The paper reports on the assessment of the use of bagasse in sugar industry for high pressure cogeneration. Study was done on a sugar mill which has recently adopted this technology. This paper investigates the efficiency of season and off season operation of sugar mill, high pressure cogeneration technology is much more efficient in bagasse to steam ratio. During seasonal operation CHP efficiency is 76.8% and during offseason its value is 29.9%.Project initial cost is high but payback period is low. It will encourage other sugar mills in Pakistan for the development of high pressure co-generation system to meet increasing energy demands in the country.
Steam turbines and its associated systems(ntpc ramagundam)abdul mohammad
Steam turbine is an excellent prime mover to convert heat energy of steam to mechanical energy. Of all heat engines and prime movers the steam turbine is nearest to the ideal and it is widely used in power plants and in all industries where power is needed for process.
In power generation mostly steam turbine is used because of its greater thermal efficiency and higher power-to-weight ratio. Because the turbine generates rotary motion, it is particularly suited to be used to drive an electrical generator – about 80% of all electricity generation in the world is by use of steam turbines.
Rotor is the heart of the steam turbine and it affects the efficiency of the steam turbine. In this project we have mainly discussed about the working process of a steam turbine. The thermal efficiency of a steam turbine is much higher than that of a steam engine.
The document provides an overview of a thermal power plant training project conducted at the Jamshoro Thermal Power Station in Pakistan. It discusses the importance of practical training and familiarizing with real-world industrial scenarios. It also briefly outlines the various processes involved in power generation including steam generation, turbine generation, synchronization, and control and instrumentation. The report aims to cover all aspects of the power plant in detail to gain experience in electrical, mechanical, chemical and control/instrumentation departments.
This lab manual document provides instructions for experiments on heat transfer in a Mechanical Engineering department. The first experiment listed is on heat transfer from a pin-fin apparatus. The objective is to calculate the heat transfer coefficient for natural and forced convection from a fin. The experiment involves measuring temperatures along a brass fin heated at one end while air passes over it naturally or in a duct. The second experiment listed is on heat transfer through a composite wall, and involves determining the total thermal resistance and conductivity of a wall made of different slab materials sandwiching a heater.
Hmt lab manual (heat and mass transfer lab manual)Awais Ali
This document describes procedures for 7 experiments on heat transfer:
1. Investigates Fourier's Law of heat conduction along a brass bar by measuring temperatures at points along the bar for different heat inputs.
2. Studies heat conduction along a composite bar and calculates the overall heat transfer coefficient.
3. Examines the effect of cross-sectional area changes on temperature profiles in a conductor.
4. Determines temperature profiles and heat transfer rates from radial conduction through a cylinder wall.
5. Measures thermal conductivity of non-metallic materials and compares to theory.
6. Determines thermal conductivity of liquids and gases.
7. Investigates the relationship between power input and surface temperature for free convection
The document provides details about an industrial training project at the Wanakbori Thermal Power Station (WTPS). It includes:
1) An acknowledgment thanking those who facilitated the training.
2) An index outlining the topics to be covered, including details of the boiler, turbine, condenser, coal handling plant, and more.
3) An abstract stating the aim was to study the mechanical instruments involved in power generation and improve practical knowledge.
Boilers have several uses including generating steam to drive turbines for electricity production, and to provide steam for heating, cooling and industrial processes. Boilers can be classified based on their orientation, water and gas flow design, furnace location, circulation method, pressure rating, mobility, and number of tubes. Common boiler types include fire tube boilers like Cochran and Lancashire where gases pass through tubes and water surrounds them, and water tube boilers like Babcock & Wilcox where water passes through tubes and gases surround them. Each boiler type has advantages like efficiency, capacity, and cost, but also limitations regarding pressure, size, and complexity.
NTPC Dadri power plant has an installed capacity of 2642 MW including 1820 MW from thermal units and 817 MW from gas units. It sources coal from Piparwara mine in Jharkhand and water from Upper Ganga Canal. The basic processes include coal handling, combustion in boilers to produce steam, steam passing through turbines to generate electricity, and condensation of steam in condensers. Key components are coal handling plant, boilers, turbines, condensers, cooling towers, ESPs for emissions control, and chimney. Fly ash is a byproduct that is used in construction materials.
Steam turbines and its associated systems(ntpc ramagundam)abdul mohammad
Steam turbine is an excellent prime mover to convert heat energy of steam to mechanical energy. Of all heat engines and prime movers the steam turbine is nearest to the ideal and it is widely used in power plants and in all industries where power is needed for process.
In power generation mostly steam turbine is used because of its greater thermal efficiency and higher power-to-weight ratio. Because the turbine generates rotary motion, it is particularly suited to be used to drive an electrical generator – about 80% of all electricity generation in the world is by use of steam turbines.
Rotor is the heart of the steam turbine and it affects the efficiency of the steam turbine. In this project we have mainly discussed about the working process of a steam turbine. The thermal efficiency of a steam turbine is much higher than that of a steam engine.
The document provides an overview of a thermal power plant training project conducted at the Jamshoro Thermal Power Station in Pakistan. It discusses the importance of practical training and familiarizing with real-world industrial scenarios. It also briefly outlines the various processes involved in power generation including steam generation, turbine generation, synchronization, and control and instrumentation. The report aims to cover all aspects of the power plant in detail to gain experience in electrical, mechanical, chemical and control/instrumentation departments.
This lab manual document provides instructions for experiments on heat transfer in a Mechanical Engineering department. The first experiment listed is on heat transfer from a pin-fin apparatus. The objective is to calculate the heat transfer coefficient for natural and forced convection from a fin. The experiment involves measuring temperatures along a brass fin heated at one end while air passes over it naturally or in a duct. The second experiment listed is on heat transfer through a composite wall, and involves determining the total thermal resistance and conductivity of a wall made of different slab materials sandwiching a heater.
Hmt lab manual (heat and mass transfer lab manual)Awais Ali
This document describes procedures for 7 experiments on heat transfer:
1. Investigates Fourier's Law of heat conduction along a brass bar by measuring temperatures at points along the bar for different heat inputs.
