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INVESTIGATION OF BAGASSE BASED COGENERATION PLANT

Conference Paper · November 2014

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 Int. Conf. on Industrial, Mechanical and Production Engineering: Advancements and Current Trends
Department of Mechanical Engineering, MANIT, Bhopal
November 27-29, 2014
INVESTIGATION OF BAGASSE BASED COGENERATION PLANT
Mahida Hirenkumar Ranjitsinh1*
1
*Assistant Professor, Shroff S.R. Rotary Institute of Chemical Technology, Ankleshwar, India,
hiren.mahida@gmail.com

Abstract:Co-generation is widely recognized worldwide as an eye-catching substitute to the conventional

power and heat generating option due to its low capital investment, short gestation period, reduced fuel
consumption and associated environmental pollution and increased fuel assortment. In this paper, energy
and exergy analysis of heat matched bagasse based co-generation plant of typical 2500 Ton capacity per
day sugar factory, using back pressure and extraction condensing steam is carried out. It is instituted that
the energetic efficiency of the whole plant is 79.57 % while the exergetic efficiency is 15.89 %. Boiler
has been found as the least efficient component with exergetic efficiency of 23.64 % and the process
heater is the most efficient component with exergetic efficiency of 89.87 %.
Keywords: Co-generation, energy, exergy, back Pressure and extraction Condensing plant.

1. Introduction

Cogeneration is the simultaneous generation of power and process heat from the single source. In
sugar factory normally cogeneration plant is used first to produce the power and then it is used
for different process heat application like drying, centrifuges, process heater etc. Cogeneration is
a thermodynamically efficient use of fuel. In separate production of electricity, some energy
must be discarded as waste heat, but in cogeneration this thermal energy is put to use. All
thermal power plants emit heat during electricity generation, which can be released into
the natural environment through cooling towers, flue gas, or by other means. Cogeneration is
recognized as an attractive tool for reducing energy crisis by different governments due to its
advantages over other simple system.

2. Literature Review

F. Petrakopoulou (2011) had found that exergy analysis is a mighty tool for development, assessment and
improvement of all existing energy systems. A conventional energy analysis denotes components and
processes into energy systems that are mightly uncoverable. S. Kelly et al.(2009) found that for complex
energy systems, with large number of components, exergy destruction of a certain component depends on
its own characteristics, but also on other components inefficiencies. The conventional energy analysis
displays certain limitations which are considerably decreased in an advanced or detailed energy analysis.
R. Saidur et al (2009) published data on boiler exergetic efficiencies are low and range from 16% to 45 %
indicating a major portion of the exergy contained in the fuel is either destroyed, lost or both and not
transferred to the products. M.P. Sharma et al (1999) had stated that exergy analysis has the purpose to
supply engineers with more useful information related to energy systems improvement potential. It is
important to identify where irreversibility exist in the thermal system be, be it in combustion or heat
exchange and optimized the system to maximize use of the fuel exergy. The poor thermal performance of
boilers compounds are problem of fossil fuel depletion, increased fuel and maintenance costs and
greenhouse gases (GHG) emissions.

3. Research Methodology & Description Of The Cogeneration Plant

H R. Mahida et at (2014) has carried out energy and exergy analysis for a co-generation plant (Steam and
power generation) of Ganesh Sugar Factory, Vataria. The analysis is carried out during the full load

*Presenting author: Mahida Hirenkumar Ranjitsinh

condition. In the existing system, the steam is generated in the low pressure boiler by burning some of its
bagasse. Cogeneration is the simultaneous generation of process heat and power from the same plant.
This is the widely practiced cogeneration plant configuration in the sugar industry. In this configuration,
the cogeneration plant generates only that much amount of steam, what is required for process heating as
it is a heat- matched plant and surplus bagasse is saved. Power generated is a by-product.

Figs. 1 & 2 describe the, heat matched cogeneration plant of a typical 2500 tcd sugar factory using back
pressure steam turbine and their representation of T-S diagram.
Manufacturing of white crystals sugars using double sulfitation process in this sugar factory requires low
pressure steam (utilizing latent heat) at 0.8 bar and 150 C for juice heating and medium pressure steam at
6.57 bar and 200 C for sulfur melting and centrifuge. In this system the steam generated by the boiler is
first utilized in producing power and then for the process heating and centrifuges. Following are the main
four components of sugar industry are Boiler, Turbine, Process Heater and Centrifuges.
Cogeneration is the simultaneous generation of process heat and power from the same plant. This is the
widely practiced cogeneration plant configuration in the sugar industry. In this configuration, the
cogeneration plant genereates only that much amount of steam, that is required for process heating as it is
a heat –matched plant and surplus bagasse is saved. Power generation is a by-product.

