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Study of A Cogeneration Plant in Sugar Mill by Using Bagasse As A Fuel
Study of A Cogeneration Plant in Sugar Mill by Using Bagasse As A Fuel
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Abstract — Bagasse cogeneration describes the use of fibrous per square meter of boiler surface. The super saturated steam
sugarcane waste, bagasse to cogenerate heat and electricity at from superheater is fed to the impulse reaction turbine by
high efficiency in sugar mills. Proposed work is a case study on means of the main valve [7]. The valve placed in between
sugarcane industry and economics is worked out for advanced superheater and the turbine is for limiting the excess flow
cogeneration power system. In generally, different kinds of
level of steam to the turbine. The turbine converts steam
co-generation plants are available based on products in industry
and bagasse is derived from several types of the cogeneration energy into mechanical energy [8].
plant. By replacing low-efficiency mill turbines with hydraulic The turbine is coupled with the Turbo Alternator with
drives and DC motors, cogeneration power increases in sugar the help of couplings. The Turbo Alternator converts
mill to operate at high efficiency (65-70%). This replacement mechanical energy into electrical energy [9]. The generated
can aid increase of power to a grid, resulting in additional electrical energy is stepped up by using power transformer
revenue for sugar plant. The research evaluates the technical and feed to bus bar with various protection systems.
feasibility and economic viability of reconfiguring the sugar
industries towards cogeneration and also quantifies the
emissions from Bagasse cogeneration. The total electric power
that can be produced and fed to the national grid, the economic
issues and the issues of emissions.
Key Words — Bagasse, Boiler, Feed Water Heater,
Condenser, Turbine, Chimney, ID Fan, S.A Fan, F.D Fan.
I. INTRODUCTION
Fig.1 shows the line diagram of steam/thermal power
plant [1]. The fuel for a thermal power plant is coal/Bagasse.
The coal is pulverized in coal pulverization plant for required
sizes to feed in the boiler unit of steam/thermal power plant
[2]. The water in boiler gets heated once the coal/bagasse is
fired in the furnace. Gradually the water gets converted into
steam after heating it up to 4800C. The steam flows through
the superheater such that the moisture content in the steam
gets evaporated and turn into super saturated steam [3]. The
hot flue gas from the boiler is fed to superheater which
increases the temperature of the superheater and removes the
moisture content. The flue gas flowing through super heater
flows through economizer and air pre-heater. The main Fig. 1 Line Diagram of Steam Power Plant
function of the economizer is that it will increase the The 132KV power generated is sent to the nearest
temperature of the feed water by utilizing the heat from the substation. The exhaust steam from steam turbine is again
hot flue gases [4]. converted into water in the condenser and it is sent to the
The feed water is again sent to the boiler for cooling tower with the water from the river/pond, where the
conversion of steam [5]. The air pre-heater increases the water is cooled and sent to circulating water pump [10]. Again
temperature of the air supplied for coal burning by deriving the water is sent through condensate extraction pump to LP
heat from flue gases [6]. By preheating the air there will be an water heater and then to HP feedwater heater. Then the water
increase in thermal efficiency and increase in steam capacity
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Dinakaran et. al., Study of a Cogeneration Plant in Sugar Mill by using Bagasse as a Fuel
International Electrical Engineering Journal (IEEJ)
Vol. 7 (2016) No.6, pp. 2226-2240
ISSN 2078-2365
http://www.ieejournal.com/
is sent to economizer and from there it is circulated to boiler overall efficiency is increased and secondly, too much
[11]. This process repeats simultaneously. The ash in the condensation in the last stages of a turbine (which would
furnace is sent to ash handling plant where it is mixed in water cause blade corrosion) is avoided. The superheated steam
in order to stop the spreading of the ash in the air and it is sent from the superheater is fed to steam turbine through the main
to ash storage plant. The electrostatic precipitator collects the valve. The Superheater is used to increase the temperature of
dust from the furnace and sends the exhaust gases through a saturated steam without raising its pressure and it is placed on
chimney. the hot flue gases path in the furnace.
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Dinakaran et. al., Study of a Cogeneration Plant in Sugar Mill by using Bagasse as a Fuel
International Electrical Engineering Journal (IEEJ)
Vol. 7 (2016) No.6, pp. 2226-2240
ISSN 2078-2365
http://www.ieejournal.com/
energy of turbine into electrical energy. The electrical output without any change in the frequency. A power transformer is
from the alternator is delivered to the bus bars through used in a substation to step-up (or) step-down the voltage.
transformer, circuit breakers and isolators. Fig.6 shows the substation transformer which is installed
upon the length of rails fixed a concrete slabs having
E. Exciter foundation 1 to 1.5 m deep.
G. Lightning Arrester
Fig. 5 Exciter
H. Potential Transformer
uses a bus isolator to protect itself. The main use of this any extra voltage cannot enter the line. Thus an isolator is
transformer is to measure the voltage through the bus. This is used after the bus also for protection.
