Gasifier Capacity - kgs / hr 40 100 150 300 450 600 900

Type of gas engine NA NA T/C & A/C T/C & A/C T/C & A/C T/C & A/C T/C & A/C
Engine Model - Cummins 6B series G855G GTA855G GTA1710G GTA1710G&855G GTA1710G -2 Nos. GTA1710G -3 Nos.
Specific biomass consumption - kgs /unit 1.3 1.3 1.2 1.2 1.2 1.2 1.2
In-house power consumption 6.25 17.5 31.25 48 72 97 144
Gross power - Peak 25.00 70.00 125.00 240.00 360.00 485.00 720.00
Gross power - Continuous 23.00 65.00 110.00 220.00 330.00 440.00 660.00
Net power utilisable 16.75 47.50 78.75 172.00 258.00 343.00 516.00
Gasifier diameter - mm 400 600 720 1025 1200 1350 1500
Biomass size - Maximum 20*20*30 40*40*40 50*50*60 60*60*75 70*70*85 80*80*100 90*90*100
Floor space requirement 4 *5 6 *6 6*8 8*8 10 * 8 10 * 12 12 * 12
Shed height 5 8 10 12 14 16 16

Project cost estimate

Cost of the gasifier 3,550,000 4,900,000 5,600,000 6,600,000 8,500,000 11,800,000 15,000,000
Supervision of E&C 100,000 100,000 100,000 150,000 200,000 300,000 300,000
Effluent treatment system 0 850,000 850,000 850,000 1,200,000 1,200,000 1,200,000
Biomass loading hoist 0 750,000 750,000 750,000 850,000 850,000 850,000
Biomass preparation, handling & drying system 200,000 250,000 350,000 500,000 800,000 1,000,000 1,000,000
Cost of VAC chiller 0 0 2,600,000 3,100,000 3,600,000 4,500,000 4,500,000
Cost of transportation & insurance 100,000 120,000 130,000 150,000 150,000 180,000 180,000
Erection & Commissioning cost 80,000 80,000 90,000 120,000 150,000 200,000 200,000
Cost of essential spares for first year operation 40,000 50,000 75,000 95,000 105,000 125,000 125,000
Cost of gasifier shed construction 550,000 550,000 650,000 750,000 850,000 950,000 950,000
Cost of covered shed for biomass storage etc 80,000 70,000 95,000 125,000 185,000 250,000 250,000
Cost of Gas, Water and other piping & cabling 60,000 90,000 120,000 150,000 200,000 300,000 300,000
Cost of sump for gasifier & cooling tower 80,000 120,000 150,000 210,000 280,000 390,000 390,000
Cost of gas engine 650,000 2,100,000 6,000,000 9,200,000 12,000,000 18,000,000 27,600,000
Ga engine synchronsisng cost 0 0 0 0 7,000,000 10,500,000 12,500,000
Cost of engine shed & other works 200,000 300,000 350,000 450,000 500,000 600,000 800,000

Total project cost 5,690,000 10,330,000 17,910,000 23,200,000 36,570,000 51,145,000 66,145,000
Less MNES subsidy - Approximate 375,000 1,050,000 1,875,000 3,600,000 5,400,000 7,275,000 10,800,000
Net project investment 5,315,000 9,280,000 16,035,000 19,600,000 31,170,000 43,870,000 55,345,000

Delivery period -months 3 3 4 4 5 6 6

Installation, integration & trial runs - months 1 1 1.5 2 2 2 2
 ECONOMICS OF USING GAS ENGINES TO GENERATE POWER

FUEL COST AT PRESENT

Fuel cost from EB / Generator 7.0 6.0 18.0 7.0 6.0 18.0 7.0 6.0 18.0

Power produced - Units per hour 65 65 65 110 110 110 220 220 220

FUEL COST WITH GASIFIER

Feed stock cost per Kg 4 4 4 4 4 4 4 4 4

Consumption of feed stock per unit 1.3 1.3 1.3 1.2 1.2 1.2 1.2 1.2 1.2

Feed stock cost 5.20 5.20 5.20 4.80 4.80 4.80 4.80 4.80 4.80

Fuel cost saving per unit of power produced 1.80 0.80 12.80 2.20 1.20 13.20 2.20 1.20 13.20

