International Journal of Engineering Trends and Technology (IJETT) – Volume 9 Number 5 - Mar 2014
Usage of Alternative Fuel in Boiler with Cost
Analysis in a Paper Industry
Sarath Paul#1, Dr. Manoj Kumar Panthalingal*2
#1
Department of Mechanical Engineering, M.Tech Production & Industrial Engineering,SCMS School of Engineering and Technology, India
*2 Department of Mechanical Engineering, Associate Professor, SCMS School of Engineering and Technology, India
Abstract- It is found that overall cost reduction is the one
of the important objective of every industry. In a paper
industry, fuel and wood materials are the important raw
materials. From this study it is found that coal is the
main fuel used in paper industry. Mainly it is used for
the production of steam in boilers which is an important
requirement in every paper industry. It is found that
during every financial year the amount spends on
purchasing coal goes on increasing. Several studies say
that cost of coal increases in the coming years and also
there is a chance of fuel scarcity. Due to the scarcity of
fuel, the steam generation is getting affected in boiler.In
this paper industry, steam is generated in three fluidised
bed combustion boilers. This paper likes to suggest the
usage of some alternative fuels in place of coal. In
Kerala, alternative fuels like cashew shell, coconut shell
etc is easily available. All these fuels have got heat value.
Even if these alternative fuels are used, coal cannot be
completely avoided in the boiler. But to a certain extent,
quantity of coal used can be reduced. This paper aims to
study the usage of alternative fuels in power boilers and
its work benefit out of this in a paper industry.This study
is very important for Government sector paper
industries for reducing the overall production cost.
Keywords- Boilers, paper industry in India, cost analysis,
indigenous coal, imported coal, cashew shell, coconut shell
I.
his study was carried out in a public sector paper industry
located at Kerala state in India. The main products of the
plant are newspaper of 44 and 48 GSM respectively. The main
raw materials of the company are coal and wood materials two
types of coal are used –Indigenous and imported coal and the
wood used for pulp is bamboo and reed. The plant has an
installed capacity to produce 100000 metric ton paper per
annum.
The first step is to identify the amount of coal with its cost
used in boiler. Then we suggest alternative fuels like coconut
shell and cashew shell in place of existing fuel in boiler. Then
its comparative cost analysis is carried out.
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II.
COAL FORMATION
Coal is considered as a fossil fuel produced from large
accumulations of vegetable matter due to partial decay and
alternation by the action of heat and pressure over millions of
years.
The formation of coal is explained by the following two
theories.
 In situ theory - According to this theory coal
formation took place at the place of vegetation itself.
The great purity of many coal seams can be better
explained by this theory.
 Drift of transportation theory -According to this
theory, the trees, etc. were uprooted and transported
by rivers to big lakes and other depressions, which
got filled and blocked hence huge piles of wood then
got buried underground .Under high temperature,
excessive pressure, absence of oxygen, presence of
bacteria and time, the cellulosic material of wood
underwent gradual decomposition with the
simultaneous liberation of gases such as Co2 and
methane. Great thickness of coal seams appears more
reasonable on the basis of this theorem.
III.
TYPES OF COAL
A. Lignite(Brown coal)
INTRODUCTION
T
After that we studied whether existing boiler is able to use the
suggested alternative fuels as fuel, and whether any
replacement is required or not.
These belong to the intermediate stage between peat and
black coals. These moisture content lies in the range of
40% .there carbon content on the dry ‘ash free basis’ ranges
from 60-75% while the oxygen is over 20% .lignite has high
volatile matter content usually up to 48%-50% and ash
content 40%.calorific value is in the range of 58007000kcal/kg. They are used has fuels in the for the power
plant and for producing producer gas.
B. Bituminous coal
They are harder and denser than lignite. Its moisture content
is 12-25% and calorific value is about 8000kcal/kg.
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International Journal of Engineering Trends and Technology (IJETT) – Volume 9 Number 5 - Mar 2014
Sub bituminous coals from a group between lignite and
bituminous coal. They are black in colour. There calorific
value is about 7000kcal/kg .there carbon content varies from
75-83% and oxygen content varies from 10-20%
VI.COST OF ALTERNATIVE FUELS
C. Anthracite
Anthracites are considered to Bethe highest rank of coal and
contain the maximum percentage of carbon i.e. about 9296%they have a very low percentage of volatile mater .there
calorific value is about 8600kcal /kg. Anthracites are used
metallurgical operations, central heating furnaces and
generation of producer gas.
IV.PROPERTIES OF ALTERNATIVE
FUELS