done so as to get the detail information of the voltage passing
through the bus to the instrument. There are two main K. Bus bar
functions in it
a. Measurement
b. Protection
I. Current Transformer
J. Isolator
BEARING
44. LUBE OIL SUPPLY PRESSURE AT GENERATOR REAR KG/CM2 0.63 0.63
BEARING
45. LUBE OIL RETURN TEMPERATURE AT TURBINE REAR °C 60 60
BEARING
46. LUBE OIL RETURN TEMPERATURE AT GEN GEAR BOX °C 51 51
47. LUBE OIL RETURN TEMPERATURE AT GENERATOR FRONT °C 50 50
BEARING
48. LUBE OIL RETURN TEMPERATURE AT GENERATOR REAR °C 46 46
BEARING
49. TURBINE THRUST BEARING TEMPERATURE (ACTIVE) (A) °C 54 54
50. TURBINE THRUST BEARING TEMPERATURE (ACTIVE) (D) °C 54 54
51. TURBINE FRONT BEARING TEMPERATURE (F) °C 87 87
52. TURBINE REAR BEARING TEMPERATURE (I) °C 69 69
53. GEAR PINION FRONT BEARING TEMPERATURE (K) °C 80 80
54. GEAR PINION REAR BEARING TEMPERATURE (J) °C 87 87
55. GEAR PINION WHEEL FRONT BEARING TEMPERATURE (M) °C 67 67
56. GEAR PINION WHEEL REAR BEARING TEMPERATURE (W) °C 63 64
57. GENERATOR FRONT BEARING TEMPERATURE (P) °C 60 60
58. GENERATOR REAR BEARING TEMPERATURE (Q) °C 57 57
59. HOT WELL TEMPERATURE °C 43 43
60. HOT WELL LEVEL % 33 32
61. CONDENSER VACUUM KG/CM2 -0.93 -0.93
62. CEP SUCTION PRESSURE KG/CM2 -0.82 -0.82
63. CEP DISCHARGE PRESSURE KG/CM2 7.6 7.6
64. CONDENSATE TEMPERATURE BEFORE EJECTOR °C 42 42
65. CONDENSATE TEMPERATURE AFTER EJECTOR °C 58 58
66. CONDENSATE BEFORE GLAND STEAM CONDENSER °C 55 55
67. CONDENSATE TEMPERATURE AFTER GLAND STEAM °C - -
CONDENSER
68. GENERATOR AIR COOLER WATER INLET TEMPERATURE °C 32 32
69. GENERATOR AIR COOLER WATER OUTLET TEMPERATURE °C 34 34
70. AXIAL DISPLACEMENT MM 0.22/0.26 0.25/0.26
71. TURBINE FRONT SHAFT VIBRATION MICRONS 65/75 66/73
72. TURBINE REAR SHAFT VIBRATION MICRONS 27/35 28/35
73. GEAR PINION SHAFT VIBRATION (HSS) MICRONS 22/33 28/31
74. GEAR WHEEL SHAFT VIBRATION (LSS) MICRONS 18/19 16/18
75. GENERATOR FRONT SHAFT VIBRATION MICRONS 33/25 37/26
76. GENERATOR REAR SHAFT VIBRATION MICRONS 24/33 21/35
2
77. HP SECONDARY OIL PRESSURE KG/CM 3.0 3.0
78. LP SECONDARY OIL PRESSURE KG/CM2 2.6 2.6
VI. CONCLUSION using this type of plants we save natural resources like coal,
Bagasse otherwise a refuse, if used as cogeneration water because the byproduct of sugar cane i.e., bagasse is
fuel is proved to have been technically feasible, economically used as raw material for combustion. By erecting the plant as
viable for the competitive industrial environment of sugar per the design it results in the reduction of atmospheric
industries, environmentally friendly because of greenhouse pollution and increases the power generation and the
neutral emissions and acceptable regarding social matters. By efficiency of the plant increases. By these designs, the step by
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Dinakaran et. al., Study of a Cogeneration Plant in Sugar Mill by using Bagasse as a Fuel
International Electrical Engineering Journal (IEEJ)
Vol. 7 (2016) No.6, pp. 2226-2240
ISSN 2078-2365
http://www.ieejournal.com/
step process of power generation will be in a progressive level [6] G.Prasad, E.Swidenbank, B.W.Hong, “A Novel Performance
Monitoring Strategy for Economical Thermal Power Plant Operation”,
such that interruption in power generation will not happen
IEEE Transactions on Energy Conversion, Vol. 14, No. 3, September
and fault identification and rectification will be easy for any 1999, PP. 802-809.
working individual. [7] S.P.Nangare, R.S.Kulkarni, “Theoretical Analysis of Energy
Utilization Measures through Energy Audit in sugar industry Power
Plant”, International Journal of Advanced Engineering Research and
Studies, Vol. 1, Issue 3, April – June 2012, PP. 168-171.