2. Studies heat conduction along a composite bar and calculates the overall heat transfer coefficient.
3. Examines the effect of cross-sectional area changes on temperature profiles in a conductor.
4. Determines temperature profiles and heat transfer rates from radial conduction through a cylinder wall.
5. Measures thermal conductivity of non-metallic materials and compares to theory.
6. Determines thermal conductivity of liquids and gases.
7. Investigates the relationship between power input and surface temperature for free convection
The document provides details about an industrial training project at the Wanakbori Thermal Power Station (WTPS). It includes:
1) An acknowledgment thanking those who facilitated the training.
2) An index outlining the topics to be covered, including details of the boiler, turbine, condenser, coal handling plant, and more.
3) An abstract stating the aim was to study the mechanical instruments involved in power generation and improve practical knowledge.
Boilers have several uses including generating steam to drive turbines for electricity production, and to provide steam for heating, cooling and industrial processes. Boilers can be classified based on their orientation, water and gas flow design, furnace location, circulation method, pressure rating, mobility, and number of tubes. Common boiler types include fire tube boilers like Cochran and Lancashire where gases pass through tubes and water surrounds them, and water tube boilers like Babcock & Wilcox where water passes through tubes and gases surround them. Each boiler type has advantages like efficiency, capacity, and cost, but also limitations regarding pressure, size, and complexity.
NTPC Dadri power plant has an installed capacity of 2642 MW including 1820 MW from thermal units and 817 MW from gas units. It sources coal from Piparwara mine in Jharkhand and water from Upper Ganga Canal. The basic processes include coal handling, combustion in boilers to produce steam, steam passing through turbines to generate electricity, and condensation of steam in condensers. Key components are coal handling plant, boilers, turbines, condensers, cooling towers, ESPs for emissions control, and chimney. Fly ash is a byproduct that is used in construction materials.
A thermal power station converts heat energy into electrical power by boiling water to produce steam that spins turbines connected to electrical generators. Water is heated in a boiler, turning it into high-pressure steam that drives the turbine, which turns a generator to produce electricity. After passing through the turbine, the steam is condensed back into water and recycled to be heated again in a closed loop system. Thermal power stations use various heat sources like coal, natural gas, nuclear reactions or solar thermal to produce the steam.
This document discusses governing systems for turbines. It describes three main governing systems - nozzle governing, throttle governing, and bypass governing. It explains how governing is achieved by varying the amount of steam supplied to the turbine via control valves. Various modes, components, and functions of governing systems are outlined, including constant pressure and variable pressure modes, mechanical and electro-hydraulic transducers, turbine latching, and runback functions. The document also provides details on start-up procedures for a 150MW steam turbine-generator unit.
This experiment aims to determine the relationship between the saturated temperature and pressure of steam in equilibrium with water between 0 and 14 bars using a Marcet boiler. The measured slope of the temperature-pressure graph is compared to theoretical values from steam tables. Results show a direct proportional relationship between temperature and pressure, with the experimental slope deviating slightly from the theoretical slope due to measurement errors ranging from 0.3-44%. The Marcet boiler can be used to study this relationship and various thermodynamic applications that involve changes in steam properties with pressure and temperature.
This document contains 6 exercises related to calculating the thermal efficiency of steam power plants operating on different Rankine cycle configurations including:
1) Ideal Rankine cycle
2) Ideal reheat Rankine cycle
3) Reheat Rankine cycle with specified turbine inlet/exit conditions
4) Regenerative Rankine cycle with one open feedwater heater
5) Reheat-regenerative cycle with one open feedwater heater, one closed feedwater heater, and one reheater.
The 6th exercise asks to determine the fractions of steam extracted from the turbine and the thermal efficiency for a plant operating on the reheat-regenerative cycle described in item 5 above.
1. Supercritical boilers operate above the critical pressure of water (221 bar), where there is no distinction between water and steam.
2. Operating above the critical pressure provides benefits like higher cycle efficiency, lower fuel consumption and emissions, and improved load change flexibility compared to subcritical boilers.
3. The key difference between subcritical and supercritical boilers is that supercritical boilers are drumless, with evaporation occurring in a single pass and flow induced by the feed pump rather than natural circulation.
Thermal Power Plant Simulator, Cold, warm and Hot rolling of Steam TurbineManohar Tatwawadi
The presentation describes the cold rolling, warm rolling and hot rolling and synchronising of steam turbine. The Temperature Matching Chart for Turbine metal and Steam is also discussed in the presentation
Ntpc kahalgaon project by bhanu kishanBHANUKISHAN1
This document provides an overview of a summer training presentation on the National Thermal Power Plant in Kahalgaon, Bihar, India. It discusses the various departments and systems within the power plant, including coal handling, the boiler and its maintenance, the turbine system, and ash handling. The power plant has a total installed capacity of 2340 MW and uses coal from local mines to generate electricity through steam turbines.
The document discusses condensers used in thermal power plants. It describes the functions of a condenser as condensing exhaust steam from turbines to be reused in the steam cycle, creating a vacuum to improve turbine efficiency, and removing non-condensable gases. Key aspects covered include the condenser's role in the Rankine cycle, operation, materials used for tubes, sources of air leakage, methods for detecting water leakage into tubes, and cleaning and testing of condenser tubes.
This document describes the key components and processes involved in a thermal power plant. Water is heated to produce steam, which spins turbines connected to generators to produce electricity. The main components are the boiler, turbines, condenser, cooling tower and auxiliary systems. Coal is pulverized and burned in the boiler to heat water and produce high pressure steam. The steam powers high, intermediate and low pressure turbines in succession to generate electricity before being condensed back into water in the condenser. The water is cooled in the cooling tower and recycled to the boiler to repeat the process.
The document expresses gratitude to various people who helped with a vocational training project at a thermal power plant. It thanks the officials who oversaw the project, the power plant staff who provided assistance, and the author's parents for their support in completing the project successfully.
This document discusses steam turbines, including their working principles and different types. It describes how potential energy from steam is converted to kinetic energy and then mechanical energy in a turbine. There are two main types of turbines - impulse turbines and reaction turbines. Impulse turbines expand steam fully in nozzles before it hits moving blades, while reaction turbines feature continuous expansion over fixed and moving blades. The document also discusses methods of compounding turbines to reduce rotor speed, including velocity, pressure, and pressure-velocity compounding.
