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


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.


What is Trigeneration?

Simultaneous production of Electricity, Heat and Cold


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.


TURBINE BASED TRIGENERATION


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.


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.


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


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


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%


Energy Balance Chart

Mechanical Output

37%

Heat in Exhaust

30%

Heat in Lube Oil

10%

Heat in Jacket20%

Radiation Loss3%


Net Output Of The System With WHRU

Mechanical

Output37%

Waste heat

recovery20%

Exhaust

10%

Water + Lub Oil

30%

Radiation

3%

`


MAIN COMPONENTS OF TRIGEN –GAS ENGINE

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Main Components of Trigen - VAM


Main Components of Trigen - Chiller


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


Reliance CHP Installation

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Installation


MUKESH AMBANI WITNESSING INSTALLATION


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

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ElectricalEfficiency

%

27,327,3

HeatEfficiency

%

54,554,5

TECHNICAL Parameters - Bio-Gas - PREMI Series


TEDOM Cento

Electric power

30 – 150 kW


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

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%

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


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

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%

35,735,134,835,336,7

HeatEfficiency

%

49,150,450,150,348,3

TECHNICAL Parameters - Bio-Gas - QUANTO Series


TYPICAL APPLICATION Animal waste in agriculture


TYPICAL APPLICATION LANDFILL GAS


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


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


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/-


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


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


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



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.


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


THANK YOU

ANAMA ENERGIES PVT. LTD., PUNE

TRIGENERATION FOR SMALL INDUSTRIAL / … Pramod...1 1 ENERGY SOLUTIONS UNDER ONE ROOF Anama Enertech...

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