NSSK Sugar Factory Bidar Intrenship Report

COGENERATION ANALYSIS IN SUGAR FACTORY
INTERNSHIP REPORT
Submitted by
MUKUND HUNDEKAR
3GN15EE025
in partial fulfillment of Summer Internship for the award of the degree
of
BACHELOR OF TECHNOLOGY
IN
ELECTRICAL AND ELECTRONICS ENGINEERING
GNDEC CAMPUS
Visvesvaraya Technological University

Belgaum, Karnataka.
JULY 2018
ACKNOWLEDGEMENT
The successful completion of any task would be incomplete without mentioning
the people who made it possible. So it’s with the gratitude that I acknowledge the help, which
crowned my efforts with success.
I express my deep-felt gratitude to my guide PROF.SHUBHA KULKARNI. has been a great
source of inspiration towards taking up this training and it was her encouragement and unfailing
support which has helped me in a long way in successfully completing this training report.
I remain indebted and highly grateful to Mr.B.S.APARANAJI (MD),Mr.V.B.ARUN KUMAR
(CE), Training In-charge (Co-Gen) and All Staff for providing me with all the necessary
information for completing the in-plant training. I also thank technical and non-technical staff ,
which was kind and co-operative during my stay in the industry.
I also take the opportunity to thank Dr.K.NEELSHETTY (H.O.D Dept. of E&E Engg.) for
his support and inspiration in carrying out this industrial training.

ABSTRACT
Many commercial and industrial facilities use boilers to produce steam or hot water for space
heating or for process heating. Boilers are typically major users of energy, and any person
involved in energy management needs to know how boiler works and how the performance of a
boiler can be maintained or improved. This article outlines the types of boilers used to heat
facilities, while providing an overview of basic boiler controls and the parameters that affect
energy efficiency.
The sugar industry is basically an agro based industry playing an important role in achieving
socio-economic development of the rural community in particular and of the region in general. It
not only occupies a prominent role in the economy of the rural but at the same time it contributes
to the economic development of the nation. Sugar industry holds second rank next to
cotton textiles in the country and it shows its importance.
Sugar industry is a vital component of Indian economy covering 67,000 villages. Cultivation of
sugar cane and production of sugar provide employment to about 36 million workers besides a
large number employed in transport and trade of cane and sugar. The industry contributes to
Rs.1600 crores annually to the central and state exchequers. Co-operative sugar mills are part of
the strategy to diversify the predominantly agricultural economy of rural India study of the
performance of cooperative sugar mills will yield valuable guidance to the policy of rural
development. The review of literature shows scarcity of comprehensive research in the financial
help of the co-operative sector of sugar industry.

INDEX
Unit Title Page

1. INTRODUCTION 1-2
THEORY OF COGENERATION
2. 3-4
RANKINE CYCLE
3. 5
STEAM DRUM
4. 6-9
FEED WATER TANK

5. 10
DEAERATION
6. 11-12
AIR PREHEATER 13-14

7.
FANS
8. 15
STEAM GENERATORS OR BOILERS

9. 16-22
BOILER PRESSURE PART DESCRICPTION

10. 23-27
11. CO-GEN WATER TREATMENT LINE PROCESS 28-29
WHAT IS THE COLD START UP PROCEDURE OF BOILER

12. 30-31
SHUTTING DOWN A BOILER

13. 32-39
14. CONCLUSION 51
PHOTOS WITH GUIDE 52

Unit 1
Introduction
Naranja Sahakari Sakkara Karkhane Limited (NSSKL) a co-operative sugar factory was
established in the year 2002 and commenced commercial operations in March 2002. The sugar
mill has installed capacity to crush 2500 tons of sugar cane per day. NSSKL has set up an 8 MW
cogeneration power plant (project activity) at Imampur Village (Near Janwada), Bidar district of
Karnataka. & Besides operating the existing cogeneration facility sugar plant operates one boiler
aggregating steaming capacity of 80 TPH at 45 kg/ square cm pressure and 4850C SH temperature
and one back pressure turbine of 8MW capacity in sugar plant with back pressure 1.5 kg/ square
cm.
Sugarcane is the main material for a sugar factory, as the sugar is refining from the sugarcane,
the sugar bagasse is also producing. Bagasse through some treatments can be used as a primary
fuel source for biomass boiler in sugar mill. High pressure bagasse fuel boilers are used to
generate heat and electrical energy to supply all the needs of a typical sugar mill, with energy to
spare.
1.1 Bagasse fuel boilers in sugar factory
Every 100 tons of sugarcane crushed, a sugar factory produces nearly 30 tons of wet bagasse. In
some countries, like Vietnam, Thailand, Philippines, there are large areas of sugarcane planting.
The sugar plants there utilize the producing waste bagasse as fuel to drive energy equipment.
The bagasse fuel biomass power plant boiler is energy saving and low emission, the resulting
CO2 emissions are equal to the amount of CO2 that the sugarcane plant absorbed from the
atmosphere during its growing phase, which makes the process of cogeneration greenhouse gas-
neutral.
1.2 High pressure bagasse fuel boilers
In order to supply electricity for sugar factory, the bagasse boiler is designed as high pressure
water tube boiler. Low carbon content in slag, and it can make comprehensive utilization of fly
ash and slag; High efficiency up to 90%, using a bagasse steam boiler in sugar factory can help
save 400 million tons of coal fuel.
EEE Dept ,GNDECB Page 1

Bagasse is the matted cellulose fiber residue from sugar cane that has been processed in a sugar
mill. Previously, bagasse was burned as a means of solid waste disposal. However, as the cost of
fuel oil, natural gas, and electricity has increased, bagasse has come to be regarded as a fuel
rather than refuse. Bagasse is a fuel of varying composition, consistency, and heating value.
These characteristics depend on the climate, type of soil upon which the cane is grown, variety
of cane, harvesting method, amount of cane washing, and the efficiency of the milling plant. In
general, bagasse has a heating value between 3,000 and 4,000 British thermal units per pound
Page | 2(Btu/lb) which is equal to 9304 kj/kg on a wet, as-fired basis. Most bagasse has moisture
content between 45 and 50 percent by weight.
The State of Karnataka has a shortfall in peak power as well as energy availability. This shortfall in
peak availability and energy demand will widen further in the subsequent years. State of Karnataka
thus requires a substantial addition to its power generating capacity to meet the power demand of its
rapidly growing industrial, agricultural and other sectors. Purchase of surplus power from
cogeneration facilities will provide cheaper, eco-friendly power and go some way to bridge the gap
between power `supply' and `demand'.
The State of Karnataka is part of the Southern Regional Electricity Grid, comprising of the States
of Andhra Pradesh, Tamil Nadu, Kerala and the Union Territory of Pondicherry. The various
installed generation capacities as on 2005-06 are given as under.