Steam turbines use the momentum of steam to generate rotary motion. They are classified based on the mode of steam action (impulse or reaction), steam flow direction (axial or radial), exhaust conditions (condensing or non-condensing), steam pressure (high, medium, low), and number of stages (single or multi-stage). An impulse turbine operates using the impulse of steam jets which impinge on turbine blades, changing the steam's direction and generating force. It consists of nozzles that direct high velocity steam onto blades attached to a circular runner, and a casing that contains these components.
The document provides an overview of the key components and processes involved in a thermal power plant. It discusses the basic principle of converting heat energy from fuel combustion into electrical energy through a steam turbine generator. The main components and processes described include the boiler, steam generation using a Rankine cycle, superheaters, reheater, economizer, turbine, condenser, and feedwater system. Auxiliary components to support combustion and power generation such as mills, fans, precipitators and the ash handling system are also outlined.
This document provides an overview of a practical training seminar presented to the CompuCom Institute of Information Technology & Management Jaipur on NTPC Kahalgaon power station. It discusses the history and setup of NTPC as India's largest power company. The summary describes the three step process of generating electricity through: 1) converting coal to steam, 2) using steam to power turbines for mechanical energy, and 3) generating electricity through power stations and distributing it via transmission lines. Key electrical equipment at the power station like alternators and transformers are also outlined.
Natural draught is produced by a chimney and provides ventilation for boiler systems. The height and diameter of a chimney can be calculated based on factors like flue gas temperature, ambient temperature, and air-fuel ratio. For maximum discharge of hot gases, the flue gas temperature should be slightly higher than ambient temperature. Chimneys provide advantages like no external power requirements but have limitations like low efficiency below 1%. Boiler performance is quantified by equivalent evaporation and efficiency, which allow standardization based on feed water temperature and pressure.
Thermal Engineering is a specialised sub-discipline of Mechanical Engineering that deals exclusively with heat energy and its transfer between not only different mediums, but also into other usable forms of energy. A Thermal Engineer will be armed with the expertise to design systems and process to convert generated energy from various thermal sources into chemical, mechanical or electrical energy depending on the task at hand. Obviously, all Thermal Engineers are experts in all aspects of heat transfer.
Many process plants (basically somewhere where some raw material or resource is converted into something useful, e.g. power plants, oil refineries, plastic manufacturing plants, etc.) contain countless components and systems which have to be designed in terms of their heat transfer; it is particularly important to ensure that not too much heat is retained so the component or process is not disrupted. Conversely, some processes or systems are designed to use heat to their advantage and a Thermal Engineer must make sure enough heat is generated and used wisely (i.e. sustainably).
The document provides details about a case study of a 9.8 MW multi-stage steam turbine at Habib Sugar Mills in Nawabshah, Pakistan. It discusses the turbine specifications and common operational problems observed like rotor vibration and bearing failure. The causes of these problems are investigated like rotor imbalance, bearing misalignment, and excessive steam supply. Remedies are suggested such as regular maintenance, balancing the rotor, proper lubrication, and preventing contamination. The study aims to ensure proper turbine operation and investigate causes of failures to recommend solutions.
The document provides an overview of thermal power generation. It discusses the need for thermal power, the basic working principles, and classifications by fuel and prime mover. The key steps in the thermal power generation process include heating water to create steam, using the steam to power a turbine connected to a generator to produce electricity, and then condensing the steam to be reused. Thermal power plants have advantages of using widely available fuels but have lower efficiency and higher emissions than other generation methods. Improving plant efficiency and reducing emissions are important areas of ongoing research and development.
This document is a seminar report submitted by Mukesh Kumar for partial fulfillment of a Bachelor of Technology degree in Mechanical Engineering. It discusses thermal power plants, including an overview of their operation and efficiency, descriptions of typical components like boilers and steam cycles, and examples of power plants located in India with a focus on those in Rajasthan. The document received certification from internal and external examiners for Mukesh Kumar's seminar work on the topic of thermal power plants.
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
The papers for publication in The International Journal of Engineering& Science are selected through rigorous peer reviews to ensure originality, timeliness, relevance, and readability.
The document provides information about an in-plant training conducted by Bhargav Kumar Tripathy at BPCL Kochi Refinery from 6 July 2015 to 17 July 2015. It includes details about the refinery such as its history, capacity expansions over time, products produced, and departments within the refinery like the Power and Utility section. The Power and Utility section oversees power generation, distribution and utilities operation at the refinery. It discusses the captive power plant that generates and distributes power to meet the refinery's needs.
A thermal power station converts heat energy into electrical power by boiling water to produce steam that spins turbines connected to electrical generators. Water is heated in a boiler, turning it into high-pressure steam that drives the turbine, which turns a generator to produce electricity. After passing through the turbine, the steam is condensed back into water and recycled to be heated again in a closed loop system. Thermal power stations use various heat sources like coal, natural gas, nuclear reactions or solar thermal to produce the steam.
This document discusses governing systems for turbines. It describes three main governing systems - nozzle governing, throttle governing, and bypass governing. It explains how governing is achieved by varying the amount of steam supplied to the turbine via control valves. Various modes, components, and functions of governing systems are outlined, including constant pressure and variable pressure modes, mechanical and electro-hydraulic transducers, turbine latching, and runback functions. The document also provides details on start-up procedures for a 150MW steam turbine-generator unit.
This experiment aims to determine the relationship between the saturated temperature and pressure of steam in equilibrium with water between 0 and 14 bars using a Marcet boiler. The measured slope of the temperature-pressure graph is compared to theoretical values from steam tables. Results show a direct proportional relationship between temperature and pressure, with the experimental slope deviating slightly from the theoretical slope due to measurement errors ranging from 0.3-44%. The Marcet boiler can be used to study this relationship and various thermodynamic applications that involve changes in steam properties with pressure and temperature.
This document contains 6 exercises related to calculating the thermal efficiency of steam power plants operating on different Rankine cycle configurations including:
1) Ideal Rankine cycle
2) Ideal reheat Rankine cycle
3) Reheat Rankine cycle with specified turbine inlet/exit conditions
4) Regenerative Rankine cycle with one open feedwater heater
5) Reheat-regenerative cycle with one open feedwater heater, one closed feedwater heater, and one reheater.
The 6th exercise asks to determine the fractions of steam extracted from the turbine and the thermal efficiency for a plant operating on the reheat-regenerative cycle described in item 5 above.
1. Supercritical boilers operate above the critical pressure of water (221 bar), where there is no distinction between water and steam.
