BAGAS S E BAS ED COGENERATION PLANTS THE NEW FEATURES

On e of t h e s u cces s s t or ies of m od er n In d ia is t h e b a ga s s e b a s ed Cogen er a t ion in t h e s u ga r m ills . Th er e is n o ot h er cou n t r y in t h e wor ld , wh ich had m ade s u ch a p h en om en a l p r ogr es s in Cogen er a t ion in s u ga r fa ct or ies a s in In d ia .

S u ga r

Pla n t s

a re

p a r t icu la r ly in t er es t in g a p p lica t ion s

for

Cogen er a t ion , s in ce b a ga s s e, on e of t h e wa s t e p r od u ct fr om t h e m ill, is a va ila b le a lm os t a t n o cos t a s feed s t ock t o fu el t h e s t ea m gen er a t or s of t h e Cogen er a t ion p la n t . Th e s u ga r m a n u fa ct u r in g p r oces s r equ ir es a la r ge qu a n t u m of t h erm a l en er gy in t h e for m of s t ea m a n d b u lk of th e s t ea m r equ ir ed for t h e p r oces s in g is n eed ed a t low p r es s u r e s u ch a s 2 .5 a t a .

It a ll s t a r t ed wa y b a ck in 1 9 9 3 , wit h t h e Gover n m en t of In d ia a p p oin t in g a com m it t ee t o look in t o t h e Cogen er a t ion p ot en t ia l in t h e In d ia n s u ga r in d u s t r y. Th e fir s t h igh p r es s u r e Cogen er a t ion p la n t , b a s ed on 6 4 a t a 4 8 0 Deg.C, s t ea m p a r a m et er s wit h a ca p a cit y of 1 8 .6 8 MW wa s com m is s ion ed in 1 9 9 5 a t M/ s .Th ir u Ar oor a n S u ga r s Lim it ed a t Th ir u m a n d a n k u d i in Ta m iln a d u .

High

p r es s u r e a n d

h igh

t em p er a t u r e cycles

a r e cr u cia l for

in cr ea s in g t h e op er a t in g efficien cy a n d t h e p ower ou t p u t fr om t h e Cogen er a t ion Pla n t s . Th e c h o ic e o f t h e le v e l o f t h e pre s s u re an d

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t e m pe rat u re fo r t h e s t e am c y c le de pe n ds o n t h e le v e l o f c o n fide n c e in t h e plan t o pe rat o rs , qualit y o f t h e fe e d wat e r & t h e wat e r t re at m e n t s y s t e m s available , t h e c o s t o f t h e h igh pre s s u re / t e m pe rat u re bo ile r & Tu rbo ge n e rat o r s y s t e m s an d t h e fin an c ial be n e fit s re aliz able fro m t h e Co ge n e rat io n plan t by way o f t h e s ale o f t h e e x po rt able po we r.

Th er m od yn a m ica lly, en er gy r ecover y from t h e Ra n k in e Cycle is m or e d ep en d en t on t h e s t ea m in let t em p er a t u r e cycle efficien cy. th an th e p r es s u r e a n d t h e h igh er t h e s t ea m in let t em p er a t u r e, h igh er t h e However , b eca u s e of t h e n a t u r e of t h e wor k in g m ed iu m , wh ich is s t ea m , t h e p r es s u r e a ls o p la ys a m a jor r ole in en s u r in g t h e op t im u m ext r a ct ion of t h e u s efu l en er gy fr om t h e wor k in g m ed iu m a n d h en ce, t h e in cr ea s e in t h e s t ea m t em p er a t u r e s h ou ld b e a ccom p a n ied b y t h e m a t ch in g in cr ea s e in t h e p r es s u r e. Th e p r a ct ica lly a t t a in a b le lim it s of t em p er a t u r es a r e in flu en ced b y t h e m et a llu r gy of t h e b oiler t u b in g, p ip in g a n d t h e t u r b in e com p on en t s a n d t h e com p lexit y of t h e Cr eep fa t igu e in t er a ct ion for t h e m a t er ia ls a t h igh er t em p er a t u r es .

