the water. Conventional ion exchange technology
can remove dissolved inorganics such as minerals and salts
and some dissolved organics. Cationic resins remove
positively charged ions such as calcium, magnesium and
sodium, replacing them with hydrogen (H+) ions. Anionic
resins remove such negatively charged ions as chloride,
nitrate and silica and replace them with hydroxide (OH-)
ions. The hydrogen and hydroxide ions then unite to form
water molecules.
When the water passes through a tank containing a
mixture of both cation and anion exchange resins, the
process is called mixed-bed ion exchange. Mixed-bed
systems can produce very high-quality water with
resistivity up to 5-10 megohms-cm.
CEDI, however, involves three simple steps in the purification
of water:
I Exchange of ions over respective resins
I Transportation of ions from a dilute chamber towards a

W A T E R

T R E A T M E N T

Electro Deionization System (EDI)

IX Process-based Plants

Regeneration is automatic

Regeneration is to be done manually or in auto plants

through various auto valves
Regeneration is done by chemicals
Chemicals are required for regeneration
Since HCl and NaOH are required, the storage and
handling facilities of these is also required
The system needs stoppage for regeneration
Effluents are generated, which need to be handled
Chances of bacterial growth
The system is complicated to handle
Air is required for separating the resins in the mixed bed
TOC may be generated by ion exchange resins
High maintenance
The system is bulky

Regeneration is by electric current (electrodes)

No chemicals are required for regeneration
Since no chemicals are required, storage and handling is
not required
The system can be operated continuously
No effluents generated
No chances of bacterial growth
The system is simple to handle
No air requirements
TOC * is not generated in the system
Low maintenance
Compact and operator friendly system
* total organic carbon (TOC)

concentrate chamber across an ion selective membrane that

allows selective ions to pass and stops the counter ions; the
transportation is controlled via applications of DC potential
to attract ions
I Continuous in-situ regeneration of resins by splitting of
water molecules into H+ and OHEDIs continuous electro-chemical regeneration provides a

constant water quality with no leakages of ions. It is a low

maintenance process requiring minimal operator
intervention. EDI can also provide low product water
conductivity of much better quality than would be possible
with RO+ mixed bed schemes.
EDI utilizes chemical-free regeneration. This means no
handling of hazardous acid and caustics are required. There
is no waste neutralization or disposal issues and no need to
invest in bulk acid and alkali handling equipment. The
advantages of EDI over conventional IX resin-based deionizers are tabulated above.

EDITORIAL BOARD
Dr JR Meshram, Director (Wind & Biomass Power), MNRE, GoI
Shri Somnath Bhattacharjee, Vice President, WII
Shri Sobhanbabu PRK, Senior Program Officer, E&E, WII

EDI has significantly lower operating costs (typically approx.

250 Watts/m3 for a feed conductivity equivalence < 50

WINROCK EDITORIAL TEAM

Editor

Layout & Design

Anita Khuller

Sasi M

The views expressed in the articles are those of the authors and do
not necessarily reflect those of MNRE or WII.
Photo courtesy: CEDI University

Sponsored by:
Ministry of New and Renewable Energy (MNRE)
Government of India
Block # 14, CGO Complex, Lodhi Road, New Delhi 110003
Tel: 91-11-2436 0707; Web: mnes.nic.in

Published by:
Dr Kinsuk Mitra, President
Winrock International India (WII)
Tel: 91-124-4303868; Fax: 91-124-4303862
Web: <www.winrockindia.org> <www.renewingindia.org>

Printed at: Kriti Communications, New Delhi

AEM - Anion Exchange Membrane

CEM - Cation Exchange Membrane

contd on pg 16...

FINANCING

Financing Bagasse-based Cogeneration Projects: An Update from IREDA

Since its inception in 1987, the Indian Renewable Energy
Development Agency (IREDA) has been at the forefront in
financing cogeneration projects for sugar industries, as a part
of its renewable energy development program. IREDA has
so far financed 36 cogeneration projects with a total loan
commitment of Rs 885 crore and installed capacity of 550
MW. IREDA has introduced attractive schemes for financing
cogeneration projects in sugar industries, which are very
competitive, compared to other institutions in the market. A
brief summary of each financing scheme is given below.

Interest Rate
IREDA Loan

IREDA Scheme for Cogeneration Projects

Minimum Promoters
Contribution

Interest Rate
IREDA Loan
Moratorium
Repayment Period
Minimum Promoters
Contribution

10.8% - 11.25% (*)

Up to 70% of the project cost
Up to 3 years
Up to 10 years after moratorium
30% of the project cost

Moratorium
Repayment Period

11.8% - 12.25% (*)

Up to 70% of the project cost
for new/greenfield sugar units
Up to 90% in existing profitmaking sugar units for the last
3 years
Up to 3 years
Up to 10 years after moratorium
or out of the proceeds of the
SDF loan in a lump sum
10% of the project cost

Financing Commissioned Projects/Takeover of Loans

IREDA can also finance already-commissioned projects by
taking over the existing loans sanctioned by other banks/FIs.
Future Plans
IREDA plans to sanction loans worth about Rs 176 crore
and disburse about Rs 123 crore for biomass power/
cogeneration projects with a capacity addition of 58 MW
during the current financial year
I The 11th five-year plan target of IREDA is Rs 1,122 crore
for sanctions and Rs 788 crore for disbursements for biomass
power/cogeneration projects.
I

IREDA Scheme for SDF-supported Cogeneration Projects

IREDA has introduced a new scheme exclusively for sugar units

for bagasse cogeneration projects availing financial assistance
from the Sugar Development Fund (SDF) in the form of quasi
equity. In this scheme, the SDF loan will be considered to be
treated as promoters contribution (this can be as low as 10%)
and the total loan for the project, up to 90%, is allowed under
this scheme. The interest rate, moratorium, and repayment
period are the same as above. Only the following differ:

Salient Features of IREDA Schemes

The funds from SDF normally take a longer time to flow into
the project. In order to facilitate sufficient flow of funds for
smooth implementation of the project, IREDA has introduced
the additional/bridge loan scheme for SDF-supported
cogeneration projects as per the table alongside.