Cost of indigenous coal

Cost of indigenous coal

Cost of imported coal

Cost of imported coal

Cost of coconut shell

Cost of cashew shell
A. De oiled and crushed cashew shell
= 4100 Rs/MT(20102011-2012)
It is found that amount spend on purchasing coal is increasing
every financial year as its requirement is also increasing every
year. Expecting work benefits/savings through an cost
analysis from data's of two consecutive years (2010-20112012).
TABLE I
COAL UTILIZATION OF YEAR 2010-2011
B. Crushed coconut shell
Size: 3m to 8mm
Ash: 4-6%
Moisture :< 12%
SL.
NO
1
C. Chip dust(wood fines)
Moisture: 11.2%
Ash: 1.86%
2
3
4
5
D. Effluent sludge
Moisture: 71.2%
Ash: 8.55%
E. Dip sludge
6
7
8
9
Moisture: 57.8%
Ash: 13.33%
V. CALORIFIC VALUE OF ALTERNATIVE
FUELS
Calorific value of indigenous coal = 3400kcal/kg
Calorific value of imported coal
= 5600kcal/kg
Calorific value of coconut shell
= 3800kcal/kg
Calorific value of cashew shell
= 4000kcal/kg
Calorific value of wood fines
= 3000kcal/kg
Calorific value of ETP sludge
= 1200kcal/kg
Calorific value of DIP sludge
= 1800kcal/kg
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= 6000 Rs/MT(20102012)
= 6100 Rs/MT(20102012)
= 4000 Rs/MT(20102011- 2012)
VII. DATA COLLECTION
Size: 3 to 10 mm
Moisture: < 15%
Ash :< 4%







