Steam Turbines and Cog en Era Ti On

8/8/2019 Steam Turbines and Cog en Era Ti On

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Steam Turbines and CogenerationSteam Turbines and CogenerationCyrus Engineer

Director

D. P. Roy

Executive Director


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Cut Costs?

How

?


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Fixed Deposit 8%

Property in Gurgaon ! 70%

Power thru Cogeneration 80%

Plus Depreciation Benefits of 80%

CO-GENERATION 160%

Return on InvestmentReturn on Investment


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Why is Co-Generation so Attractive?As the word CO-GEN goes, it signifies two SeparateGenerations,

co-existing at the same time.

Steam is a basic need of the Process industry.

Generating it at Higher pressure adds just 5 to 20% on the FuelCosts, but Premium Energy (Power) is produced.

5000 Kcal of Coal costs Rs 4.50

5000 Kcal of Electricity costs Rs.26.00

A common misnomer is that energy is being produced.Cogeneration does not produce energy, it merely converts Heatto Electrical energy. Therefore, higher the Energy (Superheat)within the steam, more the power.


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NEED FOR CONEED FOR CO--GENERATIONGENERATION GRID POWER (SEB) COST HAS GONE UP.

UNCERTAIN AND UNRELIABLE POWERAVAILABILITY.

HEAVY DEMAND CHARGES PAYMENT INSPITE OFLOAD SHEDDING.

HIGH MAINTAINANCE AND RUNNING COSTS OFD.G. SETS.

HEAVY COMPETITION IN INDUSTRY LEADING TOLOWER REALISATIONS AND PROFITABILITY

HELPS CONSERVE OUR ENVIROMENT


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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 SELECTIONTURBO GENSET SELECTION

FACTORSFACTORS

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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SELECTION OFSELECTION OF

GENERATION MODEGENERATION MODE

STAND ALONEISLAND SYSTEM SYNCHRONISEDGENERATIONIDEAL SYSTEM WHERE STEAM AND POWERLOADS ARE CONSTANT. POWER SPURTSFLUCTUATION MAY NEED STEAM VENTING.

THE ONLY SUCCESSFUL SYSTEM ONFLUCTUATION STEAM AND POWER LOADS

THE SYSTEM IS SUITABLE WHERE POWERREQUIRED IS LESS THAN OR EQUAL TOCOGENERATED POWER

WHENEVER POWER DEMAND FAREXCEEDS COGEN POSSIBILITY

WILL OPERATE EVEN WHEN POWER FROM

SEB FAILS

NEEDS SYNCHRONISATION FROM SEB OR

D.G. SET TO OPERATE. TRIPS WHEN GRIDPOWER FAILS.


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VARIATION OF POWER OUTPUTVARIATION OF POWER OUTPUT

WITH CHANGE IN BACK PRESSUREWITH CHANGE IN BACK PRESSURE

TECHNICAL

PARAMETERS

BACK

PRESSURE3 Kg/cm2 (g)

BACK


BACK


Turbine Inputconditions

10 TPH

33 Kg/cm2

g)

10 TPH

33 Kg/cm2

g)

10 TPH

33 Kg/cm2

g)

Process SteamPressure

(Back Pressure)

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

Power outputfrom turbine

600 KW 540 KW 500 KW


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VARIATION OF POWER OUTPUT WITHVARIATION OF POWER OUTPUT WITH

CHANGE IN INLET STEAM CONDITIONSCHANGE IN INLET STEAM CONDITIONS

TECHNICAL

PARAMETERS

6 TPH

9 Kg/cm2(g)

6 TPH

21 Kg/cm2(g)

6 TPH

21 Kg/cm2 (g)

6 TPH

33 Kg/cm2(g)

SteamTemperature

2500C

3 Kg/cm2 (g)

145 KW

Dry - 1900C

Saturated 3300C 3500C


(Back Pressure)

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

Power output

from turbine

220 KW 300 KW 340 KW

Quality ofexhaust Steam

7 % Wet Dry - 2100C Dry - 2100C


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VARIATION OF POWER OUTPUT WITHVARIATION OF POWER OUTPUT WITH

CHANGE IN INLET STEAM CONDITIONSCHANGE IN INLET STEAM CONDITIONS

TECHNICAL

PARAMETERS

20 TPH

32 Kg/cm2

(g)

20 TPH

42 Kg/cm2

(g)

6 TPH

63 Kg/cm2

(g)

SteamTemperature

3500C

3 Kg/cm2 (g)

1645 KW

4200C 4800C


(Back Pressure)

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

Power output fromturbine

2060 KW 2630 KW


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THUMB RULE ON BACK PRESSURETHUMB RULE ON BACK PRESSURE

Use Lowest Possible Back Pressure !

It saves you a lot on Installation and Fuelcosts.