ECONOMICS OF OPERATION WITH GASIFIER

Number of hours of operation per month 600 600 600 600 600 600 600 600 600

Fuel cost saving per month 70,200 31,200 499,200 145,200 79,200 871,200 290,400 158,400 1,742,400

Additional Labour per month - Rs. 3000 per person 18,000 18,000 18,000 18,000 18,000 18,000 36,000 36,000 36,000

Additional power consumption - units / hour 17.5 17.5 17.5 31.25 31.25 31.25 48 48 48

Additional power Cost per month 54,600 54,600 54,600 90,000 90,000 90,000 138,240 138,240 138,240

Gross saving -2,400 -41,400 426,600 37,200 -28,800 763,200 116,160 -15,840 1,568,160

Gross saving per year -28,800 -496,800 5,119,200 446,400 -345,600 9,158,400 1,393,920 -190,080 18,817,920

Gasifier & Engine maintenance cost / year 561,600 561,600 561,600 950,400 950,400 950,400 1,900,800 1,900,800 1,900,800

Net saving per year -590,400 -1,058,400 4,557,600 -504,000 -1,296,000 8,208,000 -506,880 -2,090,880 16,917,120

Net project investment 9,280,000 9,280,000 9,280,000 16,035,000 16,035,000 16,035,000 19,600,000 19,600,000 19,600,000

Payback period in months -189 -105 24 -382 -148 23 -464 -112 14

 ECONOMICS OF USING GAS ENGINES TO GENERATE POWER

FUEL COST AT PRESENT

Fuel cost from EB / Generator 7.0 6.0 18.0 7.0 6.0 18.0 7.0 6.0

Power produced - Units per hour 330 330 330 440 440 440 660 660

FUEL COST WITH GASIFIER

Feed stock cost per Kg 4 4 4 4 4 4 4 4

Consumption of feed stock per unit 1.3 1.3 1.3 1.2 1.2 1.2 1.2 1.2

Feed stock cost 5.20 5.20 5.20 4.80 4.80 4.80 4.80 4.80

Fuel cost saving per unit of power produced 1.80 0.80 12.80 2.20 1.20 13.20 2.20 1.20

ECONOMICS OF OPERATION WITH GASIFIER

Number of hours of operation per month 600 600 600 600 600 600 600 600

Fuel cost saving per month 356,400 158,400 2,534,400 580,800 316,800 3,484,800 871,200 475,200

Additional Labour per month - Rs. 3000 per person 36,000 36,000 36,000 45,000 45,000 45,000 54,000 54,000

Additional power consumption - units / hour 72 72 72 97 97 97 144 144

Additional power Cost per month 224,640 224,640 224,640 279,360 279,360 279,360 414,720 414,720

Gross saving 95,760 -102,240 2,273,760 256,440 -7,560 3,160,440 402,480 6,480

Gross saving per year 1,149,120 -1,226,880 27,285,120 3,077,280 -90,720 37,925,280 4,829,760 77,760

Gasifier & Engine maintenance cost / year 2,851,200 2,851,200 2,851,200 3,801,600 3,801,600 3,801,600 5,702,400 5,702,400

Net saving per year -1,702,080 -4,078,080 24,433,920 -724,320 -3,892,320 34,123,680 -872,640 -5,624,640

Net project investment 31,170,000 31,170,000 31,170,000 43,870,000 43,870,000 43,870,000 55,345,000 55,345,000

Payback period in months -220 -92 15 -727 -135 15 -761 -118

 18.0

660

1.2

4.80

13.20

600

5,227,200

54,000

144

414,720

4,758,480

57,101,760

5,702,400

51,399,360

55,345,000

13