Unit 2
Theory of cogeneration
There are several industries such as paper mills, textile mills, chemical factories, jute mills, rice
mills and so on where saturated steam at the desired temperature is required for heating, drying
etc. for constant temperature heating (or drying), steam is very good medium since isothermal
condition can be maintained by allowing saturated steam to condense at that temperature and
utilizing latent heat released for heating purpose. Apart from the process heat, factory also needs
power to drive various machines, for lighting and other purposes.
Earlier, steam and power purposes were generated at a moderated pressure and saturated steam
for process work was generated separately at a pressure which gave the desired heating
temperature. Having two separate units for process heat and power is wasteful, for the total heat
supplied to the steam generator for power purposes, a greater part will normally be carried away
by the cooling water in the condenser.
It is also called combined heat and power works on the concept of producing two different form
of energy by using one single source of fuel i.e, heat or thermal energy and other one is
mechanical or electrical energy. Cogen is most optimum, reliable, clean and efficient way of
utilizing fuel. There are two type of power plant Topping and bottoming cycle.
NSSKL proposes to establish a bagasse based 8 MW Co-Gen Power Plant, the peculiarities of
manufacturing process are as follows, This is a simple three step process namely Water
preparation, Steam Generation and Power Generation. The standard flow sheet as will be
adopted can be given as Production care by Instrumentation with Electronic governor,
programmable Logic Controls with MMI (maintenance management institute) & programming
stations, DCS (distributed control system) based interlocks & protection as well as for turbine
monitoring . We propose to erect Data Acquisition & Control System. This will facilitate to
operate, monitor and control the entire Co-gen plant. This will cover boiler, turbine, generation
and auxiliaries. The software will govern all functional requirements, with interlocks, alarms and
graphical display.

Fig.1

Unit 3
Rankine cycle
For each process in the vapour power cycle, it is possible to assume a hypothetical or ideal
process which represents the basic intended operation and does not produce any extraneous
effect. for the steam boiler, this would be a reversible constant pressure heating process of water
to form steam, for the turbine the ideal process would be a reversible adiabatic expansion of
steam, for the condenser it would be a reversible constant pressure heat rejection as the steam
condenses till it becomes saturated liquid and for the pump the ideal process would be the
reversible adiabatic compression of this liquid ending at the initial pressure. When all these four
processes are ideal, the cycle is an ideal cycle, called a Rankine cycle.
Fig.2. Process of Rankine Cycle

Unit 4
STEAM DRUM
Risers discharge into the drum a mixture of water, steam, foam and sludge. Steam must be
separated must be carried separated from the mixture before it leaves the drum. Any moisture
carried with steam to the super heater tubes contains dissolved salts. In the super heater, water
evaporates and the salts remain deposited on the inside surface if the tubes to form a scale, which
is difficult to remove. This scale reduces the rate of heat absorption, ultimately leading to the
failure of the superheated by overheating and rupture. The super heater tubes are exposed to the
highest steam pressure and temperature on the inside and the maximum gas temperature on the
outside. They are made of the costliest material, so, utmost care is taken so that no damage is
done to it by the excessive carryover of moisture with steam. Some of the impurities in the steam
may be vaporized silica, which may cause turbine bade deposits.
Fig.3. Separation of two phase mixture in the drum
No vapour bubble should flow along with saturated water from the drum to the downcommers.
This will reduce the density difference and the pressure head for natural circulation. The bubble

tending to flow upward may also impede the flow in the downcommer and thus affect
circulation. The drum has to secure moisture-free steam going to the super heater and bubble free
water going to the downcommer.
4.1 Steam separation

The steam/water separation in the steam drum is also based on the density difference of water
and steam. It is important to have a steady and even flow of water/steam mixture to the steam
drum. This is often realized with a manifold (header) designed for partitioning of the flow. There
are different kinds of devices for water separation such as plate baffles for changing the flow
direction, separators based on centrifugal forces (cyclones) and also steam purifiers like screen
dryers (banks of screens) and washers. . The separation is usually carried out in several stages.
Common separation stages are primary separation, secondary separation and drying. Figure 4
shows a drawing of the steam drum and its steam separators.
One typical dryer construction is a compact package of corrugated or bent plates where the
water/steam mixture has to travel a long way through the dryer. One other possibility is to use
wire mesh as a material for dryer. The design of a dryer is a compromise of efficiency and drain
ability - at the same time the dryer should survive its lifetime with no or minor maintenance. A
typical operational problem related to steam dryers is the deposition of impurities on the dryer
material and especially on the free area of the dryer (holes).
Fig.4. Steam separators enlarged Fig.5.Cross section of steam drum

4.2 Steam Drum Internals
To achieve the quality of steam required for industrial boilers, separators and driers are provided
inside the boiler drum as a part of “drum internals”. The boiler is equipped with a large steam
drum o provide adequate steam storage capacity and minimize water level fluctuations resulting
from sudden changes in steam demand. The drum internals design combines simplicity and
efficiency to produce low maintenance cost and high steam quality.
Fig.6. Steam drum internal

