A sugar factory is under designing phase , proposed capacity 15,000 tons/day.

Proposed location is in district Badin about 50 KM from coast, national electric grid and main natural
gas supply line is at about 5-8km. Electric company is ready to contract for provision and purchase
of power to and from the factory .
Factory operates only for 155 days a year( from Nov to March) on 24 hour basis.
Residential colony for staff have electric load varying from 500 during summer to 1500 kw during
operational period
Essential/critical electric load for controls ( 200kw)and security lights (500kw).
Max load for sugarcane crushing 30 kw/ton of sugar cane.
Process heating is to be done by steam.
A) What are various options available for meeting the Electric load/consumption, evaluate the best
strategy.
B) What should be most appropriate power generating installed capacity at the Plant?
C) What should be the number, size /ratings of three major equipment of power generation facility.
D) What should be the stream production rate at plant and fuel consumption .

SOLUTION

Sugarcane crushed = 1500 ton per day

Energy required to crushed 1 ton = 30kW
Time span of Crushing = 155 days

𝑘𝑊 𝑡𝑜𝑛
155 days x 30 x 1500 =6975000kW= 6975 mW
𝑡𝑜𝑛 𝑑𝑎𝑦

CONSUMPTION:
RESIDENTIAL : 1200 kW in winter and 500 in summer

SECURITY LIGHT: 500 kW

CRITICAL LOAD : 200 kW
QUESTION 1:
What are various options available for meeting the Electric load/consumption, evaluate the
best strategy.

1) One strategy is to operate Gas turbine with Gas supply line for peak time/operational time
this will divide the load on powerstation.

2) Buying electricity from Govt. at industrial tariff rate of 17.33 Rs/kw, in our case this will cause
us: 6977 x 17.33 = 120911410 Rs that wouldn’t be appropriate and economical.

3) The best strategy is to build a combine cycled power plant The dried Bagasse is burnt to
produce heat which is used to convert water into steam in boiler. The steam at high
pressure is used to rotate a turbine-generator system to produce electricity. The general
schematic of any biomass( including bagasse) based power plant is given below

FIGURE 1.1

Every 1 ton of sugar cane contain 26-27% bagasse

We have 1500 ton per day of crushed sugar cane, Factory is crushing sugar can for 155 days on 24
hour basis
1500ton/day x 155 days = 232500 tons
232500 tons sugar cane contain 62775 ton bagasse
On average 23.44 ton bagasse produces 100KWH electricity using high pressure boiler,
(4.0-8.0 MPa) turbo-alternator exhaust steam, magnetohydrodynamic generator(GHD) or turbo-
compound engines
62775 ton bagasse will generate 6277MW of electricity
6975-6277= 698 MW this quantity can be easily satisfied by using combined cycle power plant
QUESTION 2
What should be most appropriate power generating installed capacity at the Plant?

The most appropriate power generating installed capacity at the plant is comined cycle power
generation plant, the reason is that because Combining two or more thermodynamic cycles results in
improved overall efficiency, reducing fuel costs. In stationary power plants, a widely used
combination is a gas turbine (operating by the Brayton cycle) burning natural gas or synthesis gas
from coal, burning bagasse whose hot exhaust powers a steam power plant (operating by the
Rankine cycle) or vice versa. In figure 1.2 the configuration can generate 46.7 Kwh/t of electricity
which is theoretical and can be more or less in original practice.

Figure 1.2
Question 3
What should be the number, size /ratings of three major equipment of power generation
facility.

Steam Cycle with back-pressure. In this case the sugar process determines the quantity of steam
that can be produced by the boiler, once there is not a condensation system. This kind of
cogeneration system can operate just during the crush season when the factory is in operation
and the steam demand exists. The major component of combined cycle power plant is :

i) BOILER
ii) STEAM TURBINE
iii) SUGAR PROCESSER
iv) DEAERATOR

Figure 1.3
Question 4
What should be the stream production rate at plant and fuel consumption .

Usage of 6 evaporation steps at varying temperature and pressure and Sugar boiling into vacuum
pans with steam from the first effect of evaporation station, the steam generation should be 355-500
kg steam/t cane, while fuel consumed is 62775 ton of bagasse and 500 kg steam/t cane that
become fuel of Gas turbine or combine cycle plant.

Refrences
https://www.researchgate.net/publication/256115717_Analysis_of_cogeneration_systems_in_sugar_
cane_factories_-_Alternatives_of_steam_and_combined_cycle_power_plants

http://www.fao.org/fileadmin/templates/rap/files/meetings/2014/140723-d1s3.Bagasse.pdf