High Pressure Bagasse Fired Boiler

for Cogeneration in Sugar Industry

Presented by
A.K Subramanian
aksubramanian@isgec.com
Arun Tewari
atewari@isgec.com

ISGEC JOHN THOMPSON

A-4, Sector-24
Noida , India

June 2008
 ADVANTAGES OF
High Pressure Boiler - Advantages

Parameters Unit 45Kg/cm2 66Kg/cm2 87Kg/cm2 105Kg/cm2

(a) / 4400C (a) / 485 0C (a) / 5150C (a) / 540 0C
Feed Water C
0
105 150 170 220
temp to boiler (with 1 (with 1 HP (with 2 HP
HP Heater) Heater) Heaters)
(without
HP Heater)
Bagasse TPH 43.51 41.78 41.2 38.47
Quantity
Steam /Fuel - 2.29 2.39 2.42 2.59
ratio
Gross Power MW 24.8 26.5 28.0 29.0
output
Specific Steam Kg/KW- 4.03 3.77 3.577 3.44
consumption hr
Power
Generation per KW/Ton Base + 11% + 19% + 32%
ton of Bagasse

Higher the Cycle Parameters

More power output with same input quantity of fuel

2
 High Pressure Boiler - Design Basis

 Single Drum  Three Stage Feed Water Heating

(Deaerator and 2 stages of HP
 Natural Circulation heater)

 Balanced Draft
 Two stage superheater with
inter-stage attemperator
 Top Supported

 Outdoor  Pre-Dust Collector Upstream of

Electrostatic Precipitator
 Water Cooled Membrane Furnace
 Equipped with Evaporator &
 Continuous Ash Discharge
Economizer
Travelling Grate Stoker

 Rotary Drum Feeder with  Tubular Air Heater as the last

Pneumatic Spreaders stage of heat recovery

3
Travelling Grate Boiler
(170 TPH , 105 kg/cm2(g), 540 Deg C, Single Drum)

4
 High Pressure Boiler - Unique Feature

• High Up Time

• High Efficiency

• Enhanced Life

• Environment Friendly & Safe Operation

• Ease of O&M

• Boiler Engineered Using Latest Design Software

5
 High Up Time

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 • Sustained combustion even with high

furnace Zone moisture (upto 54%) in bagasse

Evaporator in place of • No Tube expansion

Boiler Bank • Eliminates leakages

…Contd.
6
 High Up Time
Contd.
FEATURES
All Pressure part tubes of
seamless construction
Structures & Equipment
designed with High
‘Importance Factor’
SA 213 T91 material for final
elements of secondary
superheater
Convective Super Heaters with
wide pitching
ADVANTAGES
• Eliminates leakages
• Longer life
• Increased Structural Integrity
• Minimum Vibration
• Longer life
• High Creep, Fatigue, Corrosion
and erosion resistance
• Avoids fouling
• Lower metal temperature
7
 Enhanced Life

FEATURES ADVANTAGES
Travelling grate bars with SG Iron • High Durability
metallurgy • Resistance to wear & tear at
elevated temperatures

Double Casing for Economizer • Protects bends from erosion

Pre-Dust Collection system at • Reduces particulate loading on

Economizer Outlet ESP & ID Fans
• Reduces Unburnt carry over to
ESP eliminating fire hazards

High Frame Size of Motors with VFD • Minimizes Heat Losses

Ferrules for Air Heater Inlet tubes & • Minimizes Erosion & Corrosion
Corton Steel material at Cold end

8
 High Efficiency

FEATURES ADVANTAGES
High pressure Secondary Air • Better turbulence & mixing
at 4 tiers • Efficient Combustion
• Minimum Unburnt Carbon Loss

Generous grate area loading & • Efficient combustion

volumetric loading of furnace • Minimum Unburnt Carbon Loss

9
 Environment Friendly & Safe Operation

FEATURES ADVANTAGES
Reliable & Proven Electro Static • Particulate emission upto
Precipitators 30mg/Nm3

Silencers for Safety Valves, Start • Noise levels as per

Up vent Valve and FD /SA Fans Occupational Health & Safety
Administration (OSHA) norms

HAZOP Studies • Safety of equipment & operating

personnel

10
 Ease of O & M
FEATURES
Stoker Shaft with Self
Lubricated Graphite bearings
Leak Proof Stoker Sealing
On-line Vibration Monitoring
System for Critical Rotating
equipment
On-line Steam & Water
Analyser system (SWAS)
ADVANTAGES
• High reliability
• Maintenance free
• Dimensionally stable
• Chemically Inert
• Non hygroscopic
• Avoids leakage
• Predictive Maintenance
• Avoids Failures
• Ensures Strict Control of
Water Chemistry
…Contd.
11
 Ease of O & M
Contd.

FEATURES ADVANTAGES
Water Cooled Membrane • Less Maintenance
Furnace • High Structural rigidity

Automated Operations with • Accurate controls

Distributed Control System • Less manpower
(DCS) & Supervisory Controls
and Data Acquisition ( SCADA)
with adequate redundancies
in Power Supply,
Communication Module and
Processor

12
 Boiler Engineered using latest Design Softwares

Process • KED Germany Steam

Calculations Plant simulator
software • PBAB
• In-House Software
Analysis software • Staad Pro 2006
• CAESER II 5.1
• For Optimisation
Modeling software • Prosteel 3D
• For High Efficiency
• CAD works for
Plants/Equipments • For Better Aesthetics
• Solid works
• For Ergonomic Design
Document • Windchill9.0 PDM
Management Link
System (PLM)
Drafting • AutoCAD 2008
ERP • BaaN 4C4

13
Boiler Engineered Using Latest Design Software

3-D model Flow Model

14
 High Pressure Bagasse Fired Boiler - Design Features

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 105 Kg/cm2(g) / 540 Deg C
outlet
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 130/220C*
and Economizer inlet
Gas temperature leaving air heater 150C

* With two stages of HP Heaters

15
High Pressure Boiler

30 MW from Single Boiler

45 MW under Condensing mode
Dhampur Sugar Mills, Asmoli (U.P.)

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

16
 Silo & Bagasse Feeding Arrangement

• 10 Minutes storage Silo

• Rotary drum feeders
• Screw Conveyors
• Pneumatic Spreaders
• With modulating dampers

Typical Schematic Drawing

17
 Continuous Ash Discharge Traveling Grate Stoker

Rugged, Efficient &

Easy to Maintain

18
 Ferrules at Air Preheater Inlet Tubes

Ferrules
made of
wear
resistant
material

Avoids Erosion at Gas Entry Side of APH Tubes

19
 Boiler Performance

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 %

* till April 2008

Performance Data
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 Deg C 150 140
heater)
Auxiliary Power Consumption KW 1912 1754
Noise level of rotating equipment at 1 meter dB 85 <85
Steam to fuel ratio - - 2.6

20
 High Pressure Bagasse Fired Boilers - Experience

Number of units in operation Number of units under Execution

105 Kg/Cm2 & 540 Deg C 2 110 Kg/Cm2 & 540 Deg C 4
87 Kg/Cm2 & 515 Deg C 25 87 Kg/Cm2 & 515 Deg C 6
66 Kg/Cm2 & 485 Deg C 21

IJT’S Presence 352 Bagasse & Biomass fired

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

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
21