Tem p er a t u r es u p t o 4 0 0 Deg.C r equ ir e t h e u s e of or d in a r y ca r b on s t eel a n d b eyon d 4 0 0 Deg.C, low gr a d e a lloy s t eels a r e em p loyed . Ab ove 5 0 0 Deg.C, t h e m et a llu r gica l r equ ir em en t s b ecom e s t r in gen t a n d exp en s ive a n d a b ove 5 5 0 Deg.C, th e r equ ir em en t s a r e ver y s t r in gen t a n d p r oh ib it ively exp en s ive. n a tu re of th e in d u s t r y. p r ovis ion of It is ext r em ely im p or t a n t s u ch as cos t , th e t h a t t h e s elect ion of t h e t em p er a t u r e is d on e k eep in g in m in d t h e Con s id er a t ion s a d equ a t e m a in t a in a b ilit y, s a fet y m a r gin s ,

exp er ien ce of t h e in d u s t r y s o fa r a n d t h e level of t h e op er a t in g

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p er s on n el a va ila b le in t h e in d u s t r y, en a b le t h e s elect ion of t h e p r a ct ica l lim it on t h e s t ea m t em p er a t u r e for t h e In d ia n S u ga r Fa ct or y.

It is a ls o im p or t a n t t o k eep in m in d th a t t h e s u p er h ea t er s t ea m t em p er a t u r e r es p on s e is a lit t le er r a t ic, even wit h a good s t ea m t em p er a t u r e con t r ol s ys t em in s u ga r p la n t b oiler s , m a in ly b eca u s e of t h e n a t u r e of t h e fu el a n d t h e d ifficu lt y t o en s u r e a cor r ect ly m et er ed qu a n t it y of fu el flow t o t h e b oiler . Con s id er in g a ll t h e a b ove, a t em p er a t u r e lim it of 4 8 5 Deg.C wa s ch os en for t h e Cogen er a t ion p la n t s t h a t h a d b een com m is s ion ed in t h e m id a n d la t e Nin et ies . Th is wa s con s id er ed a s a s a fe s elect ion givin g a d equ a t e m a r gin for u n in t en t ion ed t em p er a t u r e excu r s ion s , lik ely t o h a p p en in a b a ga s s e fir ed b oiler .

In it ia lly t h e r es p on s e fr om s u ga r in d u s t r ies for t h e n ew con cep t of h igh p r es s u r e cogen er a t ion cycle a n d s u r p lu s p ower exp or t t o gr id , wa s lu k ewa r m . However , a ft er s eein g op er a t ion of t h e fir s t few Th e s u b s equ en t op er a t ion of t h e 6 4 h a ve given va lu a b le u n it s , t h e in d u s t r y s t a r t ed evin cin g k een in t er es t in h igh p res s u r e cogen er a t ion p ower p la n t s . a ta 480 Deg.C Un it s com m is s ion ed ,

in for m a t ion wit h r ega r d t o t h e p er for m a n ce of t h e Un it s in res p ect of t h e s u p er h ea t er p er for m a n ce a n d b oiler r es p on s e.

Ha vin g ga in ed a lot of exp er ien ce wit h t h e op er a t ion a t s u p erh ea t er t em p er a t u r es a t 4 8 5 Deg.C, b oiler s wit h h igh er s t ea m p res s u r e and t em p er a t u r es wer e in t r od u ced in t o th e s u ga r in d u s t r y cogen er a t ion p la n t s . Th e n ext gen er a t ion of h igh er p r es s u r e
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cogen er a t ion p la n t s wit h 8 7 a t a 5 1 5 Deg.C b oiler ou t let s t ea m p a r a m et er s , wh ich ga ve 5 % t o 6 % h igh er ou t p u t com p a r ed t o 6 7 a t a 4 8 5 Deg.C u n it s wa s in t r od u ced in t h e s u ga r in d u s t r y. Th e fir s t 8 7 a t a 5 1 5 Deg.C u n it wa s com m is s ion ed in Ka k a t iya Cem en t S u ga r & In d u s t r ies Lt d ., in An d h r a p r a d es h , wit h a 9 0 TPH b oiler a n d a 1 7 MW t u r b ogen er a t or in t h e yea r 2 0 0 2 .

