cogen paper-sa.pptx

Cogeneration of Steam & Power

Energy price hikes in India defy age old proverbs !

What goes up never comes down !!

Energy Prices !!!

The Economics Times

Return on Investment

Fixed Deposit 8%

Property in Johannesburg! 50%

Power through Cogeneration 80%

Plus Depreciation Benefits of 80%

CO-GENERATION 160%

Co-generation of Power

Looking to the acute power shortage and the prevailing power cuts in South Africa it has become imperative that thought should be given for co generation of power.

In the larger interest of our Plant economy it becomes necessary to consider various proposals of cost saving and Co generation is one of the most attractive, cost economical proposal.

In most industries steam demand are at low pressures hence Co Generation of Power is a very viable alternative.

Need For Co-generation

Grid power (SEB) cost has gone up.

Uncertain and unreliable power availability.

Heavy demand charges payment in spite of load shedding.

High maintenance and running costs of D.G. Sets.

Heavy competition in industry leading to lower realisations and profitability

Helps conserve our environment

What are the

Options?

Co-generation Package

What is Co-generation..?

Most industries utilize steam at low pressure for heating purposes.

In order to reduce the pressure, a Pressure Reducing Valve (PRV) is fitted in most industries. This valve reduces the pressure to an acceptable level before the steam can be utilized.

Now, it is possible to reduce the Steam pressure without PRV and at the same time generate Power. The Turbine replaces the PRV and the end result is an in-house generation of Power.

Steam Turbine Cogeneration Offers Out Standing Economy

A back pressure steam turbine in a cogeneration

application is one of the most efficient ways of

producing electricity. The remarkable high

efficiency offered by cogeneration is only available

when the turbine acts as a pressure reducing

valve – That is when the high pressure steam

available is used to run a Turbine and exit the low

pressure steam for the process requirement.

Most Industries Use A Pressure Reducing Valve

Back Pressure Turbine

Simple Steam Generation in Process Industry

Steam turbine cogeneration allows you to generate electricity with the same steam which is further used for heating and process requirements. In other words with COGENERATION THE STEAM IS USED TWICE. - Once to run the generator and once again for heating and process steam requirements.

IBL has developed boilers and turbines specially only for Small & Medium Industries looking to their steam and power requirements. By going in for these advance technology boilers, we must remember that we not only save on our operating cost but also save our environment. It should be noted that an inseparable part of the energy scene is the environmental aspects related to the production of Steam & Power which today is predominantly through the burning of fossil fuels. The penalty we pay is to load the life giving environment like Air, Water and Soil with Pollutants such as dust particles, oxides of Carbon, Nitrogen, Sulphur etc. which are dangerous to human beings.

Average stack losses from the high efficient boilers are around 18%, which is primarily heat & pollutants lost to the atmosphere degrading our environment. Combustion of fossil fuels are associated with the release of Carbon dioxide, a major producer of green house effect. Gases like Methane, Carbon dioxide etc. absorb the radiant energy from the Sun causing global warming with dire consequences.

The annual environmental impact of land use for a 1000 MW coal fired THERMAL POWER plant

3680 hectares if the coal is deep mined 5650 hectares if the coal is surface mined65 hectares are required for Fuel processing895 hectares for transport390 hectares for conversion50 hectares for ash storage5 hectares for coal storage

In addition, this generation unit annually produce35,00,000 cubic feet of ash3,50,000 tones of sulphur dioxide45,00,000 tones of carbon dioxide

Turbo Set Terminology

CAPTIVE POWER GENERATION A situation where power is generated and consumed

internally.CO GENERATION

A Situation Where Steam & Part Or Full Power Is Generated.

INLET PRESSURE The steam pressure at the turbine stop valve.

BACK PRESSURE The steam pressure at the exhaust of turbine, a

situation dependant on steam consumption and electrical loading.

Turbo Set Terminology

INLET TEMPERATURE Steam temperature at the turbine stop valve.

OUTLET TEMPERATURE Steam temperature at the exhaust of the turbine.

POWER OUTPUT The net power available at the control panel.

