Boiler & Power
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Demand Side Management in Sugar Industry by
A.N.Soundararajan E I D Parry [India] Limited Sugar Factory, Pudukottai Tamil Nadu
BACKGROUND The Indian industry is a blend of variety of plants of different vintage, varied technologies, capacities and efficiencies. The industry also had continuously undertaken improvement opportunities wherever possible and increased their productivity. Some of the plants, which have incorporated all the energy conservation aspects, have achieved higher efficiencies and are realising huge benefits. To replicate these efforts and achieve national level improvements there is a need to widely disseminate the information on the major energy potential and conservation projects implemented by sugar industries. Towards achieving the above objective, this paper has been prepared.
SUGAR INDUSTRIES The sugar industry is one of the ancient and still the largest amongst the food processing industries in the world. Sugar is the only processing food available in bulk at the highest purity. India has been the originator of the sugar industry. At present, India is the second largest producers of sugar. India has the largest number of modern sugar mills, nearly 600 in number. The average capacities of the sugar mills are only 2500TCD in India, as against the average capacities of about 10000 TCD in abroad. With the recent liberalisation of the sugar industry and increasing demand for sugar and power, the sugar industry is poised for tremendous growth.
STEAM & POWER IN SUGAR INDUSTRY Sugar industry needs steam and power substantial quantity for cane crushing and the cane juice processing. The sugar cane has 28% to 30% of bagasse and is used for generation of the energy required, for the operation of the sugar mill. The bagasse is fired in the boiler, for producing steam at high pressures, which is extracted through various back-pressure turbines and used in the process. This simultaneous generation of steam and power commonly referred to as co-generation. Sugar industries, in general, are operating with low-pressure steam parameters mainly because of the restriction in usage of electrical energy for their captive use only. The steam parameters have been chosen to match with the process steam requirement and electrical power requirement for captive use. The surplus bagasse generated, was sold to the outside market. The energy content of bagasse is much more than the internal requirement of the plant.
SELECTION OF STEAM GENERATORS & POWER GENERATORS While selecting Boilers and Steam turbine, the steam parameters and operating conditions play an important role. Depending upon the level of technology adopted, various capacities of mills can produce surplus power, shown in the following Charts. With larger mill capacities and high-pressure steam the surplus power increases more than proportional. This huge potential can be further increased, if the steam & power consumption in the different sections of the plant can be minimised through highpressure steam system in sugar process.
Assumptions Bagasse % cane = 27.5 % Steam : Fuel ratio = 2.21 Steam % cane = 40%
Power generation in MW at various Steam pressure in Ata Cane TCD Steam TCH 14 22 32 42 65 85 2500 63.02 3.50 4.31 7.71 9.88 11.00 11.86 3000 75.63 4.20 5.17 9.25 11.86 13.19 14.23 3500 88.23 4.90 6.03 10.79 13.83 15.39 16.60 4000 100.83 5.60 6.89 12.33 15.81 17.59 18.97 4500 113.44 6.30 7.75 13.88 17.79 19.79 21.34 5000 126.04 7.00 8.61 15.42 19.76 21.99 23.71 7500 189.06 10.50 12.92 23.13 29.64 32.99 35.57 10000 252.08 14.00 17.22 30.83 39.53 43.98 47.42
105 12.56 15.07 17.58 20.09 22.60 25.12 37.67 50.23
Specific Steam Consum ption Vs Steam Pressure 20 Sp. Steam Consum p [kg/kW]
18 16 14 12 10
`
8 6 4 2 0 14
22
32
42
65
Steam Pressure [Ata]
Steam Pressure in Ata Sp.steam consumption
14 18
22 15
32 8
42 6
65 6
85 5
105 5
85
105
POTENTIAL FOR SURPLUS POWER
Using high pressure steam and temperature Using extraction cum condensing turbine Elimination of PRDS for steam bleeding
Elimination of steam leakages
POWER CONSUMPTION PER MT OF CANE [From 44 units to 32 units] (Sugar & Cogen)
Fully automated plant
Change to electrical drive in mills Variable frequency drive Change chain conveyor to belt conveyor Planetary gear box Energy conservation measures
Maximise Cane crushing rate
Using Energy Efficient Motors
kW per Tonne of Cane Vs Steam Pressure 140 120
kW
100 80 60 40 20 0 14
22
32
42
65
Steam Pressure [Ata]
Steam Pressure in Ata Kw per Tonne of Cane
14 34
22 41
32 74
42 95
65 106
85 114
105 121
85
105
kW per MT of Bagasse Vs Steam Pressure 500 450 400 350 kW
300 250 200 150 100 50 0 14
22
32
42
65
Steam Pressure [Ata]
Steam Pressure in Ata Kw per MT of Bagasse
14 122
22 150
32 269
42 345
65 384
85 414
105 438
85
105
POTENTIAL FOR INCREASE IN STEAM GENERATION PER MT OF CANE / BAGASSE • High fibre cane • Reduce bagasse moisture • Using HP heater, Economiser and Air pre heater • Increase combustion efficiency • High efficiency boiler • Recycle the unburnt fuel • Automation – combustion control • Using flash steam recovery from Exhaust condensate • Heating the boiler make up water (DM water) using the waste high temperature secondary condensate.