S u b s equ en t ly, m or e n u m b er of s u ga r fa ct or ies a d op t ed t h e 8 7 a t a 5 1 5 Deg.C s t ea m p a r a m et er s for t h e cogen er a t ion cycle. Pr es en t ly, a b ou t 1 2 b oiler s with s t ea m ou t let p a r a m et er s of 8 7 a t a 5 1 5 Deg.C a r e in op er a t ion in Ta m iln a d u , An d h r a Pr a d es h & Ut t a r Pr a d es h . In a d d it ion , 2 0 m ore b oiler s wit h 8 7 a ta 5 1 5 Deg.C s t ea m ou t let p a r a m et er s will b e goin g in t o op er a t ion in t h e n ext t wo s u ga r s ea s on s . Ha vin g s t a b ilis ed t h e op er a t ion of 8 4 a t a 5 1 0 Deg.C (t u r b in e in let p a r a m et er s ) t h er m a l cycle, a t t em p t s a r e b ein g m a d e t o a d op t s t ill h igh er p r es s u r e t h er m a l cycle wit h 1 0 5 a t a 5 3 5 Deg.C t u r b in e in let s t ea m p a r a m et er s .

Th e con cep t of r egen er a t ive feed wa t er h ea t in g wa s in t r od u ced in t h e Cogen er a t ion cycles , t o im p r ove t h e cycle efficien cy a n d h igh p r es s u r e feed wa t er h ea t er s h a ve b ecom e a s t a n d a r d fea t u r e in a ll t h e Cogen er a t ion p la n t s . Ba r r in g on e of t h e p la n t s , t h e 8 4 a t a 5 1 0 Deg.C cogen er a t ion p ower p la n t s wer e a d op t in g 1 7 0 Deg.C a s t h e b oiler feed wa t er in let t em p er a t u r e. wa t er in let t em p er a t u r e. However , t h e 1 0 5 a t a 5 3 5 Deg.C cogen er a t ion p la n t s will a d op t 2 1 0 Deg.C a s t h e b oiler feed Th er e is a n et in cr ea s e of 4 % t o 5 % in Alr ea d y gr os s p ower gen er a t ion b y t h e a d op t ion of 1 0 5 a t a 5 3 5 Deg.C t h er m a l cycle com p a r ed t o t h e 8 4 a t a 5 1 0 Deg.C cycle. Th r ee p la n t s in Ta m iln a d u , On e in Ka r n a t a k a a n d Two p la n t s in
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Ut t a r p r a d es h a r e p la n n in g t o in s t a ll 1 0 5 a t a 5 3 5 Deg.C t h er m a l cycle cogen er a t ion p ower p la n t s in s u ga r in d u s t r y.

Wh ile effor t s a r e b ein g m a d e for in cr ea s ed p ower gen er a t ion b y a d op t in g h igh er p r es s u r e cycle, en er gy con s er va t ion effor t s a r e a ls o b ein g b r ou gh t in t o th e s u ga r in d u s t r y for op t im is in g and in cr ea s in g t h e exp or t a b le s u r p lu s p ower t o gr id .

Th e va r ia b le fr equ en cy d r ives h a ve b een ext en s ively u s ed t o b r in g t h e a u xilia r y p ower con s u m p t ion d own a n d a Cogen er a t ion p la n t s a u xilia r y p ower con s u m p t ion t od a y m a y b e a r ou n d 8 % t o 9 % a s a ga in s t 1 2 % in t h e p la n t s d es ign ed ea r lier . A lot of n ew id ea s lik e t h e con t in u ou s b a ga s s e feed in g s ys t em , t ot a l a u t om a t ion a n d con t r ols h a d b een im p lem en t ed a n d con t in u ou s im p r ovem en t s a r e b ein g m a d e in t h e equ ip m en t a n d s ys t em d es ign t o im p r ove t h e p la n t r elia b ilit y a n d efficien cy.

