s c. natu sr. vice president (power division) mitcon consultancy & engineering services ltd
TRANSCRIPT
S C. Natu Sr. Vice President (Power Division)
MITCON Consultancy & Engineering Services Ltd.
All India potential, 7000 MW (650 sugar mills) Achievements as of September 30, 2012, 2250
MW (200 projects) Under construction, 750 MW (50 projects) Total, 3000 MW (250 projects), 43% penetration Private sector leading in States like UP, Tamil
Nadu, Karnataka & Andhra Pradesh
Co-operatives leading in Maharashtra & Tamil Nadu
Own investment & BOOT models established Conducive CERC / SERC orders, CDM, REC &
power trade, the key drivers Results of promotional measures, mainly by
MNRE
Conventional rankine cycle technology Own / saved bagasse, biomass & coal used as
primary fuels, during season & off season of the sugar mills
Travel grate type boilers designed for multi-fuel operations
High pressure / temperature steam generated and expanded through back pressure or double extraction cum condensing TG set
Medium pressure steam at 8 kg/cm2 pressure used for HP heater & process requirements
Back pressure steam at 1.5 kg/cm2 pressure used for process requirements & de-aerator
Balance steam condensed through the condenser
Power generated during season used for cogen plant auxiliaries, sugar / by-product process & balance exported to the grid
Power generated during off season used for cogen plant auxiliaries, by-products, colony & balance exported to grid
Steam to fuel ratios range from 2.4 kg/kg to 2.65 kg/kg
Steam to power ratios range from 5.2 – 5.6 kg/kw during season & 3.6 – 4.0 kg/kw during off season
PLF, 55 – 60% during season & 90% during off season
Boiler efficiencies, 68-72% on bagasse & 80% on coal
TG efficiency of 90% Station heat rates, 3600 – 3800 kcal/kwh Capex, Rs. 5.25 crore / MW for cogen power
plant & Rs. 1.0 – 1.5 crore / MW for concurrent sugar factory modernization
O&M, 3-5%
Main packages Boiler & auxiliaries Turbine, generator & auxiliaries Cooling tower or ACC Fuel & ash handling Electrical distribution / evacuation Water treatment plant Civil works
Main packages (contd.) Plant DCS EOT crane AC & ventilation system Air compressor DG set Interface HP / MP / LP steam, cooling water, DM
water & compressed air piping Fire fighting
COND.G.S.C.
Kg/Cm 2 Kcal/Kg
FLOWTPH
TEMP.°C
BFP
PRESSURE
LEGEND :-
ENTHALPY
CEP
124.5
116
115
154
98DEAERATOR
124.59.7
4
HEATERHP
22098
659
150
2.5
4.85
SJAE
BLOW DOWN1 TPH226150
BAGASSE
BOILER36.60 TPH
828110
97 540
8
249
704.5
15.51
HOTWELL
TURBINE GEN.
61.92 150407.452.5 659
0.1 580
20 MWSTEAM
18.65 MW
FLASH RECOVERY 0.5 TPH
0.49 TPHTO GSC & SJAE
SUGAR FACTORYL.P. STEAM TO
58.33 150
2.5 659
7.94 TPH
8
249
704.5
9.7
100 TPH
ETHANOL PLANTM.P. STEAM TO
0.49 TPH
FROM SJAE & GSC
110 Kg/Cm540°C
2
8
180
700.5
6
B B
G.S.C. - GLAND STEAM COOLERSJAE - STEAM JET AIR EJECTORCEP - CONDENSATE EXTRACTION PUMP
MP - MEDIUM PRESSURELP - LOW PRESSURE
CW - COOLING WATERTPH - TONNES PER HOUR
LEGENDS :-
- PRESSURE CONTROL VALVE
BFP - BOILER FEED PUMP
MA
KE
UP
9.42
4
33
33
SUGAR FACTORY 55.4 TPH, 95°C
CONDENSATE RETURN FROM
DM
WA
TE
R FEED WATER
TANK
64.82 TPH
TRANSFER PUMP
25
359
748
11.64
-
222
228
11.64
NO 1
HEATERHP
NO 2
16698
169152
826.3
535
105
96.51
CONDENSER
CW OUTLET
CW INLET
SURFACE
40600
- 40
32600
- 32
A
J
1.26 TPH
I0.19 TPH
4
1.26 J115
116
115I
10
0.19
116
COND.G.S.C.
Kg/Cm 2 Kcal/Kg
FLOWTPH
TEMP.°C
BFP
PRESSURE
LEGEND :-
ENTHALPY
CEP
124.5
116
115
154
82.8DEAERATOR
124.58.2
4
HEATERHP
22082.8
659
150
2.5
5.74
SJAE
BLOW DOWN0.8 TPH
226150
BAGASSE
BOILER30.94 TPH
828110
82 540
8
249
704.5
13.92
HOTWELL
TURBINE GEN.