Competitive interest rates among the lowest in the market

Flexi interest rate with interest reset clause
I Lower interest rates for promoters with good background
I IREDA exposure as high as 90% in SDF-supported projects
I Long repayment period
I A long moratorium period of up to 3 years before
commencement of principal repayment
I Possible financing of commissioned projects and
takeover of loans from other banks
I Co-financing arrangements, available with other FIs where
the loan requirement is more, i.e. beyond IREDA exposure
limits (IREDAs group exposure is Rs 265 crore)
I Long experience compared to other institutions in
financing/supporting biomass cogeneration projects and
providing guidance/support to prospective project developers

In case of co-financing/consortium financing, IREDA may

follow the financing terms of consortium banks/financial
institutions (FIs).

Courtesy: KBK Reddy, Sr Manager (PTS), IREDA, India

Habitat Centre, Core 4-A East Court, 1st floor, New Delhi
110 003; Tel: 2468 2218-24; Fax: 24682202; Web:
www.ireda.in

IREDA Loan
50-70% of the project cost
Minimum Promoters
Contribution
10% of the project cost
SDF Loan as Promoters
Contribution
Up to 40% of the project cost
IREDAs Bridge Loan Scheme for SDF-supported
Cogeneration Projects

I
I

(*) 1% additional during construction period - final interest rate will be decided based upon the Credit Risk Rating System (CRRS) being used in IREDA

SHARING EXPERIENCES

Bagasse Cogeneration at EID Parry: Their CDM Experience

EID Parry India Limited (EID Parry) belongs to the Murugappa
Group, which has evolved into one of the
biggest industrial houses in India. The company has been a
pioneer in many fields setting up Indias
first sugar plant at Nellikuppam (1842), a fertilizer plant at
Ennore, and a sanitaryware plant at Ranipet. EID
Parry now has four sugar mills at Nellikuppam, Pugalur,
Pudukkottai and Pettavaithallai. It won the Green Tech Award
for Safety in Sugar Mills and has obtained an ISO 14001
certification for its sugar plants in Pudukkottai and
Nellikuppam. Being progressive, and to be competitive in
the open market economy, EID Parry took the initiative to
develop the bagasse cogeneration project under the Clean
Development Mechanism (CDM) of the United Nations
Framework Convention for Climate Change (UNFCCC).
The project activity is located at Kurumbur village-Aranthangi
Taluk, Pudukkottai district in Tamil Nadu. The cogeneration
plant is a part of the existing sugar mill at Pudukkottai and
commenced operation in March 2006. The plant operates
for around 250 days during the crushing season and around
50 days in the off-season. Power export to the Tamil Nadu
Electricity Board (TNEB) from this project would be around
12 MW during the season and up to 15 MW in the off-season.
During the identified crediting period (2007-2016),
incremental electricity of approximately 102.22 MU is
expected to be produced every year. This would help reduce
86,623 tons of carbon dioxide emissions per year over ten
years.
Power produced by the project activity will be stepped up
from 11 kV to 110 kV to synchronize it with the grid and will

be supplied to the substation at Alianilai, which is around 6

km from the project site.

Technology
EID Parrys plant includes an 18-MW double extraction-cumcondensing turbo generator and auxiliary equipment, with
a 100 tph boiler (bi-drum, natural circulation water tube type)
using biomass as fuel with outlet steam parameters of 86 kg/
cm2 and 5150C +or -50C. This high pressure steam-Rankine
cycle replaced the existing low pressure system. EID Parry is
among the few sugar mills in the country proposing this
configuration. Moreover, the project has adopted an aircooled steam condenser against the conventional practice
of water-cooled condensers. This helps conserve the huge
volumes of water required for evaporative cooling, which is
replaced by circulation of atmospheric air.
The accessories and auxiliary systems for the 18-MW
cogeneration scheme include:
I A pneumatically controlled ash handling system
I Air cooled condensers
I A firing system with an unburnt re-injection system to
recover unburnt fuel
I A feed water system fitted with an online conductivity
meter to ensure quality of boiler feed water
Boiler
Capacity100% MCR
Type
Pressure
Temperature
Heating Surface
Feed Water Temperature
After Deareator
After HP Heater

100 tph (on baggasse firing)

Traveling Grate
87 ata
515+ or 5 degree centigrade
6,368 sq m
1150C
1650C

Double Extraction cum condensing Turbo set

Make
Capacity
Speed
3 ata
8 ata
No. of Stages

The EID Parry cogeneration plant

BHEL
18.55 MW
5,650 RPM
Controlled Extraction
Bleed cum Wander Extraction
Impulse 1
HP reaction - 33
LP reaction - 02

CLEAN DEVELOPMENT MECHANISM

Operational Data During Season and Off-season
Detail (in MW)

Season

Power generation
Power export
Captive power (sugar & cogen)

18
12.2
5.8

Off-season
15 *
13
2

* power generation up to 18 MW is possible

I

All electric motors and fans fitted with variable frequency

drives (VFDs)
I A deareator and HP heater in the feed water system
I Reverse osmosis (RO) systems for feed water supply (make
up)
I An electrostatic precipitator to keep stack emissions under
permissible levels
I An effluent treatment plant to take care of waste water
I A distributed control system (DCS) for boiler and turbine
operation
I A fire protection system
I Air conditioning and ventilation systems for the control
room, panel room and TG building
I Compressed air systems for instruments and control
systems
I Electrical systems and a lightning protection system
I Switchyard and power evacuation facilities of suitable
standards
The power generated is sufficient to meet the captive
electricity requirements of the sugar factory and the extraction
steam meets the process steam requirements. The surplus
electricity is exported to the TNEB grid.
The estimated amount of emission reductions over the chosen
crediting period are:
Years
Estimation of Emission
Reductions in tons of tCO2e
2007-08 to 2016-17
(10 years)

