TRIGENERATION FOR SMALL INDUSTRIAL / … Pramod...1 1 ENERGY SOLUTIONS UNDER ONE ROOF Anama Enertech...
Transcript of TRIGENERATION FOR SMALL INDUSTRIAL / … Pramod...1 1 ENERGY SOLUTIONS UNDER ONE ROOF Anama Enertech...
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1 ENERGY SOLUTIONS UNDER ONE ROOF Anama Enertech Solutions Pvt. Ltd.
TRIGENERATION FOR SMALL INDUSTRIAL / OFFICE
BUILDING APPLICATIONS
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About Us
ANAMA GROUP is dedicated to provide Cogeneration and Tri-generation solutions in Steam, Gasand Liquid fuel-based systems , energy optimization solutions for industries and supply of greenenergy. Contributing to energy efficiency and environment for over last seventeen years.
ANAMA ENERGIES PVT.LTD.• Steam Turbine Based Cogeneration and Tri-generation.
– Tailor made CHP solutions through extensive range of steam turbines – Back pressure, Extraction cum condensing as well as condensing turbines
• Natural Gas based Co-generation. - CHP solutions using Gas Engines and Turbines with Waste heat recovery system
• - Vapor Absorption, Process heat projects from waste heat of gas engines• Biogas/Biomass based Power generation and CHP.
– Representative of Caterpillar Biogas engines– Technology licensee of IISC – Bangalore – Biomass briquette based process steam and CHP– Biomass gasification for process/power
ANAMA ENERTECH SOLUTIONS PVT.LTD. :• Energy Audits , Energy efficiency projects implementation , monitoring .
ANAMA GREEN FUELS PVT.LTD. : • Bio mass based briquette manufacturing, supply, fuel switch over projects implementation.
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What is Trigeneration?
Simultaneous production of Electricity, Heat and Cold
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WHAT IS TRI GENERATION
Simultaneous production of power/electricity , hot water and/or steam , and
chilled water from one fuel.
Trigeneration power plant is a co generation power plant that has added absorption chillers for producing chilled water from the heat that would have been wasted from the cogeneration power plant.
Basic objective is to achieve maximum system efficiency .Trigeneration plants can achieve system efficiencies exceeding 90%.
Benefits :
• Reduced energy consumption for a specific requirement
• Reduced dependence on outside energy supply
• Reduced green house gas emissions
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TYPES OF TRI GENERATION
Steam based Tri generation : Turbine exhaust steam used for meeting process
heating load and chilling requirements for Refrigeration & air conditioning.
Natural Gas Engine based Tri generation : Heat from Jacket and Exhaust of Natural Gas engines used to meet heating requirements and chilling requirements of Refrigeration & Airconditioning.
Natural Gas Turbine based Tri Generation : Natural gas turbine exhaust used for heating and chilling requirements
Bio gas based Tri generation : Heat from Jacket and Exhaust of Bio Gas engines used to meet heating requirements and chilling requirements of RAC.
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TURBINE BASED TRIGENERATION
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CHILLERS
• Steam with as low as 0.5 kg/cm2-g can be used for Chilling of Water upto
3.5 deg.C
• These Chillers are used for Process Cooling ,Industrial Air-Conditioning
and Comfort air-conditioning.
• The Steam fired design allows the machine to be fuelled by waste heat or
available steam. This contributes to the conservation of the worlds fuel
resources and makes economic sense.
• Require minimal amount of Electricity to run ancillary systems.
• Completely ozone safe/no CFC's or HCFC's.
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Absorption Refrigeration
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Customer : Govind Dairy, Phaltan
Steam Parameters
Inlet Steam Pressure = 21 kg/cm2-g
Inlet Steam Temperature = 340 deg.C.
