ISGEC JOHN THOMPSONA-4, Sector-24Noida , India

High Pressure Bagasse Fired Boilerfor Cogeneration in Sugar Industry

Presented byA.K Subramanian

aksubramanian@isgec.com

Arun Tewariatewari@isgec.com

June 2008

Higher the Cycle Parameters More power output with same input quantity of fuel

ADVANTAGES OF

High Pressure Boiler - Advantages

Parameters Unit 45Kg/cm2

(a) / 4400C66Kg/cm2

(a) / 485 0C87Kg/cm2

(a) / 5150C105Kg/cm2 (a) / 540 0C

Feed Water temp to boiler

0C 105 (without

HP Heater)

150 (with 1 HP Heater)

170 (with 1 HP

Heater)

220 (with 2 HP Heaters)

Bagasse Quantity

TPH 43.51 41.78 41.2 38.47

Steam /Fuel ratio

- 2.29 2.39 2.42 2.59

Gross Power output

MW 24.8 26.5 28.0 29.0

Specific Steam consumption

Kg/KW-hr

4.03 3.77 3.577 3.44

Power Generation per ton of Bagasse

KW/Ton Base + 11% + 19% + 32%

2

Single Drum

Natural Circulation

Balanced Draft

Top Supported

Outdoor

Water Cooled Membrane Furnace

Continuous Ash Discharge Travelling Grate Stoker

Rotary Drum Feeder withPneumatic Spreaders

Three Stage Feed Water Heating(Deaerator and 2 stages of HPheater)

Two stage superheater withinter-stage attemperator

Pre-Dust Collector Upstream ofElectrostatic Precipitator

Equipped with Evaporator &Economizer

Tubular Air Heater as the last stage of heat recovery

High Pressure Boiler - Design Basis

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Travelling Grate Boiler

(170 TPH , 105 kg/cm2(g), 540 Deg C, Single Drum)

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• High Up Time

• High Efficiency

• Enhanced Life

• Environment Friendly & Safe Operation

• Ease of O&M

• Boiler Engineered Using Latest Design Software

High Pressure Boiler - Unique Feature

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FEATURES ADVANTAGES

Single Drum Boiler • High Ligament efficiency of drum• Better Circulation due to non heated

(outside gas path) down comers

Tall Furnace • High Residence time (3 seconds)• Low Unburnt Carbon

Refractory Band at lower furnace Zone

• Sustained combustion even with highmoisture (upto 54%) in bagasse

Evaporator in place of Boiler Bank

• No Tube expansion• Eliminates leakages

High Up Time

…Contd.

6

FEATURES ADVANTAGES

All Pressure part tubes of seamless construction

• Eliminates leakages • Longer life

Structures & Equipment designed with High ‘Importance Factor’

• Increased Structural Integrity• Minimum Vibration• Longer life

SA 213 T91 material for final elements of secondary superheater

• High Creep, Fatigue, Corrosion

and erosion resistance

Convective Super Heaters with wide pitching

• Avoids fouling• Lower metal temperature

High Up TimeContd.

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FEATURES ADVANTAGES

Travelling grate bars with SG Iron metallurgy

• High Durability• Resistance to wear & tear at

elevated temperatures

Double Casing for Economizer • Protects bends from erosion

Pre-Dust Collection system at Economizer Outlet

• Reduces particulate loading on ESP & ID Fans

• Reduces Unburnt carry over toESP eliminating fire hazards

High Frame Size of Motors with VFD • Minimizes Heat Losses

Ferrules for Air Heater Inlet tubes & Corton Steel material at Cold end

• Minimizes Erosion & Corrosion

Enhanced Life

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FEATURES ADVANTAGES

High pressure Secondary Airat 4 tiers

• Better turbulence & mixing• Efficient Combustion• Minimum Unburnt Carbon Loss

Generous grate area loading & volumetric loading of furnace

• Efficient combustion • Minimum Unburnt Carbon Loss

High Efficiency

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FEATURES ADVANTAGES

Reliable & Proven Electro Static Precipitators

• Particulate emission upto 30mg/Nm3

Silencers for Safety Valves, Start Up vent Valve and FD /SA Fans

• Noise levels as perOccupational Health & SafetyAdministration (OSHA) norms

HAZOP Studies • Safety of equipment & operating personnel

Environment Friendly & Safe Operation

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FEATURES ADVANTAGES

Stoker Shaft with Self Lubricated Graphite bearings

• High reliability• Maintenance free• Dimensionally stable• Chemically Inert• Non hygroscopic

Leak Proof Stoker Sealing • Avoids leakage

On-line Vibration Monitoring System for Critical Rotating equipment

• Predictive Maintenance• Avoids Failures

On-line Steam & Water Analyser system (SWAS)

• Ensures Strict Control of Water Chemistry

Ease of O & M

…Contd.

