aX\o00 aiv9sa. SAAT ae CO-GENERATION SANJAY CHAUHAN, & 1. ASST. PROFESSOR SUGAR ENGG,*The simultaneous generation of electricity and thermal energy is called co-generation. * It produces two forms of energy from a single fuel some one of the forms of energy must always be heat and other may be electrical or mechanical energy. * One of the common examples other than this technology is used in sugar production. * Almost all sugar mills in India are traditionally using co-generation by using bagasse as a fuel. Sugar production by sugar cane after juice extraction the residue of sugar cane is very valuable and is known as bagasse. This bagasse is being used in sugar industries for generation of power.* Bagasse have fibrous material & have good calorific value and burns very easily. * Co-generation operation can be improved by reducing moisture content at milling and also later using dryer with flue gas. * Energy generation with sugar cane bagasse and trash has the potential to supply a substantial amount of electricity. * Sugar industry require electricity and steam in the production process here bagasse is being burnt in boilers to produce steam for its use in the process and turbine generator for power generation. After self consumption the supplies electricity will be available for sale to the grid. * The production of electricity by using bagasse as a fuel in a bagasse based boiler. This electricity fulfils the requirement of the sugar factory & surplus electricity can be export to the grid. ay A* Co-generation unit is installed near the sugar industry campus. So that bagasse which is bi-product of sugar industry can be easily send to co-generation plant’s boiler by belt conveyor. * Now a day’s boiler of high pressure & temperature are being used to utilize more thermal energy of fuel, reduce losses and higher efficiency of boiler. Co-generation based on ranking cycle is not new to the sugar factory and sugar industry has made great strides in this area. * Is olden days the power cycle a ducted was band on 14 ata and 21 ata. * This has been gradually increasing 32,45,66,85,110 with the latest being at 125 ata and 540°C with the size of the co-generation plant going above 40MW, the use of 135 ata pr cycle and reheat cycle are being explored.BASIC CONCEPT OF COGENERATION PLANT * The fuel of cogeneration plant is bagasse. This bagasse is feed into the boiler furnace for combustion as fuel. * The water in boiler get heated when the bagasse is fired in furnace. Gradually the water get converted in to steam after heating it up to 480°C. The steam flow through the superheater such that moisture content in the steam gets evaporated and turn into super saturated steam. The hot flue gas from the boiler is feed to superheater & removes the moisture content. The flue gas flowing through super heater flows through economizer & pre heater. The main function of the economizer is that it will increase the temperature of the feed water by utilizing the heat from the hot flue gases.ron age Drawing: + The feed water is again sent to the boiler for conversion of steam. * The air per heater increases temperature of the air supplied for fuel burning by driving heat from the flue gases. * By preheating the air there will be an increase in thermal efficiency and increase the steam capacity per square meter of boiler surface. * The S.H. steam from super heater is feed to the impulse reaction turbine by means of main valve. The valve placed in b/w super heater & the turbine is for limiting the excess flow level of steam to the turbine. The turbine converted steam energy into mechanical energy. * The turbine is coupled with the turbo alternator with the help of coupling. The turbo alternator converted mechanical energy into electrical energy.