2. Operating above the critical pressure provides benefits like higher cycle efficiency, lower fuel consumption and emissions, and improved load change flexibility compared to subcritical boilers.
3. The key difference between subcritical and supercritical boilers is that supercritical boilers are drumless, with evaporation occurring in a single pass and flow induced by the feed pump rather than natural circulation.
Thermal Power Plant Simulator, Cold, warm and Hot rolling of Steam TurbineManohar Tatwawadi
The presentation describes the cold rolling, warm rolling and hot rolling and synchronising of steam turbine. The Temperature Matching Chart for Turbine metal and Steam is also discussed in the presentation
Ntpc kahalgaon project by bhanu kishanBHANUKISHAN1
This document provides an overview of a summer training presentation on the National Thermal Power Plant in Kahalgaon, Bihar, India. It discusses the various departments and systems within the power plant, including coal handling, the boiler and its maintenance, the turbine system, and ash handling. The power plant has a total installed capacity of 2340 MW and uses coal from local mines to generate electricity through steam turbines.
The document discusses condensers used in thermal power plants. It describes the functions of a condenser as condensing exhaust steam from turbines to be reused in the steam cycle, creating a vacuum to improve turbine efficiency, and removing non-condensable gases. Key aspects covered include the condenser's role in the Rankine cycle, operation, materials used for tubes, sources of air leakage, methods for detecting water leakage into tubes, and cleaning and testing of condenser tubes.
This document describes the key components and processes involved in a thermal power plant. Water is heated to produce steam, which spins turbines connected to generators to produce electricity. The main components are the boiler, turbines, condenser, cooling tower and auxiliary systems. Coal is pulverized and burned in the boiler to heat water and produce high pressure steam. The steam powers high, intermediate and low pressure turbines in succession to generate electricity before being condensed back into water in the condenser. The water is cooled in the cooling tower and recycled to the boiler to repeat the process.
The document expresses gratitude to various people who helped with a vocational training project at a thermal power plant. It thanks the officials who oversaw the project, the power plant staff who provided assistance, and the author's parents for their support in completing the project successfully.
This document discusses steam turbines, including their working principles and different types. It describes how potential energy from steam is converted to kinetic energy and then mechanical energy in a turbine. There are two main types of turbines - impulse turbines and reaction turbines. Impulse turbines expand steam fully in nozzles before it hits moving blades, while reaction turbines feature continuous expansion over fixed and moving blades. The document also discusses methods of compounding turbines to reduce rotor speed, including velocity, pressure, and pressure-velocity compounding.
Steam turbines use the momentum of steam to generate rotary motion. They are classified based on the mode of steam action (impulse or reaction), steam flow direction (axial or radial), exhaust conditions (condensing or non-condensing), steam pressure (high, medium, low), and number of stages (single or multi-stage). An impulse turbine operates using the impulse of steam jets which impinge on turbine blades, changing the steam's direction and generating force. It consists of nozzles that direct high velocity steam onto blades attached to a circular runner, and a casing that contains these components.
The document provides an overview of the key components and processes involved in a thermal power plant. It discusses the basic principle of converting heat energy from fuel combustion into electrical energy through a steam turbine generator. The main components and processes described include the boiler, steam generation using a Rankine cycle, superheaters, reheater, economizer, turbine, condenser, and feedwater system. Auxiliary components to support combustion and power generation such as mills, fans, precipitators and the ash handling system are also outlined.
This document provides an overview of a practical training seminar presented to the CompuCom Institute of Information Technology & Management Jaipur on NTPC Kahalgaon power station. It discusses the history and setup of NTPC as India's largest power company. The summary describes the three step process of generating electricity through: 1) converting coal to steam, 2) using steam to power turbines for mechanical energy, and 3) generating electricity through power stations and distributing it via transmission lines. Key electrical equipment at the power station like alternators and transformers are also outlined.
Natural draught is produced by a chimney and provides ventilation for boiler systems. The height and diameter of a chimney can be calculated based on factors like flue gas temperature, ambient temperature, and air-fuel ratio. For maximum discharge of hot gases, the flue gas temperature should be slightly higher than ambient temperature. Chimneys provide advantages like no external power requirements but have limitations like low efficiency below 1%. Boiler performance is quantified by equivalent evaporation and efficiency, which allow standardization based on feed water temperature and pressure.
Thermal Engineering is a specialised sub-discipline of Mechanical Engineering that deals exclusively with heat energy and its transfer between not only different mediums, but also into other usable forms of energy. A Thermal Engineer will be armed with the expertise to design systems and process to convert generated energy from various thermal sources into chemical, mechanical or electrical energy depending on the task at hand. Obviously, all Thermal Engineers are experts in all aspects of heat transfer.
Many process plants (basically somewhere where some raw material or resource is converted into something useful, e.g. power plants, oil refineries, plastic manufacturing plants, etc.) contain countless components and systems which have to be designed in terms of their heat transfer; it is particularly important to ensure that not too much heat is retained so the component or process is not disrupted. Conversely, some processes or systems are designed to use heat to their advantage and a Thermal Engineer must make sure enough heat is generated and used wisely (i.e. sustainably).
The document provides details about a case study of a 9.8 MW multi-stage steam turbine at Habib Sugar Mills in Nawabshah, Pakistan. It discusses the turbine specifications and common operational problems observed like rotor vibration and bearing failure. The causes of these problems are investigated like rotor imbalance, bearing misalignment, and excessive steam supply. Remedies are suggested such as regular maintenance, balancing the rotor, proper lubrication, and preventing contamination. The study aims to ensure proper turbine operation and investigate causes of failures to recommend solutions.
The document provides an overview of thermal power generation. It discusses the need for thermal power, the basic working principles, and classifications by fuel and prime mover. The key steps in the thermal power generation process include heating water to create steam, using the steam to power a turbine connected to a generator to produce electricity, and then condensing the steam to be reused. Thermal power plants have advantages of using widely available fuels but have lower efficiency and higher emissions than other generation methods. Improving plant efficiency and reducing emissions are important areas of ongoing research and development.