Inlet Steam Flow = 3 TPH
Outlet Steam Pressure = 3.5 kg/cm2-g
Power Output = 133 Kwe
Chilling by VAM = 200 TR
Power Saving due to Chiller = 70 Lac Rs. (@ 1 Kw/TR & 7000 hrs p.a. & 5Rs. Per unit cost)
Power Saving due to Turbine = 47 Lac Rs. (@ 5 Rs. / unit , 7000 hrs p.a. )
Additional Fuel cost due to high pressure & temp. steam generation :
( @ 1.5 Rs./ kg & 534 kg/hr additional fuel,7000 hrs.)= Rs. 56 Lakh
Net Saving of Project = 61 Lac Rs.p.a.
Investment for Equipment = 115
Investment for Pipping and Other Modification = 45
Total Investment of Project = 160 Lac Rs
Payback Period Without Depreciation = 2.6 Yrs.
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COMPARISION OF VCRS Vs VARS Vs VARS WITH STEAM
TURBINE
Description
Vapour Compression
Refrigeration
Machine (VCRS) -
Present
Vapour Absorption
Refrigeration
Machine (VARS) -
Steam
Vapour Absorption Refrigeration Machine (VARS) -
Steam Turbine
1 Chilling Require (TR) 120 120 120
2Power require for Chilling (Kwe) @
1.1 Kwe / TR132 6 6
3Total Power Require for Plant
including Chiller Power (Kwe)432 306 395
4 Power Tarrif (Rs/Unit) 5 5 1.50
5Steam Consumption in Plant
(kg/Hr)8000 9242 9242.0
6Steam Rate (Rs/kg) - NG Fuel @
9.6 Rs/m30.8 0.8 0.8
7 Steam Require for Chilling 0 1242 1242
8 Cost for Chilling Operation(Rs/Hr) 660 1024 1003
9Power Cost of Plant (Rs/Hr) -
Except Chiller Power1500 1500 583.5
10 Total Per Hr Cost of Plant (Rs/Hr) 2160 2524 1587
11Net Saving Due to System w..r..t.
present (Rs/Hr) 0 -364 573
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12 Total Investment (Rs.Lac) 25 50 125
13 Net Annual Saving Due to System (Rs. Lac) 0 -29 46
14 Payback Period Without Depreciation (Yrs.) No Payback -1.7 2.7
COMPARISION OF VCRS Vs VARS Vs VARS with Steam
Turbine
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TRI GENERATION WITH ENGINE
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MAIN COMPONENTS OF TRIGENERATION SYSTEM
INPUT TO TRIGEN SYSTEM : 2.5 MW th of Natural gas
( GAS ENGINE)
ELECTRICITY OUTPUT : 1 MW ( 40% of Input) used for distribution
Lighting, A/C , selling to grid etc.
EXHAUST GASES FROM SYSTEM : 20 % TO 30% at 400 C High temp heat
Used for cooling with VAM ( rooms / storage etc.)
JACKET COOLING WATER SYSTEM :20 % at 90 C Low temp heat Used for
Warm water applications ( Kitchen , Laundry , Rooms , Pool etc.)
