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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
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
Sugar
Power Based
Steam Based
Heat Based
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
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
WHY COGENERATION ?
COGENERATION SYSTEM
-CYCLES
Water Desalination
District Heating
Sugar Industries
Cement Industries
Steel Industries
Ceramic and Gas Industries
Petro-Chemical Industries
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
: 1200 tons
Power (Net)
: 585250 kWh
Energy Cost
: Rs 77.3 lakhs
Net Savings
Rs 4 0 / ton of Cement
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 DIFFERENT INSIGHT
The
Energy requirement of a
industry
planning
is
well
addressed
by
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
=
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
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
= 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
0 . 7 5 kWh / kg of F P
Fuel Consumption
0 . 6 8 7 5 kg / kg F P
3.2 kWh
4.3
C HP
PLANT SIZING
Power Requirement
7 7 . 3 x 1 0 6 kWh / y
10%
Period of Operation
8 640 h/y
9 942 kW
8 0 % ( avg )
( 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
= 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
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
= 24.2%
Quite
Attractive
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
TOP
Priority
as
these
are
A
N
Y
Q
U
E
S
T
I
O
N
S
!