4.3 Arrangement
The steam and water mixture entering the drum from the riser tubes and the bank tubes
are collected in a separate chamber formed by baffle panels inside the drum. The baffling is done
in the drum to separate the downcomer tubes from the riser tubes. The steam water mixture
passes via the baffle before entering the secondary separators.
The secondary steam dryer consist of several layers of screens (wire mesh) stacked one
above the other where the entrained moisture in steam is removed. The water thus separated is
returned to the water side of the drum. Dry steam leaves the drum through the top steam outlet
nozzles.
4.4 Installation
To prevent moisture from bypassing the top screen dryer and mixing with the dry steam
as it leaves the drum, all the joints in the dryer assembly must be absolutely tight. Seal welding,

where indicated on the drawing, must be carefully done. All bolts are to have two washers, one
at the back of the nut and one in front of the bolt ahead. Joints which are bolted to be made as
tight as possible.
All bolted joints are to be retightened after initial bolting. Gaskets shall not be used.
Joints in feed piping are to be absolutely tight. ‘U’ bolts on the feed piping should allow for feed
pipe expansion.
4.5 Steam purity and quality
Impurity damages
Impurities in steam causes deposits on the inside surface of the tubes. This impurity deposit
changes the heat transfer rate of the tubes and causes the superheater to overheat (CO3 and SO4
are most harmful). The turbine blades are also sensitive for impurities (Na+ and K are most
harmful). The most important properties of steam regarding impurities are:
• Steam quality, Water content: percent by weight of dry steam or moisture in the mixture
• Solid contents, Steam purity: parts per million of solids impurity in the steam
Steam quality
There are salts dissolved in feedwater that need to be prevented from entering the superheater
and thereby into the turbine. Depending on the amount of dissolved salt, some impurity
deposition can occur on the inner surfaces of the turbine or on the inner surface of superheater
tubes as well. Steam cannot contain solids (due to its gaseous form), and therefore the water
content of steam defines the possible level of impurities. The water content after the evaporator
(before super heaters) should be << 0.01 %-wt (percents by weight) to avoid impurity deposition
on the inner tube surfaces. If the boiler in question is a high subcritical-pressure or supercritical
boiler, the requirements of the steam purity are higher (measured in parts per billion).
Steam purity
The solid contents are a measure of solid particles (impurities) of the steam. The boiler water
impurity concentration, solid contents after the steam drum and moisture content after the steam
drum are directly connected: e.g. If the boiler water impurity concentration is 500 ppm and the
moisture level in the steam (after the boiler) 0,1 %, the solids content in the steam (after the
boiler) is 500 ppm * 0,1 % = 0,5 ppm.

Unit 5
Feed water tank
A boiler should have as large feed water reserve as is needed for safe shutdown of the boiler. The
heat absorbed by the steam boiler should be taken into account when dimensioning the feed
water reserve (feed water tank). The exact rules for the choice of feed water reserve are included
in respective standards. The feedwater tank of the recovery boiler is shown in figures 9, 10 and
11. Condensate (from turbine) and fully demineralized (purified) makeup water are the normal
inputs to the feed water tank. Gas removal takes place in the deaerator before condensate and
makeup water reach the feed water tank. The deaerator handles feedwater gas removal and
chemical feeding. Low pressure steam is used to remove gases containing oxygen from the
feedwater. The steam used for gas removal (including gases containing oxygen) continues from
feed water tank to a specific condenser, where the heat from low-pressure steam is recovered.
The feedwater tank is heated with low-pressure steam (usually 3-6 bars). The steam assists the
gas removal from the feedwater tank.
Fig.7.Feedwater tank drawing

Unit 8
Deaeration
WHAT IS DEAERATION?
It is essential to remove the dissolved gases – "deaerate" – before it can be released in the boiler
or the feed tank, to prevent corrosion of the tank, the boiler and the steam system. While
dissolved gases and low pH levels in the feedwater can be controlled or removed by the addition
of chemicals, it is more economical and thermally efficient to remove these gases mechanically.
This mechanical process is known as de-aeration and will increase the life of a steam system
dramatically.
HOW IS DE-AERATION DONE?

Deaeration is based on two scientific principles. The first principle can be described by Henry's
Law. Henry's Law asserts that gas solubility in a solution decreases as the gas partial pressure
above the solution decreases. The second scientific principle that governs deaeration is the
relationship between gas solubility and temperature. Easily explained, gas solubility in a solution
decreases as the temperature of the solution rises and approaches saturation temperature. A
Deaerator utilizes both of these natural processes to remove dissolved oxygen, carbon dioxide,
and other noncondensable gases from boiler feedwater. The feedwater is sprayed in thin films
into a steam atmosphere allowing it to become quickly heated to saturation. Spraying feedwater
in thin films increases the surface area of the liquid in contact with the steam, which, in turn,
provides more rapid oxygen removal and lower gas concentrations. This process reduces the
solubility of all dissolved gases and removes it from the feedwater. The liberated gases are then
automatically vented from the Deaerator, without allowing steam to escape to the atmosphere.
With these principles in mind, Steamline employs a two-stage system of heating and deaerating
feedwater. This system reduces dissolved oxygen concentration to less than 0.005 cc/liter (7
ppb), and completely eliminates the dissolved gas concentration.

Fig.8. Deaeration

Unit 7
AIR PREHEATER
Air Preheater is a heat transfer surface in which air temperature is raised by transferring
heat from flue gas. Since air heater can be successfully employed to reclaim heat from flue gas at
lower temperature levels than is possible with economizer, the heat rejected to chimney can be
reduced to a higher extent thus increasing the efficiency of the boiler. Apart from increasing the
efficiency of the boiler, preheated air has got the following other advantages:
 Improved combustion stability.

 Intensified and improved combustion
 Intensified combustion permits faster load variation and load fluctuation.
 High heat transfer rate in the furnace and hence lesser heat transfer area
requirement.
 Less unburnt fuel particles in the flue gas.
 Since this is a non-pressure part and also a non-rotating equipment of the boiler, it
does not warrant a shutdown of the unit due to corrosion of the heat transfer
surface.
7.1 Arrangement
This air preheater consists of a large number of steel tubes expanded into tube plates at
the ends. Flue gas flows thorough the tube and air flows outside the tube the air heater is divided
into two blocks easy maintenance.
7.2 Maintenance
During annual overhaul, air preheater should be thoroughly cleaned. Leakage in air
preheater can be checked during operation by analyzing flue gas for Co2 drop across the air
preheater. The leakage is generally through the tube joints, corrosion, etc.
7.3 Wet Scrubber
We offer five principal designs customizable to meet your requirements:

