This document discusses cogeneration and improving energy efficiency in sugar mills. It provides information on: 1) Cogeneration involves the combined production of electrical power and useful thermal energy from a common fuel source. This allows for better utilization of resources and independence in power and steam. 2) Major advantages of cogeneration include lower production costs, quick return on investment, and ability to use biomass fuels. It also provides a solution to power problems when hydropower availability is low. 3) Case studies show potential energy savings through retrofitting with high-pressure boilers, improving control systems, reducing downtime, and acquiring best available technologies for new projects.

1. High Pressure and efficient Boilers forHigh Pressure and efficient Boilers for
Cogeneration applicationsCogeneration applications
•

2. What is CO-GENERATION?
• This is a combined / integrated System of
production of Electrical power and useful heat by
sequential use of energy from a common fuel source
generally bagasse).
• To generate surplus power
For Best Utilization of resources
. To have Independency in power and steam

3. The Major advantage of Co- GenThe Major advantage of Co- Gen
power is ;-power is ;-
• A-Most techno- commercial viable Projects with short pay back.
• B-Cost of power production is very cheap compare to that of
• purchase power.
• C-Dependability and reliability with quality of power.
• D-Quick return on investments.
• E-Restore ecological imbalance.
• F-Ability to use Bio-Mass and organic matters like wood, grass and
agro wastes and also municipal wastes.
• G-Availability of power between Nov. to May when Hydel power availability
less.
• H-provides ecmomical and timely solution of Power problems.

4. CO-GENERATION in SUGAR MILLS

5. How Cogeneration Saves Energy

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

7. • Better Power Quality
• Improved Reliability and run ability
• Lower Energy Costs
• Reduction CO2 in the environment
• Conserve Natural Resources
• Support Grid Infrastructure
– Fewer T&D Constraints
– Defer Costly Grid Upgrades
– Price Stability
Benefits of cogeneration

8. Steps for conservationSteps for conservation
1.Government of India enforced the1.Government of India enforced the
energy conservation act 2001 with effectenergy conservation act 2001 with effect
from 1.3.2002.from 1.3.2002.
2.The initial phase of 5 years would be2.The initial phase of 5 years would be
implementation of the act .implementation of the act .
3.The act provides mainly for efficient use3.The act provides mainly for efficient use
of energy and its conservation.of energy and its conservation.
4.Industry using4.Industry using

9. Mandatory Requirement of ActMandatory Requirement of Act
• Those unit having connected load of 5000 KWh
are called as ‘ Designated Energy Consumer’.
• As per the act it is mandatory for all designated
Energy Consumers to get Energy Audit
conducted by an Accredited Energy Auditor. And
to designate or appoint an Energy Manager.

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

11. FEASIBILITY STUDY (TYPICAL STEPS)
Energy auditing
Technical Analysis
Inception
Implementation Planning
Financing
Operation and maintenance

12. CASE STUDIESCASE STUDIES
• A-IMPROVEMENT PROJECT By
• I-BY RETROFITTING
• II- -RENOVATION &TECHNOLOGICAL
UPGRADATION
• B-INITIATING NEW PROJECTS

13. RETROFITTINGRETROFITTING
• Replacement of old 18/21Kgs/cm to HP >100bars
boilers
• A-Provision of Better control system.
• B-Efficiency improvement by Automation
• C-Reduction of unaccountable losses by
• providing dust extraction system
• D-Reduction of Boiler & TG down time &
• efficiency improvement by water & steam
• quality control