LOSSES FROM ENGINE : 10% TO 20%
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Energy Balance Chart
Mechanical Output
37%
Heat in Exhaust
30%
Heat in Lube Oil
10%
Heat in Jacket20%
Radiation Loss3%
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Net Output Of The System With WHRU
Mechanical
Output37%
Waste heat
recovery20%
Exhaust
10%
Water + Lub Oil
30%
Radiation
3%
`
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MAIN COMPONENTS OF TRIGEN –GAS ENGINE
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Main Components of Trigen - VAM
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Main Components of Trigen - Chiller
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Electricity units Generated = 44 kwh
Natural Gas Consumption = 16.4 m3/hr
Per unit cost considering gas consumption = 3.29Rs /Unit
Amount of Chilling = 9 TR
Amount of Hot water at 65 deg Celcius = 1100 kg/hr
Savings on account of chilling = 49.5 Rs/Hr
Savings on account of Hot water generation = 46.5RS/hr
Total Savings due to heat recovery benefit = 96 Rs/hr
Savings per Unit due to Heat recovery Benefit = 2.18 rs/hr
Per unit cost Considering H recovery benefi t = 1.11Rs /hr
Electricity Duty On Co- generation Plants = .40 Rs/hr
Interest Cost per Unit = 1.0 Rs/Hr
Service & Maintenance Cost per Unit = 0.4 Rs/Hr
Final per unit Cost = 2.91 Rs/unit
TOTAL 44 KW
CHP 1 CHP2
VAM
PHE
22 KWe
95 Deg C
Natural Gas 16.4 m3/hr
7 Deg C
12 Deg C
22 KW e
85 Deg C water
95 Deg C
85 Deg C Water
65 Deg C water To Kitchen
65 Deg C water To Bath Rooms
Natural Gas Based Co Generation System,
at Retail Outlet Reliance Hazira Surat
Normal Water 30 Deg C
1100 KG/HR @ 65 DEG
HOT WATER TANK
9.1 TR Chiller
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Reliance CHP Installation
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Installation
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MUKESH AMBANI WITNESSING INSTALLATION
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TEDOM Premi
Electric power 22 kW
TYPICAL RANGE OF BIO-GAS CHP UNITS
TotalEfficiency
%
81,881,8
ElectricalOutput
(kW)
2121
Unit Type
Premi S22 AP BIOPremi S22 AP twin BIO
HeatOutput(kW)
4242
Bio-GasConsumption
(m /h)+
11,811,8
3
ElectricalEfficiency
%
27,327,3
HeatEfficiency
%
54,554,5
TECHNICAL Parameters - Bio-Gas - PREMI Series
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TEDOM Cento
Electric power
30 – 150 kW
TYPICAL RANGE OF BIO-GAS CHP UNITS
TotalEfficiency
%
73,580,288,483,382,3
ElectricalOutput
(kW)
3295
105130142
Unit Type
Cento M33 SP BIOCento L100 SP BIOCento M120 SP BIOCento M130 SP BIOCento L150 SP BIO
HeatOutput(kW)
49147171215207
Bio-GasConsumption
(m /h)+
16,946,449,463,765,2
3
ElectricalEfficiency
%
29,031,533,631,433,5
HeatEfficiency
%
44,548,754,851,948,8
TECHNICAL Parameters - Bio-Gas - CENTO Series
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TEDOM Quanto
Electric power
190 – 1100 kW
TYPICAL RANGE OF BIO-GAS CHP UNITS
TotalEfficiency
%
84,885,584,985,685,0
ElectricalOutput
(kW)
2853855787701100
Unit Type
Quanto G300 SP BIOQuanto G400 SP BIOQuanto G600 SP BIOQuanto G800 SP BIOQuanto C1100 SP BIO
HeatOutput(kW)
392553833
10971450
Bio-GasConsumption
(m /h)+
123169256335487
3
ElectricalEfficiency
%
35,735,134,835,336,7
HeatEfficiency
%
49,150,450,150,348,3
TECHNICAL Parameters - Bio-Gas - QUANTO Series
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TYPICAL APPLICATION Animal waste in agriculture
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TYPICAL APPLICATION LANDFILL GAS
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TYPICAL APPLICATION WATER TREATMENT PLANT
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Typical Configuration
Gas Engine1632 KW
WHRS8,00,000 Kcal/hr
Expansion
Tank
Radiator For
Hot Air
Heat
Exchanger
Chiller70 TR
Flue Gas To Chimney
Heat Exchanger
Cooling
Tower
Radiator
Engine Jacket
Cooling Water
Chilled
Water
7 deg. cel
Cold
Water
12 deg cel
Hot Water
Hot Air
133 deg.cel
Flue Gases479 deg cel
5000 m3/hr
@30 deg cel
135 deg cel
44 m3/hr
91 deg cel
83 deg Cel
90 m3/hr
38 deg cel
32 deg
cel129 deg cel
165 deg cel
15 m3/hr
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Saving Chart
(For Hot Water Generation with Chilling)
• Data Available: Typical Calculation
Gas Engine: GE 08TIR Power Generation = 146KW
Fuel Consumption = 40.5 NM3/hr Fuel CV = 8850KCal/NM3 (Natural Gas)
Flue Gas Qty: 1680 M3/hr. (704 Kg/hr) @ 570 deg. Cel.