REDUCTION OF STEAM CONSUMPTION PER MT OF CANE [From 52% to 40% on Cane] • Fully automated plant – Cane to sugar • Optimum [imbibition] addition of water in mills • Continuous pans for sugar boiling • Spray pond for cooling system • Efficient Steam bleeding system for juice and sugar boiling •
Flash steam recovery from vapour condensate
•
Elimination of 9 ata steam for sulphur melting, sugar washing and sugar drying
•
Using plate type heat exchanger for juice heating
•
Application of Thermocompressor system
BENEFITS OF ENERGY SAVINGS The major benefits of energy saving in sugar industry can be broadly classified as • Bagasse can be saved, which can be directly sold in the market. • Passing the surplus steam through an extraction cum condensing turbine, provided a commercial cogeneration system is available, can generate additional power
SUMMARY
In the recent years, with the increasing power ‘Demand supply’ -gap the generation of power from the excess bagasse has been found to be attractive. This also offers an excellent opportunity for the sugar mills to generate additional revenue for the mills. This also contributes to serve the national cause in a small way by bridging the ‘Demand supply’ –gap.
A.N.Soundararajan E I D Parry [India] Limited Sugar Factory, Pudukottai Tamil Nadu
BACKGROUND The Indian industry is a blend of variety of plants of different vintage, varied technologies, capacities and efficiencies. The industry also had continuously undertaken improvement opportunities wherever possible and increased their productivity. Some of the plants, which have incorporated all the energy conservation aspects, have achieved higher efficiencies and are realising huge benefits. To replicate these efforts and achieve national level improvements there is a need to widely disseminate the information on the major energy potential and conservation projects implemented by sugar industries. Towards achieving the above objective, this paper has been prepared.
SUGAR INDUSTRIES The sugar industry is one of the ancient and still the largest amongst the food processing industries in the world. Sugar is the only processing food available in bulk at the highest purity. India has been the originator of the sugar industry. At present, India is the second largest producers of sugar. India has the largest number of modern sugar mills, nearly 600 in number. The average capacities of the sugar mills are only 2500TCD in India, as against the average capacities of about 10000 TCD in abroad. With the recent liberalisation of the sugar industry and increasing demand for sugar and power, the sugar industry is poised for tremendous growth.
STEAM & POWER IN SUGAR INDUSTRY Sugar industry needs steam and power substantial quantity for cane crushing and the cane juice processing. The sugar cane has 28% to 30% of bagasse and is used for generation of the energy required, for the operation of the sugar mill. The bagasse is fired in the boiler, for producing steam at high pressures, which is extracted through various back-pressure turbines and used in the process. This simultaneous generation of steam and power commonly referred to as co-generation. Sugar industries, in general, are operating with low-pressure steam parameters mainly because of the restriction in usage of electrical energy for their captive use only. The steam parameters have been chosen to match with the process steam requirement and electrical power requirement for captive use. The surplus bagasse generated, was sold to the outside market. The energy content of bagasse is much more than the internal requirement of the plant.
