Substitution of Petroleum Fuel with Green Fuel In

Mechanised Laundry Unit, Indore

Current Status:
Boiler is running on High Speed Diesel having an hourly consumption of 39.5
litres (info as provided by CDO). The boiler is running for about 22 hrs per day ,
thus consuming more than 800 litres per day. With the increase in the bulk
diesel price the cost of running the boiler per day is close to Rs 55000. Along
with this the laundry unit also consumes 60 Kw of power per day costing Rs 6.25
per unit.
Technical Specifications of Boiler
Steam Pressure:
Fuel Consumption (HSD kg/hr)
Electric Supply:
Total Load:
Operations:

10.54/15 kg per sqcm

34.8
3 Phase/440 V/50 Hz
59 Kw
20-22 hrs per day

Why Change?
Green House Effect
The current electricity consumption is about 40000 units per month, taking into
consideration the transmission and distribution losses, each unit consumed at
the users end requires 2 units to be generated at the thermal power plant. Thus
in all, a total of 60 thousand generated units are used in a month.
Each unit which is generated results in an emission of 1.02 Kg of CO 2. Thus
consuming 60 Kw per hour results in an emission of about 60 tonnes of CO2
per month. Thus changing to green power would not only reduce the emissions
due to the electricity used by the railways but would reduce emissions by upto
two times that amount due to the reduction in the transmission and distribution
loss.

Savings on Imported Fuel:

The switch from petroleum based fuels to locally sourced Biomass would result in
the creation of employment opportunities in rural areas. Thus dependency on
imported fuels would decrease and wealth would flow in rural areas.
Economy:
The switch to biomass based power would also result in monetary savings as the
change from diesel whose cost is increasing day by day to biomass based
gasification technology would guarantee savings of 10% over HSD.

Corporate Social Responsibility: Apart from having environmental and

monetary benefits, switching to biomass based technology also has social
benefits.

To maintain a guaranteed supply of Biomass fuel, we are setting up ABPC

(Agri Biomass Processing Centre) in villages. These centres would be
managed and run by our NGO arm Stree Shakti Sansthan. The
processing centres would include charring kilns, threshers and chippers for
processing of biomass which is available locally.
Each ABPC requires an acre of wasteland in rural areas which would be
given by the local government. The land is mostly needed for charring and
drying of the biomass with just a small area required for briquetting
machine and storage.
Training is provided to beneficiaries to operate the machines and also
charring. Charring is a great source of additional income for rural women
as it requires less work and helps them earn 150-200 Rs per day.
Each briquetting press is supported by at least 40-50 kilns to ensure
regular supply of char and ensure a daily production capacity of 8-10 M.T.
per day.

Requirements of ABPC

Wasteland: one acre

Shed: 1000 sq ft
Briquetting press: one
Muller Mixer: one
Charring Kilns: 20-25
Threshers/ Chipper: according to Biomass
Training and Awareness Staf

We would want Indian Railways to support such initiatives by setting up

infrastructure in rural areas, through their CSR initiatives, as they not only
support green power but also help create employment in rural areas.

ABPC in Berasia, Bhopal

Technical Specifications
a) Biomass Gasifier System
The gasifier is a down draft system that thermally cracks biomass of specified size
and moisture content into a combustible low BTU gas. The system includes a thermal reactor, open
top feed system, automatic moving auger for ash removal, coarse & fine gas filtration system, gas
cooler and other associated blowers and piping. The thermal reactor is a bottom supported cylindrical
metallic construction with suitable ceramic/insulation internal lining to withstand the thermal load as
well contain the heat generated within the reactor system. The top of the reactor also acts as fuel
storage and drying zone so as to reduce the intervals between fuel feeds. The ash removal system is a
positive displacement system that consists of a rotating auger and is designed to discharge
ash/charcoal of less than 1/2" size.
The gas cleaning system includes a hot cyclone followed by a coarse filter and a fine filter.
The gas cooling system has two coolers. The initial cooling by a indirect type wet scrubber
followed by a dry radiator cooler. The gas pumping system is designed to evacuate hot raw gas from
the reactor and deliver cold and filtered producer gas to the gas engine at the required pressure.

Connected Load Detail

SNo
1
2
3
4
5

Description
Gas Blower
Biomass Agitator
Ash Auger
Cooling Fan
Water Pump
Total

Qty
1
1
1
2
1

Load in Kw
1.75
.75
.75
.5
.75
4.5

Consumption in Kw
1.5
.5
.5
.4
.55
2.95

List of mandatory spares & consumables

01. High temperature grease (upto 250 Deg C grade)
02. Asbestos tape 50 mm wide x 6 mm thick
03. Gas Filter

b) Biomass Generators
S.N
o
1
2
3
4
5
6
7
8

Particular

Specs

Rated Power
Rated Current
Dimensions(cm)
Dry Weight
Power at 1500 rpm (BHP)
No of Cylinders
Bore x Stroke
Swept Volume(lts)

30 (24)
42
200 x 70 x 125
1125
38
4
110 x 120
4561

Legend
1. Gasifier

2. Drain Tub 3. Distance Piece

6. Coarse Filter
7. Fine Filter I
Filter 10. Control Valve

4. Scrubber 5. Drain Box

8. Fine Filter II

9. Safety

11. Blower
Genset

12. Flare

13. Shut of Valve 14. Seperation Box 15.

SCOPE OF SUPPLY:
1. Thermal Gasifier Reactor with Fuel feed hopper
2. Ash removal system & Bottom water trough with water pumping system
3. Gas scrubbing and pumping system complete with piping and motors
4. Fuel feeding System, Platform with ladders for fuel feeding
5. Gas Filter & Coolers
6. 100% producer gas Engine Generator set complete with accessories and control panel as per
detailed offer

Financial Offer:
The overall system cost for 60 KW biomass gasification based power system
would be Rs 30,00,000 . The project can be either bought out or build operate
and maintain the plant. The following components would be supplied and
commissioned.

SNo Item
1
Biomass Gasifier System
Suitable for 60 Kw power
and supporting boiler for
steam
2

Producer Gas Genset 30KVA

Qty
1

3
4
5
6

Producer Gas Genset

40 KVA
Packaging and Forwarding
Erection and commissioning
Training

The fuel cost for running the plant would come up to be Rs 4 per unit . This would
ensure a savings on overall electricity cost by atleast 5 % after taking into
account the maintenance and manpower cost.

Boiler Modification from HSD to Biomass

The overall cost of conversion of boiler from HSD to biomass would come up to
be Rs 1.34 cr. The fuel cost for running the plant would come up to be Rs
10,000 per day after commissioning. Thus ensuring a reduction in cost by 50%
in 24 months. As daily expenditure on HSD is close to Rs 55000 per day.

Terms of Payment:
We would seek a work order with a mobilizing advance of 3 Months i.e. Rs 45
Lakhs(2 months and 1 months operating cost).