BACK PRESSURE / CONDENSING SETS Turbine type determined by exhaust pressure at the

turbine exhaust.

Essential Requirements For Co-generation

PROCESS STEAM PRESSURE The process steam pressure (back pressure)

determines the effectiveness of cogen. Lower the pressure requirement, higher the power

generation, better is the payback. PROCESS STEAM DEMAND

The process steam requirement determines the effectiveness of cogen.

Higher the requirement, better is the payback. POWER REQUIREMENT IN PLANT

The power demand will determine the following :- Boiler pressure Type of power generator

Turbo Genset Selection Factors

TURBINE SELECTION FACTORS Steam Flow – Max, Average and Design Back Pressure Power Output Achievable

POWER GENERATOR SELECTION FACTORS Steam Flow Fluctuations Power Load Fluctuations

TURBINE EFFICIENCY Specific Steam to Power Ratio Turndown Ratio

Boiler Selection Factors

OUTPUT CONDITIONS Max. Steam Flow Min. Steam Flow Turbine Inlet Pressure Turbine Outlet Temperature

FUEL EFFICIENCY Type of Fuel Feeding Overall Efficiency Position of Superheater

POWER EFFICIENCY Internal Power Consumption of the Boiler

Selection Of Generation Mode

ALTERNATOR INDUCTION GEN

The only system suitable for power outputs beyond 800 kw

System ideally suitable for outputs below 800 kw

Will operate even when power from SEB/Genset fails

Needs excitation from SEB or D. G. Set to operate. Trips when grid power fails.

Suitable for constant and continuous steam and power demand.Any fluctuation will require steam venting

Suitable for fluctuating steam and power demand.Caters to fluctuation easily without steam venting.All balance power is covered up by the grid.

Typical Steam Generation Capacities And Power Generation From A Medium Pressure

Boiler System

Boiler Capacity Add.Fuel Power Generation Kg /Hr Consumed. KW

Kg/Hr3000 34 1504000 48 2106000 75 3408000 107 53310000 138 72012000 194 960

Note:-Boiler Design Pressure 33 Kg/Cm2

Back Pressure from Turbine at 3 Kg/Cm2

Inlet Superheat considered 350 DegºC.Coal Calorific Value taken at 4500 Kcal /Hr.The above figure are indicative and Approximate and taken from the Mollier

Diagram.

Variation Of Power Output With Change In Back Pressure

TECHNICAL PARAMETERS

BACK PRESSURE 3 Kg/cm2 (g)



Turbine Input conditions

10 TPH 33 Kg/cm2 (g)



Process Steam Pressure(Back Pressure)

3 Kg/cm2 (g) 4 Kg/cm2 (g) 5 Kg/cm2 (g)

Power output from turbine 720 KW 660 KW 600 KW

Variation Of Power Output With Change

In Inlet Steam Pressure

TECHNICAL PARAMETERS

10 TPH 21 Kg/cm2(g)



10 TPH 67Kg/cm2 (g)

Steam Temperature

Saturated 380ºC 420ºC 490ºC

Process Steam Pressure(Back Pressure)

3 Kg/cm2 (g) 3 Kg/cm2 (g) 3 Kg/cm2 (g) 3 Kg/cm2 (g)

Power output from turbine

220 KW 625 KW 720 KW 960 KW

Quality of exhaust Steam

7 % Wet Dry – 210ºC Dry – 220ºC Dry – 240ºC

IB Turbo Range of Steam Turbines

Saturated Steam Turbine – PRT - 4/6

Single stage 40 - 250 KW

Inlet pressure from 15 Kg/Cm2 - 6

Kg/Cm2

Outlet pressures from 1.0 Kg/Cm2 - 4

Kg/Cm2

Back Pressure Steam Turbine – BT - 4/6

Single stage 100 - 750 KW


Kg/Cm2

Inlet super heat Minimum +50 C – Maximum 390 C


Kg/Cm2

IB Turbo Range of Steam Turbines

Back Pressure Steam Turbine – MBT - 6

Multi stage 1000 - 10000

KW


Kg/Cm2

Inlet super heat Minimum 35º C –

Maximum 51º C


Kg/Cm2

Condensing / Extraction Steam Turbine BCT - 6

Multistage stage 1000 - 10000 KW


Kg/Cm2

Inlet super heat Minimum 350

C – Maximum 510 C

Bleed pressures from 1.5 Kg/Cm2 -12

Kg/Cm2

COGENERATION

COMBINED HEAT

&

POWER (CHP)