S u ga r Mills h it h er t o op er a t in g wit h 5 0 % s t ea m on ca n e a r e t od a y t a lk in g of r ed u cin g t h e s t ea m con s u m p t ion t o 3 5 % s t ea m on ca n e a n d s om e of t h e m ills h a ve even a ch ieved t h e s a m e level of s t ea m con s u m p t ion for t h e p r oces s . Power con s u m p t ion in t h e s u ga r m ills is b ein g r ed u ced b y in t r od u ct ion of va r ia b le fr equ en cy d r ives , ep i-cyclic gea r s ys t em , et c. A s u ga r m ill wit h Cogen er a t ion s t r ives t o p r even t t h e wa s t a ge of ever y Kilowa t t -h ou r of p ower a n d k iloca lor ie of s t ea m en er gy.

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E ffor t s a r e a ls o b ein g m a d e t o r ed u ce p ollu t ion in t h e cogen er a t ion p la n t s . On e of t h e s ign ifica n t a r ea con tr ib u t in g t o wa t er p ollu t ion is t h e coolin g t ower b low d own . Air cooled con d en s er s (ACC) t o con d en s e s t ea m fr om t h e t u r b ogen er a t or h a ve b een in t r od u ced in t h e s u ga r in d u s t r y cogen er a t ion p ower p la n t s r ep la cin g t h e coolin g t ower s . E ven t h ou gh t h e in it ia l cos t of t h e p la n t in cr ea s es wit h t h e a d op t ion of a ir cooled con d en s er s , t h er e is s ign ifica n t r ed u ct ion in wa t er p ollu t ion a n d ACC will b e t h e on ly a n s wer for p la n t s wit h r ed u ced wa t er a va ila b ilit y. Two s u ga r p la n t cogen er a t ion u n it s h a ve gon e in t o op er a t ion wit h ACC a n d t wo m or e p la n t s in Ta m iln a d u a r e b ein g im p lem en t ed wit h ACC.

Look in g a t t h e n u m er ou s p la n t s a lr ea d y com m is s ion ed a n d m a n y u n d er im p lem en t a t ion , on e t h in g t h a t s t r ik es is t h a t ea ch p la n t is u n iqu e in d es ign . Th e fa ct or s lik e t h e cr u s h in g ca p a cit ies , s t ea m con s u m p t ion , p ower con s u m p t ion , op er a t ion in p a r a llel wit h t h e exis t in g low p r es s u r e s ys t em s , et c. m a k e t h e d es ign p la n t s p ecific. Mos t of t h e h igh p r es s u r e b oiler s a r e d es ign ed wit h m u lt i fu el fir in g ca p a b ilit y t o en a b le t h e op er a t ion d u r in g t h e off-s ea s on a ls o.

Th e a d va n t a ges of b a ga s s e b a s ed Cogen er a t ion , lik e t h e p r oject s b ein g en vir on m en t fr ien d ly, r ed u ct ion in t h e t r a n s m is s ion a n d d is t r ib u t ion los s es wit h t h e p la n t s loca t ed in r u r a l a r ea s , et c. a r e well k n own . Th e m os t s ign ifica n t con t r ib u t ion of Cogen er a t ion is t o t h e s u ga r in d u s t r y it s elf, b y wa y of b r in gin g in en er gy d is cip lin e in t h e s u ga r m ills . Un d ou b t ed ly, Cogen er a t ion is on e of t h e b es t t h in gs t h a t h a s h a p p en ed t o t h is cou n t r y in gen er a l a n d t o t h e In d ia n s u ga r in d u s tr y in p a r t icu la r .

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