866,230 @ 86,623 per year

to climatic and tariff policy changes were major barriers for

EID Parry in undertaking the project activity. The specific
barriers faced by EID Parry in implementing the project
activity are described below:
Technological Barrier
The project activity involved the replacement of the low
pressure system with high-pressure cogeneration technology.
The dearth of success stories on the performance of highpressure technology and the lack of skilled manpower to
operate such systems posed major barriers to EID Parry as
described below:
Performance uncertainties: At high operating pressures, boiler
metallurgy (the ability to withstand thermal and mechanical
stress) and water chemistry assume critical importance. Any
loss of performance or frequent maintenance shutdowns
would correspondingly reduce the power and steam output.
EID Parry was wary that such a situation would not only
impact the energy sale revenue but also affect the primary
manufacturing process (the sugar plant depends on the
cogeneration system for its power and steam requirements).
Lack of trained manpower: Since the operation and
maintenance (O&M) of high-pressure systems is
complicated and requires frequent monitoring and control
of critical parameters, a trained and experienced O&M team
is required.
In fact EID Parrys apprehension about the performance
uncertainty and lack of experienced and trained manpower
was justified shortly after. A few months after implementation
of the project activity, high silica content was noticed in the
boiler feed water that resulted in deposition of scales in the
turbine blades, necessitating the shut down of the
cogeneration plant. The reason was found to be failure of all
the RO membranes in the water treatment plant. All the RO
membranes had to be replaced. The turbine had to be

Barrier Analysis
During 2004, EID Parry explored the opportunity to improve
the operational margins of its Pudukkottai sugar factory by
diversifying into surplus power generation and its export to
the grid. A detailed study was conducted on the feasibility of
surplus energy generation, by adopting a high pressure
cogeneration system to improve the cogeneration efficiency.
Though the study projected an acceptable rate of return
through energy sales to the grid, the huge investment
requirements, technological uncertainties and vulnerability

Bagasse handling
system at EID
Parry

O V E R C O M I N G

B A R R I E R S

The
electrical
substation at
EID Parry

transported to the supplier for removal of scales and necessary

rectification work. Consequently, the project activity was shut
down for around 60 days (20% of expected annual operating
days) resulting in significant loss of revenue. The root cause
for the above was identified as lack of experience of the
operating personnel in the water treatment and high pressure
steam system. Subsequently, specialized training was given
to the operating team on the above aspects and on the
importance of maintaining the above parameters within
limits, for trouble-free operation of the plant.
Grid Interconnection
The project activity involves export of power to the TNEB
grid which necessitates interconnection and
parallel operation of the power plant with the grid. Normally,
such power plants are interconnected to the
grid through a substation in a ring feeder system. EID Parrys
project activity, being located in a remote
area, had to connect to the grid in a radial feeder. For this,
EID Parry had to adopt the alternate option of grid
interconnection through the loop in - loop out (LILO) system
instead of the conventional interconnection through a
substation. Since the radial feeders are prone to
more instabilities than a ring feeder system, the project activity
is more prone to be affected by grid instabilities and therefore
frequently switches to islanding mode. The
risk of equipment damage is higher considering the frequency
of such disturbances.

Institutional Barrier
For their earnings, the project depends on the payment from
TNEB against the sale of electricity to the grid. The Power
Purchase Agreement (PPA) between EID Parry and TNEB is
designed such that the quantity of energy delivered and tariff
payable are liable for revision. The provisions of the PPA
allow TNEB to revise the power purchase tariff as per orders
released by the Tamil Nadu Electricity Regulatory
Commission (TNERC) from time to time. This posed a

significant threat to the long term cash flow and feasibility of

the project activity. Presently TNEB is under pressure to
reduce its power purchase cost from Independent Power
Producers (IPPs) so that it can afford to lower power supply
tariffs to its consumers. Any downward revision of the
purchase tariff will have serious negative impact on the
project returns, as was the case with biomass power plants
in the neighboring state. EID Parry had to take this risk and
face this institutional barrier over which they have limited or
no control. It may be noted that shortly after implementation
of the project activity, TNERC has revised the purchase tariff
for bagasse cogeneration plants as follows:
I If in any financial year the plant load factor is above 55%,
the energy exported in excess of it shall be paid at rates
applicable to fossil-fuel based generating stations
I Grid support and grid availability charges shall be levied
Higher upfront cost: The investment required for
implementation of a high-pressure system was significantly
increased due to the installation of an air-cooled condenser
as against the conventional practice of water cooled
condensers (water availability is limited in this area).

Impact of CDM Registration

EID Parry has implemented the project activity despite the
various risks associated with it. As mentioned above,
technical problems related to the plant operation have already
led to the untimely shut down of the plant and a significant
loss of production. Moreover, the bagasse availability for
2006-07, the first year of the project operation, was expected
to be only 70% of the rated capacity. Also, there were changes
in TNERCs policies. The CDM registration will certainly
improve the financial sustainability of the project activity
by facilitating carbon revenues that would serve to
Break-up of the Project Cost
Particulars
Civil
Boiler
TG Set
Air Cooled Condenser
Bagasse/Ash Handling System
Water Treatment Plant
DCS
Other Mechanical Equipment
Electrical Equipment
Total Civil, Plant & Machinery

Value
(Rs lakh)
932
2,201
1,696
715
420
140
192
369
810
7,475

I M P A C T S
Performance Data
Financial Year
Description
Unit 2006-07
Running
Days
Power
Generated
Power
Exported
Captive
Consumption
Power
Imported
Cogen % on
Generation
Steam
Consumed
Steam
Extracted
(in MT)
3 ata and 9
ata to Sugar
Capacity
Utilization

Nos.

2007-08

247

307

2008-09
up to
April 08
30

&

B E N E F I T S

The current TNEB rate is Rs 3.15 during the season and

Rs 3.01during the off-season based on which the revenue
earned is as below:

Power Export
2006-07
Power Export
2007-08

Season
Off-season
Season
Off-season

Lakh Units

Rs Lakh

419.60
148.10
556.48
357.95

1,321.73
445.77
1,752.92
1,077.44

kWh 81,593,011 127,543,700 12,885,600

kWh 57,966,000 93,310,000 9,230,000
kWh

8,826,285 133,035,28 1,301,313

kWh

1,545,000

638,000

6,000

10.82

10.43

10.10

MT

650,747

62,255
Cogen Power Generation and Export 2006 - 2007

MT

412,155

44,822

MT

301,635

34,022

93.57

96.74

Financial Year
Description

Running Days
Steam Generated
Fuels Consumed
Bagasse
Lignite
Coal
Groundnut Shells
Wood Chips
Wood Shavings
Cane Trash
Coconut Fronds
Saw Dust
Bamboo Chips
Capacity
Utilization

2008-09
Unit 2006-07 2007-08
up to
April 08
Nos.
247
307
MT
- 650,747
MT 237,591 275,140
MT 236,518 266,063
MT
1,073
1,402
MT
0
966
MT
0
0
MT
0
0
MT
0
0
MT
0
0
MT
0
0
MT
0
0
MT
0
0
%

88.32

30
62,255
25,121
22,281
2,754
86
350
0
0
0
0
0
0
86.46

Cogen Power Generation and Export 2007 - 2008

overcome the project risks by offsetting part of the financial
losses. Moreover, its financial viability would encourage
financial institutions (FIs) to readily fund similar ventures by
other promoters.
The successful operation of the project plant would
demonstrate the viability of high efficiency grid connected
power generation and encourage similar initiatives in other
sugar industries in the country.