When it comes to Power Produced,

Increasing Back Pressure by 1 Kg/cm2 is the

equivalent of increasing Boiler Steampressure by about 6 Kg/cm2


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ADVANTAGES WHEN

PURCHASING FROMCOGEN PACKAGE

SUPPLIERS

1. One point source for both systems

2. Proper System integration with Process

3. One Point Guarantee and Responsibility.

4. Complete Steam piping design.

5. Electrification and Grid Synchronisationassistance.

6. One Point for Boiler and Turbine Service.


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Case Study Newsprint Paper MillDamanganga Paper Mills

A single machine produces 140 Tons of Newsprint per day.

A Boiler of 12 Ton at 21 Kg pressure operates on Plastic and otherwastes (With proper Flue Gas Scrubbing Plant)

The turbine produces 9000 units on an average per day on a steam load

of 200 Tons/day.

Back pressure is maintained at 2.5 to 3 Kg.

Power is generated at 80 paise per unit compared to Grid power at Rs.

5.20 per unit.

Therefore the saving is Rs.39,000 per day.

In operation for the last 15 months, it has saved Damanganga Paper Millsover Rs. 1.75 Crores till date.


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Damanganga Paper MillTurbine Installation


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Case Study Best Paper Mills, Vapi.

A single machine produces 80 Tons of Kraft Paper per day.

A Boiler of 12 Ton at 32 Kg pressure operates on Coal

The turbine produces 8000 units on an average per day on a steamload of 160 Tons/day.


Power is generated at 1.40 paise per unit compared to Grid powerat Rs. 5.20 per unit.

Therefore the saving is Rs.30,000 per day.

In operation for the last 12 months, it has saved Best Paper Millsover Rs. One Crore till date.


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Best Paper MillInstallation Photos


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Case Study TextilesSangam Processors, Bhilwara

The unit processes Synthetic Cloth (Suitings)

The connected machinery includes 40 Jiggers, 11 Jet Dyeing, 3 OpenDecadising, 3 Rotary machines, 4 Drying ranges, KD, Zero-Zero, SuperFinish and Hydrolic Jigger.

The turbine produces 7000 units on an average per day on a steam loadof 1,35,000 Kg/day.


The Boiler consumes 41 Tons of Lignite or 24 Tons of imported Coal perday.

Power is generated at Rs. 1.50 per unit. Therefore the saving isRs.21,000 per day.

In operation for the last 16 months, it has saved Sangam Processorsover a Rs. One Crore till date.

S P Bhil


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Sangam Processors, BhilwaraInstallation Photos

Case Study Calcium Carbonate


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Case Study Calcium CarbonateSagar Lime Chem, Saharanpur

There are 6 Drying Cylinders which consume steam at 2 Kg pressure.

There is no electrical connection with the Grid. The entire power load of 300 Amps is met by the steam turbine.

The turbine produces 4500 units on an average per day on a steam loadof 72 Tons/day.

Back pressure is maintained at 2 to 2.5 Kg.

Power is generated at Rs. 1.50 per unit.

Therefore the saving on Grid Power is Rs.15,000 per day or Rs. 50

Lacs per year.

In UP there is very poor availability of Power and most units operate DGSets, where power generation cost Rs. 10 per unit. In such case thesavings would be Rs. 38000 per day or Rs. 1.3 Crores per year.

The additional investment for cogeneration was just 50 Lacs!


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Sagar Lime Chem, Saharanpur

Installation Photos

Case Study Rice Mill


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Case Study Rice MillGiriraj Rice Mill, Burdwan

The plant processes 200 Tons of Paddy per day.

IBL modified the Plant to suit the Cogen system.

There is no electrical connection with the Grid.Power load of 380 KW is met by the Back Pressure Steam turbine.A 500 KW condensing Turbine meets the requirement of the Cold Store.

The Back pressure turbine produces 8500 units on an average per day on asteam load of 190 Tons/day. Back Pressure Turbine Power is generated at80 paise per unit.

The condensing Turbine Produces 8000 units at Rs. 3.50 per Unit

The average cost of Power is just Rs 2.10 per unit.

Therefore the saving on Grid Power is Rs.40,000 per day or Rs. 120 Lacs

per year.

The additional investment for Turbo Generation was Rs. 190 Lacs


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Giriraj Rice Mill, Burdwan

Installation Photos


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Unique Low Pressure Application

Cochin Kagaz, KeralaCochin Kagaz was

operating a 10 Ton Husk

fired Boiler at 10 Kg/cm2

pressure.

IBL installed a Superheater

and Back PressureTurbine.

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.

How Power Generation cost is calculated


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CO GEN SYSTEM 32 KG LOW PRESS SYS

Process Steam Requirement 7500 Kg/hr 7500 Kg/hr

Process Steam Pressure 3.5 Kg/cm2 10.5 Kg/cm2Cost of Equipment 17000000 Rs. 8500000 Rs.