 Micro-Vane scrubber with no moving parts
 Dynamic scrubber with integral fan
 High efficiency venture scrubber

 Multi-venture scrubber
 Packed towers for gas absorption.
BSML employs high efficiency venture scrubber
7.4 Operation
The design of the MicroPul Venture Scrubber consists of a “wet approach” venturi followed by a
liquid entrainment separator. Dust laden gases enter the venturi and instantly make contact with
the tangentially introduced scrubbing liquid swirling down the venturi’s converging walls. At the
venturi throat, the gas and liquid streams collide and the liquid breaks down into droplets which
trap dust particles. This gas/liquid mixture passes through a flooded elbow, and then enters the
entrainment separator through a tangential inlet. Centrifugal action removes the heavy wetted
particles from the gas stream. As an alternate, when very large diameter separators are required,
the liquid is separated by passing the stream through a chevron-type mist eliminator baffle.
The dust/liquid mixture is discharged from the separator bottom drain and the cleaned gas leaves
through the top of the separator.
Fig.9. MicroPul Venture Scrubber
Unit 8

Fans
Fans provide air for ventilation and industrial process requirements. Fans generate a pressure to
move air (or gases) against a resistance caused by ducts, dampers, or other components in a fan
system. The fan rotor receives energy from a rotating shaft and transmits it to the air.
8.1 Id fan
ID fan is basically mentioned here for Induced draft fan and ID fan is always located between dust
collector and chimney. ID fan will take the hot flue gases from furnace via dust collector (dust separation
system or Fume Extraction system) and will deliver to chimney. ID fan will handle the flue gases i.e. hot
air.
ID fan will produce the pressure lower than the atmospheric pressure in the system or we may
say that ID fan will produce the negative pressure in the furnace to remove the flue gases from
furnace via electrostatic precipitators and to push the flue gases to chimney.
Do not get confused about the dust collector system. Dust collector system also designated as
fume extraction system or dust separation system. Somewhere we also used to electrostatic
precipitators in place of dust collector system for removing dust particle from flue gases for
maintaining the clean environment.
8.2 Fd fan
FD fan, which is mentioned here for forced draft fan, is used basically for providing the required
quantity of hot air to the furnace for smooth and uniform combustion of fuel. FD fan will
produce the positive pressure inside the system i.e. furnace.
Unit 9

Steam generators or boilers
A steam generator generates steam at the desired rate at the desired pressure and temperature by
burning fuel in its furnace. Steam generators are used in both fossil-fuel and nuclear-fuel electric
generating power stations this chapter will, however, cover only fossil-fuel steam generators.
Nuclear fuel steam generators are of very different design.
9.1 Classification of boilers
Relative position of hot gas and water
• Fire tube boiler-Hot gasses pass through the tubes that are surrounded by water.
 Horizontal return tubular.
 Vertical tubular.
 Lancashire.
 Cochran.
 Cornish.
 Locomotive fire box.
 Scotch marine etc.
• Water tube boiler- The tubes contain water and the hot gases flow outside.
 Babcock and Wilcox.
 Stirling boiler.
 La Mont boiler.
 Benson and
 Loeffler boiler.
METHOD OF FIRING

• Internally fired boiler

 Lancashire.
 Locomotive and
 Scotch.
• Externally fired boiler
 Babcock and Wilcox.
9.2 Pressure of steam
• High pressure (>80 kg/cm2)

 Babcock and Wilcox Lamont etc
• Low pressure (<80 kg/cm2)
 Cochran.
 Cornish.
 Lancashire and
 Locomotive.
9.3 According to the axis of shaft
 Vertical tubular
 Horizontal tubular
9.4 Method of circulation of water
 Natural circulation
 Forced circulation
9.5 Nature of service to be performed

 Land boilers
 Portable boiler
 Mobile boilers
9.6 Fire tube boilers
A fire tube boiler is a type of boiler in which hot gases / flue gases (products of combustion)
from a fire (heat source) pass through one or more tubes running through a sealed container of
water. The heat energy from the gases passes through the sides of the tubes by thermal
conduction, heating the water and ultimately creating steam. A fire-tube boiler is sometimes
called a "smoke-tube boiler" or "shell boiler" or sometimes just "fire pipe".
9.6 Types of Fire Tube Boiler

• Cochran boiler,
• Lancashire boiler,
• Scotch marine boiler,
• Locomotive boiler etc.
9.7 Water tube boiler
A water tube boiler is a type of boiler in which water circulates in tubes heated externally by the
hot gases / flue gases. Water tube boilers are used for highpressure boilers. Fuel is burned inside
the furnace, creating hot gas which heats up water in the steam generating tubes. The drums are
used for storage of water and steam. As they are not required to contain tubular heating surface,
they can be much smaller in diameter than the fire tube shell and can, therefore, be built to resist
high pressure Generation of steam is quicker as water is subdivided into small volume. The
initial cost, operational cost and maintenance costs of water tube boiler are higher than that of an
equivalent fire tube boiler.
Types of water tube boiler

• Babcock & Wilcox boiler,
• Stirling boiler etc.
Fig.10.Water Tube Boiler
Fig.11.Comparision between water tube and fire tube boiler
9.8 boiler mountings

Mountings are required for proper and safe functioning of the boiler which is generally mounted
over the boiler shell.
Water Level Indicator

 The water level indicator is needed to ascertain the water level of a boiler.
 Two water level indicators should be fitted for each boiler in such a place that the water
level can be constantly seen.
Pressure gauge
 A pressure gauge is an instrument by means of which the pressure exerted inside a vessel
can be measured.
 There are two types of pressure gauges, one is Bourdon tube pressure gauge and the
other is diaphragm type gauge.
Safety Valve
 The safety valve (pressure relief valve) is used in a boiler to relieve the pressure of steam
when it is above the working pressure.
 Its function is to discharge a portion of the steam from the boiler automatically when the
steam pressure exceeds the normal limit. It is mounted on the top of the shell.
9.9 Fusible plug
The function is to extinguish the fire in the event of water level in the boiler shell falling below a
certain specified limit.