= 3700 Rs/MT(20102011)
= 3800 Rs/MT(20112012)
10
11
12
13
ITEMS
UNIT
2010-11
Steam generated
MT
785979
MCL coal consumed
Indigenous coal C grade
Indigenous coal E grade
Indigenous coal F grade
Total indigenous coal
Imported Coal High Moisture
Imported Coal - CV-6000
Imported Coal -low CV
Imported Coal –New
Imported Coal -CV more than
6000
Imported Coal-Indigenous
source
Total Imported coal
MT
MT
MT
MT
MT
MT
MT
MT
MT
75308
15892
0
0
91200
0
0
38686
10126
0
MT
20988
MT
MT
69800
161000
Total coal (Imp. + indig. )
Wood Fines
MT
5577
DIP Sludge
Eff. Sludge
Total Sludge
MT
MT
MT
0
960
960
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International Journal of Engineering Trends and Technology (IJETT) – Volume 9 Number 5 - Mar 2014
TABLE II
COAL UTILIZATION OF YEAR 2011-2012
SL.
NO:
1
2
3
4
5
6
7
8
9
10
11
12
13
ITEMS
UNIT
2011-12
Steam generated
MT
345848
MCL coal consumed
Indigenous coal C grade
Indigenous coal E grade
Indigenous coal F grade
Total indigenous coal
Imported Coal High
Moisture
Imported Coal - CV-6000
Imported Coal -low CV
Imported Coal –New
Imported Coal -CV more
than 6000
Imported Coal-Indigenous
source
Total Imported coal
Total coal (Imp.+ indig. )
Wood Fines
MT
MT
MT
MT
MT
MT
74428
15892
0
0
90320
0
DIP Sludge
Eff. Sludge
Total Sludge
Heat generated from 5% of coconut
Shell replaced (kcal)
Equivalent Indigenous coal (MT) =17328000000/(3400*1000)
required for generating same heat
=5096MT
Cost of 5% replaced coconut shells (Rs)
4560*4000
=Rs 18240000
Cost of indigenous coal saved (Rs)
5096*3700
=Rs 18855200
Therefore, Savings (Rs)
i.e
MT
MT
MT
0
38686
10126
0
MT
23868
MT
MT
MT
72680
163000
2246
MT
MT
MT
800
815
1615
VIII.COST ANALYSIS
From the coal utilization data collected (2010-2011-2012) out
in paper industry, undergo an cost analysis by replacing the
coal with alternative fuels like coconut shell and cashew shell
separately
= Rs 18855200- Rs 18240000
= Rs 615200
B.COST ANALYSIS OF YEAR 2010-2011
(By replacing imported coal with coconut shell)
Imported coal
Indigenous coal
Total coal during the year (2010-11)
5% of imported coal replaces
With coconut shell
Cost of imported coal (Rs/MT)
CV of imported coal (Kcal/Kg)
Cost of coconut shell (Rs/MT)
CV of coconut shell (Kcal/kg)
69800MT
91200MT
161000MT
Heat generated from 5% of coconut
Shell replaced (Kcal)
3490*3800*1000
=13262000000
3490MT
Rs 6000
5600
Rs 4000
3800
Equivalent Imported coal (MT) =13262000000/(5600*1000)
required for generating same heat
=2368MT
Cost of 5% replaced coconut shells (Rs)
Cost of imported coal saved (Rs)
A.COST ANALYSIS OF YEAR 2010-2011
(By replacing indigenous coal with coconut shell)
4560*3800*1000
=17328000000
Therefore, Savings (Rs)
i.e.
3490*4000
= Rs 13960000
2368*6000
= Rs 14208000
= Rs 14208000- Rs13960000
=Rs 248000
i.e. Total savings during 2010-2011 = Rs 248000+ Rs
615200
Indigenous coal
Imported coal
91200MT
69800MT
Total coal during the year (2010-11)
5% of indigenous coal replaces
With coconut shell
161000MT
Cost of indigenous coal (Rs/MT)
Rs 3700
C. COST ANALYSIS OF YEAR 2011-2012
(By replacing indigenous coal with coconut shell)
3400
Rs 4000
3800
Indigenous coal
Imported coal
Total coal during the year (2011-12)
5% of indigenous coal replaces
CV of indigenous coal (Kcal/Kg)
Cost of coconut shell (Rs/MT)
CV of coconut shell (Kcal/Kg)
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4560MT
i.e.
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= Rs 863200
90320MT
72680MT
163000MT
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International Journal of Engineering Trends and Technology (IJETT) – Volume 9 Number 5 - Mar 2014
With coconut shell
Cost of indigenous coal (Rs/MT)
CV of indigenous coal (Kcal/Kg)
Cost of coconut shell (Rs/MT)
CV of coconut shell (Kcal/kg)
Heat generated from 5% of coconut
Shell replaced (kcal)
4516MT
Rs 3800
3400
Rs 4000
3800
4516*3800*1000
=171608000000
E . COST ANALYSIS OF YEAR 2010-2011
(By replacing indigenous coal with cashew shell)
Indigenous coal
Imported coal
91200MT
69800MT
Total coal during the year (2010-11)
161000MT
5% of indigenous coal replaces
Equivalent Indigenous coal (MT)=171608000000/(3400*1000) With coconut shell
required for generating same heat
=5047MT
Cost of indigenous coal (Rs/MT)
Cost of 5% replaced coconut shells (Rs)
4516*4000
CV of indigenous coal (Kcal/Kg)
= Rs 180640000
Cost of cashew shell (Rs/MT)
4560MT
Cost of indigenous coal saved (Rs)
4000
Therefore, Savings (Rs)
5047*3800
= Rs 19178600
= Rs 19178600-Rs 180640000
i.e.
= Rs 1114600
D. COST ANALYSIS OF YEAR 2011-2012
(By replacing imported coal with coconut shell)
Rs 3700
3400
Rs 4100
CV of cashew shell (Kcal/kg)
Heat generated from 5% of cashew
Shell replaced (Kcal)
Equivalent Indigenous coal (MT) =1824000000/(3400*1000)
required for generating same heat
=5364MT
Cost of 5% replaced coconut shells (Rs)
Cost of indigenous coal saved (Rs)
Imported coal
Indigenous coal
Total coal during the year (2011-12)
72680MT
90320MT
163000MT
5% of indigenous coal replaces
With coconut shell
Cost of imported coal (Rs/MT)
CV of imported coal (Kcal/Kg)
3634MT
Rs 6100
5600
Cost of coconut shell (Rs/MT)
CV of coconut shell (Kcal/kg)
Rs 4000
3800
Heat generated from 5% of coconut
Shell replaced (Kcal)
Equivalent Imported coal (MT)
=13809200000/(5600*1000)
required for generating same heat
3634*4000
= Rs 14536000
Cost of imported coal saved (Rs)
2465*6100
= Rs 15036500
= Rs 15036500- Rs 1453600
i.e
= Rs 500500
i.e. Total savings during 2011-2012 = Rs 1114600+
Rs 500500
i.e.
= Rs 1615100
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4560*4100
= Rs 18696000
5364*3700
= Rs 19846800
=Rs 19846800- Rs 18696000
=Rs 1150800
F. COST ANALYSIS OF YEAR 2010-2011
(By replacing imported coal with cashew shell)
Imported coal
69800MT
Indigenous coal
91200MT
Total coal during the year (2010-11)
5% of imported coal replaced
With cashew shell
161000MT
Cost of imported coal (Rs/MT)
CV of imported coal (Kcal/Kg)
Cost of cashew shell (Rs/MT)
CV of cashew shell (Kcal/kg)
Rs 6000
5600
Rs 4100
4000
3490MT
=2465MT
Cost of 5% replaced coconut shells (Rs)
Therefore, Savings (Rs)
Therefore, Savings (Rs)
i.e.
3634*3800*1000
=13809200000
4560*4000*1000
=1824000000
Heat generated from 5% of cashew
Shell replaced (Kcal)
3490*4000*1000
=13960000000
Equivalent imported coal (MT) =13960000000/(5600*1000)
required for generating same heat
=2492MT
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International Journal of Engineering Trends and Technology (IJETT) – Volume 9 Number 5 - Mar 2014
Cost of 5% replaced cashew shells (Rs)
Cost of imported coal saved (Rs)
3490*4100
= Rs 14309000
2492*6000
= Rs 14952000
Therefore, Savings (Rs)
i.e
= Rs 14952000-Rs 14309000
= Rs 643000
i.e. Total savings during 2010-2011 = Rs 1150800 + Rs
643000
i.e.
= Rs 1793800
G. COST ANALYSIS OF YEAR 2011-2012
(By replacing indigenous coal with cashew shell)
H. COST ANALYSIS OF YEAR 2011-2012
(By replacing imported coal with cashew shell)
Imported coal
72680MT
Indigenous coal
Total coal during the year (2011-12)
5% of indigenous coal replaces
With cashew shell
Cost of imported coal (Rs/MT)
CV of imported coal (Kcal/Kg)
Cost of cashew shell (Rs/MT)
CV of cashew shell (Kcal/kg)
90320MT
163000MT
Heat generated from 5% of cashew
Shell replaced(Kcal)
3634MT
Rs 6100
5600
Rs 4100
4000
3634*4000*1000
=14536000000
Equivalent Imported coal (MT) =14536000000/(5600*1000)
required for generating same heat
=2595MT
Indigenous coal
Imported coal
90320MT
72680MT
Cost of 5% replaced coconut shells (Rs)
3634*6100
=Rs 14899400
Total coal during 2011-12
5% of indigenous coal replaces
With coconut shell
163000MT
Cost of imported coal saved (Rs)
2595*6100
= Rs 15829500
4516MT
Cost of indigenous coal (Rs/MT)
CV of indigenous coal (Kcal/Kg)
Cost of cashew shell (Rs/MT)
CV of cashew shell (Kcal/kg)
Rs 3800
3400
Rs 4100
4000
Therefore, Savings (Rs)
i.e.
= Rs 15829500- Rs 14899400
= Rs 930100
i.e. Total savings during 2011-2012
Heat generated from 5% of cashew shell
replaced (Kcal)
Equivalent Indigenous coal (MT)
required for generating same heat
4516*4000*1000
=18064000000
=1824000000/(3400*1000)
=5312MT
Cost of 5% replaced coconut shells (Rs)
4516*4100
=Rs 18515600
Cost of indigenous coal saved (Rs)
5312*3800
= Rs 20185600
Therefore, Savings (Rs)
i.e.
= Rs 20185600- Rs 18515600
= Rs 1670000
= Rs 1670000+ Rs 930100
= Rs2600100
IX. RESULTS
We got the total savings of respective each year (2010-20112012),
 Total savings during 2010-2011
= Rs 863200 + Rs 1793800
i.e.