ECONOMICS OF CO GENERATION

Fuel Consumption with Coal 5000 Kcal/kg 1207 Kg/hr 1085 Kg/hr

Extra Fuel Consumption for Power Generation 123 Kg/hr

Cost of Fuel per Kg 3.50 Rs/KgAdditional Fuel Cost 429 Rs/hr

Additional Fuel Cost per Day 10295 Rs/day

Power Generated at 7.5 TPH Load 420 KW

Extra power for Cogen Boiler 30 KW

Power available to Plant 390 KWPower Produced Per Day 9360 KW/Day

Basic Cost of Power due to Fuel Only 1.10 Rs/Unit

Cost Of SEB Power 4.50 Rs/Unit

Savings in power per unit 3.40 Rs./unit

Savings in power per day 31825 Rs/day

Savings in Power Generated per month 954746 Rs/month

Savings in Power Generated per year 11138707 Rs/year

DIFFERENTIAL COST OF COGEN

PROJECT 8500000 Rs.

Interest Cost @ 12% per day 2795 per day

Interest Cost @ 12% per unit 0.30 Rs./unit

Final Power Cost 1.40 Rs./unit

Payback Period 1 year

How Power Generation cost is calculated


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About

IB Turbo was incubated by Industrial Boilers Ltd. to

cater to the requirement of Small Steam Turbines in2001.

IB Turbo started manufacturing turbines in 2002.

Today, IBT Turbines are in operation in all parts ofIndia as well as in Singapore, Thailand and Vietnam


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IB Turbo Range of Steam Turbines

Model BT 4 & BT - 6

Type Back Pressure Single Stage. Operating range 100 to 800 KW

Inlet Pressure 8.5 Kg/cm2 to 37 Kg/cm2

Inlet Steam temp. range Saturated at 99% Dryness to 3800C

Back Pressure 1.1 Ata to 5 Kg/cm2

Power Outputs available

Induction Generation

Alternator Based Synchronised Generation

Alternator Based Stand Alone

Status 100 Turbines in Operation


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Model MBT 6

Type Bleed + Back PressureTurbine Operating range 1 to 3 MW

Inlet Pressure 33 Kg/cm2 to 63 Kg/cm2 Inlet Steam temp. Superheated 300 - 4800C Back Pressure Upto 9 Kg/cm2

Model BCT 6


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Model BCT 6 Type Bleed + Condensing Turbine Operating range 1 to 3 MW Inlet Pressure 8.5 Kg/cm2 to 63 Kg/cm2

Inlet Steam temp. Superheated 300 - 4500C Back Pressure 1.1 Ata to 9 Kg/cm2

Power Outputs available Alternator Based Stand AloneAlternator Based Grid Parallel


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Induction Generator with BT- 4 Turbine


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BT- 6 Turbine with Alternator (600 KW)

Ashoka Distillery, Hatim

AGROPAK-TD


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AGROPAK TDThe Power Generation

High Pressure FBC Boiler

Built-in Superheater Choice of Fuel Feeding Systems

- In Bed for Coal, Lignite, Saw Dust.

- Over Bed for Rice Husk.

Bio Gas Compatible. Microprocessor Controlled Fuel Feeder

Water cooled, Suvega Tube Waterwall.

Packaged Concept, Minimum welding atInstallation site. No Expansion of tubes

Steady Steam Pressure and Temperature forcritical turbine applications.

Loaded with high efficiency drum internals.


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BI-DRUM

The Power GenerationHigh Pressure FBC Boiler

High Efficiency Boiler.

Built-in Superheater

Choice of Fuel Feeding Systems

- In Bed for Coal, Lignite, Saw Dust.- Over Bed for Rice Husk.

Bio Gas Compatible.

Microprocessor Controlled Fuel Feeder

Loaded with high efficiency drum internals.


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Round the year availability

Low Cost of Fuel

Ease of Operation

Less Pollution Less Labour Requirement

Low Power Consumption

Essentials for selection of Boiler fuelsFuels appropriate for

Cogeneration in Indian Context

Coal

Lignite

BagasseSaw Dust

Rice Husk

Natural GasAgro Residues

Industrial wastes

H h d i


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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.


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Successful Industrial ApplicationsSynchronised Generation

Paper

Textiles Food Processing Breweries

Malt

Stand Alone Generation Distilleries Rice Calcium Carbonate Solvent extraction


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WORLDWIDE SUPPORTUSA (Sold as Moss Boilers)Belgium (Sold as BIC)Malaysia (Sold as Visdamax)

ThailandKenyaNepalSri Lanka

TurkeyAustraliaBangladeshMyanmar


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NATIONWIDE SUPPORTIBL OFFICES AND REPRESENTATIVESMUMBAI

VAPINEW DELHIKOLKATTACHENNAI

HYDERABADAHMEDABADSURATBHARUCH

PANIPATAMRITSARINDOREBHILWARA

PALI


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Documents

Steam Turbines and Cog en Era Ti On