This document is a seminar report submitted by Mukesh Kumar for partial fulfillment of a Bachelor of Technology degree in Mechanical Engineering. It discusses thermal power plants, including an overview of their operation and efficiency, descriptions of typical components like boilers and steam cycles, and examples of power plants located in India with a focus on those in Rajasthan. The document received certification from internal and external examiners for Mukesh Kumar's seminar work on the topic of thermal power plants.
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
The papers for publication in The International Journal of Engineering& Science are selected through rigorous peer reviews to ensure originality, timeliness, relevance, and readability.
The document provides information about an in-plant training conducted by Bhargav Kumar Tripathy at BPCL Kochi Refinery from 6 July 2015 to 17 July 2015. It includes details about the refinery such as its history, capacity expansions over time, products produced, and departments within the refinery like the Power and Utility section. The Power and Utility section oversees power generation, distribution and utilities operation at the refinery. It discusses the captive power plant that generates and distributes power to meet the refinery's needs.
The document provides information about the Dholpur Combined Cycle Power Plant (DCCPP) in Dholpur, India. It was set up due to the availability of land, water, transmission network and proximity to transportation. The total cost was 1155 crore rupees. The main equipment was supplied by BHEL and the fuel is R-LNG supplied by GAIL. It uses a combined cycle configuration where waste heat from the gas turbine powers a steam turbine, achieving higher efficiency. The plant uses natural gas to run both a gas turbine and steam turbine.
The document summarizes the internship experience of Samman sammi at KAPCO, which has a combined cycle power plant. Key details include:
- KAPCO has 10 gas turbines, 10 heat recovery steam generators (HRSGs), and 5 steam turbines paired with gas turbines, following an efficient energy model.
- The auxiliary systems and coordination between the main units and staff make KAPCO highly efficient.
- The internship provided valuable learning about the basics of combined cycle power plants.
CLEAN COAL TECHNOLOGIES, CHALLENGES AND FUTURE SCOPEIAEME Publication
Clean Coal Technologies (CCT) are technological developments that lead to efficient combustion of coal with reduced emissions. It is achieved through combustion or gasification. A combination of clean coal technologies is necessary to achieve maximum power with enhanced energy conversion. The efficiency and quality of the power generation depends upon the coal content. Clean coal technologies, challenges and the future scope are summarized in this paper.
The document is a report on an industrial training at a Gas Turbine Power Station (GTPS) in Vijjeswaram. It discusses electricity production in India and provides an introduction to GTPS. It then explains how electricity is produced through gas using simple and combined power cycles. Combined cycle power plants use both gas turbines and heat recovery steam generators (HRSGs) to achieve higher efficiency. GTPS uses the combined cycle process, with exhaust from gas turbines used to produce steam for the steam turbine. The report also provides overviews of the key components involved - gas turbines, HRSGs, and steam turbines.
This document provides information about Harsh Kumar's summer training project at the National Thermal Power Corporation (NTPC) Dadri power plant in India. It includes:
- An overview of NTPC as the largest power company in India, operating coal and gas-fired thermal power plants.
- Details of the NTPC Dadri plant, which has both coal and gas-fired units totaling 2,642 MW capacity.
- Descriptions of the key components and processes within a thermal power plant, including the coal handling plant, mills, boilers, turbines and generators.
- An explanation of the basic thermal power plant cycle that converts fuel energy to electrical energy.
The document is a report on a vocational training completed by Debokti Ghosh at the Titagarh Generating Station of CESC Ltd from July 4-16, 2016. It provides an overview of CESC and the Titagarh Generating Station, describing the basic cycles and processes involved in thermal power generation including the coal handling plant, water treatment plant, and boiler operations. The report acknowledges those who assisted and supported the training.
1) Sugarcane is an energy-rich crop containing the energy equivalent of 1 barrel of oil per ton of cane.
2) Cogeneration in sugar mills, the combined production of electricity and steam from bagasse, is an efficient use of the waste that saves 15-40% of energy compared to separate production.
3) Integrating sugar, ethanol, and power production makes the sugar industry more sustainable and profitable by diversifying revenue sources and utilizing byproducts.
RGTPP is located near Ramgarh Town district head quarter, Jaisalmer (Rajasthan), which is largest district of the state. Its installed capacity at about 60 km from is 270 MW. And this plant is located in largest state of India, based on area
There was problem in maintaining desired quality standards in electric supply to Jaisalmer on account of excess losses because of longer transmission lines. To rectify above problem and to utilize available natural gas in this area RGTPP was established in this border district whose existing capacity is 270 MW.
The document provides an overview of the cogeneration plant at the ONGC Hazira Gas Processing Complex in Surat, India. It discusses the objectives and advantages of the cogeneration process, describing how it simultaneously generates electricity and steam. It also outlines the major systems involved like the gas turbines, boilers, heat recovery steam generators, and electrical distribution network. The cogeneration unit is able to generate up to 61.5 MW of power to meet the needs of the gas processing facilities and nearby townships.
A brief study on different Power Generation Units in Pakistan. Progress of Energy Sector 1947 - 2017. Production Capacity and Resources all are compiled in this brief presentation.
This document provides an overview of cogeneration technology. It discusses the basic principles of cogeneration, which involves generating both electricity and heat from a single fuel source. It describes the main types of cogeneration systems, including those using gas turbines, steam turbines, reciprocating engines, and combined cycles. Key components like generators, heat recovery boilers, and transmission systems are also outlined. The document concludes with industrial case studies and discussions of equipment, operations, performance analysis, and control/monitoring at Ugar Sugar Works Ltd.
The document discusses the function and process of thermal power plants. Coal is the most common fuel used in thermal power plants. Coal is burned to heat water and create steam, which spins turbines connected to generators to produce electricity. The steam is then cooled and recycled to repeat the process. Thermal power plants in Pakistan are located in major cities like Karachi, Lahore, and Quetta. A future non-conventional thermal plant is being built in Thar to use local coal reserves through gasification. Key factors for locating thermal plants include availability of fuel, land for operations and disposal of ash byproduct.
The document provides an introduction to the Ramgarh Gas Thermal Power Plant (RGTPP) located in Rajasthan, India. Some key points:
- RGTPP is located near Ramgarh Town, about 60 km from Jaisalmer, Rajasthan. Its initial installed capacity was 270 MW.
- The plant was established to address problems with power supply to Jaisalmer due to long transmission lines and excess losses.
- The plant's capacity was later increased with the addition of two more units - a 75 MW gas turbine and 37.5 MW steam turbine.
