Comparsion of Existing sugar mill system Vs HP system

DESCRIPTION Existing System HP System

Sugar Plant Operating Data

Crushing Capacity (TCD) 8500 8500
Crushing Capacity (TCH) 354 354
Bagasse Generated (TPH @ 29% on Cane) 106.25 106.25
Bagasse for Bagacillo & Losses (TPH) 3.33 3.33
Bagasse available for usage in Cogeneration (TPH) 102.92 102.92
2.5 bar (a) steam requirement 200 120
(Existing system (steam base drives / no FFEs) 200 120
Electrical Power requirement of the sugar mill (kw) (With steam drives) 5000
Electrical Power requirement of the sugar mill (kw) (With Electric drives) 7500
Average Number of Days of Season Operation 130 130
Annual Bagasse Generation considering 97% plant Capacity Utilization (MT) 311477 311477

Season Operation
High Pressure Cogeneration System
Boiler Outlet Steam Pressure (bar(a)) 22.00 66.00
Boiler Outlet Steam Temperature (Deg.C) 330.00 485.00
Boiler Feed Water inlet Temperature (Deg.C) 105 105.00
No. of Boilers 5 1
Total Boiler Steam Generation capacity 240 140.00
Actual HP Steam Generation in Seaosn (TPH) 200 140.00
Bagasse consumption (TPH) 95 63
Backpressure TG Capacity (MW) / Extraction cum condensing TG 13.00 26000
Number of Extraction Condensing TGs 0 1
Backpressure TG Capacity (MW) 5.0 NA
Number of Backpressure TGs 4 NA
Generation in Extraction Condensing TGs in Season NA 26350
Generation in Backpressure TG in Season (kW) 5000 NA
HP Cogen Auxiliary Power Consumption (kW) 2000
Electrical Power requirement of the sugar mill (kw) 7500
Net Export to Grid 16500

Bagasse Balances Existing System HP System

Bagasse from Crushing Operations 311477 311477
Bgasse Consumption 296400 196560
Total Bagasse Consumption in Season (MT) 15077 114917

Off-Season Operation
Number of Boilers in Operation 1
Number of TGs in Operation 1
Total Steam generation (TPH) 105.00
Bagasse consumption (TPH) 43.00
No of days available for off season 111
Gross power generation (kW) 26000
Power consumption in sugar plant (kW) 400
Auxiliary power consumption (kW) 2000
Exportable Power in Off-season (kW) 23600.00

Annual Export
kwh (season) @ 95 % 48906000
kwh (off-season) @ 95% 59917235
Total Sale. (KWH) 108823235
Net Sale @ 11.42 Rs/Kwh 1242761346

one billion two hundred forty-two million seven hundred sixty-one thousand three hundred forty-six

Advantages of High-pressure Boilers:

High-pressure boilers use the forced circulation of water which ensures the positive circulation of
water and increased evaporative capacity.
They require less heat of vaporization.
They are compact and thus require less floor space.
Due to the high velocity of water, the tendency of scale formation is minimized.
All parts are uniformly heated and the danger of overheating is minimized.
The steam can be raised quickly to meet the variable load requirements without the use of
complicated control devices.
The plant efficiency is increased. With the use of high-pressure boilers, the steam generation is
economical.