5.63 1505452.212.5 659
0.14 580
20 MWSTEAM
20 MW
FLASH RECOVERY 0.4 TPH
0.41 TPHTO GSC & SJAE
52.62 TPH
8
249
704.5
8.2
100 TPH
ETHANOL PLANTM.P. STEAM TO
0.41 TPH
FROM SJAE & GSC
110 Kg/Cm
540°C
2
8
180
700.5
6
B B
G.S.C. - GLAND STEAM COOLERSJAE - STEAM JET AIR EJECTOR
CEP - CONDENSATE EXTRACTION PUMP
MP - MEDIUM PRESSURELP - LOW PRESSURE
CW - COOLING WATERTPH - TONNES PER HOUR
LEGENDS :-
- PRESSURE CONTROL VALVE
BFP - BOILER FEED PUMP
MA
KE
UP
6.4
4
33
33
SUGAR FACTORY 0 TPH, 95°C
CONDENSATE RETURN FROM
DM
WA
TE
R FEED WATER
TANK
6.4 TPH
TRANSFER PUMP
25
359
748
9.84
-
222
228
9.84
NO 1
HEATERHP
NO 2
16682.8
169152
826.3
535
105
81.59
CONDENSER
CW OUTLET
CW INLET
SURFACE
404300
- 40
324300
- 32
A
J
0.11 TPH
4
0.11 J115
116
I
0.28 TPH
I
4
0.28 115
116
Extra high pressure boiler (87 kg/cm2 pressure & 110 kg/cm2 pressure), commercialized
Matching back pressure, single / double extraction cum condensing type TG sets, commercialized
Air cooled condensers and RO type water treatment plants for overcoming water quality and availability issues, commercialized
Plant DCS, VFDs, ACVFD drives, grid synchronization, etc. technologies, commercialized
Extended off season by utilization of cane trash & other biomass materials, getting progressively commercialized
Equipment, technology & services available indigenously
All India potential, 18000 MW from agro waste materials (excluding sugar mills)
Potential will explode with energy plantation on waste lands for power generation
Achievements as of September 30, 2012, 1250 MW (160 projects) & under construction, 250 MW (20 projects), only 8% penetration
Conducive CERC / SERC orders, CDM, REC & power trade, the key drivers
Results of promotional measures, mainly by MNRE
Conventional rankine cycle technology, similar to bagasse cogen
Extra high pressure boiler (67 kg/cm2 pressure & 87 kg/cm2 pressure), commercialized
Variety of biomass materials established, although fuel linkage difficult
Equipment, technology & services available indigenously Independent biomass power plant models established,
yet captive power plants in industries through biomass in experimental stages
Continuation of MNRE / MoF fiscal & financial support Rationalization of tariffs, other provisions of ERC orders
& adequate hikes due to rise in capital & operating costs Consideration capex for essential sugar mill
modernization for tariff determination Demonstration & commercialization of fuel linkage
mechanisms & energy plantation models Capacity building & information Dissemination Technology development / demonstration, difficult
biomass materials like paddy straw, mustard husk Level playing field for CDM, REC & power trade
Engineering / consultancy services
Technology transfer & equipment / EPC supply
O&M contracts
Financing, equity & debt
Capacity building
Information dissemination
Consultancy / engineering company, established in 1982 Central / State Government stakeholders, 59.5% of shares &
Private shareholders, 40.5% shares Profit making & IS/ISO 9001:2008 certified company Sugar & Power, infrastructure, energy & carbon,
environment, agri business, finance & market research, biotechnology, main consultancy / engineering divisions
Latest infrastructure & experienced manpower (totaling to 225, engineering about 100)
Offices in Pune, Mumbai, New Delhi, Ahmedabad, Chennai & Nagpur
MITCON Consultancy & Engineering Services Ltd.
To become a ‘One Stop’ service provider for decentralized Power Projects on any fuel, from concept to successful commissioning & establish at the National & International Levels
MITCON Consultancy & Engineering Services Ltd.
Vision
Services (Sugar, Power & Ethanol Projects) Pre-investment (Feasibility study, fuel / biomass / cane survey, bankable
DPR, loan syndication, lender engineering, approval services, MNRE capital grant & excise duty exemption certificates, project developer interface services, etc. )
Pre-contract Engineering (Basic / detailed design engineering, plant layouts,
specifications and drawings, EPC / packaged bid documents, bidding / bid evaluation / recommendations, pre-contract discussions, assistance in signing EPC / package contracts & manpower planning )
MITCON Consultancy & Engineering Services Ltd.
Post-contract Engineering / Project Management (Kick start meetings with vendors / EPC contractors,
PERT / CPM networks, inspection / expediting, vendor drawling services and approvals, site supervision, monitoring of erection / commissioning, plant stabilization & plant MIS development)
Post-commissioning (Witnessing PG tests, trouble shooting, plant MIS,
contract to compliance reports, etc. )
MITCON Consultancy & Engineering Services Ltd.
Macro Assignments & Training
◦Macro and Policy Studies for biomass, bagasse, natural gas, fossil fuel based industrial captive / cogen power for sugar, distillery & ethanol sectors
◦Organized number of regional / national / international business meets, interaction meets, workshops, seminars, training and skill up-gradation programs
MITCON Consultancy & Engineering Services Ltd.
