Emerging Trends in Sugar Mill Cogeneration Training on …s3.amazonaws.com/zanran_storage/ ·...
Transcript of Emerging Trends in Sugar Mill Cogeneration Training on …s3.amazonaws.com/zanran_storage/ ·...
1 Sustainable Environment through Clean and Efficient Energy Projects
Arul Joe Mathias
Biomass and CDM expert
6-8 September 2006
Arnoma Hotel, Bangkok, Thailand.
Training on and transfer of efficient EU technologies in the sugar sector in Thailand
(SPF- Sugar)
Emerging Trends in Sugar Mill Cogeneration
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Sugar Cogeneration in ThailandSugar Cogeneration in Thailand
• Mostly low pressure boilers
• Some are very old (over 30 years)
• Inefficient cogeneration plants.
• Boilers have been designed deliberately with low efficiency.
• Purchase of used equipments from western countries are
common.
• Cogeneration within the same company
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Developments in the past few yearsDevelopments in the past few years
• Use of medium pressure boilers (over 30 bar)
• Excess electricity export to the national grid.
• Use of alternative biomass fuels (rice husk, bark, other wood waste etc.)
• Several mills are studying the possibilities to upgrade/implement new projects
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• Professional approach in project development.• Systematic feasibility studies and
Implementation • Tendering• Negotiation• Contract management • Use of special purpose company
Developments in the past few yearsDevelopments in the past few years
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Process energy required:Electricity: 25-30 kWh/t of sugarcane0.4 tonne of steam
Waste:290 kg Bagasse ~ 100 kWh electricity
1 tonne of Sugarcane 100 - 121 kg Sugar
Energy requirement and supply in the sugar industry
Energy requirement and supply in the sugar industry
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Power generation potential (partly utilised) in ASEAN
2,0306,09021,000Philippines
5,22015,66054,000Thailand
11,40734,220118,000 Total
1,1603,48012,000Vietnam
2,9978,99031,000Indonesia
Max. Power Generation Potential (GWh/year)
Bagasseproduction(1,000 tonnes)
Sugar cane production (1,000 tonnes)
Country
Bagasse = Sugar cane * 0.29; 1 kWh = 3 kg of bagasse (including steam for process)
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Role of European Technology in Thailand’s Sugar CogenerationRole of European Technology in Thailand’s Sugar Cogeneration
A project implemented in Danchang
Bioenergy, Thailand with European
technology set a new benchmark for sugar
cogeneration in Thailand
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Owner/Developer : Mitr Phol Sugar Corporation Limited
Size : 27,000 TCD (2.25 million TCY)
Location : Dan Chang, Suphanburi province
Existing equipment : Consisting of several old boilers and turbines
New boilers : 2 x 120 tph, 68 bar, 5100C
Grate type : Water cooled vibrating grate
New turbine : Extraction condensing turbine (41 MW gross)
Dan Chang Bio EnergyDan Chang Bio Energy
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Fuel : Bagasse, cane leaves, wood bark and rice husk
Off-taker : Electricity Generation Authority of Thailand (EGAT)
Electricityexport to EGAT : 25 MW
Export tariff : 2.14 Baht/kWh (grid); 1.85 Baht/kWh (sugar mill)
Management : Special Purpose Company
Supplier : ALSTOM
Contract type : Fixed price, fixed time turnkey with LD
Dan Chang Bio EnergyDan Chang Bio Energy
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Major Technical Attractions
• First high pressure boiler in ASEAN sugar industry
• Boiler efficiency above 90 % (LHV basis)• First high pressure turbo-generator system• Turbine efficiency around 85 % (design)• Cogeneration efficiency above 70 %• Optimized plant design• High flexibility in operation• Consistent electricity export: above 25 MW
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Major Technical Attractions
• Multi-fuel firing capability• Water cooled vibrating grate furnace• Modern control system (DCS),
monitoring• Use of steam transformers• No delay in construction and operation • Plant met the performance guarantee
figures agreed in the contract• Excellent workmanship
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P-1--
LP Turbine
HP Turbine
Condenser
ex
Condensate P1 Condensate P2
Gland ST Cond.
Deaerator
BFP-2 BFP-3BFP-1
Main Steamfrom
Boiler2
Pegging Steamto St.coil A/H
Eco.Boiler12
Steam Transformer
Gen.
Gear
Feeder air fan
Secondary air fan
Submerge Ash conveyer
BlowDownFlush
BlowDownTank
ATM
5 bar HDR
Service W.
2x50%CW.Pump
2x100%Aux.cooling Pump
LubeOil unit
GEN.cooler
lube oil
Samplingcooler
SA.Fanbearing
Vacuumpumpcooler
Spare Spare
Make Up water
SodiumHypochlorite
dosing
Sulphuric Aciddosing
Mechanical DepartmentThermal Power Plant Construction
Project Division(EGAT)
DWG.by Chatchawan B
Issue 19/9/2003
Dan Chang Bio Energy
Process diagram
SIZE FSCM NO DWG NO REV
SCALE 1 : 1 SHEET 1 OF 1
ATM
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Environmental Management
• No black smoke during the boiler operation.• Efficient wet scrubber system to control the
particulate emission• Clean bottom ash collection system (wet)• Clean fly ash collection system (wet)• Proper ash disposal (used as fertiliser in the
sugar plantation land sites)
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Environmental Performance
• CO2 mitigation potential : 80,000 ton CO2/year
• Particulate emission within Thai limitations
• Stack emission
CO 70 - 260 ppm
NOx 200 - 215 ppm
SO2 0 - 8 ppm
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Sugar Cogeneration: Future trendSugar Cogeneration: Future trend
• Several sugar mills expected to implement high
pressure system
• Old plants are expected to be replaced by new
projects
• Year round operation of the cogen plant expected
• Boilers will be designed for multi-fuels
• Potential to implement more than 20 high pressure
systems in Thailand
• Confidence level in the industry will drive even
higher pressure systems (close to 100 bar)
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Thank You !
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