Flue Gas Temp to Chimney: 160 deg. Cel.
• Assumption: Fuel Cost = Rs. 9 per NM3
No. of Hrs in operation = 8000 hrs.
Total Heat Recovery from Exhaust Flue Gas = 75,912 Kcal/hr
The Fuel Required to generate hot water / steam if the same heating application is through Steam Boiler / Hot Water generator consisting of 80% Boiler efficiency
= 75912/0.8 = 94890 Kcal/hr
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Savings Chart ------ continued
Fuel Saved / hr = 94890/8850 = 10.72 NM3/hr
Net Saving on account of WHRS = 10.72 X 9 = Rs. 96.5 per hr.
Net Saving per annum = Rs. 7, 72, 000/-
Description Qty Rate Cost /
hr
In Rs
Saving /
hr
In Rs
Cost/year
In Rs
Saving/year
In Rs
Fuel 40.5
NM3/hr
Rs. 9 per
NM3
364.4 29,15,280/-
Power Gen 146KWH Rs. 5 per
Unit
730 58,40,000/-
Waste Heat
Recovery
Saving
75,912
Kcal/hr
Sea Above
Calculation
96.5 7,72,000/-
Total: 29,15,280/- 66,12,000/-
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Steam Generation with Co-gen
• Data Available: Typical calculation
Gas Engine: 612 GSNL Power Generation = 1632KW
Fuel Consumption = 440 NM3/hr. Fuel CV = 8850KCal/NM3 (Natural Gas)
Flue Gas Qty: 8839 Kg/hr @ 479 deg. Cel.
Flue Gas Temp to Chimney: 150 deg. Cel.
• Assumption: Fuel Cost = Rs. 9 per NM3
No. of Hrs in operation = 8000 hrs.
• Steam generation from
Waste Exhaust Flue Gases= 1263 kg/ hr @ 10.5 kg/cm2 D&S Steam.
• Power Generation from steam turbine for parameter :
Inlet : 10.5 kg/cm2 Exhaust = 1 kg /cm2 Steam flow = 1.26TPH
Power Generation = 50 KW
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So Exhaust Steam for process Heating = 1260 X 540 = 6,80,400 Kcal/hr
The Fuel Required to generate hot water / steam if the same heating application is through Steam
Boiler / Hot Water generator consisting of 80% Boiler eff. = 680400/0.8 = 8,50,500 Kcal/hr
Description Qty Rate Cost / hr
In Rs
Saving / hr
In Rs
Cost/year
In Rs (Cr)
Saving/year
In Rs (Cr)
Fuel 440
NM3/hr
Rs. 9 per
NM3
3,960/- 3.168
Power Gen 1632
KWH
Rs. 5 per
Unit
8,160/- 6.528
Power Co-
Gen
50 KWH Rs. 5 per
KWH
250/- 0.20
Waste Heat
Recovery
Saving
680400
Kcal/hr
Sea Above
Calculation
864/- 6.192
Total 3.168 13.6434 ENERGY SOLUTIONS UNDER ONE ROOF Anama Enertech Solutions Pvt. Ltd.