Experience
National & International experience of two decades, private, public sector & co-operative sector clients
Micro level services to over 200 sugar factories, several biomass & fossil fuel based industrial cogen / captive power projects & distilleries / ethanol plants
A dedicated team of qualified and experienced in-house staff and associate experts at various offices
State-of-the-art engineering design / drawing equipment
MITCON Consultancy & Engineering Services Ltd.
Experience (contd.)
Program partner & lead program partner of MNRE, Govt. of India
Macro level assignments and promotional work with IREDA, Winrock International India, USAID, UNDP, financial institutions & banks
International exposure & events participation Founder member of World Alliance for Decentralized
Energy (WADE) and patron member of Cogeneration Association of India (Cogen India)
MITCON Consultancy & Engineering Services Ltd.
International
Pure Diet Mocambique Limitada, Mozambique Sugar Corporation of Uganda Ltd., Uganda Alliance Tire Co. Ltd., Israel Delta Energy Inc, UK Sindicatum Carbon Capital, Singapore Charter Oak Energy, Renova Engineering PC & Nitash Inc, USA NUCON Energy Corporation, USA Ratnala, Behl & Co., USA Entech Energy Consultants Ltd., UK UNDP-GEF USAID Winrock International India Swiss Development Corporation
MITCON Consultancy & Engineering Services Ltd.
Coverage
Sectoral
Power Biomass Sugar Chemical Steel Ethanol Paper Rice Mills Infrastructure Waste Heat Recovery
Geographic
Maharashtra Tamil Nadu Bihar UP / Uttarakhand Karnataka Andhra Pradesh Goa Gujarat Madhya Pradesh Punjab Rajasthan
MITCON Consultancy & Engineering Services Ltd.
Coverage
Services (End of Pipe, Concept to Commissioning)
Pre-investment Engineering Project Management Macro Assignments Events / Training
Fuel Types
Biomass Bagasse Coal Natural gas Waste heat recovery
Size Range
1 MW to 600 MW
MITCON Consultancy & Engineering Services Ltd.
Micro Level
Establishment in private, public, co-operative & other sectors, across India at the national level
Fuel assessment / DPRs / TEV studies / appraisals / loan syndication / lender engineering for public, private & co-operative sector clients & banks / FIs
Owner Engineering / Consultancy Services for biomass power, bagasse cogen along with concurrent sugar factory modernization / expansion & coal fired power plants
MITCON Consultancy & Engineering Services Ltd.
Micro Level (contd.)
EPC consultancy services for TANGEDCO / Govt. of TN, 12 cogen power plants along with concurrent sugar factory modernization projects (installed capacity 183 MW), in advance stages of construction & expected to commission in Sept – Dec, 2012)
EPC consultancy services for HPCL Bio Fuels Ltd., integrated sugar expansion / modernization (3500 TCD), cogen power plants (20 MW) & ethanol plants (60 KLPD) at Lauriya & Sugauli in Bihar
MITCON Consultancy & Engineering Services Ltd.
Micro Level (contd.)
Consultant to Urjankur Trust for Shri Datta SSKL & Shri Tatyasaheb Kore Warana SSKL, DPR preparation & EPC consultancy for concurrent sugar factory modernization projects
Appointment as LIE by PNB, 2X600 MW imported coal based power plant of ITPCL at Cuddalore, Tamil Nadu
Project developer interface, consultancy & engineering services for BOOT projects for IREL, BPCL & DCM
Pre-investment & engineering services for existing / new sugar plants & ethanol plants
MITCON Consultancy & Engineering Services Ltd.
Micro Level (contd.) Engineering services for first 67 Kg/cm2 pressure
bagasse cogen power plant (Mula SSKL, 2006), first 87 Kg/cm2 pressure (YM Krishna SSKL, 2010) & first 110 Kg/cm2 pressure (Shankar SSKL, 2011) in Maharashtra
Engineering services for biomass, bagasse, coal based power plants, 412 MW commissioned capacity (31 projects) & 470 MW under erection (18 projects)
Approved TEV consultants & lender engineers for large no. of banks & financial institutions
MITCON Consultancy & Engineering Services Ltd.
Macro Level All India Bagasse Cogen Study for IREDA, New Delhi Program Partner & Lead Program Partner of MNRE Member Secretary, Cogen India & Vice Chairman,
WADE Cane Cogen Handbook of USAID / WII (Partner) Assessment, Strategy & Action Plan for Non Sugar
Cogen Market Development Initiative for USAID / Nexant
Guidelines for Captive Cogen – A handbook for Govt. of Maharashtra, Department of Energy
UNDP-GEF-MNRE project, Removal of Barriers to Biomass Power Generation in India
Renewable Energy Certificates MITCON Consultancy & Engineering Services Ltd.
S. C. NatuSr. Vice President (Power Division)MITCON Consultancy & Engineering Services Ltd.1st Floor, Kubera ChambersShivajinagar, Pune - 411 005Tel : (020) 25534322 / 3309, 66289136 (D), 09822684102 Fax : (020) 25533206E-mail : [email protected]
MITCON Consultancy & Engineering Services Ltd.