4. CO-GENERATION in SUGAR MILLS

5. How Cogeneration Saves Energy

6. COGENERATION PLANT LAYOUT Feed water PRDS BOILER ALTERNATOR TURBINE TO PROCESS TO PROCESS Fuel Air TO POWER SUPPLY CONDENSER TO COOLING TOWER

8. Steps for conservation 1.Government of India enforced the energy conservation act 2001 with effect from 1.3.2002. 2.The initial phase of 5 years would be implementation of the act . 3.The act provides mainly for efficient use of energy and its conservation. 4.Industry using

10. Energy Saving potential areas in sugar industries 1.Convertion from low Pressure to HP Boilers 2.Steam Boilers (Reducing moisture percentage in Bagasse) 3.Crushing section 4.Evaporator section

15. Comparison of performance during various seasns from 1998 to 2002 40.7 4.84 7.06 11.9 11.9 8.96 11.23 10.3 7.06 % Lost % on Available Hours 14 53.7 59.3 51.08 110 51-05 110-25 109-25 97-15 97-10 Hrs-Mts General Cleaning 13 94.3 66 4 70 70-00 24-25 4.-00 53-55 11.-10 Hrs-Mts Electrical 12 97.5 176 4.5 181 180-45 24-55 4.-30 59-30 64-35 Hrs-Mts Mechanical 11 204-10 154-55 142-15 57-50 6.-00 Hrs-Mts No Cane 10 Rs 51.57 lakhs per season DOWN TIME ANALYSIS 4.19 1.08 24.68 25.8 25.18 25.46 24.68 KWH Power / Ton of Cane 9 49.74 49.45 48.75 50.71 48.76 % Steam % Cane 8 2.32 1.19 50.11 51.3 51.3 50.4 50.11 50.56 50.66 % Bagasse Moisture 7 8.187 9.23 9.758 9.11 9.51 % Recovery 6 3918.42 4247.98 4063.22 3857 4217.33 MT Crop Day Average 5 4614.77 4783.32 4576.34 4311.12 4541.39 MT Crushing Rate/24 hours 4 4230.29 4385.11 4194.98 3951 4162.95 MT Crushing Rate/22 hours 3 188 165 159 191 173 No. of Crop Days 2 736663 700916 646051 736838 729598 MT Cane Crushed 1 Actual Actual Actual Actual Actual UOM PARTICULARS SL NO. % Saving scope Diff Min Max 1998-99 1999-00 2000-01 2001-02 2002-03

16. Coomparison of performance with best two seasons 6173-40 3816-33 4148-39 HRS Total Available Hours 15 80-120 90to130 % Sugar quality ICUMSA 14 1.73 1.78 1.86 % Pol % Bagasse 13 50.52 50.11 50.66 % Bagasse Moisture 12 78.18 % Cane Preparatory Index 11 31.22 30.32 29.56 % Bagasse % Cane 10 4.415 4.449 4.52 % Molasses % Cane 9 0.037 0.049 0.1 % d)Unknown Loss 0.99 1.211 1.27 % c)Final Molasses 0.05 0.07 0.08 % b)Filter Cake 0.54 0.541 0.55 % a)Bagasse 1.617 1.871 2 % Total Losses 8 10.963 11.618 11.5 % Pol in Cane 7 9.357 9.758 9.51 % Recovery 6 2796.416 4063.216 4217.3 MT Crop Day Average 5 3076.152 4576.344 4541.4 MT Crushing Rate / 24 hours 4 2819.806 4149.982 4162.9 MT Crushing Rate / 22 hours 3 258 159 173 No. of Crop Days 2 721475.5 646051.4 729598 MT Cane Crushed 1 2500 5000 5000 MT Plant Sanctioned Capacity %saving scope Min Max 1994-95 2000-01 2002-03 UOM PARTICULAR SL NO