SELECTION OF STEAM GENERATORS & POWER GENERATORS While selecting Boilers and Steam turbine, the steam parameters and operating conditions play an important role. Depending upon the level of technology adopted, various capacities of mills can produce surplus power, shown in the following Charts. With larger mill capacities and high-pressure steam the surplus power increases more than proportional. This huge potential can be further increased, if the steam & power consumption in the different sections of the plant can be minimised through highpressure steam system in sugar process.
Assumptions Bagasse % cane = 27.5 % Steam : Fuel ratio = 2.21 Steam % cane = 40%
Power generation in MW at various Steam pressure in Ata Cane TCD Steam TCH 14 22 32 42 65 85 2500 63.02 3.50 4.31 7.71 9.88 11.00 11.86 3000 75.63 4.20 5.17 9.25 11.86 13.19 14.23 3500 88.23 4.90 6.03 10.79 13.83 15.39 16.60 4000 100.83 5.60 6.89 12.33 15.81 17.59 18.97 4500 113.44 6.30 7.75 13.88 17.79 19.79 21.34 5000 126.04 7.00 8.61 15.42 19.76 21.99 23.71 7500 189.06 10.50 12.92 23.13 29.64 32.99 35.57 10000 252.08 14.00 17.22 30.83 39.53 43.98 47.42
105 12.56 15.07 17.58 20.09 22.60 25.12 37.67 50.23
Specific Steam Consum ption Vs Steam Pressure 20 Sp. Steam Consum p [kg/kW]
18 16 14 12 10
`
8 6 4 2 0 14
22
32
42
65
Steam Pressure [Ata]
Steam Pressure in Ata Sp.steam consumption
14 18
22 15
32 8
42 6
65 6
85 5
105 5
85
105
POTENTIAL FOR SURPLUS POWER
Using high pressure steam and temperature Using extraction cum condensing turbine Elimination of PRDS for steam bleeding
Elimination of steam leakages
POWER CONSUMPTION PER MT OF CANE [From 44 units to 32 units] (Sugar & Cogen)
Fully automated plant
Change to electrical drive in mills Variable frequency drive Change chain conveyor to belt conveyor Planetary gear box Energy conservation measures
Maximise Cane crushing rate
Using Energy Efficient Motors
kW per Tonne of Cane Vs Steam Pressure 140 120
kW
100 80 60 40 20 0 14
22
32
42
65
Steam Pressure [Ata]
Steam Pressure in Ata Kw per Tonne of Cane
14 34
22 41
32 74
42 95
65 106
85 114
105 121
85
105
kW per MT of Bagasse Vs Steam Pressure 500 450 400 350 kW
300 250 200 150 100 50 0 14
22
32
42
65
Steam Pressure [Ata]
Steam Pressure in Ata Kw per MT of Bagasse
14 122
22 150
32 269
42 345
65 384
85 414
105 438
85
105
POTENTIAL FOR INCREASE IN STEAM GENERATION PER MT OF CANE / BAGASSE • High fibre cane • Reduce bagasse moisture • Using HP heater, Economiser and Air pre heater • Increase combustion efficiency • High efficiency boiler • Recycle the unburnt fuel • Automation – combustion control • Using flash steam recovery from Exhaust condensate • Heating the boiler make up water (DM water) using the waste high temperature secondary condensate.
REDUCTION OF STEAM CONSUMPTION PER MT OF CANE [From 52% to 40% on Cane] • Fully automated plant – Cane to sugar • Optimum [imbibition] addition of water in mills • Continuous pans for sugar boiling • Spray pond for cooling system • Efficient Steam bleeding system for juice and sugar boiling •
Flash steam recovery from vapour condensate
•
Elimination of 9 ata steam for sulphur melting, sugar washing and sugar drying
•
Using plate type heat exchanger for juice heating
•
Application of Thermocompressor system
BENEFITS OF ENERGY SAVINGS The major benefits of energy saving in sugar industry can be broadly classified as • Bagasse can be saved, which can be directly sold in the market. • Passing the surplus steam through an extraction cum condensing turbine, provided a commercial cogeneration system is available, can generate additional power
SUMMARY
In the recent years, with the increasing power ‘Demand supply’ -gap the generation of power from the excess bagasse has been found to be attractive. This also offers an excellent opportunity for the sugar mills to generate additional revenue for the mills. This also contributes to serve the national cause in a small way by bridging the ‘Demand supply’ –gap.
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