Chemical plants
Petrochemical plants / Refineries
Sugar and palmoil industries
Wood and paper production
City‘s departments
Iron and steel industries
IPP / Contracting
Food industries
Energy-from-waste plants
Ship and offshore industries
APPLICATIONS
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FEATURES
• REDUCED ELECTRICITY COSTS
• REDUCED DEPENDANCE ON EXTERNAL SOURCE
• 100 % DEPRECIATION RIGHT IN THE FIRST YEAR WITH NET TAX SAVING
• CDM BENEFITS OF CARBON CREDITS
• HIGH OPERATIONAL RELIABILITY
• COMPACT CONSTRUCTION
• LOW NOISE LEVEL
• REMOTE CONTROL , EXTERNAL MONITORING POSSIBLE
• INTEGRATED CONTROL SYSTEM
• REDUCED DISTRIBUTION LOSSES
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INSTALLATION POSSIBILITIES
• Milk farms & Dairy
• Food industries
• Residential complex
• Boiler Room
• Hospital
• Hotel
• Industry
• Sewage Treatment Plant
• Water Dump
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PER UNIT COST FROM NATURAL GAS BASED CHP UNIT
Details Cento 88 Cento T100 Cento T160 Cento T-300 Unit
Electrical Output 88.00 100.00 160.00 302.00 KW
Natural gas Consumption 26.20 31.50 46.10 84.32 M3/HR
Natural Gas Cost 9.00 9.00 9.00 9.00 Rs/m3
Per unit cost considering
only power generation 2.91 2.84 2.59 2.51 Rs/KW
Heat output 123.00 143.00 220.00 452.00 KW/hr
Amount of Chilling
Possible32.14 37.34 63.37 119.54 TR
Heat Recovery Benefit per
unit 1.98 1.87 1.98 1.98 Rs/hr
Per Unit Cost Considering
Heat Recovery Benefit0.93 0.97 0.61 0.53 Rs/hr
Service & Maintenance
Costs 0.40 0.40 0.40 0.40 Rs/hr
Final Per Unit Cost with
Electicity Duty, Service &
Maintenance Cost
1.33 1.37 1.01 0.93 Rs/hr
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Advantages of co- and tri-generation
• Fuel cuts: The successful installation of CHP and CHCP leads to reduction of fuel consumption by approximately 25% compared with conventional electricity production.
• Emissions reduction: With the use of natural gas, rather than oil or coal, the emissions of SO2 and smoke are reduced to zero.
• Economic benefits: Energy costs of trigeneration units are lower than those of the “conventional” units. In successful installations of CHP the price reduction is in the range of 20-30%.
• Increase of the reliability of the energy supply: The CHP station connected to the electric network, where it provides or absorbs electricity guarantees uninterrupted operation of the unit, in case of interruption of the station’s operation or electricity supply from the network. On country level, it reduces the need of installation of large electric power stations and increases the stability of the electric network of the country. It also improves employment at local level.
• Increase of electricity networks stability: Trigeneration units offer significant relief in electricity networks during the hot summer months. Cooling loads are transferred from electricity to fossil fuel networks, since the cooling process changes from the widespread compression cycles to the absorption ones. This further increases stability of electricity networks and improves system efficiency.
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Questionnaire For Waste Heat Recovery System
1. Customer Name & Address:
2. Phone & Fax No.:
3. Email ID:
4. Contact Person & Designation :
5. Existing Details of Gas Engine/ Gas Turbine/ DG Set:
Engine Model & Capacity:
Fuel Fired:
No. of Units:
No. of Standby Units:
Total operating Hrs per day & per Annum:
Flue Gas Quantity of each Unit:
Flue Gas Temp at exhaust of Unit:
6. No. of Units to be coupled to WHRS:
7. Details Required process heat in Kcal/hr:
8. Application of Recovered Heat:
9. Heating Recovery Medium: Steam / Hot water / Thermic Fluid / Hot Air:
10. Heat Recovery Medium Details: Temperature / Pressure etc:
11. Details of Existing Boiler / Heat Generating / Supplying Equipment:
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Questionnaire For Waste Heat Recovery System
Please indicate:
• Existing Boiler Tons/Hr:
• Boiler Design Pressure Kgs/ CM2. G:
• Existing Operating Pressure Kgs/cm2. G:
• Steam Temperature in Deg. Cel.:
• Application:
• Plant Voltage:
• Average Steam Cost in Rs. Per Ton:
• Existing Plant Electrical Load:
• Total Plant Electrical Load (Electricity Board Approved):
Pressure Reducing Station Details Chart:
No Flow Rate
(Kgs/hr)
Inlet Pressure
(Kgs/cm2G)
Exhaust Pressure
(Kgs/cm2G)
Operating Hrs Per
Year
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THANK YOU
ANAMA ENERGIES PVT. LTD., PUNE