17. Possible increased in crushing of cane per season= 24220 MT/season Remarks:Possible saving of running hours =128 hours 128 hours 213.8 341.8 694.65 1477.49 2325 Qtls Process Stock-Brown Sugar 30 8.82 11.23 7.06 % Lost % on Avaible Hours 29 33.17 112.166 167.83 168-45 167-50 112-10 HRS Others 28 11.2 97.16 109.416 164-00 109-25 97-10 HRS General Cleaning 27 5.-30 4.-00 11.-10 HRS Electrical 26 93 4.5 64.58 152-15 4.-30 64-35 HRS Mechanical 25 54-15 142-15 6.-00 HRS No Cane 24 DOWN TIME ANALYSIS 9.83 9.923 9.68 % Peak Period Recovery 23 Rs 21.62 lakhs/season 25.18 24.68 KWH Power / Ton of Cane 22 2.77 47.41 48.76 47.41 48.75 48.76 % Steam % Cane 21 93.43 91.66 91.27 % Reduced B.House Extraction 20 95.89 96.02 95.73 % Reduced Mill Extraction 19 3.69 3.78 4.12 Milling Loss 18 295.62 293.58 259.14 % Imbibition% Fiber 17 544-45 428-25 292-55 HRS Down Time Hours 16

18. 75-45 10.-20 21-35 12.-40 20-45 5.-55 5.-00 0-00 HRs b)Engineering(Mech&Elec) 6.-00 0-00 0-00 0-00 0-00 0-00 6.-00 0-00 HRs a)Want of Cane 292-55 19-35 51-50 43-45 38-15 35-25 102-20 1.-45 HRs Stoppage Hours 8 3855-44 172-28 692-10 676-15 705-45 636-35 641-40 330-51 HRs Total Working Hours 7 4148-39 192-03 744-00 720-00 744-00 672-00 744-00 332-36 HRs Total Available Hours 6 167 8 31 29 31 27 27 14 Days Season Days-Crushing Day 5 173 8 31 30 31 28 31 14 Days Season Days-Crop Day 4 696220 25397 114975 13123.3 14747 13227.5 113875 3100 Qtls Sugar Production 3 9.61 6.68 8.75 10.14 10.66 10.06 8.84 8.05 % Recovery 2 729598 21860 128072.4 127097 140288 134980 128742 48558.3 MT Cane Crushed 1 %saving Min Max TOTAL JUNE.03 MAY.03 APL.03 MAR.03 FEB.03 JAN.03 DEC.02 UOM PARTICULARS SL NO ANALYSIS OF PERFORMANCE FOR THE SEASON 2002-2003(MONTH WISE)

19. Remarks: Saving of power in terms of money will be Rs 77.15 lakhs /month. @Rs 5.00/KWH 32.2 23.27 34.3 24.63 34.3 25.57 25.13 24.69 23.27 23.61 23.61 Units Power per Ton of Cane 23 48.76 70.91 48.18 47.96 48.37 47.62 47.69 49.47 % Steam % Cane 22 4.52 4.93 4.85 4.66 4.61 4.37 4.17 4.26 % Molasses % Cane 21 31.35 34.15 31.55 31.51 31.71 30.99 30.45 29.6 % Final Molasses Purity 20 29.56 31.63 30.75 30.19 29.42 29.06 28.82 27.53 % Bagasse % Cane 19 1.86 1.9 1.84 1.84 1.85 1.86 1.88 1.89 % Pol % Bagasse 18 91.27 90.46 91.14 91.19 91.15 91.39 91.49 91.66 % Reduced BH. Extraction 17 95.73 94.48 95.64 96.02 96.12 95.88 95.31 94.79 % Reduced Mill Extraction 16 0.1 0.288 0.263 0.06 0.058 0.057 0.062 0.069 % d)Unknown 0.08 0.105 0.087 0.08 0.084 0.083 0.081 0.08 % c)Filter Cake 0.55 0.6 0.57 0.56 0.545 0.54 0.543 0.521 % b)Bagasse 1.27 1.45 1.369 1.31 1.306 1.218 1.143 1.13 % a)Final Molasses 2 2.443 2.284 2.01 1.993 1.898 1.828 1.8 % Total Losses 15 11.5 9.11 11.025 12.14 12.627 11.947 10.656 9.844 % Pol % Cane 14 4368.85 2732.5 4131.368 4382.66 4525.41 4999.27 4768.2 3468.45 MTs Crushing Day Average 13 4217.33 2732.5 4131.368 4236.57 4525.41 4820.73 4153 3468.45 MTs Crop Day Average 12 4541.39 2731.8 5037.504 4510.66 4771 5088.96 4815.3 3522.43 MTs Crushing Rate / 24 hours 11 4162.95 2504.2 4617.712 4134.77 4373.12 4664.88 4414 3228.9 MTs Crushing Rate / 22 hours 10 7.06 10.-20 6.97 6.08 5.14 5.27 13.75 0.53 % Down Time % Available 9 112-10 9.-15 30.15 1.-50 17-00 3.-15 48-50 1.-45 HRs e)Others 97-10 0-00 0-00 29-15 0-00 26-15 41-40 0-00 HRs d)General Cleaning 1.-20 0-00 0-00 0-00 0-30 0-00 0-50 0-00 HRs c)Process

