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Cogeneration
 
KEL is operating a 7200 TCD capacity sugar unit at Baheri in Bareilly District, Uttar Pradesh. As a result of modernisation activity taken up at KEL, there was substantial reduction in process steam consumption and therefore increased availability of bagasse. It was decided to use the additional savings of bagasse as result of the modernisation of the plant synergitically in a high pressure & temperature efficient cogeneration power plant at KEL.
 
The plant has been installed nearby the existing sugar factory and suitable interconnections have been made to use the exhaust steam & electricity from the Cogen plant to the sugar factory & fuel conveyors for conveying bagasse from the sugar factory to the Cogen plant.
 

Baheri sugar unit is located in high cane intensity, Tarai region of UP and therefore has assured availability of raw material (Sugarcane) for crushing and therefore assured availability of bagasse to run the Cogen plant.

 
The plant & machinery of the Cogeneration plant at Deoband consists of the following
  • 190 tph 115 ata/543 degree C high pressure/temperature boiler

  • 44 MW, direct drive; double extraction condensing type TG set

  • All auxilliaries (Includes cooling towers, water treatment plant, fuel & ash handling system, power evacuation system among others)

The Cogeneration plant at Baheri was commissioned on 17th July 2012. The construction began after Bhumi Pujan was done on 15th December 2010 and therefore the construction period was only 19 months. The surplus power (after meeting the sugar factory's requirement and Cogeneration plant's in-house requirement) is exported to the UPPCL, for which KEL has a Power Purchase Agreement for 32 MW. Our installed capacity is 39 MW in the sugar crushing season and 44 MW in offseason. Auxiliary power consumption of Cogeneration plant is 3.5 MW.
 
Cogeneration is also a major de-risking activity for our sugar business which suffers from the cyclicality of the sugar market as the power generation from bagasse gives additional revenue generation stream. Our Cogeneration plant is amongst the most efficient bagasse based plants of India.
 
The temperature & pressure configuration selected for our Cogeneration plants is one of the most modern and state of the art. The conversion of total enthalpy of steam in a 115 ata cycle is one of the highest for generating power.
 
  COGENERATION TECHNOLOGY
The engineering of the plant has been done by M/s. Avant - Garde Engineers & Consultants of Chennai who are the most reputed consultants in bagasse based Cogeneration in India.
 
Cogeneration is simultaneous generation of power which is exported to the grid along with the production of sugar. During the crushing season, sugarcane is crushed in the milling house to extract sugarcane juice and the byproduct; bagasse is conveyed to the boiler where it undergoes combustion in the furnace to generate very high pressure steam at 115 ata and 543 C. This superheated steam is fed in the turbine to generate the power which is surplus and has to be exported to the grid after meeting the requirement of the sugar-distillery complex as well as the auxiliary power requirement of the Cogeneration. The low pressure steam extracted from the turbine at a low pressure of 1.5 ata and 120 C is then fed in the boiling house in the first body of the Evaporator for concentrating the sugar levels in the cane-juice for the production of sugar. Steam in the evaporator body condenses and the condensate is returned back to the high pressure boiler where is used for generating steam. Thus there is simultaneous generation of power and sugar which is known as Cogeneration.
 
Being run by an environment friendly fuel (bagasse) this process does not add to nett Carbon Dioxide (a greenhouse gas) into the atmosphere.
 
  BOILER SPECIFICATION
 
SR. No Parameter Units Guaranteed Data
1 Steam flow at MCR TPH 190
2 Steam pressure at Main steam stop valve outlet kg/cm2(a) 115
3 Steam temperature at Main steam stop valve outlet °C 542+5, -3
4 Efficiency at 100% BMCR on GCV basis with bagasse % 70.70
5 Steam purity    
  Solids content ppm ≤0.10
  Silica ppm ≤0.02
 6 Dust concentration at the outlet of ESP mg/Nm^3 50
 
  TURBINE SPECIFICATION
SR. No Parameter Units Guaranteed
1 Inlet Steam Pressure kg/cm2 g 108.96
2 Inlet steam temperature ° C 538.00
3 Steam inlet Flow TPH 151.50
4 Turbine Power MW 40.00
5 Feed water temperature ° C 199.60
 
 
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