Fig. 1 BPST cogeneration plant Fig. 2 T-S diagram

4. Analysis of Plant

Following are the assumptions while calculating different parameters.

 The bagasse production is estimated at 30% of crane crushing.
 Steam to bagasse ratio is constant and is 2.0.
 Kinetic and potential component of exergy are negligible.
 For reference environment pressure and temperature conditions are 1.0135 bar and 25C.
 The chemical exergy of fuel bagasse is considered as base to determine the overall exergetic
efficiency of the plant.
 The exergy of flue gases and steam/water flows is used to determine the loss of exergy in the
components of co-generation plant.
 The piping losses except that between boiler outlet and turbine inlet are negligible.
 Int. Conf. on Industrial, Mechanical and Production Engineering: Advancements and Current Trends
Department of Mechanical Engineering, MANIT, Bhopal
November 27-29, 2014
Table 1 Data collected at various point in the plant

Description Temp Pressure Flow Enthalpy Energy Entropy Exergy

[C] [ Bar] [Kg/Sec] [KJ/Kg] [KJ/Sec] [KJ/Kg.K] [KJ/Sec]
DM water into 60 1.01325 1.135 251.1 284.55 0.831 11.182
boiler
Bagasse into 25 1.01325 4.6 CV= 7650 35151.75 45439.95
boiler
PH outlet to 90 0.8 8.05 398 3205.89 1.250 98.186
boiler
Air flow into 25 1.01325 18 0 0 0 0
boiler
Flue gas out 150 15 1431.07
from boiler
Steam outlet 380 32 9.2 3182.8 29249.93 6.8194 10451.83
from boiler
Steam inlet to 364 32 9.2 3148 28930.12 6.7657 10286.43
turbine
Steam inlet to 150 0.8 8.05 2777.8 22375.17 7.720 3736.92
process heater
Steam inlet to 200 6.57 1.13 2852.4 3237.474 7.0125 850.52
centrifuges
Flue gas outlet 110 1.01325 15 971.77
of Economizer
Water inlet to 25 1.01325 1.135 104.8 118.94 0.307 0
economizer
Water outlet 60 1.01325 1.135 251.1 284.99 0.831 29.68
from
economizer

4.1 Boiler Analysis:

4.1.1 Energy Analysis of Boiler:

 HeatOutput 
 st    *100 (1)
 HeatInput 
 29249.93 
 st    *100  75.69
 284.99  35151.75  3205.89 
4.1.2 Exergy Analysis of Boiler:
 Exergy out 
 sec ond    * 100
 Exergy in  (2)
 10451.83  1431.07 
 sec ond   *100  26.08
 11.182  45439.95  9.186 
4.2 Turbine Analysis:
4.2.1 Energy Analysis of Turbine:

*Presenting author: Mahida Hirenkumar Ranjitsinh

The energetic efficiency of the turbine is given by following equation
 m3 h3  m4 h4  WCG

 st    * 100 (3)
 m2 h2 
 22375.17  3237.474  2646 
 st    *100  97.67
 28930.12 
4.2.2 Exergy Analysis of Turbine:
The exergetic efficiency of the turbine is given by following equation
 m3 e3  m4 e4  WCG 
 sec ond    * 100
 m e
2 2  (4)
 3736.92  850.52  2646 
 sec ond    *100  70.32
 10286.43 

4.3 Plant Analysis:

4.3.1 Energy Analysis of the plant:
The overall efficiency of the plant is given by
 WT  E 
 st    * 100
 E 
 fuel  (5)
 2646  22375.17  3237.479  284.99 
 st    *100  79.57
 35151.75 

4.3.2 Exergy Analysis of Plant:

The overall efficiency of the plant is given by
 WT  E 
 sec ond    * 100

(6)
 E fuel 
 2646  3736.92  850.52  11.182 
 sec ond    *100  15.89
 45439.95 

5. Result & Discussion

Table 2 Energetic & Exergetic Efficiency of Different Components

Components Energy Analysis (%) Exergy Analysis (%) Losses ( KW )

Boiler 75.69 23.64 33666.41

Turbine 97.67 56.60 3052.99
Economizer 28.00 69.97 429.62
Process Heater 91.60 89.87 425.48
Piping 98.90 98.41 165.4
Plant 79.57 15.89 38195.32
 Int. Conf. on Industrial, Mechanical and Production Engineering: Advancements and Current Trends
Department of Mechanical Engineering, MANIT, Bhopal
November 27-29, 2014