Courtesy: KN Radhakrishnan, Vice President (Commercial),

EID Parry (India) Ltd, Dare House, 234 NSC Bose Rd ,
Chennai 600 001, India; Tel: +91 44 25306480; Fax:
25357064; Web: www.eidparry.com

COGENERATION TECHNOLOGY

Multi-fuel Boilers for Power Generation

Multi-fuel boilers, based on biomass, for generation of power,
are a recent development in our country. Therefore, we are
still at a learning stage. No doubt, ample data is available,
based on the various difficulties faced by industrial boiler
users in the field. Some independent power producers (IPPs)
have come up in South India, Rajasthan and Uttar Pradesh
who are using multi-fuel boilers, mainly for bagasse, mustard
husk, rice husk, etc. Based on their feedback, many
modifications are incorporated by boiler manufacturers.
Therefore, day by day, there are several improvements in
multi-fuel biomass-based boilers. This article describes the
various intricacies of such boilers.

Why multi-fuel boilers?

The following are some of the reasons why biomass-based
IPPs are installing multi-fuel boilers these days.

25 tph x 45 kg/cm2 pressure rice husk/saw dust/coal-fired AFBC boiler

at Merino Industries Ltd, Hapur, Uttar Pradesh

The analysis of various biomass fuels along with Indian and

imported coal, which requires to be addressed by designers/
manufacturers, are mentioned in the table alongside.

Seasonal availability of biomass fuel: Though seasonally

available, sometimes a particular biomass fuel is inadequate
for running the power plant for 300-330 days in a year.
I Biomass fuels, being bulky in nature, require large storage
areas so that they can be sourced as and when required. But
the quality of biomass fuel in storage often deteriorates.
I There are also risks of fire hazards for stored biomass fuel.
I As per the Ministry of New and Renewable Energy (MNRE)
guidelines, 30% use of coal is permitted for running biomass
IPPs round the year. Imported coal, which is usually better
in quality than Indian coal, is possible to procure at some
places and is often used in multi-fuel boilers.

70 tph x 67 kg/cm2 pressure bagasse/coal/rice husk-fired traveling

grate boiler at Daurala Sugar Works, Daurala, Uttar Pradesh

Design Aspects
Based on feedback from IPPs, the following are certain design
aspects of biomass-based multi-fuel boilers that need to be
taken into consideration by boiler designers:
For almost all biomass fuels, the critical issue is super
heater temperatures due to the presence of alkalis in these
fuels. The super heater tubes fail if the super heater
temperature exceeds 4850 to 4950C. In some IPPs, super
heater tube failures have occurred in the early 2-3 months
itself resulting in longer shut downs of power plants and
subsequent loss of revenue.
I The deposition of potassium chloride in the ash causes
corrosion and erosion of boiler tubes leading to tube
failure. Such failures occur when biomass such as mustard
husk, corn cobs and cane trash, containing chlorine and
potassium, reacts while burning and forms ash, which
has a melting point of around 7000C. This ash, containing
potassium chloride, builds up a hard clinker over the
boiler tubes leading to their erosion and subsequent
failure.
I

In addition to the above, the following characteristics of

biomass fuels need to be taken into account by boiler
designers:

MOVING WITH THE TIMES

Analysis of Various Biomass Fuels & Coal
Chemical
Components
Carbon %
Hydrogen %
Oxygen %
Nitrogen %
Sulfur %
Moisture %
Ash %
GCV * (kCal/kg)

Bagasse

Mustard
Husk

23.5
3.25
21.75
0
0
50
1.5
2,270

50.11
3.78
28.85
1.1
0.67
8.5
6.99
4,045

Maize Wood
Stalks Chips

Rice
Husk

38.8
6.13
35.32
1.31
0.14
11.51
6.79
2,942

38
4.5
29.5
0.2
0.3
13
14.5
3,200

45.6
4
37.45
0.5
0.07
9.33
3.05
4,700

Cane
Trash
43.8
3.68
34.52
0.54
1.48
6.48
9.5
3,550

Corn
Cobs

Groundnut Indian
Shells
Coal

30.33
4.35
8.00
1.55
3,480

47.7
4.3
34.4
0.5
0.4
10.2
2.5
4,150

41
3
7
0.6
0.4
8
40
3,500

Imported
Coal
60
4
10
1.5
0.3
9.1
14
6,400

* GCV - Gross Calorific Value

Ash content and its fusion temperature should not exceed

7000C to 7500C
I Moisture content of the fuel
I Percentage of oxygen
I Alkali compounds in the fuel
I Contents of sulphur in the fuel
I

Conclusion
From the above it can be seen that biomass ash fusion
temperature influences the furnace outlet gas temperature,
which needs to be at least below the ash fusion temperature
of ash. Boiler manufacturers/designers need to select such a
configuration of boiler pressure and temperature which will
not have any operational problems leading to costly
breakdowns. Boiler manufacturers/designers should advise

users on issues relating to biomass storage, handling, and

feeding systems, when used as the main fuel, and also when
combined with Indian or imported coal, so as to achieve
trouble-free, smooth operation of the plant.
Sitson India (P) Ltd was incorporated in 1978 as a
partnership firm to provide specialized engineering
services in the field of boilers. Sitson specializes in
manufacturing water tube multi-fuel boilers. Sitson has
manufactured boilers up to 110 tph, 65 kg/cm2 and 5100C
suitable for fuels like coal, bagasse, oil and biogas. Sitson
has also developed a complete range of soot blowers as
an import substitute and has been supplying these to most
boiler manufacturers and actual boiler users.

