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ENERGY

MANEUVERING
IN
INDUSTRIES
Dr R S E T H U M A D H A V A N
PROFESSOR
I E S , A n n a U n i v e r s i t y, C h e n n a i

FOR ANY
INDUSTRIAL PRODUCTION
ACTIVITY

POWER
&
THERMAL ENERGY
ARE

LIFELINE

ENERGY SHARE PATTERN - TYPICAL


Tea

Textile
Thermal 1 0 %

Thermal 9 2 %

Electrical 8 %

Electrical 9 0 %

Sugar Mill
Thermal 4 0 %

Electrical 6 0 %

THINK
OF
COGENERATION
when Power & Thermal
Share are Comparable

PRINCIPLE OF
COGENERATION
Cogeneration or Combined Heat and Power ( C H P )

T Y P E S of C O G E N E R A T I O N
Types

Remark

Industry

Complete Process and


Power and
Steam Demand of the
Steam Balanced process met

Sugar

Power Based

Complete Power Demand


met, Steam/heat is only
incidental

Steam Based

Complete Steam Demand


of the process met, Power Petrochemical
is only incidental.

Heat Based

Heat is used in the Process,


Power is only incidental.

Textile

Cement

Note : One must decide the basis for the Cogeneration Plant
 Either P o w e r B a s e d

or

Steam Based

V I A B I L I T Y w/o : C o g e n
Separate Production of Electricity & Heat

Total Efficiency = ( 3 6 + 8 0 ) / 2 0 0 = 5 8 %

WITH COGEN

Efficiency =
=

( 30 + 55 ) / 100
85%

ECONOMICS
Fuel

: Coal @ Rs 5 0 0 0 / t o n

w/o Cogen : 1 6 0 0 kWh of Power / ton


+
6 t p h of Steam / ton
with Cogen : 1 300 kWh of Power / ton
+
4 . 5 tph of steam / ton

REVENUE IN
SIMPLE TERMS

Without Cogen

Rs 1 3 0 0 0 from 2 tons of
Coal ( Rs 6 500 from 1 ton of Coal )
With Cogen

Rs 1 0 3 5 0 from 1 ton of Coal

WHY COGENERATION ?

 Increased Energy Efficiency


 Reduction / Elimination of GHG
 Less chance of Acid Rain
and many more reasons
MOST IMPORTANTLY
THE ECONOMICS

COGENERATION SYSTEM
-CYCLES
Water Desalination
District Heating
Sugar Industries

Cement Industries
Steel Industries
Ceramic and Gas Industries
Petro-Chemical Industries

CONFIGURATION USED IN SUGAR MILL

COGENERATION USED IN
CEMENT INDUSTRIES

CEMENT INDUSTRY
REVENUE MODEL
Cement Production

: 10 000 tons

Coal Consumption

: 1 200 tons

Power

: 6 62 000 kWh

Energy Cost

: Rs 81 lakhs

With Bottoming Cycle Cogen


Coal

: 1200 tons

Power (Net)

: 585250 kWh

Energy Cost

: Rs 77.3 lakhs

Net Savings

: Rs 4 lakhs / 10000 tons of Production

Rs 4 0 / ton of Cement

COGENERATION STATUS IN INDIA


No

States
Pradesh

BM Power / Cogen ( M W )

Andhra

381

( 10. 6 % )

Bihar

Chhatisgarh

Gujarat

31

Haryana

45

Karnataka

Madhya

Maharashtra

Odisha

20

10

Punjab

125

11

Rajasthan

12

Tamil

Nadu

539

( 15.0 %)

13

Uttar

Pradesh

777

( 21.6 % )

14

Uttarakhand

10

15

West

26

43

Pradesh

Bengal

Total

250

490

( 13.6 % )

16
757

( 21.0 % )

91

3600

A Typical 6 MW Biomass Power Plant

A DIFFERENT INSIGHT

The

Energy requirement of a

industry
planning

is

well

addressed

by

for a Sustainable and

Renewable Energy.
i.e. Overall Energy Management of
a Process Industry as Cogen / CHP
may not be viable in all industries

PROJECT : T E F R

CLIENT

: ABC

PREPARATION
LTD

S E P 2 0 13

P R O D U C T I O N
ANNUAL GROWTH :

25%

1.2
1.03
1.0
0.82
0.8
0.6

0.66
0.53
0.42

0.4
0.2
0.0
2008-09

2009-10

2010-11
Year

2011-12

2012-13

POWER
77.3

80

61.8
60
40

49.5
39.6
31.7

20
0
2008-09

2009-10

2010-11
Year

2011-12

2012-13

STEAM
3

2.83

Steam

Lakh tons

2.25
1.81

1.45
1.15
1

0
2008-09

2009-10

2010-11
Year

2011-12

2012-13

FUEL
80000

70750
56250

60000

45250
36250

40000

28750
20000

0
2008-09

2009-10

2010-11
Year

2011-12

2012-13

SUM-UP

SCENARIO

P r o d u c t i o n = 1 0 3 0 5 7 tons
Power

= 7 7 . 3 x 106 kWh

Steam

= 0 . 2 8 x 106 tons

Fuel

= 70 750

tons

S P E C I F I C
ENE RGY

CONSUMPTION

E S T A B L I S H E D

Electricity
Specific Power Consumption
=

7 5 0 kWh / ton of Finished Product

Thermal
Specific Steam Consumption
=

2 .7 5 tons / ton of

Finished Product

Option

Scheme

1 0 0 % T A N G E D C O Power
+
1 0 0 % Steam from Low Pressure Boiler

1 0 0 % Electricity from Wind Mill


+
1 0 0 % Steam from Low Pressure Boiler

Combined Generation of Power &


Steam from procured Agro Fuel

COSTING
(i) T h e r m a l
Boiler Cost ( 25 tph

Steam Cost

= Rs 2

crores
= Rs25 crores / y

(i) E l e c t r i c a l
Investment ( Transformer

+ Cable etc.)

