cogen paper-sa.pptx
TRANSCRIPT
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Cogeneration of Steam & Power
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Energy price hikes in India defy age old proverbs !
What goes up never comes down !!
Energy Prices !!!
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The Economics Times
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Return on Investment
Fixed Deposit 8%
Property in Johannesburg! 50%
Power through Cogeneration 80%
Plus Depreciation Benefits of 80%
CO-GENERATION 160%
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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.
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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
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What are the
Options?
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Co-generation Package
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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.
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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.
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Most Industries Use A Pressure Reducing Valve
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Back Pressure Turbine
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Back Pressure Turbine
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Simple Steam Generation in Process Industry
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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.
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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.
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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.
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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
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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.
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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.
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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
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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
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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
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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.
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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.
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Variation Of Power Output With Change In Back Pressure
TECHNICAL PARAMETERS
BACK PRESSURE 3 Kg/cm2 (g)
BACK PRESSURE 4 Kg/cm2 (g)
BACK PRESSURE 5 Kg/cm2 (g)
Turbine Input conditions
10 TPH 33 Kg/cm2 (g)
10 TPH 33 Kg/cm2 (g)
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
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Variation Of Power Output With Change
In Inlet Steam Pressure
TECHNICAL PARAMETERS
10 TPH 21 Kg/cm2(g)
10 TPH 21 Kg/cm2 (g)
10 TPH 33 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
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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
Inlet pressure from 21 Kg/Cm2 - 35
Kg/Cm2
Inlet super heat Minimum +50 C – Maximum 390 C
Outlet pressures from 1.0 Kg/Cm2 - 5
Kg/Cm2
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IB Turbo Range of Steam Turbines
Back Pressure Steam Turbine – MBT - 6
Multi stage 1000 - 10000
KW
Inlet pressure from 33 Kg/Cm2 - 105
Kg/Cm2
Inlet super heat Minimum 35º C –
Maximum 51º C
Outlet pressures from 1.5 Kg/Cm2 - 5
Kg/Cm2
Condensing / Extraction Steam Turbine BCT - 6
Multistage stage 1000 - 10000 KW
Inlet pressure from 33 Kg/Cm2 - 105
Kg/Cm2
Inlet super heat Minimum 350
C – Maximum 510 C
Bleed pressures from 1.5 Kg/Cm2 -12
Kg/Cm2
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COGENERATION
COMBINED HEAT
&
POWER (CHP)
STEAM + POWER
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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
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5872400
567600
1
2
Energy Utilised by Turbine Kcal/Hr - 567 600Energy Available in Back Pressure Kcal/Hr - 2 872 400
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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.
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Induction Generator with BT-4 Turbine
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Alternator with BT-4 Turbine
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A Co-Gen Installation in a Paper Mill
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A Co-Gen Installation in a Textile Mill
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A Turbine Installation in a Distillery
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BT-4 Turbine
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Successful Application
Induction Generator BasedPaperTextilesFood Processing
Alternator BasedDistilleriesRice
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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
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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
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IBL’s Certifications
•ISO 9001:2008
•EUROCERT S.A.
•ASME R, U S & PP Stamps.
•IBR
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Worldwide Support
• South Africa• USA• Myanmar• Kenya• Nepal• Sri Lanka• Malaysia• Thailand• Australia• New Zeeland
IBL has International Offices and
Representatives
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Nationwide SupportIBL Offices And Representatives
Mumbai Vapi New Delhi Kolkata Chennai Hyderabad Bangalore Ahmadabad Surat Bharuch Panipat Amritsar Indore Bhilwara Pali
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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.
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Thank You
VISIT USAT
http://www.indboilers.comhttp://www.ibturbo.com
Technical Director: Rohinton EngineerEmail:[email protected]