A 35 tph x 63 kg/cm2 pressure, 4900C coal/bagasse/saw dust-fired FBC boiler

at Mujafarnagar, Uttar Pradesh

Courtesy: Nilesh Jadhav, ME,

Director - Technical, &
DS Bhamare, ME Mechanical, MBA, Director
Sitson India (P) Ltd, W-76,
MIDC Phase-II Dombivli (E)
Thane 421204, Maharashtra,
India
Tel: 91 251 871394, 871653,
Fax: 91 251 870878
E-mail:
sitson@bom5.vsnl.net.in
Web: http://
www.sitsonboilers.com

T E C H N I C A L

T R A I N I N G

Capacity Building: In-Plant Training on Sugar Cogeneration

Modern and high efficiency sugar mill cogeneration plants
employ sophisticated technology in equipment such as
boilers, turbines, for water treatment, power evacuation, fuel
and ash handling, and plant automation and control, which
demand highly skilled operations and maintenance (O&M)
staff. Therefore, training of technical personnel is the key to
successful operation of any plant. It is an investment with
many short-term and long-term benefits. The direct benefit
is improvement in the bottom line by reducing the plant O&M
costs and downtime. Indirectly, effective training programs
can help upgrade and maintain the skills level of O&M staff,
and improve their morale and efficiency. Plants with trained
staff have often performed better and experienced higher
availability.
Participants inside the SCM Sugars plant

Private sector sugar mills in India, with Tamil Nadu,

Maharashtra, Karnataka, Andhra Pradesh and Uttar Pradesh
taking the lead, have mainly contributed to the growth of
this sector till date. Extra high pressure and temperature
configurations beyond 105 kg/cm2 and 5150C have been
commercialized in the private sector, and the export of power
to state electricity board (SEB) grids with year-round
operation, have fetched them substantial revenues. The
technology, equipment supply, skilled manpower, and related
technical and financial services have now been established
for these projects.

The Need
Senior managers from many sugar mills are hesitant to
implement cogeneration projects with high-temperature/
pressure configurations due to the lack of skilled and trained
manpower.

The Solution
Taking into consideration the felt need of sugar mills, and
encouraged by the success of earlier residential in-plant
training programs (ITPs) for sugar mill professionals on

The SCM Sugars cogeneration power plant (26 MW)

10

bagasse-based cogeneration, at select sugar mills, for both

existing and prospective cogenerators, two training programs
at Shree Pandurang SSK, Maharashtra (a co-operative sugar
mill), and SCM Sugars, Karnataka (refer case study in Vol
32)both with successfully operating cogeneration power
plants were organized in February and March 2008. These
programs were particularly designed for engineers and
technocrats of sugar mills.
SCM Sugars Ltd presently operates a 3,500 tcd sugar mill
and 26 MW cogeneration plant (implemented in 2004).
They installed a high-pressure boiler of 88 ata, 5150C for
high-thermal efficiency and better use of bagasse, resulting
in more steam, and hence more power generation.
Shree Pandurang SSKL successfully commissioned their
9-MW cogeneration power plant with 67 kg/cm2 pressure/
4950C temperature configurations, with the ability to
operate their plant on a year-round basis. The plant has
been in operation since July 2006.
These programs were supported by the Ministry of New and
Renewable Energy (MNRE), and co-sponsored by Saikrupa
Industries, Danfoss, SITSON, ISGEC John Thompson, Rekha
Enterprises, Woodward Governor, IKE Electric, Union Bank,
Walchandnagar, OCB Engineers, VRL Automation, Shree
Renuka Sugars, and Methods (India). All these organizations
sent training faculty to discuss the latest technology and O&M
practices related to their cogeneration equipment.

O P T I M I Z I N G

E F F I C I E N C Y

Objectives & Achievements

The main objective of the ITPs was to build capacity of sugar
mill plant personnel to conceive, design, implement, operate
and maintain grid-connected high-efficiency cogeneration
power plants, using a variety of biomass fuels at their units,
overcome challenges, and achieve long-term integration and
viability.
The other objectives were:
I To maximize power export through improved operations
of existing equipment; and
I To improve energy efficiency of cogeneration plant
equipment and sugar operations, for extending in-house fuel
supply.
The program was customized to address the specific needs
of participants. Special emphasis was laid on:
I Enabling smooth and trouble-free operation of equipment;
I Reducing downtime/breakdown hours of equipment;
I Bringing down O&M costs;
I Upgrading technical skills and ensuring safety of
operations;
I Raising awareness of various project development issues;
and
I Facilitating exchange of experiences with other
participants.
The programs were designed for O&M staff and technical
managers of existing and prospective sugar mill cogenerators,
as well as independent power producers.

Putting Theory Into Practice

Detailed presentations were made on the various project
development aspects for sugar mill cogeneration projects,
the latest technologies/techniques in boilers, turbines, power

Inauguration of the training program at Shree Pandurang Sugars

evacuation, fuel/ash handling, water treatment, and plant

automation and control.
Besides these, both host mills staff described their
experiences in operating and maintaining their cogeneration
plants, along with the problems faced and achievements
made. This, along with the site visits to each section everyday,
helped participants put the theory sessions into practice.
The host mills and MITCON (the organizers) presented papers
on project planning, development and implementation, civil
construction issues (refer page 12 of this issue), energy
optimization opportunities/schemes, fuel linkage issues in
the sugar mill and cogeneration plant, power trading, and
business opportunities with the Clean Development
Mechanism (CDM).

In Summation
Written and verbal feedback received from both faculty and
participants was encouraging and useful for further improving
the programs. A common request received during the
programs was to increase the length of the plant visits after
the theory sessions.
The Training Manuals distributed at both venues comprised
papers and presentations contributed by the faculty.