Power Cost = Rs 40

TOTAL

= Rs 5 crores
crores / y

COST

Total Investment = ( 2 + 5 )
= Rs 7 crores
Recurring

= (25 + 40)
= Rs 65 crores/y

CAPITAL COST
W M Capacity Required

35 MW

I n v e s t m e n t = R s 2 0 0 crores

THERMAL

POWER

OPERATING

COST
6

Steam Generation

= 0.28x10

Fuel

Reqt.

= 70 750 tons / y

Fuel

Cost

= Rs 2 345 / ton

tons / y

= (70 750 x 2345)


= Rs16.6 crores / y
Other Cost

= Rs8.3 crores / y

Steam Cost

= Rs 24.9 crores / y

= Rs 890 / ton

OVERALL ECONOMICS
Investment
(i) W i n d M i l l

Rs 200 crores

(ii) B o i l e r

Rs

2 crores

Rs

202 crores

Operating Expenses
(i) W i n d M i l l

Rs

28

crores/y

(ii) B o i l e r

Rs

25

crores/y

Rs

53

crores/y

RETURN ON INVESTMENT

202 crores

Investment =

Rs

A v. R e t u r n

Rs1

Payback Period

21 years

IRR

<1%

0 crores / y

(Quite Poor indeed)

HEAT TO POWER RATIO


Specific
Power Consumption =

0 . 7 5 kWh / kg of F P

Fuel Consumption

0 . 6 8 7 5 kg / kg F P

3.2 kWh

Heat to Power Ratio = ( 3 . 2 / 0 . 7 5 ) =

HENCE CHP SCHEME


IS VIABLE

4.3

C HP

PLANT SIZING

Power Requirement

7 7 . 3 x 1 0 6 kWh / y

In house Power Consumption =

10%

Period of Operation

8 640 h/y

Power Plant Capacity

9 942 kW

Plant Operating Load

8 0 % ( avg )

Power Plant Size

( 9 9 4 2 / 0.8 )

1 2 4 2 7 . 5 kW

S a y 1 2 . 5 MW

STEAM PARAMETERS
Steam Requirement

= 0.28 x 10
Quantity

No

Steam

HP

LP1

LP2
Total

6 tons / y

million tons / y

Pr
ksc ( g )

0. 112
0.112
0.056
0.280

40

17

40

20

EXTRACTION - CUM
- CONDENSING TURBINE
Flue
1

Fuel+
Air

Turbine

Boiler
5

PRV

Deaerator

Process
Hot Well

BFW

I N V E S T M E N T
Capital

Cost

Captive Power Plant Rating


@ 12.5 MW

= Rs 62 crores

OPERATING

COST

Fuel Required

= 1 0 3 6 8 0 tons / y

Fuel Cost

Rs 2 345 /ton

Rs 24.31 Crores/y

Other Cost @ 50 % =

Rs 12.16 Crores/y

Total Opr Cost

Rs 36.47 Crores/y

say

Rs 36 crores/y

RETURN ON INVESTMENT
I n v e s t m e n t = Rs 6 2 C r o r e s
Total Opr Cost

= Rs 3 6 C r o r e s / y

Cost S a v i n g s = ( 6 5 - 3 6 )
= Rs 2 9 C r o r e s / y

Payback Period = 2 years 9 months


IRR

= 24.2%

Quite

Attractive

WASTE HEAT RECOVERY


What is Waste Heat?
 Heat generated in a process by fuel combustion
or chemical reaction and then released to the
environment without any further treatment or
extraction.
 Deals with the tapping or extraction of these
waste heat for some other useful purposes and
thereby maximizing the fuel efficiency.

Q u a l i t y of
 High Temp.

Waste Heat
(6 2 0 0C 1 6 5 0 0C)

 Medium Temp. ( 2 5 0
 Low Temp.

(25

0C

0C

-650

250

0C

0C)

HIGH TEMP
Regenerator

Heat Wheel

HR

DEVICES
Recuperator

BENEFITS OF WHR
Direct Benefits
 Reduction in Utility Consumption and Costs
 Reduction in Process Costs

Indirect Benefits
 Reduction in Auxiliary Energy Consumption
 Reduction in Equipment Costs
 Reduction in Pollution

CONCLUDING

REMARKS

 Cogeneration & Waste Heat Recovery shall be


accorded

TOP

Priority

as

these

are

absolutely Sustainable. Of course, the benefits


are well known
 If not viable, look for Energy Maneuvering
Model where Hybridization can happen
 Renewable Energy Other alternate to depend
on ( though expensive )

A
N
Y

Q
U
E
S
T
I
O
N
S
!

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