25. KCP Boiler 70 TPH, 43.4ata & 400 ºC TBW Boiler 70 TPH, 67ata & 485 ºC 9.74 MW, 70 tph TG Comparison Prevailing System Proposed System Multi fuel Boiler 105ata, 525 º C, 88% Topping up TG set 18.6 MW, 61 tph TG GEC Turbine SIEMENS Turbine C C 11 KV BUS 9.74 MW, 70 tph TG 18.6 MW, 61 tph TG C C GEC Turbine SIEMENS Turbine 67ata & 485 ºC 42ata & 400 ºC

26. Actual Thermal Efficiency of existing power plant on date Heat value of KPC boiler ≈ 767 Kcal/kg (from steam table) (at 43.4 ata and 400ºC) Then net heat value of KPC boiler ≈ 767 – 105 ≈ 662 Kcal/kg. Thermal efficiency of KPC boiler = η th = (Net heat value * Total Steam generation) / (CV of the bagasse * total bagasse consumption) η th = (662 * 122759) / (2277 * 61672) = 57.99% ≈ 58% ( against 69% of design) Heat value of TBW boiler = 807.7 Kcal/kg (From steam table) (at 67 ata and 485 ºC) Then net heat value of TBW boiler ≈ 807.7 – 105 ≈ 702.7 Kcal/kg GCV of coal = (CV of coal * total coal consumption) / Total fuel consumption = (5500 * 4622) / 56213 = 452.22 Kcal/kg GCV of Bagasse = (CV of bagasse * total bagasse consumption) / Total fuel consumption = (2277 * 51591) / 56213 = 2089.77 Kcal/kg Then net GCV = 452.22 + 2089.77 = 2542 Kcal/kg

27. Then net heat gain = heat gain * steam required for cane * efficiency of Topping TG set = 13.8 * 125*10 3 * 0.9 = 1552.5 Kcal/kg Total power generation = 1552.5/860 = 1.8 MW Transfer rate = 1800 * 24 * 330 * 1.96 = 2.79 crore.

28. Thermal efficiency of TBW boiler = η th = (Net heat value * Total Steam generation) / (Net GCV * total fuel consumption) = (702.7 * 129399) * 100 / (2542 * 56213) η th = 63 % (against 71.75 % of design) Average thermal efficiency of KPC & TBW boiler = (58+63) / 2 = 60.5 %

29. Expected direct efficiency of multifuel boiler = 84% Then fuel saving = 84 – 60.5 = 23.5% Cost of fuel saving = Actual cane crushed * % of fuel caned * % fuel save for 02-03 = 729598 * 0.3 * 0.235 = Rs. 51436.65 Then total saving of bagasse = 51437 * 500 = Rs. 2,57,815 = 2.57 crore Net gain in power = 2.79 crore Net gain in fuel save = 2.57 crore Then total gain = 2.79+2.57 = 5.36 crore

30. Heat value of AFBC boiler = 821.5 Kcal/kg (from steam table) (at 515 º C and 105 kg/cm 2 ) Then net heat gain = 821.5 – 807.7 = 13.8 Kcal/kg From data Budgeted crane crushed/year = 775000 M.T Actual crane crushed/year = 72598.401 M.T No. of crop days = 170 days % Steam required for crane = 48% % of bagasse in cane = 30% Then steam required for cane/hr. = (budgeted cane crushed * %steam reqd. for cane) / (No. of days * 24) = (775000 * 0.48) / (170*24) = 91.176 tph ≈ 100 tph For maximum efficiency steam required for cane/hr = 100/0.80 = 125 tph