Fig.12. Fusible Plug
9.10. Feed Check valve
The feed check valve is used to control the supply of water to the boiler and to prevent the
escaping of water from the boiler when the pump pressure is less or the pump is stopped. It is
fitted over the shell slightly below the normal water level of the boiler.
Fig.12.Feed check valve
9.11. Steam stop valve

The function of the stop valve or junction valve is to regulate the flow of steam from the boiler
to the main steam pipe. To shut off the steam completely when required.
Fig.13. Steam stop valve
Unit 10

Boiler pressure part descricption
The Boiler is a bi-drum with fin-welded wall construction. The various heat transfer
sections of the boiler are grouped as follows:
1. Furnace
2. Super heater
3. Boiler bank
4. Economizer.
10.1. FURNACE
Furnace is the primary part of the boiler the chemical energy available in the fuel is
converted to thermal energy by means of combustion. The furnace is designed for efficient and
complete combustion. The major factors that assist efficient combustion are the fuel residence
time inside the furnace, temperature inside the furnace and turbulence which causes rapid mixing
between fuel and air. The design of the boiler furnace has the following advantages.
a. Inside the furnace not only combustion but also heat transfer is taking place
simultaneously.
b. The maintenance work involved in repairing the fire bricks (which is otherwise
required) is practically eliminated.
c. Due to heat transfer in the furnace, the flue gas temperature leaving the furnace is
reduced to acceptable levels of the super-heating surfaces.
d. Higher heat loading is possible as heat is being simultaneously removed by heat
transfer and hence economy in surfacing.
The furnace is of fin-welded wall construction. In the fin welded wall construction, the water
wall tubes are placed at specified pitches with fins to form gas tight enclosures. The buckstays
provide help in withstanding loads on furnace due to pressure, wind and seismic load and at the
same time allows for free expansion due to temperature change. The shape of the furnace is
decided to ensure a gas path, which will fill the furnace and provide maximum heat absorption.

The expansion of the furnace wall should be watched carefully during initial start-up. The
expansion between different corners at the same plane should be noted so that any constraint for
free expansion could be identified. The cause should be immediately investigated and rectified at
the earliest opportunity.
The fuel loading in the furnace should be done such that the heat loading is uniform in the
furnace. Any leakage of air through furnace should be avoided.
10.2. SUPERHEATER
Superheaters are meant to raise the steam temperature above the saturation temperature by
absorbing heat from the flue gas. By increasing the temperature of the medium (steam) the useful
energy that can be recovered increases, thus the efficiency of the cycle also. Superheating the
steam also eliminated the formation of condensate during transporting of steam in pipelines and
inside the early stages of turbines, which is harmful to the turbine blades and pipelines.
The super heater is a heat exchanger in which heat is transferred to the saturated steam to
increase its temperature. It raises the overall cycle efficiency. In addition, it reduces the moisture
content in the last stages of the turbine and thus increases the turbine internal efficiency.
In modern utility high pressure boilers, more than 40% of the total heat absorbed in the
generation of steam takes place in the super heaters. So, large surface area is required to be
provided for superheating of steam.
Super heaters are commonly classified as either convective superhaeters, radiant super
heaters or combined super heaters, depending on how heat is transferred from the gases to steam.
Convective super heaters are located in the convective zone of the furnace, usually ahead of the
economiser.

Fig.14. Heat absorption in super heater coils
10.3. Operation and Maintenance

The following points must be taken care to ensure longer life and higher availability of the
pressure parts
The metal temperatures at all the locations should be kept within permissible value. This can be
accomplished by keeping the steam temperature at the outlet of the super heater within a
particular value. However, operating the boiler with low feed water temperature along with high
excess air may result in exceeding the limit. There should be no hesitation to bring down the load
on the boiler if this temperature cannot be brought under control by other means. Keeping the
water walls clean, reducing the excess air and raising the feed water temperature will help
reducing the heat pick-up in super heaters.
Raising and lowering of steam parameters should be restricted to the value given in the starting
diagram.
Super heaters are to be steam blown to keep them reasonably clean. Fly ash with high moisture
content may stick to the heat transfer surface resulting in low super heater outlet steam
temperature, the boiler should be shut down at the earliest by routine procedure adopted for
maintenance work. Otherwise, large number of tubes may fail due to steam erosion and
impingement.
In case of tube failure, which can be identified by the noise in the boiler gallery, the furnace
fluctuations, the differences in steam and water flow, gas and steam temperature, the boiler

should be shut down at the earliest by routine procedure adopted for maintenance work.
Otherwise, large number of tubes may fail due to steam erosion and impingment.
Drum level should be maintained at recommended level both during starting and at all conditions
of operation to avoid carryover and in extreme cases flooding of super heaters. Entry of wet
steam into super heater first rows will result in removal of the oxide film due to thermal shock
and accelerate stress corrosion.
10.4. Boiler bank
The boiler bank is almost a convection heat transfer section with some amount of non-
luminous radiation. The arrangements of tubes are mostly in line. Please refer boiler bank data
sheet.
In this bi-drum boiler the top drum and the bottom drum are connected by a set of tube
called bank tubes. Generally as a rule, two or three rows of these bank tubes are called as
downcomers through which the low temperature feed water entering the top drum will pass on to
the lower drum. The baffle arrangement inside the top drum has been suitably arranged to
separate the downcomer and riser tubes. The steam generated in the bank tubes will raise through
the remaining tubes into the top drum. Thus a natural circulation of water is established through
the boiler bank. Stainless steel baffles have been arranged in the bank tube area.
10.5. Economiser.
Introduction
The function of an economizer in a steam generating unit is to absorb heat from the flue
gases and add this as sensible heat to the feed water before the water enters the evaporative
circuit of the boiler. Provision of this additional heating surface increases the efficiency of steam
generating unit saving in fuel consumption, thus the name ‘Economizer’ christened.
Location and arrangement