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Ease of O & M

FEATURES ADVANTAGES

Water Cooled Membrane Furnace

• Less Maintenance• High Structural rigidity

Automated Operations with

Distributed Control System

(DCS) & Supervisory Controls

and Data Acquisition ( SCADA) with adequate redundancies in Power Supply, Communication Module and Processor

• Accurate controls• Less manpower

Contd.

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Process Calculations software

• KED Germany Steam Plant simulator

• PBAB• In-House Software

• For Optimisation

• For High Efficiency

• For Better Aesthetics

• For Ergonomic Design

Analysis software • Staad Pro 2006• CAESER II 5.1

Modeling software • Prosteel 3D• CAD works for

Plants/Equipments• Solid works

Document Management System (PLM)

• Windchill9.0 PDM Link

Drafting • AutoCAD 2008

ERP • BaaN 4C4

Boiler Engineered using latest Design Softwares

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3-D model Flow Model

Boiler Engineered Using Latest Design Software

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Design Fuel : 100% Mill Wet Bagasse, 77% Rice husk , 70% Indian coal

Net Steaming capacity at MCR for Bagasse 170,000 Kg/hr

Main Steam Pressure/Temperature at MSSV outlet

105 Kg/cm2(g) / 540 Deg C

Peak capacity of Boiler 187,000 Kg/hr

Steam temperature control range 60-100% MCR

Boiler design pressure 124 Kg/cm2(g)

Feed water temperature at De-aerator outlet and Economizer inlet

130/220C*

Gas temperature leaving air heater 150C

* With two stages of HP Heaters

High Pressure Bagasse Fired Boiler - Design Features

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30 MW from Single Boiler45 MW under Condensing modeDhampur Sugar Mills, Asmoli (U.P.)

High Pressure Boiler

170 TPH, 105 kg/cm2(g), 5400 C

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• 10 Minutes storage Silo• Rotary drum feeders• Screw Conveyors• Pneumatic Spreaders • With modulating dampers

Typical Schematic Drawing

Silo & Bagasse Feeding Arrangement

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Rugged, Efficient & Easy to Maintain

Continuous Ash Discharge Traveling Grate Stoker

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Avoids Erosion at Gas Entry Side of APH Tubes

Ferrules made of wear resistant material

Ferrules at Air Preheater Inlet Tubes

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Parameters Units Design values Achieved values

Steam Flow at MCR TPH 170 171.38

Steam Pressure at Main Steam Stop Valve Kg/Cm2 105 105.4

Steam temperature at Main Steam Stop Valve Deg C 540 + 5 539

Boiler Thermal efficiency on LHV Basis % 89.1 89.5

Back end Temperature (Gas leaving Air heater)

Deg C 150 140

Auxiliary Power Consumption KW 1912 1754

Noise level of rotating equipment at 1 meter dB 85 <85

Steam to fuel ratio - - 2.6

Commissioned in : October, 2007

Electricity generation* : 60 millions units of electricity

Electricity to grid : 58.5 millions units were exported to grid

Boiler Availability* : 97.6 %

Performance Data

* till April 2008

Boiler Performance

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105 Kg/Cm2 & 540 Deg C 2

87 Kg/Cm2 & 515 Deg C 25

66 Kg/Cm2 & 485 Deg C 21

Number of units in operation Number of units under Execution

110 Kg/Cm2 & 540 Deg C 4

87 Kg/Cm2 & 515 Deg C 6

IJT is executing India’s largest

Bagasse based 36 MW Cogeneration Power Plant

in Maharashtra, India

with 180 TPH, 110 kg/cm2(g), 5400 C Boiler

on Turnkey basis

IJT’S Presence 352 Bagasse & Biomass fired boilers

IJT’S Experience Overseas 25 nos. boilers generating more than 300 MW

High Pressure Bagasse Fired Boilers - Experience

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