REFERENCES
[8] Saori Shibatani, Motohiro Nakanishi, Nobumi Mizuno, Fumihito
[1] M.M.Salama, M.M.Elgazar, S.M.Abdelmaksoud, H.A.Henry, “Solving Mishima, Yoko Akiyama, “Study on Magnetic Separation Device for
Short Term Hydrothermal Generation Scheduling by Artificial Bee Scale Removal from feed-water in Thermal Power Plant”, IEEE
Colony Algorithm”, International Electrical Engineering Journal Transactions on applied superconductivity, Vol. 26, No. 4, June 2016.
(IEEJ), Vol. 6 (2015), No. 7, PP. 1973-1987. [9] Samir Ansari, Vikash Kumar, Arindam Ghosal, “A Review on Power
[2] M.Premalatha, S.Shanmuga Priya, V.Sivaramakrishna, “Efficient Generation in Thermal Power Plant for Maximum Efficiency”,
Cogeneration scheme for sugar industry”, Journal of Scientific & International Journal of Advanced Mechanical Engineering, Vol. 4,
Industrial Research, Vol. 67, March 2008, PP. 239-242. No. 1 (2014), PP. 1-8.
[3] G.V.Pradeep Varma, T.Srinivas, “Design and analysis of a [10] C.Dinakaran, “Implementation of Shunt and Series FACTS Devices
cogeneration plant using heat recovery of a cement factory”, Case for Overhead Transmission Lines”, International Electrical
Studies in Thermal Engineering (Elsevier), Vol. 5 (2015), PP. 24-31. Engineering Journal (IEEJ), Vol. 6 (2015), No. 8, PP. 2009-2017.
[4] Francesco Fantozzi, Sandro Diaconi Ferico, Umberto Desideri, “Study [11] M.S.Krishnarayalu, “Unit Commitment with economic load
of a cogeneration plant for agro-food industry”, Applied Thermal dispatch”, International Electrical Engineering Journal (IEEJ), Vol. 6
Engineering, Vol. 20 (2000), PP. 993-1017. (2015), No. 5, PP. 1913-1916.
[5] Domenico Panno, Antonio Messineo, Antonella Dispenza,
“Cogeneration Plant in a pasta factory: Energy saving and
environmental benefit”, Energy (Science Direct, Elsevier), Vol. 32
(2007), PP. 746-754.
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International Electrical Engineering Journal (IEEJ)
Vol. 7 (2016) No.6, pp. 2226-2240
ISSN 2078-2365
http://www.ieejournal.com/
APPENDIX
TYPES OF EQUIPMENT USED IN COGENERATION PLANT
AVR PANEL:
SL.NO : S30381
MAKE : BHEL
NOMINAL OUTPUT : 7.12 A, 78.4 V
CEILING OUTPUT : 11.27 A, 150 V
LOAD : EXCITER HELP
COOLING : AN
MAXIMUM AMBIENT : 50°C
AUXILIARY DC SUPPLY : 1100
AUXILIARY AC SUPPLY : 415 V, 3 PHASE, 50HZ
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Dinakaran et. al., Study of a Cogeneration Plant in Sugar Mill by using Bagasse as a Fuel
International Electrical Engineering Journal (IEEJ)
Vol. 7 (2016) No.6, pp. 2226-2240
ISSN 2078-2365
http://www.ieejournal.com/
TURBO GENERATOR:
MAKE : BHEL, HYDERABAD
DRIVE : ST
KVA : 25500
KW : 20400
POWER FACTOR LAG : 0.8
FREQUENCY : 50
RPM : 1500
PHASE : 3 AC
CONNECTION : STAR
STATOR VOLTS : 11000
STATOR AMPS : 1338
ROTOR VOLTS : 93
ROTOR AMPS : 838
AMBIENT AIR : 39°C
COOLING : CACW
DUTY : CONT.