It is useful to locate the economizer ahead of air heaters and following the super heaters
and boiler bank tubes. Counterflow arrangement is normally selected so that heating surface
requirement is kept minimum for the same temperature drop in the flue gas. The economizer
tubes are placed in line arrangement. With higher feed water temperature (105 Deg.C) low
temperature corrosion or bonded deposits in economizer will be seldom encountered Economizer
tubes are supported in such manner that sagging, undue deflection and expansion restriction will

not occur at any condition of operation. For on load cleaning, the most common arrangement is
to provide soot blowers at gas inlet to economizer. Even though on load cleaning is sufficiently
effective, it is usual to water wash economizer during each off-season.
Caution : To avoid low temperature corrosion of Economizer Coils, feed water temperature
entering economizer should not be less than 90 Deg.C Raw Make-up water should not be fed to
the economizer directly.
Based on the tube economizers are CI gilled tube, Round gilled tube, coiled tube type Horizontal
finned tubes (Here, making contact of fins with tubes for perfect heat transfer) and Based on the
boiler efficiency Non condensing economizer (Finned spiral form at exit of boiler in duct form)
Condensing economizer An economizer is a heat exchanger which raises the temperature of the
feed water leaving the highest pressure feedwater heater to about the saturation temperature
corresponding to the boiler pressure.
Fig.15. Economiser coil and the temperature profiles of flue gas and water
This is done by the hot flue gases exiting the last super heater or reheater at a temperature
varying from 370 0C to 540 0C. The term economizer was used historically because the throwing
away of such high temperature gases involved a great deal of energy loss. By utilizing these
gases in heating feedwater, higher efficiency and better economy were achieved, and hence the
heat exchanger was called economizer.

Unit 11
Co-gen water treatment line process

11.1 Purpose of water treatment
Water treatment is required for satisfactory operation of the boiler. It must be devised to prevent
depositing of scale and to prevent corrosion from acids, oxygen and other such harmful elements
that may be in the water supply. A qualified water treatment chemist should be consulted and the
water systematically treated.
Objectives
The basic objectives of water treatment are:
1. Prevent the accumulation of scale and deposits in the boiler.
2. Remove dissolved gases from the water.
3. Protect the boiler against corrosion.
4. Maintain the highest possible boiler fuel efficiency.
5. Decrease the amount of boiler down time from cleaning.
11.2. Water softener
It is highly recommended that a zeolite water softener be used for all make-up to the boiler. It is
intended that this be used in addition to the chemical treatment of the boiler. Water softening
removes calcium and magnesium, the primary causes of hard boiler scale.
11.3. Continuous monitoring required

Water treatment should be checked and maintained whenever the boiler is operating. The boiler
operator should be sure that the boiler is not operating for long periods without proper water
treatment. Water treatment may vary from season to season or over a period of time. Therefore,
the water treatment procedure should be checked not less than four times a year, and possibly
more frequently as the local water conditions may indicate.

Fig.16.Typical type of water treatment line

Unit 12
What is the cold start up procedure of boiler
 PRE CHECK UP FOR COLD START UP OF BOILER

 Check all maintenance work are completed and all permit are returned.
 Check all foreign materials has been removed from the pressure parts
 Check all the access doors are closed
 Check all equipments are trail run successfully.
 Check all interlock test and prior test to start up are completed
 Check no jamming in rotary equipment, lubrication oil, cooling water system is normal.
 Check all the oil level meter are operation.
 Check all the position of valve is normal
 Check HFO & LDO pump are running in recirculation.
 Fill the deaerator with initial filling line.
 CONFORM THE POSITION OF THE FOLLOWING VALVES

 All blow down and drain valves on boiler and water wall should be closed condition.
 All boiler and superheater filling valves are closed condition.
 Soot blower master steam valve should be closed condition.
 Main steam line stop valve should be closed condition.
 De-superheater spray valve should be closed condition.
 Drum vents should be open condition
 Superheater header drains should be open condition.
 Fill the boiler with initial filling line and observe the water coming from the vent of
economizer, drum vents, and superheater vents sequentially.
 CBD & IBD drains should be closed condition.
 START BOILER LIGHT UP

 Start the (ACW) industrial cooling water system.
 Start the instrument air compressor.

 Start the APH motor it that is rotary APH.

 Put the auxiliary steam system (PRDS) in operation for oil heating.
 Start the ID and FD fan.
 Start the scanner air fan.
 Start the HFO/LDO pump with recirculation.
 Adjust the fan speed and opening of dampers, increase the air flow up to 30% of total air
flow.
 Maintain the furnace draft of approximately -4 mm.
 Start boiler feed water pump and keep drum level as per purge permissive.
 Make sure all purge permissive are satisfying and start purge for 5 minutes.
 Start the oil burners by maintaining furnace draft.
 Visually check the flame of oil burner is that healthy or not.
 When prepare for heavy fuel firing, be sure that atomizing steam is in service and oil
temperature reach to permissive value.
 Change the position of oil guns on each elevation for uniform heating of furnace.
 Increase the furnace temperature by 5 deg c per minute.
 The firing should be continued nearly 8 hours.
 Start the HP dosing pump with minimum stroke.
 Observe the drum upper and lower metal temperature increase uniformly.
 Close the drum vents when drum pressure reaches to 2 kg/ sqr cm.
 Observe the expansion reading of boiler within limit.
 Close the main steam line vent when the pressure reaches to 5 kg/sqr cm.
 Change the auxiliary steam line and connect to common header if available.
 Check all drains of the boiler should be closed condition.
 Slowly open the main steam line bypass valve.
 Observe all condensate removed from line and open slowly main steam valve to turbine
and observe hammering of steam line.
 Charge the sample cooler line and ask D M plant operator to check all the parameter of
water and steam.
Unit 13
Shutting down a boiler

When a boiler has to be removed from service for maintenance, inspection, or layup,
The following procedure should be followed:
 Before shutting the boiler down, give it a good blow down to remove as much sediment
as possible. Stop when the drain runs clear.
 Put the boiler steam pressure control in manual mode, and slowly reduce the firing rate.
Watch the main steam header pressure to make sure that the other boilers are taking up
the load. Do not reduce the firing rate below that necessary to maintain a stable flame.
 When the boiler is at the minimum firing rate the fuel can be shut off at the main gas
cock. Alternatively, this is often a good time to test the low water level shutdown switch,
or some other boiler interlock. If this method is chosen make sure you note it in the
logbook.
 Allow the fan to post-purge the furnace with a reduced air flow, and then shut the fan
down. Be particularly careful not to let the fan supply large amounts of cold air into the
furnace in the winter.
 Close the boiler header stop valve.
 Open a steam drum vent valve when the boiler pressure drops to slightly above
atmospheric pressure. This will prevent a vacuum from forming (not doing this has
resulted in a fatality in recent years, when maintenance personnel proceeded to open the
manhole cover from the water drum of a boiler which had drawn a vacuum). If the boiler
is going to be shut down for an extended period of time it will need a proper lay-up. This
topic is described in the module “Boiler Maintenance”.
13.1 Cane preparation