Total savings during 2011-2012
= Rs 1615100 + Rs 2600100
i.e.
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= Rs 2657000
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= Rs 4215200
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International Journal of Engineering Trends and Technology (IJETT) – Volume 9 Number 5 - Mar 2014
X. CONCLUSIONS
We know that, now days the use of coal for the energy
generation is increasing day by day which leads to high
expenses and thereby scarcity/unavailability of coal is also
increasing constantly. Therefore we can introduce some fuels
as alternative fuels such as coconut shell & cashew shell.
After analyzing the cost, heat value and availability of
alternative fuels, we have suggested for a limited usage of
alternative fuels. By this project; we expect annual savings of
approximately above Rs.26 lakhs (2010-11) and above Rs.42
lakhs (2011-12) respectively. In the competitive field of
industry, any amount saved is very important for the survival
of the industry.
So I think that this suggestion using alternative fuels will be
much beneficial for HNL in their day to day process.
ACKNOWLEDGMENT
First of all we should thank God almighty for blessing us
with the wisdom to complete this work. We should also thank
all the staff members and department heads of Hindustan
Newsprint Ltd and all the staff members and our colleges of
SSET. We should also thank our dear parents and dear friends,
who always support us.
REFERENCES
[1]
[2]
[3]
[4]
Hindustan Newsprint Limited, Annual Report 2011-2012.
Available and Emerging Technologies for Reducing Greenhouse Gas
Emissions from Industrial, Commercial, and Institutional Boilers,
Policies and Programs Division ,Office of Air Quality Planning and
Reduction in Rural Domestic Energy Sector Through Alternative Fuel
Replacement, International Journal of Renewable energy research,
Vol.2, No.1, 2012.Standards , U.S. Environmental Protection Agency,
October 2010 .
K. J. Sreekanth, N. Sudarsan, S. Jayaraj, Achieving Certified Emission
Utility Department working manuals
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