CO-GENERATION - AN INDIAN MODEL
VINAY KUMAR
MANAGING DIRECTOR
4/8/2015
1
OUTLINE OF PRESENTATION
•Co-generation
•Indian Energy Scenario
•Renewable Energy Development
•Power Generation from Renewal source of Fuel
•Power generation from Bagasse in sugar industry
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CO-GENERATION
Co-generation in simple terms is defined as a
process of using single fuel to produce two
forms of energy i.e.
•Thermal energy - for process
•Electrical energy- for utilities
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NEED FOR CO-GENERATION
Power is the basic need for any activity. The
growth of economy calls for commensurate growth
in the infrastructure facilities.
India is facing a very significant power deficit today
to- the tune of 20,000 MW (18% of peak deficit).
Besides the above, it is estimated that requirement
of fossil fuel shall be as under :•450 million tonnes of coal
•94 million tonnes of oil
Most of this energy consists of non-renewable
sources and thereby in effect unsustainable.
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BENEFITS OF CO-GENERATION
For the End-users/Co-generators:
•
Additional income from selling surplus electricity
•
Additional income from selling CHG
a)
Certified Emission Reduction (CER)
b)
Increasing security for clean energy supply
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For the Power utility & National Economy
•
Saving primary energy consumption
•
Reducing transmission and distribution losses
•
Less burden on Government for power
generation investment
•
Less environmental pollution
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INDIAN ENERGY SCENARIO
•
Total population
-
1.18 billion
•
Rural population
-
0.7 billion
•
Total number of villages
-
640,000
•
Number of un-electrified villages-
125,000
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INSTALLED POWER SCENARIO
• TOTAL INSTALLED CAPACITY : 1,48,265 MW
• GROSS GENERATION
: 640 billion units
• PER CAPITA CONSUMPTION
: 620 kWh/ annum
• ENERGY SHORTAGE
: about 8%
• PEAK SHORTAGE
: about 18 %
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POWER GROWTH PERSPECTIVE
*
Electricity demand growing @ 8% annually
*
Capacity addition of about 92,000 MW
required in the next 10 years
*
Challenge to meet the energy needs in a
sustainable manner
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THE CHALLENGE & VISION
*
India is facing formidable challenges in
meetings its energy needs and providing
adequate energy of desired quality in a
sustainable manner and at a reasonable costs.
*
To meet the above challenge, Government of
India took the decision to develop 10% power
from renewable source by 2012.
*
The Government vision is to provide power to
all citizens.
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RENEWABLE ENERGY IN INDIA - POTENTIAL
Wind Power
-
48000 MW
Small Hydro
-
15000 MW
Biomass Power
-
16000 MW
Bagasse Cogen
-
5000 MW
Solar Energy
-
20 MW/Sq Km
Waste to Energy
-
2500 MW
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BIOMASS
TYPES OF BIOMASS WHICH CAN BE USED
• Agricultural Field Residues
• Agro Industrial Residues
• Bagasse
• Wood from plantation
• Waste wood from industrial operations
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CONVERSION TECHNOLOGIES
Biomass Technologies Currently Deployed
• Combustion
• Gasification
Cogeneration
• Bagasse cogeneration in sugar mills
• Non-bagasse cogeneration in other industries
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STATE WISE POTENTIAL OF CO-GENERATION IN
SUGAR INDUSTRY
Sl.No
Name of State
Potential to export of
power in MW
1.
Uttar Pradesh & Uttarakhand
1250
2.
Haryana
350
3.
Punjab
300
4.
Andhra Pradesh
300
5.
Tamil Nadu
450
6.
Karnataka
450
7.
Maharashtra
1250
8.
Bihar
300
9.
Gujarat
350
All India Total
5000
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14
0
4/8/2015
State
450
Karnataka
350
Gujarat
1250
5000
5000
All India
300
Bihar
Maharashtra
450
300
Andhra
Pradesh
Tamil Nadu
300
Punjab
500
350
1000
Haryana
1500
1250
2000
Uttar Pradesh &
Uttarakhand
5500
4500
4000
3500
3000
2500
Potential to export of power MW)
15
STATE WISE STATUS OF CO-GENERATION
State
Number of units
Total Co-generation (MW)
Uttar Pradesh
57
1254.5
Punjab
3
41.0
Andhra Pradesh
13
195.0
Tamil Nadu
24
550.0
Karnataka
27
610.0
Maharashtra
21
416.5
Bihar
2
23.0
Total
147
3090.0
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4/8/2015
Number of Units
All India
Bihar
Maharashtra
Karnataka
610.00
550.00
416.50
147
2
23.00
21
27
24
13
195.00
1000
Tamil Nadu
500
Andhra
Pradesh
1254.50
1500
3
41.00
57
2000
Punjab
Uttar
Pradesh
3090
3500
3000
2500
0
Total Co-geneation
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PROMOTIONAL INCENTIVES FOR BIOMASS PROJECTS
*
Accelerated depreciation 80% in first year
(boiler and turbine)
*
Income Tax holiday under section 80 1A for 10
years.
*
Concessional import duty, excise duty
exemptions on equipments & components
required for initial setting up of the project.
*
Sales tax exemption in some states.
*
IREDA provide loan for biomass power / cogeneration projects.
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*
Preferential tariff in 14 states.
*
Ministry of Food provide concessional loan
for Co-generation project @ 4% to the
40% of the project cost.
*
Ministry of New and Renewable Energy
also grant capital subsidy @ 60 lacs per
MW upto the maximum of 8 crores per
project.
