4/10/22, 3:18 PM Power plant and calculations: Best practices to reduce the Auxiliary power consumption (APC) in Sugar

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Best practices to reduce the Auxiliary
power consumption (APC) in Sugar based
Cogeneration plants.

Auxiliary power consumption is

directly related with power plant profit.
Lesser the APC more will be the power
export & hence more profit. So it
becomes duty of every power plant professions
to strive to reduce APC
wherever possible.
Below table gives the area wise APC in Bagasse/coal based
power plants
Sl
No. Area APC
in %
1 Boiler fans 35-38%
2 Boiler feed water pumps 35-36%
3 Turbo generator & its auxiliaries 10-12%
4 Bagasse feeding system 2-2.5%
5 Coal feeding system 1%
6 Bagasse handling system 4-4.5%
7 Coal handling system 1.5- 2%
8 Ventilation, AC & Air 4-5%
Compressors
9 Water treatment plant 2-3%

Note: Bagasse based Cogeneration

plant have incorporated coal handling
system as supporting system & also
run the power plant in non-season days.
So APC for bagasse handling/feeding
& coal handling/feeding has been
considered separately.
Now a day there is huge scope for
reduction of plant APC. Here scope of APC
reduction at various areas of plant
has been discussed.
A-Boiler:
1-Improve the
combustion efficiency:
Combustion efficiency improvement
will directly relate to the air consumption.
Improved combustion will reduce
load on FD, SA & ID fans, hence power
consumption will reduce. In
cogeneration plants or ion any power plants Boiler
fans consume around 35-38%
of total auxiliary power consumption.
In order to reduce the air
requirement & to improve the combustion efficiency
Superior Speeds up to 7000MB/s
need to concentrate on
bellow areas
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Select good quality of fuel,
write.if
using bagasse the moisture should be 49
to 50%, as the moistureKingston
increases
excess
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4/10/22, 3:18 PM Power plant and calculations: Best practices to reduce the Auxiliary power consumption (APC) in Sugar based Cogeneration plants.
increases. This loads the FD, SA & ID fans
more than requirement.
Arrest all leakages in air &
flue gas paths
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Modify combustion air ducts to
reduce resistance to air flow

16-Perfect reasons for increasing the fuel consumption of Boilers

Opportunities for energy conservation in power plant...

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For A HomeAs discussed above Boiler fans consume 35-38% of total APC,
so need to Superior

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For high speed fans, ensure the silence fitted at suction
size has
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How Ensure all inspection & man way doors are sealed
properly
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neck is
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KC3000 masters

elektrostore.co.uk Monitor draught losses in flue gas duct, air ducting, APH,
Economiser intensive

& ESP regularly

applications with

 Follow lubrication schedule, replace damaged

bearings to reduce speeds up to

vibrations & bearing temperature. High vibration

bearings consume 7,000/7,000MB/s

more power read/write.

3-Boiler feed water pumps (BFP)

Boiler feed water consume around

35% of total APC of the plant. Hence it is
OPEN utmost important to reduce the BFP
power consumption. Attention must be
given on following points to reduce BFP
power consumption.
Select optimum capacity BFPs, Under
load running pumps have low
efficiency
Better to install HT drives for
BFP
Incorporate VFD to BFPs Stone
Operate BFP in Auto mode based on
discharge header pressure &
drum pressure Electric
Do not operate the pump with
discharge valve throttled
Ensure BFP ARC valve has no
leakage
Radiators
Ensure BFP has sufficient suction
pressure Cheaper Prices
Maintain Deaerator level on
higher set point side. Guaranteed
Replace worn out balance &
counter balance discs We Stock the Premier
Schedule pumps servicing as per
OEM guidelines. And replace Range at Discounted
impeller wear rings or impellers if clearance found
more. More Rates. Check Our Prices
clearance between wear ring & impeller will lead to higher power Before You Buy.
consumption
Follow lubrication schedule, replace
damaged bearings to reduce elektrostore.co.uk
vibrations & bearing temperature.
Do not uses BFP discharge water
for de-super heating of LP process
steam, instead use CEP discharge water
Clean suction strainers regularly
4-ESP
OPEN
Implement hopper heater automation by thermostat
Optimize the charge ratio of Transformer

Questions & Answers on ESP troubleshooting

B-Fuel
feeding system:

Fuel feeding system consumes

around 2-4% of total APC. Hence it need to give
attention to reduce APC in this
area. Following are the some listed action points
to reduce APC.
Incorporate VFDs to all fuel
feeding systems, as fuel feeding system
never run on 100% load.Superior Speeds up to 7000MB/s
KC3000
Select planetary type gear masters
boxes
to fuelintensive applications
feeding system, with speeds up to 7,000/7,000MB/s read/

as planetary Learn More

write.efficiency
gear boxes found of higher
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4/10/22, 3:18 PM Power plant and calculations: Best practices to reduce the Auxiliary power consumption (APC) in Sugar based Cogeneration plants.
Follow regular preventive
maintenance to reduce wear, tear & friction
of rotating parts, which
ultimately lead to more power consumption
CLOSE ADS Replace all loose V belts. Loose
V belts lead to increased power CLOSE ADS

consumption
C-Turbo
generator & Auxiliary:

Turbine auxiliary consume around

10-12% of total APC of the plant. Following

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the APC
Electric
For A Home Maintain lube & control oil
filters clean Superior

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Maintain cooling tower fills

& drift eliminators clean to get required
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Incorporate VFDs to all cooling
water pumps s
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degree.
a Fraction
Cheaperof Cost.
the Replace CT fan aluminium blades
by FRP
Why Buy
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How
the Brand
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and Pay Ensure cooling tower surrounding
area is free of trees & structures for
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Save. free flow of air
Incorporate VFDs to Condensate
extraction pumps (CEP) KC3000 masters

elektrostore.co.uk intensive

Ensure hot well make up is going

on from gravity water from feed tank
applications with

or surge tank
speeds up to

Schedule regular cleaning of heat

exchangers like steam condenser, 7,000/7,000MB/s

oil cooler, ejectors & Generator air

cooler & gland steam condensers read/write.
Replace TG building exhaust fans
by turbo ventilators
D-Fuel
handling (Coal & Bagasse handling):

OPEN Ensure motors selected for all

Bagasse belt conveyors are of optimum
rating
Incorporate planetary gear boxes
to belt & chain conveyors
Replace all damaged idlers
regularly. Damaged idlers lead to more
friction in the system
Ensure Vertical gravity take up
height is optimum (1 to 1.5% of
conveyor length) Cheaper
Ensure belt scrapers (cleaners)
& skirt boards are not over rubbing the
belt to avoid friction &
wear/tear Than
Follow regular preventive
maintenance & lubrication schedule for
conveyor pulleys bearings &
idlers
Manufacturer
Remove saturated bagasse/coal
from deck plates of conveyors Low Cost Electric Boilers
regularly to avoid friction We Stock the Premier
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E-Compressors/blowers
& Ventilation/air conditioning system
Before You Buy.
For air compressors optimise
discharge air pressure & set loading & unloading
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times as per
requirement
Clean air filters regularly
Replace all globe valves by gate
valves or ball valves
Ensure compressor discharge air
line is of correct size to avoid
pressure drop in the line
For pneumatic ash handling system
operate ash handling plant in OPEN
probe mode or else optimize cycle time &
conveying time
Incorporate VFDs to ventilation
system
Optimize the usage of Air
conditioning system in offices, meeting halls
etc
Avoid compressed air for cleaning
applications
F-Water
treatment plant

Thumb rules water treatment plant

Ensure enough capacity of tanks

for Speeds
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that the
operation time of the plant can be reduced
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Plan to get more quantity of
return condensate from process
write.
Optimize boiler & CT blow
down to reduce pumping power
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4/10/22, 3:18 PM Power plant and calculations: Best practices to reduce the Auxiliary power consumption (APC) in Sugar based Cogeneration plants.
Incorporate drain condensate
recovery system to reduce pumping
power as well as to conserve thermal energy
CLOSE ADS Operate DM plant at its full
capacity & carryout regeneration as per out CLOSE ADS
-54%
put OBR given by OEM to reduce pumping power as well
as water
consumption
Use treated N-pit water as  service water

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proper ventilation to the motors. For every 10 °C increase in
Superior

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is estimated
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Synchronous
motors are more suitable to improve power factor. s
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the Balance
the three phase power supply, an unbalanced voltage can
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input power by 3–5%.
the Brand
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Save. Ensure
the motor proper rewinding, an improper rewinding could lead
to efficiency
reduction. KC3000 masters

elektrostore.co.uk Ensure
proper alignment between motor and load ends (fans, pump, -5% -14% intensive

gear box, blower

etc.) to avoid more power consumption and failures. applications with

2-Lighting speeds up to

Incorporate timers for plant lighting systems like

conveyors, street, bagasse & 7,000/7,000MB/s

coal yards etc

read/write.
Replace all CFL & incandescent bulbs by LED
bulbs

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July 03, 2020

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1 comment:
ARUN PRASATH 13 October 2021 at 06:04

its very useful sir, i got some notes from here.

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4/10/22, 3:18 PM Power plant and calculations: Best practices to reduce the Auxiliary power consumption (APC) in Sugar based Cogeneration plants.
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