- The plant generates power using natural gas supplied via pipeline from oil and gas fields in western Raj
Use of Process Analyzers in Fossil Fuel PlantsIves Equipment
In spite of all efforts concerning energy savings and efficiency, the growing world population and the aspired higher 'standard of living' will lead to a further in- crease of world energy demand. In this context, almost half of the primary energy demand will continue to be covered by solid fuels, particularly by coal, until 2020 and many years beyond.
Energy Management - Biomass Based CogenerationIshan Parekh
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Bagasse based high pressure co-generation in Pakistan
1. International Journal of Engineering Science Invention
ISSN (Online): 2319 – 6734, ISSN (Print): 2319 – 6726
www.ijesi.org ||Volume 5 Issue 3|| March 2016 || PP.62-67
www.ijesi.org 62 | Page
Bagasse based high pressure co-generation in Pakistan
Roman Ahmad
Department of Mechanical Engineering, UET Taxila, Pakistan
Abstract: The paper reports on the assessment of the use of bagasse in sugar industry for high pressure
cogeneration. Study was done on a sugar mill which has recently adopted this technology. This paper
investigates the efficiency of season and off season operation of sugar mill, high pressure cogeneration
technology is much more efficient in bagasse to steam ratio. During seasonal operation CHP efficiency is
76.8% and during offseason its value is 29.9%.Project initial cost is high but payback period is low. It will
encourage other sugar mills in Pakistan for the development of high pressure co-generation system to meet
increasing energy demands in the country.
Keywords: Bagasse Cogeneration, CHP Efficiency, Pakistan, Steam, Sugar Mills
I. INTRODUCTION
Cogeneration, the concept of utilizing the same fuel resource for meeting with the requirements of
both thermal and electrical energy, is gaining wide acceptance and encouragement world over. Cogeneration is
widely practiced in the process Industries and any process industry which employs low pressure steam for the
process has the potential to become a virtual power house. With increasing concern on global warming, the use
of renewable energy, which has the positive effect of not adding to the global warming, is being looked at with
renewed interest. The Cogeneration cycle with its higher cycle efficiency, compared to the power cycles,
ensures that the scarce natural resources are put to better use.
Currently Pakistan has an installed electric generation capacity of about 20,000 MW, with the
demand far exceeding this installed capacity and the access to electricity in Pakistan is about 62%. With a fast-
growing economy and demography, the projection for the demand in 2030 is forecast to be 100,000 MW [1].
This calls for a tremendous growth rate in the power sector. The Government of Pakistan is making all out
efforts to increase the generation capacity by tapping all conventional and non-conventional sources of
electricity generation. Born out of this Government’s initiative to augment the generation through non-
conventional energy sources is the “National Policy for Power Cogeneration by Sugar Industry” promulgated in
January 2008 [2].The Government of Pakistan has recognized that Bagasse based Cogeneration can play a
significant role in the country’s efforts to augment the electricity generation.
Bagasse based cogeneration for power export to grid is considered as a reliable source of getting
grid quality power and hence has been adopted by many countries. Each sugar mill can become a Power
Generation Company to export power to the electricity grid by installation of high pressure boilers and
extraction condensing turbo generators. Cogeneration plants with high pressure boilers and matching turbo
generators, exporting power to grid, have been installed in sugar industries in India, Mauritius, Thailand, Re-
Union Islands, United States, etc.
With the advantages like no transportation of fuel, reduction in transmission losses, eco-friendly
power generation, etc. sugar plants could perform as supplementary power generating companies and make any
country move towards self-reliance in power sector. Sugar Industry in Pakistan is ranked as country’s second
largest agro based industry after textiles. Presently there are about 83 sugar mills in Pakistan producing about
3.5 million Metric Tons of sugar per annum and total crushing capacity 597900TCD, which can produce
approximately 3000 MW during crop season [3].
The subsequent sections of the study highlights the RSML’s Cogeneration project, features of the
plant and equipment, estimate the price at which it could sell its electricity and estimate of the capital cost etc.
The results of this study could then be used by other environmentally conscious companies.
II. RSML’s Background
RSML with the daily crushing capacity of 12,000 MT is one of the bigger mills in the sugar
industry. Before the use of high pressure technology RSML produced combined heat and power from three 240
TPH boilers with operating parameters of 23 bar and 350C.All three boilers have power dumping grate stroker
with pneumatic spreader system for fuel burning having bagasse firing efficiency of 82%.110 TPH steam was
used in process house and the remaining 130 TPH was used for 15 MW power generation using three turbo
generators of capacity 4MW each and one with 6MW generation capacity. This whole power was consumed
within the facility without any export to national grid.
2. Bagasse Based High pressure Co-generation in Pakistan
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III. Bagasse Production
The cane residue, what remains after the juice is squeezed out, is called the bagasse and is an
excellent fuel. Ramzan Sugar Mills Limited (RSML) is a 12,000 TCD sugar plant operating for about 120 days
in a year. The factory has a crushing capacity of about 500 TCH (on 24 hour basis).By considering utilization
factor 90%,the total cane crushed for 120 days is 1296000 Tons. The bagasse generation in the plant is 30% on
cane After a deduction of 1% towards the use of bagacillo (fine bagasse used for enhancing filtration) in the
sugar process and towards losses, a bagasse quantity of 29% on the cane crushed is available for use in the
boilers. So, the total bagasse production is 375840 Tons. Using this bagasse, the company currently generates 60
MW of electricity for 150 days including crushing period of 120 days.
Figure 1: Fuel balance-season operation
IV. Design Fuels for the new Cogeneration Plant
The design and guarantee fuels for the cogeneration plant will be bagasse generated from the sugar
mill and imported coal. The bagasse generated per hour will be 150 TPH. This 150 TPH bagasse will be with 50
% moisture content. Out of the generated bagasse, 5 TPH will be used for meeting the process requirements and
the balance of 145 TPH will be made available for the Cogeneration boilers operation.