14. Case StudiesCase Studies
• Introducing New HP Boiler without affecting
Present Existing System

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

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

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

18. ANALYSIS OF PERFORMANCE FOR THE SEASON 2002-2003(MONTH WISE)
S
L
N
O PARTICULARS UOM DEC.02 JAN.03 FEB.03 MAR.03 APL.03 MAY.03 JUNE.03 TOTAL Max Min
%savi
ng
1 Cane Crushed MT 48558.3 128742 134980 140288 127097 128072.4 21860 729598
2 Recovery % 8.05 8.84 10.06 10.66 10.14 8.75 6.68 9.61
3 Sugar Production Qtls 3100 113875 13227.5 14747 13123.3 114975 25397 696220
4 Season Days-Crop Day Days 14 31 28 31 30 31 8 173
5 Season Days-Crushing Day Days 14 27 27 31 29 31 8 167
6 Total Available Hours HRs 332-36 744-00 672-00 744-00 720-00 744-00 192-03 4148-39
7 Total Working Hours HRs 330-51 641-40 636-35 705-45 676-15 692-10 172-28 3855-44
8 Stoppage Hours HRs 1.-45 102-20 35-25 38-15 43-45 51-50 19-35 292-55
a)Want of Cane HRs 0-00 6.-00 0-00 0-00 0-00 0-00 0-00 6.-00
b)Engineering(Mech&Elec) HRs 0-00 5.-00 5.-55 20-45 12.-40 21-35 10.-20 75-45

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

20. % Recovery during 2002-03
8.05 8.84
10.06 10.65 10.14
8.75
6.68
0
2
4
6
8
10
12
Dec Jan Feb Mar Apl May Jun
Recovery

21. %bagasse moisture
27.53 28.82 29.06 29.42 30.19 30.75 31.63
0
5
10
15
20
25
30
35
Dec Jan Feb Mar Apl May Jun
Dec Jan Feb Mar Apl May Jun
%bagassemoisture
Column 7
29
28.6
28.2
27.8
27.4

22. power consumption per ton of cane
crushed
23.61 23.61 23.27 24.69 25.13 25.57
34.3
0
5
10
15
20
25
30
35
40
Dec Jan Feb Mar Apl May Jun
powerconsumedpertonofcane

23. BY Technological Up gradationBY Technological Up gradation
• A-Replacement of old low pressure Boilers to
High pressure to get the benefits
improved cycle efficiency.
• B-Providing Topping up TG Set to optimize
expenses on Electrical system.
• C-Better environments by Providing
• Emission monitoring.

24. Acquire Best Available Technology inAcquire Best Available Technology in
New ProjectsNew Projects
• A-Select Most modern and reliable
• equipments
• B-Design Tailor make System.
• C-Select Flexible System for Better
utilization of resources and Better economy.

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

26. Actual Thermal Efficiency of existing power plantActual Thermal Efficiency of existing power plant
on dateon 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 = ηth = (Net heat value * Total Steam generation) / (CV of
the bagasse * total bagasse consumption)
ηth = (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 485ºC)
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*103
* 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 = ηth = (Net heat value * Total Steam generation) /
(Net GCV * total fuel consumption)
= (702.7 * 129399) * 100 / (2542 * 56213)
ηth = 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 515º C and 105 kg/cm2
)
Then net heat gain = 821.5 – 807.7
= 13.8 Kcal/kg
From data
Budgeted cane crushed/year = 775000 M.T
Actual cane crushed/year = 72598.401 M.T
No. of crop days = 170 days
% Steam required for cane = 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

31. The Major advantage of Co- GenThe Major advantage of Co- Gen
power is ;-power is ;-
• A-Most techno- commercial viable Projects with short pay back.
• B-Cost of power production is very cheap compare to that of purchase
power.
• C-Dependability and reliability with quality of power.
• D-Quick return on investments.
• E-Restore ecological imbalance.
• F-Ability to use Bio-Mass and organic matters like wood, grass and agro
and
• municipal wastes.
• G-Availability of power between Nov. to May when Hydel power availability
• less.
•
Continue---
• H-provides ecmomical and timeluy solution of Power problems.

32. STEPS FOR SAVINGSSTEPS FOR SAVINGS
• !-Saving of Bagasse by adopting high technology HP Boilers
• 2-Reduction of moisture in bagasse 50 to 45% by improving Milling
Technique.
• 3-Reduction in Process steam consumptions in evaporator and Prime
movers
• BLTFF evaporators
• 4- Reduction in live s team consumption by using multi stage reaction
Turbines.
• 5- Reduction in over consumptions of power TCH using new technique of
•
• Variable drives and high efficient auxiliaries.
• 6-improve crushing rate by having quality power