The group of participants at the SCM Sugars training program

For those interested in joining the next programs in late

2008, or for copies of the detailed Training Manuals of the
above programs, please email
cogenindia2005@yahoo.com or cogenindia@gmail.com

11

P R O J E C T

P L A N N I N G

Civil Construction for Bagasse-based Cogeneration

Power Projects: Key Issues
Civil construction for bagasse-based cogeneration power
projects is an important component of project planning and
implementation, and can basically be categorized under the
following major heads:
I Site for the project
I Statutory permissions
I Planning and designing of civil works
I Estimation
I Coordination with various agencies
I Means and materials of construction
I Supervision of site works
I Measuring
I Completion/time limits including all final statutory
requirements

Project Site
Most cooperative sugar factories in Maharashtra are situated
in the rural sector. Land availability in the vicinity of the
present sugar factories, for most sugar factories, may not
prove to be a problem as the power projects can be easily
put up adjacent to the sugar factory complex within the
factory fencing area itself. Some power projects have also
utilized the present infrastructure and buildings of the
existing sugar factory for their cogeneration power
projects depending on the present layout of the sugar
factory and the place available for expansion. The
important factors to be considered in identifying land for
power projects would be:
I The proximity of the power project to the existing sugar
factory and the basic raw material to be utilized, namely
bagasse, and the ease of transmission of the finished product,
electricity
I The terrain, contours and strata available at site and the
bearing capacity of the soil
I The predominant wind direction at site
I The sun path diagram at site
I Ease of accessibility and availability of sufficient land for
the power project and its ancillaries
I Sufficient space for future expansion of the power and
sugar projects, and their ancillaries

Statutory Permissions
Statutory permissions for the cooperative sector include all
necessary permissions from the Office of the Commissioner
of Sugar, Pune, to the plans/estimates and the civil contractors

12

bills, the State Level Committee for civil work tenders, the
Pollution Control Board for the chimney and water treatment
plants (if required), local planning, sanctioning and approving
authorities of the State Government, State Electricity Board
(SEB) for the various related switchyard layouts and provisions
for the meter room, control rooms, etc, the factory inspector,
and financial institutions.

Planning & Designing of Civil Works

The civil works for bagasse-based cogeneration power
projects broadly include:
I The boiler foundations and the boiler building (if required)
I The boiler auxiliary foundations
I The chimney structure and/or RCC chimney suitable for
the boiler
Generally, outdoor-type boilers are preferred and the boiler/
chimney are planned such that the bagasse and boiler soot
do not affect the power house building (which houses the
turbo-generators, their foundations and the working platform
around the equipment), cooling tower, switch yard and other
ancillaries. However proximity of the boiler to the power
house and the control panel room is also necessary.
The power house should be clean, and the size of the power
house should allow free movement on the working platform
and a bay for maintenance and repairs of the equipment,
which also serves the purpose of lifting equipment by an
overhead crane at the time of erection. The power house
operating platform and the boiler operating platform need
to be connected by a walkway. The height of the power house
is governed by the gantry height as well as the type of turbine
equipment being used for power generation. Side walls could
be bricks or blocks and roofing could be m.s color pre-coated
sheets. Proper light and ventilationas the house is likely to
be heated, especially in the summer, and exchange of air,
and if possible, forced ventilation systems, should be
adoptedare important, using roof air extractors, proper
openings in the walls and translucent sheets in the roof.
Planning for equipment erection and providing proper
openings in the walls, especially for the condensor and
various inlet and outlet piping, is necessary and should be
planned for in the initial stages itself. Designing of the turboalternator foundations should be accorded a very serious view
taking into consideration all the site and soil conditions.

PROJECT IMPLEMENTATION

All the control panels for the boiler, turbine, fuel handling
systems, water treatment plants, etc, could be housed at one
location at various levels for ease of operation, preferably
adjacent to the power house building. Control panel rooms,
should, preferably, be planned with RCC slabs for the roof.
They need to be planned considering proper air conditioning
systems and false flooring/ceiling systems for provision of
cables below the floors and/or above the ceiling. Toilet and
pantry arrangements could be planned for the engineers and
supervisors working on the operating floors and the control
panel rooms.
The tunnels for feeding bagasse and/or other fuel need to
be planned properly for ease of feeding and care should
also be taken to ensure no water seepage in the tunnels.
Storage of the fuel needs to be planned properly and may
require to be covered, at some locations, during the
monsoons. Proper and adequate sheds for the labor
working in the fuel yards should be planned and provided
for, along with proper sanitation and drinking water
facilities at well planned locations.
Process water requirements/tank size need to be ascertained.
The water treatment plant could be planned in the vicinity
of the boiler and/or on top of the process water tank.
The capacity of the cooling tower needs to be ascertained
as per the cooling water requirement, especially for
condensing-type turbines. Cooling tower panels could be
housed adjacent to the tower.
Details of the cable trenches at the various locations
including the power house, boiler, switch yard, cooling tower,
fuel and ash handling systems, weigh bridges, etc, should be
confirmed from the machinery suppliers and technical
consultants, and work could be taken up in the final phases
of the civil works. Ease of accessibility for equipment erection
near and in the power house, boiler and other areas, will
necessarily govern the layout for the roads. The workers toilet
block could be planned near the power house or in the open
area for fuel storage. Fire hydrants along all roads and near
the fuel storage areas are very important, and the process
water tank could be partitioned for providing this requirement
of water. The potable water tank location could be on top
of the power house staircase or on the top slab of the panel
rooms.
The layout of the client and SEB switch yards needs to be
approved by the SEB prior to taking up any works. The meter

room/panel rooms should be located in the switch yards.

The floor level of the switch yard should be such that water
accumulation and stagnation is not allowed at any location.
The area also needs to be protected by providing chain link
fencing around the periphery. Aggregate cover needs to be
provided over the whole switch yard area.
The existing DG sets and compressors of the sugar factory
could be utilized for the power project. If required, a separate
foundation for the new equipment needs to be provided.
Additional housing needs to be planned in the residential
sector of the sugar industry for the additional staff to be
recruited for the power project.

Estimation
For cooperative sector mills, the Office of the Commissioner
of Sugar, Pune, needs proper estimation of all the civil and
allied works to be based on the District Schedule of Rates
(DSR) for the relevant years. The plans and estimates also
need to be approved by the Technical Cell of the
Commissioners Office, only after which the civil work
tenders can be floated.

Coordination
Close coordination with the various agencies, which include
the client, technical consultants, architect/engineer,
machinery suppliers, civil contractors, machinery erectors
and government agencies, is crucial at all stages. Meetings
on a regular basis for maintaining the schedule of the project
works is the most important factor at the time of putting up
the project.