The design fuels, namely the bagasse and the imported coal, are with the HHVs of 9311.44 kJ/kg and 23,550.75
kJ/kg respectively. As the plant efficiencies, referred by the Regulatory Authorities are based on the Lower
Calorific Value (LCV) of the fuels, the following gives the calculation of the LCVs from the HHVs for the
design fuels. For solid fuels the HHV and the LCV, in SI units, are related by the following formula:
LCV = HHV – (218.55 * H2% + 24.28 * H20 %)
For Bagasse, LCV = 9311.44 – (218.55*2.895 +24.28*50)
LCV = 7457.09 kJ/kg
For Design Coal, LCV = 23,550.75 – (218.55*3.5+24.28*8.5)
LCV = 22,470.2 kJ/kg
Table 1 gives the ultimate analysis of design bagasse and imported coal (As Fired Basis)
Table 1: Bagasse and Coal Ultimate Analysis
Bagasse Coal
Carbon 23.96% Carbon (wt %) 58.50%
Hydrogen 2.93% Hydrogen (wt %) 3.00%
Oxygen 21.36% Nitrogen (wt %) 0.90%
Moisture 50% Sulfur (wt %) 0.33%
Nitrogen 0.07% Oxygen (wt %) 4.00%
Ash 1.55%
Sulphur 0.15%
Total 100%
HHV 2224kcal/kg
3. Bagasse Based High pressure Co-generation in Pakistan
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V. High pressure Cogeneration design for RSML
The Cogeneration scheme proposed, at REL, envisages two identical units of 30 MW capacity each.
Each unit will be designed with a 155 TPH capacity boiler with the outlet steam parameters of 110 bar (a) and
540 Deg.C, with the feed water inlet temperature of 210 Deg.C. Each of the Turbogenerators will be of 30 MW
nominal capacity and designed with an extraction (with two uncontrolled extractions and one controlled
extraction) condensing turbine. The Cogeneration plant will be designed with all the auxiliaries for the new
boilers and the turbo generators and with all the auxiliary plant and systems like the fuel and ash handling
system, Cooling water system, feed water system, Raw water and DM water system, Instrument air system,
Electrical system for its successful operation. The plant will be capable of meeting all the process steam and
power requirements of RSML's sugar mill's expanded capacity at 12,000 TCD crushing. Operating in
synchronization with the sugar mill and with the national electricity grid and using the bagasse generated in the
sugar mill during the season operation, the Cogeneration plant will export power to the sugar mill and to the
grid. During the off season the sugar mill does not operate but the Cogeneration power plant will operate, in full
power generation mode, on the saved bagasse and / or on coal to export bulk of the power generated to the grid.
The net electrical output of the power plant during the season operation will be 54,364 kW,
considering the auxiliary power consumption of 5300 kW in the Cogeneration plant. However a Cogeneration
plant gives both electrical and thermal energy outputs. The thermal energy output is supplied through the
process steam supplied to the sugar plant. The total process steam supplied to the sugar mill is 205 TPH at the
parameters of 3 bar (a) and 8 bar(a) With thermal energy of 2719.33 kJ and 2779.62 kJ. The fuel supplied for
the operation of both the boilers will be 122.04 TPH of bagasse with LCV value of 7457.09 kJ/kg. The Fuel heat
input to the boilers per hour will be 910.063 GJ /hr.
Figure 2: Power balance-season operation
The Cogeneration plant efficiencies are expressed in many ways. The electric efficiency of the
plant is the plant will be electrical energy generated as a percentage of the total fuel heat input. This is not the
true reflection of the plant efficiency as this omits the thermal energy output from the plant altogether. However
the net electric efficiency of the plant will be 21.51% (54364x3600x1000/910.063E09). This is the efficiency
during the season operation of the Cogeneration plant. Taking into consideration the thermal energy supplied
from the Cogeneration plant, the efficiency, called the Combined Heat and Power (CHP) Efficiency can be
calculated as
The net electric power : 54,364 kW: 195.71 GJ/hr.
Heat energy supplied to Sugar process : 585.26 GJ/hr
Heat Energy returned to Cogeneration plant : 81.62 GJ/hr
Net Thermal Energy Supplied :( 585.26-81.62) per Hour : 503.64 GJ.
CHP Efficiency: ((195.71+503.64)/910.063)x100 : 76.85%
During the off-season operation there will be no requirement of process steam for the sugar mill and
hence there will be no thermal energy output from the plant to the sugar mill. The Cogeneration plant will
supply electric power to the sugar mill for the maintenance work of the sugar mill and also for meeting with the
requirements of the colony and the offices. The power export to the grid will be 52,000 kW. The fuel supplied
for the operation of both the boilers, under bagasse and coal firing will be 94.26 TPH and 32.42 TPH. The Fuel
heat input to the Cogeneration power plant, based on LCV of bagasse and coal, per hour of off-season operation
will be 702.903 GJ/hr and 728.48 GJ/hr. The net electric efficiency of the plant, based on LCV, under bagasse
firing will be 28.02% (54,700 x 3600 x 1000/702.903E06). The net electric efficiency of the plant, based on
LCV under coal firing will be 27.03% (54,700x3600x1000/728.487E06).
4. Bagasse Based High pressure Co-generation in Pakistan
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Figure 3: Power balance-off season operation
Under the off-season operation also, the CHP efficiency is applicable, as the plant will be supplying
5 TPH of 8 bar (a) steam to the Dairy unit attached with sugar mill. The respective CHP efficiencies under
bagasse and coal firing will be 29.99% under bagasse firing and 28.94% under coal firing.
VI. ON Season Operation and Off Season Operation
According to system readings during sugar mill season operation, bagasse consumed by each
Boiler is 61.02 TPH and Steam produced by each Boiler is 155 TPH, so 1TPH bagasse produces 2.54 TPH
steam.310 TPH steam from two boilers produces59.6MWh. Hence 1 MWh is generated by 5.2 TPH steam.
From above results 1 MW production requires approximately 2.045 TPH of Bagasse, by taking 3000PKR per
ton of bagasse we get per unit fuel price of 6.1pkr during on season. Total generation during sugar mill season
operation is 59.664 MW with Sugar Mill, dairy and auxiliary loads 13 MW, 2MW, 5.3MW respectively. Hence
the total power exported to grid is 39.364 MW. Since the cogeneration unit also exports power to sugar mill and
dairy so, Total Exportable Power is 54.364 MW. The total exportable units with 90 % capacity utilization and
120 days 24 hr operation comes out to be 14, 09, 11,488 KWh.