*The generated electrical energy is stepped up by using powe transformer and feed to using bar with various protection system. * The electricity generated either 11KV /132KV is sent to the neare: substations. * The exhaust steam from steam turbine is again converted into water in the condenser and it is seat to the cooling tower. * Part of exhaust steam at required design pr. of turbine can be extracted for use in boiling house as process steam as 2.5 ata & 7 ata etc and remaining exhausted steam is sent for condenser. Again the condensate water is sent through condensate extraction pump to L.P. water heater and then to H.P. feed water heater. Then the water is sent to the economizer and from there if it is circulated to boiler. This process is repeats simultaneously. * The ash in the furnace is sent to ash handling plants where it is mixed with water in order to stop the spreading of ash storage plant.STEAM TURBINE COGENERATION SYSTEM Back pressure Turbine 1. MeEMo : Seiten Koh = &. Becke Presse See Sct Ae a] —* Feedpune process rt Tee Boks PrekRonr T Fee ee ite et a Dome cea Da = ie —2. Extraction Condensing Turbine3. Gas Turbine CogenerationElise ree = reve ate wy a Seemann SS. Baan NS ae Dcometinimeta CALCULATION FOR POWER GENERATION heat output eat input * Boiler ef ficiency n = heat in steam output (kcals) heat in fuel input(keals) . “_ Quantity of steam gerevation evaporation rate =O vantity of fuel consumption 2 + The efficiency of a boiler is expressed as the % of useful heat available from the total knergy available by burning the fuel. This is expressed on the basis of gross calorific value (GCV). There are two method of boiler testing on efficiency calculation. ”A1t9$6F, BSSG0C] % (> wo BAO =Eline ‘mito * Efficiency = 100-(1+2+3+4+5+6+7+8) ee eee wee GaudioSTEAM TURBINE ANALYSISBX\\o0G6 4 sae DLUOO GE NO A” 0 spe SSAT 1 Be Mm seen ACTUAL HEAT EXTRACTION + Calculate the actual heat extraction in turbine at each stage, + Steam ellthalpy at turbine inlet=h, Keal/kg + Steam enthalpy at 1” extraction = h, Keal/kg + Steam enthalpy at 2"4 extraction = h, Kcal/kg. + Steam enthalpy at condenser = h, Kcal/kg, Due to wetness of steam in the condensing stage, the enthalpy of steam cannot be considered as equivalent to saturated steam. Typical dryness value {is 0,88-0.92. This dryness value can be used as first approximation to estimate heat drop in the last stage. However it is suggested to calculate last stage efficiency from overall turbine efficiency and other stage efficiency. i i Cheha eie ee ee ew weex ise: tag tacowr 9 ‘romani 5 sean Bole ale Be Catone ALLOTOL Z ih ter Owection= = IN NOOO BNA) Mem Se oop CALCULATE ENTHALPY DROP + Heat extraction from inlet to stage -1 extraction (h) = hy-h, Kcal/kg + Heat extraction from 1* to 2 extraction (hg) = hy-h3 Kcal/kg * Heat extraction from 2 extraction to condenser (h;) = hy-h, Keal/kg,Be oe Leeesetneantiiaeinsiaeal R- & Ss Ou WSOC MARSTONS— AMAUIONSSLOESLOW mEVEW EW p Xen game KEY ‘ it Paco ran ste THEORETICAL ENTHALPY DROP. + Theoretical enthalpy after 1% extraction =H, + Theoretical enthalpy after 2 extractidn =H, + Theoretical enthalpy at condenser =H, = Theoretical heat extraction from inlet stage to extraction, hy + Theoretical heat extraction From 1% -2"4 extraction, hg= Hy-H) * Theoretical heat extraction from 2" extraction- condensation = H,-H; e eeeececeeHo OF benaniunithiantanl ou RTC -MANONS—ANMAONS —SUSOW VW A Mca teats mix vie - - Epo eet s Fiomarien Si. Beton COMPUTE TURBINE CYCLE EFFICIENCY = _Heat extraction actual Efficiency of 1 stage = jac extraction theoretical ha -h2 7 “hI= HA + Efficiency of 2 sta ey rN heat extraction actual _ h2—h3 ~ Heat extraction theoretical H1—H2 + Efficiency of condensing stage = = f : au ‘a2 a5 eeee ¢ KK Ye 4° [7 shape Outlt k IG Shape Effect convert to Smart Paragraph Beestna PLANT HEAT RATE + Heat rate, Keal/kwh = M x tu M-Mass flow rate of steam in Kg/hr. h,- Enthalpy of inlet steam in Keal/Kg hy,- Enthalpy of feed water in Kcal/kg * P— Average power generated in KW * Plant heat consumption =fuel consumed for power generation (kg/hr) /power generated in (kw)