STEAM + POWER

Heat & Mass Balance for Boiler & Steam Turbine

BACK PRESSURE

Boiler Capacity Kg/Hr. 10000

Working Pressure Kg/Cm2 33

Super heat Temperature Deg. C. 350

Boiler Efficiency % 82Steam Enthalpy Kcal/Kg. 749

Feed Water Temperature C. 105

Fuel Calorific value Kcal/Kg. 4500

Boiler's fuel consumption Kg/Hr. 1745

Facility's fuel input in Kcal/Hr. 7853659

Power Output Kw. 600

Energy Available to the Boiler Kcal/Hr 7853659

Energy Available from the Boiler Kcal/Hr 6440000

5872400

567600

1

2

Energy Utilised by Turbine Kcal/Hr - 567 600Energy Available in Back Pressure Kcal/Hr - 2 872 400

Unique Low Pressure ApplicationCochin Kagaz, Kerala

Cochin Kagaz was operating a 10 Ton Husk fired Boiler at 10 Kg/cm2 pressure.

IBL installed a Super-heater and Back Pressure Turbine.

Power now generated – 200 KWH (4.8 MW per day)

Steam Inlet pressure to turbine 9 Kg/cm2

Investment Rs. 50 Lacs, Savings – Rs. 40 lacs / year

Turbine is in operation for last 3 years.

Induction Generator with BT-4 Turbine

Alternator with BT-4 Turbine

A Co-Gen Installation in a Paper Mill

A Co-Gen Installation in a Textile Mill

A Turbine Installation in a Distillery

BT-4 Turbine

Successful Application

Induction Generator BasedPaperTextilesFood Processing

Alternator BasedDistilleriesRice

How much does it cost to Generate Power ?

Thru Back Pressure Turbine Between Rs. 0.80 per unit to Rs. 1.50 per unit.

Thru Condensing Turbine Between Rs. 3.00 per unit to Rs. 4.50 per unit.

Thru Bleed + Condensing Turbine Between Rs. 2.50 per unit to Rs. 4.00 per unit.Note: 1 South African Rand equals 5.17 Indian Rupee

IBL’s Range of Product

IBL has a wide range of Product to meet the Steam & Power Need of the Industry

Hi-Pressure Co-Generating systems FBC boilers.

Agro fuel FBC boilers Oil / Gas Fired boilers

Urjash Burner Systems Manual Coal Fired boilers.

Agricultural Waste Fired boilers Waste heat recovery boilers.

Water Treatment Plants. Economisers.

Heat Recovery Systems. Incinerators

Hot Air Generators. Air Pollution Control Systems.

Autoclaves with Quick closing Doors

IBL’s Certifications

•ISO 9001:2008

•EUROCERT S.A.

•ASME R, U S & PP Stamps.

•IBR

Worldwide Support

• South Africa• USA• Myanmar• Kenya• Nepal• Sri Lanka• Malaysia• Thailand• Australia• New Zeeland

IBL has International Offices and

Representatives

Nationwide SupportIBL Offices And Representatives

Mumbai Vapi New Delhi Kolkata Chennai Hyderabad Bangalore Ahmadabad Surat Bharuch Panipat Amritsar Indore Bhilwara Pali

Considering the energy crisis on one hand and the need for Industrialization on the other, we come to the conclusion that whatever fuel available has to be conserved and optimum utilization of all available resources. The President of India in his speech this year spoke at length on Energy Independence.

How are we to achieve it?

Cogeneration is one of the ways.

As the old saying goes, better late than never, be applied in conserving this valuable source of energy and also help save our environment.

Thank You

VISIT USAT

http://www.indboilers.comhttp://www.ibturbo.com

Technical Director: Rohinton EngineerEmail:[email protected]

http://www.indboilers.com/






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