Energy Analysis Exergy Analysis

Efficeency 150 150

Efficiency
100 100
50 50
0 Energy 0 Exergy

Econo…
Process…

Econo…
Process…
Piping
Plant
Turbine
Boiler

Piping
Plant
Turbine
Boiler
Analysis Analysis

Components Components

Fig. 3 Energy Analysis Fig. 4 Exergy Analysis

Outcomes of the above table and graphs:

 The boiler is the least efficient component in the plant with exergetic efficiency of 23.64% & the
process haeater is the most efficient component with exergetic efficiency of 89.87%. Thus boiler is
the major component contributing most of the plant’s total inefficiency, due to its inherent nature.
 In the boiler the process generates three kinds of losses. First loss can be seen as difference between
exergy of fuel and flue gasss marked as exergy loss due to combustion. Second loss exists due to
heat transfer between flue gases and steam &the last one is exergy loss in flue gases.
 Exergetic efficiency of the boiler improves substantially with higher HP steam inlet condition. Thus,
increasing steam generation pressure and temperature in one of the options to reduce exergy losses
and improve exergetic efficiency.
 From the energy and exergy analysis of the cogeneration plant, it is seen that the energy analysis
attributes all the inefficiencies to losses as 20.43%. The first law effciency of the plant is 79.57%,
while the exergetic efficiency of the plant is 15.89%.
 It has been seen that maximum loss of exergy is while converting the chemical exergy of the fuel
such as 9889 KJ/ Kg to heat. This is due to high production of entropy generation during the burning
of fuel. Maximum of the energy is lost during this process of conversion. By supplying air-fuel at
high temperature, use of catalyst and lowering the product gas temperature, the production of entropy
can be reduced and hence higher combustion efficiency may be obtained.
 Energy and exergy losses in the turbine may be due to the blade tip losses, increase in the
interstagegland leakages. Therefore proper clearance of different labyrinths should be maintained in
order to improve the performance.
 In general operating the boiler at proper air- fuel ratio, supplying fuel- air mixture at higher
temperature, use of suitable combustion catalyst, selection of appropriate pipe size, proper insulation,
reduction in stean leakages may help in overall energetic and exergetic efficiency of the plant.

6. Concrete Conclusion

 The development of bagasse drying system, utilizationof crane trash, tops of fuels, biomass based
fuels etc. Development and integration of bagasse and filter cake based gassifier system, storage,
handling and densifying bagase, development of circulating fluididized bed boilers using bagasse as
fuel & memberane technology (reverse osmosis) for juice concentration are some of the R & D areas
where considerable work is required to be done.

*Presenting author: Mahida Hirenkumar Ranjitsinh

  In the present sugar factory the output steam of the centrifuges also contains some amount of energy
and exergy is lost in the atmosphere. If any process or equipment that utilize this loss is a positive
idea behind increasing first law & second law efficiency of the whole plant.

Acknowledgements

The author acknowledge the support for the research project “Energy and exergy Alalysis of Bagasse
Based Cogeneration Plant - A case study” granted by Shree Ganesh Khand Udyog Sahkari Mandli
Limited, Vataria for providing all the actual datas of plant.

References:

F. Petrakopoulou (2011), Conventional and Advanced Exergetic Analysis applied to a

Combined Cycle Power Plant Article in Press, Energy, doi: 10.1016/J.energy.2011.05.028

H R. Mahida, G.M. Bramhakshatriya, Jariwala S.D. Jariwala (2014), Exergy Destruction

Analysis of NHEC & Thermax Boiler with Various Operating Conditions in ICMEETS
Proceedings of 1st International Conference on Mechanical Engineering: Emerging Trends for
Sustainability, Bhopal, India, PP. 1056-1061.

M.P. Sharma, J.D. Sharma(1999), Bagasse based cogeneration for Indian sugar mills, Renew.
Energy (6) PP. 1011-1014 .

P.K. Nag: Power Plant Engineering , 2nd ed., ( TMG Publications , India 2003)

R. Saidur, J.U Ahmed, and H.K. Masjuki(2009), Energy, Exergy and Economic Analysis of
Industrial Boilers , Energy Policy, Vol. 38, PP. 2188 – 2197.

S. Kelly, G. Tsatsarenis, T. Morosuk(2009), Advanced Exergetic Analysis: Approaches for

splitting the Exergy Destruction into Endogenous and Exogenous Parts, Energy (34) PP. 384-391

Nomenclature

Abbreviated form Full Form Abbreviated form Full Form

B Boiler e Specific Exergy
DM De-Mineral Plant E Exergy
BPTS Back Pressure Steam Turbine first First Law Efficiency
PH Process Heater second Second Law Efficiency
CF Centrifuge

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