Figure 4: Cogeneration scheme-season operation
During off season bagasse consumed by each Boiler is 47.13 TPH and Steam produced by each
Boiler is 118.3 TPH, so 1TPH bagasse produces 2.51 TPH steam.236.6 TPH steam from two boilers produces
60 MWh. Hence 1 MWh is generated by 3.9 TPH steam. From above results 1 MW production requires
approximately 1.57 TPH of Bagasse, by taking 3000PKR per ton of bagasse we get per unit fuel price of 4.7
PKR during off season.
5. Bagasse Based High pressure Co-generation in Pakistan
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Figure 5: Cogeneration scheme-Off season operation
After 120 days of season operation plant will run for 29 more days on saved bagasse, with a target of
total 180 operational days we have to buy bagasse for remaining 31 days or it will run on imported coal by
mixing it with saved bagasse. Total generation durind sugar mill off season operation is 60 MW with Sugar
Mill, dairy and auxiliary loads 1 MW, 2MW, 5.3MW respectively.Hence the total power exported to grid is 51.7
MW.Since the cogeneration unit also exports power to sugar mill and dairy so, Total Exportable Power is 54.7
MW.The total exportable units with 90 % capacity utilization and 120 days 24 hr operation comes out to be 7,
87, 68,000KWh.
VII. Assessment of Cogeneration system
Overall Plant Performance using single unit of boiler and turbine [4]
a. Overall Plant Heat Rate (kCal/kWh)
[Ms× (hs-hw)]/Power output (kW) = [155000× (826.15-215.13)]/30000=3156kcal/kwh
Where,
Ms = Mass Flow Rate of Steam (kg/hr)
hs = Enthalpy of Steam (kCal/kg)
hw = Enthalpy of Feed Water (kCal/kg)
b. Overall Plant Fuel Rate (kg/kWh)
Fuel consumption (kg/hr)/power output (kW) =59400/30000=1.99 kg/kwh
VIII. Total Project Cost
This section gives the project cost for the proposed Cogeneration power plant. Table 2 gives the
details of the costs for the civil, mechanical and electrical works. These costs included in the Table cover the
complete civil, mechanical and electrical works of the complete Cogeneration plant. The costs include the
equipment design, procurement, manufacturing, supply and the erection and commissioning of the complete
plant. No taxes and duties are included in the costs.
The estimated cost of Civil works is US$ 5.5.00 Million
The estimated Cost of Mechanical works is US$ 30.00 Million
The estimated cost of electrical & instrumentation works US$ 7.00 Million
Total Works Cost US$ 42.5.00 Million
Table 2: Total project cost
Serial
No.
Description Total Cost in Million USD
1 Project works cost 42.5
2 Contingency @ 5% 2.10
3 O & M mobilization cost 0.3
4 Fuels for commissioning and Testing Cost 0.25
5 Development & Pre-operative cost 2.5
6 Cost of insurance during construction 0.4
7 Land cost 0.05
8 Financing Charges 0.5
9 Interest during construction 0.2
6. Bagasse Based High pressure Co-generation in Pakistan
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IX. Expanses and Profit
The RSML’s cogeneration project life is 25 years. During operation there are two types of expanses,
fixed Operation & Maintenance cost and other one is variable Operation & Maintenance cost. The project tariff
is set on the basis of fuel cost, fixed & variable O&M cost, working capital, insurance, and return on equity,
loan repayment and interest. Considering all these factors and taking payback period of five years, the tariff rate
is decided to be 10.50 PKR for 180 days operation.
X. Conclusion
The paper is written to encourage other sugar mills in Pakistan for the development of high pressure
cogeneration system adopted by RSML, Pakistan to meet increasing energy demands in the country. The
crushing capacity of RSML is 10,000 TCD and this could be achieved through 24 hours of operation of the
plant. RSML had adequate steam and power generation capacities for meeting the total steam and power
requirements of the sugar plant.. The boilers used in past were with the steam parameters of 24 bar (a) and 350
deg.C, which was on the lower side compared to the modern day sugar mill boilers. The total aggregate steam
generation capacity in the sugar mill was 240 TPH. Although these boilers were not very old, the fuel
consumption in the boilers was quite high with the steam to fuel ratio of about 2. Even though the fuel was
generated in-house, considering the fuel value of bagasse and realizing the available potentials for the better
utilization of bagasse, the above consumption in the boilers was quite high and the operation was inefficient
compared to modern day standards. All the existing turbo generators in the plant operated with an inlet steam
parameters of around 21 bar (a) and 340 Deg.C. Here again the turbines were of older design and not
comparable to the new generation of turbines with regard to the efficiency.
The sugar Industry, world over, is passing through a difficult period. The sugar prices are low and on the other
hand the cost of the basic raw material which is the sugar cane and the production costs keep increasing. The
sugar industry can hope to come out of this situation only by cutting down the cost of production, by adopting
energy efficient processing, and going in for Cogeneration of Power and for the better utilization of molasses
and bagasse, the by-products from sugar manufacturing.
Under the above scenario, where there is a potential to improve the energy efficiency of the sugar plant by
retiring inefficient boilers and turbo generators, it is prudent for the sugar mills to go in for new high pressure
and high efficiency boilers and matching turbo generators. Such systems, in-addition to generating additional
power for export which improves the bottom line of the sugar mill operations, improves the energy efficiency of
the sugar mill process itself. Although initial cost is high but it is one time investment and the payback period of
project is short which favours its implementation in sugar industry. With the selection of the controlled
extraction cum condensing turbines for such applications, as the extraction steam requirements are very large in
the sugar mill applications, the extraction steam pressure is maintained almost constantly and this helps in larger
vapor production and less use of the exhaust steam in the process.
References
[1] https://en.wikipedia.org/wiki/Electricity_sector_in_Pakistan
[2] http://www.ppib.gov.pk/Co-Generation%20Policy%202008.pdf
[3] http://www.pres.org.pk/2013/3000-mw-electricity-can-be-generated-from-83-sugar-mills/
[4] Yunus A. C and Michael A. B. (1994).Thermodynamics: an Engineering Approach second Edition; McGraw Hill. New York
[5] Hugot E. (1986). Handbook of Cane engineering, third edition, Elsevier Science Publishers, New York, April1986
[6] Bagasse-based co-generation at Hippo Valley Estates sugar factory in Zimbabwe, Journal of Energy in Southern Africa, Vol
23 No 1, February 2012