Cane is bought from cane yard to Sugar Factories on the trucks and trawlers. Cane
weighing is take place with the help of Three Weigh Bridges. These Weigh Bridges are a very
England Design. 02 Weigh Bridges are for Gross Weight and 01 Weigh Bridges is for Tare
Weight Capacity of the Weigh Bridges is 50 Tons.
13.2 Mill House:

After weighing of the cane, sugarcane is moved to the mill station for the extraction of
the juice. There are two mills working for the extraction of the juice named as:
 Mill house Tandem No. 1
 Mill house Tandem No. 2
Cane Unloaders:
There are two types of UN loaders
• Mechanical type cane UN loader
• Hydraulic type cane UN loader
The function of cane unloaded is to pick the cane from the tractor and put in to the
carrier. Cane Unloading is done with the help of Electric Hoists. Three Electric Hoist are
attached to Mill Tandem .The Function of these Electric Hoists is to Lift the Cane loaded Truck
and throw it to Dumping Carrier. It can lift 40-50 ton at a time.
Lifting Speed 13-20 ft/min
Lifting Height 20 m
13.3. Dumping Carrier:
There are three dumping carrier in each mill tandem. In which sliding plates are attached
which carry the cane to the main carrier. Idler Pulleys are used to support the chain on which
sliding plates move. These idler pulleys are coated with some material so that to stop wear and
friction. V-Belt drive used to transmit power from motor driven shaft to gear system and from
there with the chain sprocket mechanism it drives the Dumping.
Dumping Carrier Length 42 ft
Dumping Carrier Angle 18deg
When high torque load is to be transmitted. We use chain sprocket mechanism. By the
Formula of power as torque is very high and speed is low then slippage takes place. So belt
could not be used there and chain sprocket mechanism is the better choice.
13.4. Main Carrier:

After passing out through the Dumping cane carriers, sugarcane moves into the Main
cane carrier. Mill Tandem no. 1 has main cane carriers of different lengths. Main cane carrier in
Tandem no. 2 has three cutters while main carriers of Tandem no. 1 shown in fig. 3.9.1 have two
levelers on it to move the cane in an organized way.
Fig. 17. Mill house Tandem 1
13.5. Levelers:
As the name implies it function is to provide evenly feed to cutters. Mill Tandem No. 1
has two Levelers. These are rotated by the motors. As they rotate they level the sugarcane
passing through the levelers. Leveling the cane not only increases the capacity of the Tandem but
also it makes the juice extraction easy.
Leveler 1 No Of arms 26
Leveler 2 No of arms 24
13.6. Pusher Drum:

The function of the pusher drum is to push the compact sugar cane to the Fabrizer.
Dia. of Drum 2250 mm
Length of the Drum 7200 mm
13.7. Fabrizer:
Fabrizer does the same function in tandem no 1 as Shredder in tandem no 2. In Fabrizer it
takes input feed from the top and pushes it to the bottom. It has anvil plate on the top. Then it has
feed rake bar and rake bar under carrier. It is Turbine Driven.
13.8. Magnetic Iron Separator:

Iron or other harmful metals may attach to the sugar during harvesting or transporting.
These particles must be removed otherwise they may harm the mills. The purpose of magnetic
iron separator is to separate the iron particles attached to the sugarcane.
13.9. Cutters:
The purpose of cutters here is to cut the cane in small pieces so that they are easily
shredded and juice cane be extracted more efficiently. There are three cutters for Mill House
Tandem No. 2. As shown in fig 3.5.9.1
Cutter #01 No. of knives 70

Cutter # 02 No. of knives 70
Cutter # 03 No. of knives 52
13.10. Cane Shredder:

The main function of the shredder is to rapture the structure in order to open the cells of
the cane. It is driven by Backpressure Impulse Turbine. This Shredder is covered by anvil plate,
it is below the Shredder. It has very low spacing in mm with hammers. Shredder has Stainless
steel hammers with beadings. Shredder gets feed from below and takes it above .that is why its
anvil plate is below.
13.11. Rotary Mills:

This is the area where juice is extracted from the cane and is separated from the bagasse.
Numbers of mills for Mill House Tandem No.1 and Tandem No. 2 is different. Rotary Mills are
run by the turbines which provide sufficient Mechanical Energy to rotate the mills. Cane passes
through these rotary mills and juice is extracted from the cane by rotary motion of the mills
leaving bagasse behind.
13.12. Mill House Output:

Screened cane juice and bagasse is the output of the mill house. Fig. 4 shows the mill
process.
Fig.18. Mill House Crushing
The manager needs to process the cane as soon as possible if sugar losses are to be
avoided yet needs to have a sufficient supply in storage for times when cutting and transport are
stopped, whether deliberately or not. Typically, cane is processed within 24 hours of cutting;
Cane preparation is critical to good sugar extraction, particularly with diffusion

extraction. This is achieved with rotating knives and sometimes hammer mills called
"shredders". However shredding requires extra energy and more equipment;
13.14. Cogeneration Plant

What is Cogeneration?
A cogeneration system is the sequential or simultaneous generation of multiple forms of useful
energy (usually mechanical and thermal) in a single, integrated system. CHP systems consist of a
number of individual components – prime mover (heat engine), generator, heat recovery, and
electrical interconnection – configured into an integrated whole. The type of equipment that
drives the overall system (i.e. the prime mover) typically identifies the CHP system. Prime
movers for CHP systems include reciprocating engines, combustion or gas turbines, steam
turbines, micro-turbines, and fuel cells. These prime movers are capable of burning a variety of
fuels, including natural gas, coal, oil, and alternative fuels to produce shaft power or mechanical
energy. Although mechanical energy from the prime mover is most often used to drive a
generator to produce electricity, it can also be used to drive rotating equipment such as
compressors, pumps, and fans. Thermal energy from the system can be used in direct process
applications or indirectly to produce steam, hot water, hot air for drying and chilled water for
processing. Cogeneration is shown in fig. 3.2.1.
Fig.19. Cogeneration
13.15. Steam Turbine Cogeneration System