ALTITUDE : <1000M
TOTAL WEIGHT : -
OVER SPEED : 10%
GAS PRESSURE : NA
WINDING INSULATION : CLASS F
STANDARD : IEC - 34, IS : 4722
TYPE : TA11 1240 12P - 15
PROTECTION : IP- 54
SL.NO. : 1408
YEAR : 2001
BRUSHLESS EXCITER:
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Dinakaran et. al., Study of a Cogeneration Plant in Sugar Mill by using Bagasse as a Fuel
International Electrical Engineering Journal (IEEJ)
Vol. 7 (2016) No.6, pp. 2226-2240
ISSN 2078-2365
http://www.ieejournal.com/
MAKE : BHEL
TYPE : EAR 80/9 -15/16 - 217
INSULATION CLASS : F
SL.NO. : 10558
YEAR : 2001
STANDARD NO. : IS : 4722
KW : 94
CONT. VOLTS : 102
CONT. AMPS : 922
RPM : 1500
EXCITATION W : 544
EXCITATION V : 77.41
EXCITATION A : 7.03
UPS PANEL-1:
CAPACITY : 15 KVA
INPUT : 415 V, 50 HZ
OUTPUT : 230 V
MAKE : HI - REC
SL.NO. : 01082296
EARTH SWITCH:
MAKE : VERSATECK, HYDERABAD
VOLTS : 132 KV
AMPS : 1250 AMPS
SL.NO. : 671
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Dinakaran et. al., Study of a Cogeneration Plant in Sugar Mill by using Bagasse as a Fuel
International Electrical Engineering Journal (IEEJ)
Vol. 7 (2016) No.6, pp. 2226-2240
ISSN 2078-2365
http://www.ieejournal.com/
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Dinakaran et. al., Study of a Cogeneration Plant in Sugar Mill by using Bagasse as a Fuel
International Electrical Engineering Journal (IEEJ)
Vol. 7 (2016) No.6, pp. 2226-2240
ISSN 2078-2365
http://www.ieejournal.com/
OLTC MOTOR:
VOLTS : 415 V
FREQUENCY : 50 HZ
KW : 1.1
CONTROL SUPPLY : 110 V, 50 HZ
POT : 1000 OHMS
LV : 0.43 KV
RATED LINE AMPS
HV : 131.2 A
LV : 3333.4 A
NUMBER OF PHASE : 3
MAXIMUM TEMP. RAISE OVER ON
AMBIENT OF 50°C
TOP OF OIL : 50°C
AVERAGE WINDING : 55°C
IMPEDANCE VOLTAGE HV / LV : 6.793 %
MAKERS SL.NO. : D – 3262
REF. NO. : TIP – 1001
VECTOR GROUP : DYN11
FREQUENCY : 50 HZ
INSULATION
HV SIDE KV : L175AC28
LV SIDE KV : L1AC3
HVN KV : L1AC3
CORE AND COIL MASS : 3040 Kg
TANK AND FITTING MASS : 2300 Kg
MASS OF OIL : 1140 Kg
TOTAL MASS : 6500 Kg
TRANSPORT MASS(OIL FILLED) : 5200 Kg
DIAGARM DRG. NO. : A328614
VOLUME OF OIL : 1315 Ltrs
YEAR : 2002
WTICT:
RATIO : 3333 / 175 AMPS
BURDEN : 10 VA
ACC.CLASS : 3
NCT:
RATIO : 4000 / 1 A
ACC. CLASS : PS
Vk : > 500 V
IMAG : < 30 MA AT Vk / 2
RCT@75 : < 14 OHMS
ESP TRANSFORMER–1:
SL.NO. : 0796 - 01 - 03 - 2001
TYPE : ADOR KARONA
KVA : 49.8
AC INPUT VOLTAGE : 415 V
AC INPUT CURRENT : 120 A
AC OUTPUT VOLTAGE : 70731 V
AC OUTPUT CURRENT : 0.700 A
FREQUENCY : 58 HZ
PHASE : SINGLE PHASE
DC VOLTAGE (PEAK) : 95000 V
DC CURRENT : 500 MA
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Dinakaran et. al., Study of a Cogeneration Plant in Sugar Mill by using Bagasse as a Fuel
International Electrical Engineering Journal (IEEJ)
Vol. 7 (2016) No.6, pp. 2226-2240
ISSN 2078-2365
http://www.ieejournal.com/
ESP TRANSFORMER-2:
SL.NO. : 0795 - 01 - 03 – 2001
TYPE : ADOR KARONA
KVA : 49.8
AC INPUT VOLTAGE : 415 V
AC INPUT CURRENT : 120 A
AC OUTPUT VOLTAGE : 70731 V
AC OUTPUT CURRENT : 0.700 A
FREQUENCY : 58 HZ
PHASE : SINGLE PHASE
DC VOLTAGE (PEAK) : 95000 V
DC CURRENT : 500 MA
DISEL GENERATOR:
MAKE : CATTERPILLAR
SL.NO. : 9IRGS00058
RATING : 725 KVA
KW : 580
VOLT : 415
HZ : 50
POWER FACTOR : 0.8
R.P.M. : 1500
AMPS : 1009
DIRECTION OF ROTATION : CW
AMBIENT : 40°C
INSULATION CLASS : H
ENCL. TYPE : IP23
YEAR OF MFG. : 2002
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Dinakaran et. al., Study of a Cogeneration Plant in Sugar Mill by using Bagasse as a Fuel