Means & Materials of Construction

Economy could be sought by using locally available materials
for construction. Bricks of concrete blocks for walls, precoated sheets or RCC slabs for roofing, slip form technology
for RCC chimney works, the minimum grade of M20
concrete, preferably of the design mix for all RCC works and
foundations, aluminium sections with glass partitions for
panel rooms, concrete admixtures for water proofing the
cooling tower and hydraulic structures, readymade epoxy
grouting materials for all foundations, could be some of the
materials used for construction purposes. Floorings could use
industrial vacuum dewatering systems, paving blocks for the
factory area and vitrified tiles for the operating platforms with
anti-static flooring for the control rooms.
contd on pg 16...

13

QUALITY O&M PRACTICES

Efficient O&M of Electrical Systems: The Davangere Experience

Davangere Sugar Company Ltd (DSCL) is situated at
Kukkuwada village, Davangere Taluk and District, Karnataka.
DSCL installed their 24.5-MW cogeneration unit in 2003
with an investment of Rs 80 crore. This was completed within
a year the lowest time period achieved in India so far by
any 24.5 MW sugar cogeneration unit. DSCLs unit was also
the first in Karnataka to install a high-pressure/temperature
configuration of 86.5 kg/cm2 pressure and 5150C temperature
in a sugar cogeneration unit. Commercial operation began
on 24 March 2004. Since commissioning, the cogeneration
unit has been running continuously, without any major
problems.

The Importance of Electrical Systems

The performance of a cogeneration power plant depends on
the quality of operation and maintenance (O&M) practices
of the electrical system. At DSCL, they have devised one of
the best systems for the smooth functioning of the plant. Their
cogeneration electrical system consists of the following
components:
I A 24.5 MW generator (TD Power Systems)
I 11 kV switchgear and 11/66 kV switchyard (Alstom/Areva
T&D India)
I LT switchgears (GE)
The 24-MW alternator is a brushless, AC, four-pole generator.
Other details include:
I Type: TC 210; Output kVA: 30,562.5; PF: 0.8 lag
H Voltage: 11 kV; Armature current: 1,604 amp
H Speed: 1,500 rpm; Insl Cl: F
H Degree of protection: IP 54
H Excitation method: brushless excitation with AVR control
I Exciter output voltage: 270 V; Current: 480 amp;
Frequency: 150 Hz; No. of phases: 3; No. of poles: 12
I Excitation system: Separate exciter (stator side)
I Excitation voltage: 100 V; Excitation current: 21A
I AVR: ABB make; Unitrol@f
The 11 kV switchgears/circuit breakers are VCBs.
I TG and Imp/Exp CB rating: 2,000 Amp
I Transformer Feeder CB rating: 630 Amp
I Type: HWX (Alstom)

Switchyard Equipment Details

I
H

Generator Transformer:
Make: Alstom, Rating: 30 MVA, Type: Double wound,

14

Voltage (HV/LV):66/11 kV, Current (HV/LV) :262.7/1576.5

H Type of Cooling: ONAN, Vector Group: Ynd11
I OLTC -CTR Make, Type: EQ 16.
I Auxiliary Transformers (2 No.S):
H Make: Alstom, Rating: 2.5 MVA, Voltage (HV/LV):11/0.433
kV, Current (HV/LV) :131.2/3333.4; Type of Cooling: ONAN,
Vector Group: DyN11
I 66 kV Circuit Breaker: SF6 type, Alstom make
I CT Ratio:400/1 , KPTCL Metering CTR:200/1
I PT Ratio: 11kV/Rt3/110/Rt3

Generator Protections
I

The generator main protection relay (ABB, REM-543

Numerical Relay) consists of the following protections:
H Differential protection
H Earth fault (51N)
H Voltage restraint over current (51V)
H Inst./IDMT over current (50/51)
H Low forward & reverse power
H Rotor earth fault (64 F)
H Loss of excitation (40)
H Under/over voltage/frequency
I Automatic Voltage Regulator (AVR) Trips
I Other trips when the temperature of the generator bearings
increases

Generator Transformer and Line Protections

I

Traf. differential protection KBCH (Alstom) relay

Over current & earth fault P121, Alstom
I Line protections:
H Relay type P341, Alstom make
H Direct/non-direct earth fault, under/over voltage, under/
over frequency, df/dt, vector shift
I

Major Problems Faced

The turbine tripped on differential protection. In the Neutral
Grounding Register (NGR), the bus bar melted at the B-phase
because of looseness in the stud bolt system. Permanent
measures were taken to tighten the NGR stud-bolt system.
The system was modified by connecting the bus bar joint
directly to the NGR without using stud-bolts. This put an
end to the problem, by avoiding thermal loss and heating of
bus bars.There are three types of maintenance followed:
I Predictive Maintenance
I Preventive Maintenance
I Planned Maintenance

EFFICIENT ELECTRICAL SYSTEMS

Predictive Maintenance
I Daily checklist for all the equipment to
know the equipment conditions/health
I Defects generation (around 300 to 400
nos) by the employees and addressing the
same
I Area auditing for better performance,
improvement & plant upkeep

Plant Performance Data

2005-06
Generation
164,555,000 units
Export
138,855,000 units
Import
286,000 units
Plant
consumption 15,376,300 units
Average %
of plant
consumption
9.34%

Preventive Maintenance
I Daily, weekly, monthly and yearly
maintenance schedule for all equipment to
keep them free from defects & to have
highest productivity
I Predictive & preventive maintenance is done regularly

Planned Maintenance
I Maintenance is planned well in advance for annual shut
down, between season & off-season periods
I Generator, switch gear and ESP maintenance is done and
tested as per the supplier procedure
I During annual shutdown, attending transformers oil
filtration, testing & OLTC servicing are important
I Relays are tested during the period
I All motors are overhauled

TG Commissioning
The switchyard was commissioned successfully on 19 March
2004. It was synchronized on 24 March at 10.50 am in the
first attempt itself a rare event in the history of commissioning
of turbines in cogeneration plants. All generator parameters
were found well within the limit. Successful testing of load
throw-offs and over-speed was conducted. The turbine was
loaded gradually without any problem.

Energy Conservation
DSCL has taken major steps to conserve energy to
minimize consumption. The lowest in-house energy
consumption achieved so far for a month was 7.03%
(August 2006) and as low as 6.74% in a day (on 29 August
2006). Based on the potential for energy conservation,
variable speed drives were installed for all the equipment
and strictly monitored. For energy conservation in the
lighting load, a P20 energy saver transformer was installed
and the same monitored regularly. The savings from the
lighting at full loading was 20%.

