COGENERATION

WITH REFERENCE TO SUGAR INDUSTRY

SAMEER SINHA
VICE PRESIDENT – CORPORATE PLANNING
TRIVENI ENGINEERING & INDUSTRIES LIMITED

PRESENTED AT
U. S. – INDIA
ENERGY EFFICIENCY TECHNOLOGY COOPERATION CONFERENCE

2nd May 2006

COGENERATION

Simultaneous production of two forms of

energy
– Heat
– Electricity / Mechanical Energy

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 POWER SCENARIO IN INDIA
Deficit of power
– Shortage of 8.3% and Peaking shortage of 12.5%
Power for all by 2012 – NEP
– 1,00,000 MW additional capacity (approx.) required to meet this
objective
Power requirement in 2031-
2031-32: 6,00,000 – 8,00,000 MW
(expected)

Huge Requirement of Power

Govt. encouraging captive power plants to export surplus
power to the grid

COGEN POTENTIAL IN INDIA

Primarily applicable for industries using large quantity of process
process
steam
Industry Potential (MW)
Alumina 59
Caustic Soda 394
Cement 78
Cotton Textiles 506
Iron and Steel 362
Man-
Man-made fibers (Including Nylon and PFY) 144
Paper 594
Refineries 232
Sugar 5131
Sulphuric acid 74
Total 7454
Source: TERI

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 SUGAR COGEN HISTORY
Traditionally all sugar factories doing
cogen
– For 100% captive power and steam usage
Cogen now means: Surplus power export
to the grid
- Sugar industry has highest potential of 6200 MW
exportable power
- Actual exportable capacity functional in sugar industry
till 2005: 850 MW
Source: ISMA latest surveys

OLD TO NEW COGEN SYSTEM

A TRANSFORMATION
Traditionally low temperature and pressure
steam & power systems
– Inefficient generation of energy
Sugar factories move towards enhanced
capacity and technological upgradation
– Using high temperature and pressure steam &
power system
Same quantity of bagasse ⇒ Enhanced power
generation ⇒ Export surplus power
Same qty. of Power Captive Use
bagasse Generation Export Surplus Power

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OLD TO NEW COGEN SYSTEM
A TRANSFORMATION
Then
– Earlier sugar industry used only upto 46 ata
pressure steam and power generation systems
Now
– Few 87 ata/515º
ata/515ºC cogen systems commissioned
and working very efficiently in the last 4 years
– 105 ata/535º
ata/535ºC cogen systems being
contemplated in near future
India is the Global Leader in high pressure and
temperature sugar cogen
In other countries system is generally limited to 46 ata

REGULATORY ISSUES
Concerns
– PPA not being honoured
– Plants asked to back down
– No preferential tariff to cogen power
– No mandatory purchase of cogen power
Remedies
– Regulatory commissions have been appointed
Laying down scientific policies to address tariff and other
issues
Forum of regulators formed – To bring in some uniformity
across various states
– New thinking in power sector: Electricity Act 2003,
NEP

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 COGEN REGULATORY
FRAMEWORK IN U.P.
SERC is functional
Tariff order for five years. Tariff for each year is
fixed in this period.
Must Run status provided
Banking & wheeling allowed
PPA for 20 years
7.5% procurement from renewable energy
sources mandatory for distcoms
(subject to availability)

CASE FOR TRIVENI COGEN

Replacement required for existing old & obsolete
low pressure boilers
Additional steam required due to expansion of
sugar factory
Add value to Bagasse
Assists mitigation of effect of sugar downcycle
Financially attractive
Leads to incidental efficiency improvement in
sugar factory

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TRIVENI’S COGEN BUSINESS

Cogen Plants

Deoband 22 MW
Khatauli Phase-I 23 MW
Khatauli Phase II 23 MW, under construction

CASE STUDY - DEOBAND

System Description
One of the most technologically advanced & energy efficient cogen
plants
– 120 TPH, 87 ata and 515º
515ºC boiler
– 22 MW double extraction condensing TG
– Large no. of VFDs
– Top end DCS
– Generation at 11 kV and export at 132 kV to UPPCL
– Elaborate fuel and ash handling (dense phase ash handling)
– Aesthetically pleasing – use of fly-
fly-ash blocks
– ESP for pollution control - Well within norms - provision to handle more
stringent norms

Project cost: Rs 760 M

Implementation period 11-

11-12 months – One of the fastest
implementations in the country

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 CASE STUDY - DEOBAND
Typical cogeneration scheme

Bagasse
from Boiler Power
Turbine Grid
sugar
mill

Steam
Sugar

Steam
Steam
Sugar factory
factory
process Condenser
HP Heater

CASE STUDY - DEOBAND

Season Operation
Steam during season
– Generation = 120 TPH @ 87 ata
– To sugar plant = 78 TPH @ 3 ata
Power balance
– Generation = 22.25 MW
– In-
In-house consumption = 2.25 MW
– Sugar plant = 5.00 MW
– Export = 15.00 MW
Season Operation Parameters
– 1 MT Bagasse = 2.43 MT Steam
– 1 MW Power = 5.39 MT Steam
– 1 MW Power = 2.22 MT Bagasse

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 CASE STUDY - DEOBAND
Off-Season Operation
Steam during off-
off-season
– Generation = 89 TPH @ 87 ata
– To sugar plant = 0 TPH
Power balance
– Generation = 22.50 MW
– In-
In-house consumption = 2.10 MW
– Sugar plant = 0.65 MW
– Export = 19.75 MW
Off-
Off-Season Operation Parameters
– 1 MT Bagasse = 2.43 MT Steam
– 1 MW Power = 3.95 MT Steam
– 1 MW Power = 1.62 MT Bagasse

CASE STUDY - DEOBAND

Performance
Plant totally stabilized and excellent
performance
PLF
– PLF for 230 days of operation ~ 95%
PLF for Feb. 2006 - > 99%
PLF for March 2006 - 100%
PLF for April 2006 - >98%

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 CASE STUDY – DEOBAND
Viability

Payback period: ~5 years

Additionally Carbon Credits benefit of
approx. 80,000 CERs p.a.

CASE STUDY - DEOBAND

Impact on Sugar Factory
Move to minimize process steam consumption
– Increased bagasse saving ⇒ Extended Off-
Off-season
operation of cogen
Installation of efficient equipment like Continuous Vacuum
Pans and extensive vapour bleeding
Change in product mix
Extensive automation
Move to minimize electrical consumption in
sugar factory
– Maximize export to the grid
Installation of VFDs,
VFDs, energy efficient AC motors to run the
mill

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SELF PERPETUATING CYCLE

Energy
efficiency
requires Cogen
cogen drives
plant further
efficiency
in sugar
factory

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