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INDIAN MODEL OF CO-GENERATION.
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A-CASE STUDY - EXISTING 5000 TCD SUGAR PLANT
EQUIPMENTS:•
Replacing / scrapping of the existing low
pressure power
plant
which
includes
boilers, turbines and accessories
after
installation of efficient co-generation plant
with high pressure 87 kg/cm2 boiler, turbine,
switch yard, transmission line and other
accessories.
•
Replacing the existing inefficient turbine drive
for Mill replace with energy efficient VFD –
A.C. motors.
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*
Replacing
of
the
existing
inefficient
turbines drives for fibrizer / shredder with H.T.
motors after installation of Co-generation
plant.
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INVESTMENT:S.No. Details of Equipments
Cost
(Rs.)
in
1)
25 MW power plant with 120 TPH boiler of 87 : 1150.00
kg/cm.2 with cooling tower, Water Treatment
Plant, switch yard, 132 KV line etc.
2)
Replacement of mill drive turbine with AC : 20.00
VFD motors & transformers, cabling etc.
3)
Replacement of fibrizer / shredder turbine : 10.00
drive with HT motors, starters & cabling etc.
4)
Miscellaneous
: 5.00
Total
: 1185.00
Million
Less : Scrap value of discarded equipments : 40.00
approx.
Net : Total expenditure
: Rs.1145.00
USD-25.50 million
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RETURN ON INVESTMENT:S.No. Description
Units Value
1)
Generation of power / tonne of cane with a KWH 154
condensing, extraction cum back pressure
turbine
(1 Tonne) 1000 kgs of cane x 32% bagasse
x 2.4 steam generation / 5 kg steam / KWH
2)
In house consumption per tonne of crush KWH 30
(30 KWH/ Tonne crush at peak capacity)
3)
Exportable power per tonne of cane (154 – KWH 124
30)
4)
Revenue earning per tonne of cane crush Rs.
through power export @ Rs. 4.00 x 124
KWH
5)
Revenue earning in one season of cane Rs
crush through power export @ 4.00 x 124
x800000
Thus, the return on investment is less than 3 years.
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496.0
39.60 million
i.e. USD-8.8
million
24
B-CASE STUDY NEW 5000 TCD SUGAE PLANT
MAIN EQUIPMENTS AND THEIR COST:S.No Details of Equipments
Cost in Million
(Rs.)
1)
Sugar Plant -5000 TCD
:
Rs. 330.00
2)
Boiler-120 Tonne, 87 Kg/cm2g.
:
Rs. 120.00
3)
T.G.Set-25 MW.
:
Rs. 130.00
4)
Switch Yard & Electrical
:
Rs. 80.00
5)
Miscellaneous
:
Rs. 40.00
Total
:
Rs. 700.00
USD-15.55
million
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RETURN ON INVESTMENT (Power Export):S.No. Description
Units
Value
1)
Capacity
:
TCD
5000
2)
Working days
:
days
160
3)
Cane crush
:
lac Tons 8
4)
Bagasse generation 32% on cane
:
lac Tons 2.56
5)
Steam generation at a ratio of 2.4
:
lac Tons 6.14
6)
Power generation at a rate of 5 tons :
steam / MWH
MWH
1,22,800
7)
In house consumption 30 KWH per :
ton of crush
MWH
24000
8)
Exportable power (6-7)
MWH
98800
9)
Revenue earning @ Rs. 4000 / MWH :
(Rs. 4.00/ KWH)
Million
Rs. 395.2
10)
Earning in 3 season Rs. 395.2 x 3
Million
Rs. 1185.6
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:
:
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EXECUTION OF TIME REQUIRED
1)
Planning & Placement of order
:
2 Months
2)
Execution & Erection
:
10 to 12 months
Total
:
12 to 14 months
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PERFORMANCE DATA
Performance of the Haidergarh Chini Mills (a unit of Balrampur
Chini Mills Ltd.) a 5000 TCD plant for 3 years is given below
for reference purpose only.
Sl.No.
Particulars
Years
Total
2006-07
2007-08
2008-09
790000
472000
150000
1412000
71688
23250
294756
1)
Cane crush (Tonnes)
2)
Power
(MWH)
3)
Net exported power 87690
(MWH)
52392
18450
158532
4)
Revenue earned @ 3.00 / KWH (Rs.)
-
-
4756 lacs
million
5)
Return on investment -< 3 years
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generated 121660
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CONCLUSION
•
This is the appropriate time to plan for adoption of such
technologies which can bring extra revenue to sugar
mills.
•
Return on investment is normally 3-5 years depending
upon selection of technology and sizing of equipment.
•
Selection of proper, size and addition of appropriate
technology play a major role for maintaining higher plant
load factor and higher efficiencies of the plant.
•
NFCSF provided consultancy services for around 20
sugar co-generation project from inception to
commissioning.
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OVERALL VIEW OF POWER PLANT
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CONTROL ROOM
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VIEW OF BOILER
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VIEW OF ALTERNATOR
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VIEW OF COOLING TOWER
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VIEW OF SWITCH YARD 11kv/132 kv
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THANKS
NATIONAL FEDERATION OF COOPERATIVE SUGAR FACTORIES LIMITED
‘ANSAL PLAZA’ BLOCK-C, 2ND FLOOR
AUGUST KRANTI MARG,
NEW DELHI-110049 (INDIA)
Tel. : 26263425, 26263436, 26263696
Fax : 011-26263658, e-mail : nfcsf@spectranet.com
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