Steam turbines are one of the most versatile and oldest prime mover technologies still in
general production. Power generation using steam turbines has been in use for about 100 years,
when they replaced reciprocating steam engines due to their higher efficiencies and lower costs.
The capacity of steam turbines can range from 50 kW to several hundred MWs for large
utility power plants. Steam turbines are widely used for combined heat and power (CHP)
applications. The thermodynamic cycle for the steam turbine is the Rankin cycle. The cycle is
the basis for conventional power generating stations and consists of a heat source (boiler) that
converts water to high-pressure steam. In the steam cycle, water is first pumped to medium to
high pressure.
It is then heated to the boiling temperature corresponding to the pressure, boiled (heated
from liquid to vapor), and then most frequently superheated (heated to a temperature above that
of boiling). A multistage turbine expands the pressurized steam to lower pressure and the steam
is then exhausted either to a condenser at vacuum conditions or into an intermediate temperature
steam distribution system that delivers the steam to the industrial or commercial application. The
condensate from the condenser or from the steam utilization system returns to the feed water
pump for continuation of the cycle.
The two types of steam turbines most widely used are the backpressure and the extraction
condensing types. The choice between backpressure turbine and extraction-condensing turbine
depends mainly on the quantities of power and heat, quality of heat, and economic factors.
The extraction points of steam from the turbine could be more than one, depending on the
temperature levels of heat required by the processes.
13.16. Back Pressure Steam Turbine

A back pressure steam turbine is the simplest configuration. Steam exits the turbine at a
pressure higher or at least equal to the atmospheric pressure, which depends on the needs of the
thermal load. This is why the term backpressure is used. It is also possible to extract steam
from intermediate stages of the steam turbine, at a pressure and temperature appropriate for the
thermal load. After the exit from the turbine, the steam is fed to the load, where it releases heat
and is condensed. The condensate returns to the system with a flow rate which can be lower than
the steam flow rate, if steam mass is used in the process or if there are losses along the piping.
Make- up water retains the mass balance.

Unit 14

Conclusion
The first phase of practical training has proved to be quiet fruitful. It provided an opportunity for
encounter with such hardworking engineers. The architecture of the power plant the way various
units are linked and the way working of whole plant is controlled make the student realize that
engineering is not just learning the structured description and working of various machines, but
the greater part is of planning proper management. It also provides an opportunities to learn low
technology used at proper place and time can cave a lot of labour. But there are few factors that
require special attention. Training is not carried out into its tree sprit. It is recommended that
there should be some project specially meant for students where presence of authorities should
be ensured. There should be strict monitoring of the performance of students and system of
grading be improved on the basis of work done. However training has proved to be quite fruitful.
It has allowed an opportunity to get an exposure of the practical implementation to theoretical
fundamentals.

NSSK Sugar Factory Bidar Intrenship Report

Caricato da

Informazioni sul documento

Titolo originale

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

NSSK Sugar Factory Bidar Intrenship Report

Caricato da

Copyright:

Formati disponibili

COGENERATION ANALYSIS IN SUGAR FACTORY

Visvesvaraya Technological University

The successful completion of any task would be incomplete without mentioning

crowned my efforts with success.

I express my deep-felt gratitude to my guide PROF.SHUBHA KULKARNI. has been a great

I remain indebted and highly grateful to Mr.B.S.APARANAJI (MD),Mr.V.B.ARUN KUMAR

which was kind and co-operative during my stay in the industry.

his support and inspiration in carrying out this industrial training.

cotton textiles in the country and it shows its importance.

help of the co-operative sector of sugar industry.

Unit Title Page

FEED WATER TANK

AIR PREHEATER 13-14

STEAM GENERATORS OR BOILERS

BOILER PRESSURE PART DESCRICPTION

11. CO-GEN WATER TREATMENT LINE PROCESS 28-29

WHAT IS THE COLD START UP PROCEDURE OF BOILER

SHUTTING DOWN A BOILER

PHOTOS WITH GUIDE 52

1.1 Bagasse fuel boilers in sugar factory

1.2 High pressure bagasse fuel boilers

EEE Dept ,GNDECB Page 1

EEE Dept ,GNDECB Page 2

EEE Dept ,GNDECB Page 3

EEE Dept ,GNDECB Page 4

Fig.2. Process of Rankine Cycle

EEE Dept ,GNDECB Page 5

Fig.3. Separation of two phase mixture in the drum

EEE Dept ,GNDECB Page 6

4.1 Steam separation

Fig.4. Steam separators enlarged Fig.5.Cross section of steam drum

EEE Dept ,GNDECB Page 7

4.2 Steam Drum Internals

Fig.6. Steam drum internal

EEE Dept ,GNDECB Page 8

4.5 Steam purity and quality

EEE Dept ,GNDECB Page 9

Feed water tank

Fig.7.Feedwater tank drawing

HOW IS DE-AERATION DONE?

EEE Dept ,GNDECB Page 11

EEE Dept ,GNDECB Page 12

 Improved combustion stability.

7.3 Wet Scrubber

We offer five principal designs customizable to meet your requirements:

EEE Dept ,GNDECB Page 13

BSML employs high efficiency venture scrubber

Fig.9. MicroPul Venture Scrubber

EEE Dept ,GNDECB Page 14

EEE Dept ,GNDECB Page 15

Steam generators or boilers

9.1 Classification of boilers

Relative position of hot gas and water

EEE Dept ,GNDECB Page 16

• Internally fired boiler

9.2 Pressure of steam

• High pressure (>80 kg/cm2)

9.3 According to the axis of shaft

9.4 Method of circulation of water

9.5 Nature of service to be performed

EEE Dept ,GNDECB Page 17

9.6 Fire tube boilers

9.6 Types of Fire Tube Boiler