Conclusion
Based on the above important issues, it can be concluded

2006-07

2007-08

179,725,450 units 162,369,620 units

150,867,000 units 120,816,000 units
92,800 units
142,800 units
14,053,715 units

12,215,501 units

7.81%

7.52%

that good operation and team work results in better and more
efficient operation and maintenance practices.
Courtesy: Girish S, Sr Engr, Electrical Dept Cogeneration,
Davangere Sugar Company Ltd (DSCL), Kukkuwada
Village, Davangere Taluk, Karnataka
Email:girish_siddappa2005@yahoo.com

Additional Sugar Cogeneration Projects

Come Up in Maharashtra & Tamil Nadu
In March 2008, the Tamil Nadu Government cleared a Rs-865crore plan to set up over 185 MW of cogeneration power plants
in cooperative/public sector sugar mills. The Tamil Nadu
Electricity Board (TNEB) will establish the power plants jointly
with the Sugar Department, which runs the 15 cooperative and
two public sector mills in the State. TNEB will raise a 13-year
loan from the Rural Electrification Corporation Ltd (REC) covering
about 80-90% of the project cost. The members in the
cooperatives will bring in 10% and the balance would be in the
form of equity from the Government. The sugar mills will run
the cogeneration facilities, which will power the mills, and the
surplus power will be exported to the State grid.
In 2007, the state and central governments came up with a
scheme under which sugar cooperatives had to contribute 5%
of the total project cost as their equity for the project, 5% would
be provided by the state government as a grant, 30% of the
project cost would be raised as a loan through the Centers Sugar
Development Fund (SDF), which is available at a 4% rate of
interest, and the rest would be raised by sugar cooperatives
through financial institutions for which the state government
would stand guarantee.
The scheme evoked a good response and, as in April 2008,
proposals of 15 sugar cooperatives in Maharashtra have been
cleared by the state government and many more are in the
pipeline. These would generate around 75 MW of power.

Source: www.business-standard.com &

www.thehindubusinessline.com

15

CIVIL CONSTRUCTION ISSUES

...contd. from pg 13

Supervision
Strict supervision over the site civil work activities and protocol
of all the major/minor foundations/works by the technical
consultants and machinery suppliers is very essential and should
be insisted upon. All the inserts, openings, etc, should be reconfirmed by all the relevant agencies at the time of protocol,
along with the protocol of the major foundations.

Measuring
The site civil works need to be measured and certified from
time to time and CPM/PERT charts maintained. The final bills
of the works done also need to be forwarded to the Technical
Cell, Commissioner Office, Pune, for their final approval.

Time Limits & Statutory Requirements

On completion of the civil works the civil agencies need to
coordinate with the machinery suppliers and erectors at the
time of equipment erection for grouting and minor
rectification purposes. Certifying stability of all the cast
foundations and civil works by the competent authority under

whose supervision the civil works have been carried out, is

also necessary. Approvals and completion certificates from
the local/statutory authorities would form a part of the
completion of the project civil work activities. Time limits
for the civil construction of a power project could vary from
4 to 6 months, depending on the size of the project.
Courtesy: Ninad S Patil, Architect, 2nd floor, S 12, 15 & 16,
Utility Centre, Opp. Rajiv Gandhi Bhavan, Sharanpur Road
Nashik 422 002, Maharashtra; Tel: 0253 2581016,
09822497424; Email: nspatil_nsk@yahoo.com
Mr Patils firm includes Consulting Architect Engineers
working in the sugar industry sector for the past four decades.
Some of their recent bagasse-based cogeneration projects
include Mula SSK Ltd (12 MW), Shri Dnyaneshwar SSK Ltd
(16.96 MW), Loknete Baburao Patil SSK Ltd, Angar (8 MW).
They have also put up various biomass-based power projects
for the private sector, sugar plants of various capacities,
distillery and ethanol projects, grain-based distillery projects,
several small, medium and heavy industrial projects, and
various other projects in the educational, commercial,
hospital, housing, and infrastructure sectors.

CEDI...contd from pg 2

Photo courtesy: CEDI Doshion

Veolia Water Solutions

microsiemens/cm) than conventional ion exchange

processes. The lack of acid and caustic regeneration means
less operator attention and lower labor costs. Capital costs
can also be expected to be lower, especially because no
chemical storage, pumping and neutralization equipment is
required. Additionally, EDI has a significantly smaller footprint
than conventional ion exchange processes less plant space
will be required to provide the same quantity of water.
Doshion Veolia Water Solutions (DVWS) has successfully
incorporated the EDI technology in pharmaceutical segments
for the last three years with over 50 installations working
across India. The next generation series MPower with
capacities up to 100 m3/h is ready
for the cogeneration industry. While
the advantages of EDI are very
lucrative to utility managers, the use
of EDI requires proper care in terms
of monitoring of feed water limiting
conditions and protection against
unwanted variations in power
supply. Prolonged ignorance to
feed water limiting conditions may
result in irreversible fouling, and

16

ultimately, premature failure of the system. A combination

of reverse osmosis and CEDI therefore provides an attractive
alternative for utility managers and must be explored for
setting up new projects.
Courtesy: Sanjeev Srivastava, Sr Gen Mgr Intellectual
Capacity Building, DVWS Solutions; Cell: 09377962007
Email: technology@doshion.com; Web: www.doshion.com
An engineering graduate from IIT, Roorkee, Mr Srivastava
has spent 17 years in water/waste water management in
various industries. DVWS is a joint venture between Doshion
Ltd and Veolia Water Systems that executes small, medium
and large EPC projects for water/waste water management
facilities in municipal, infrastructural and industrial projects.
This technology can be extensively used for new water
projects in the sugar industry, involving cogeneration and/or
distillation. The benefits include lower operating expenses,
better environmental protection, and a better plant life. The
technology becomes more critical if the feed water contains
challenges such as particulates, colloids, silica and salinity.
For a typical 100 tph plant, the water quality requirement
shall be moderate to stringent depending upon the boiler
selection. Though the final treatment scheme largely
depends upon the source of water and fluctuations, a
scheme incorporating UFROEDI shall be highly
beneficial to project managers.