Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
IN SESHASAYEE PAPER MILL
Dr T.G.Sundara Raman
CII
Hyderabad
16 June 2010
1
International practice in running Steam turbo‐generator
[STG] battery
GENERAL
• Run STG of higher cycle efficiency at increased loads and
yet meeting the process steam demands
• Other STGs at lower loads thus acting as slave
Chemical Recovery Boiler [CRB] & Coal fired Boiler[CFB]
Cogen units
• Run CRB Cogen with black liquor solids as fuel
• CFB Cogen shall cater to balance load
2
HP COGEN BATTERY IN PREMIER PAPER MILLS
APPM 64 64
ITC 64 64
JK* 88/106 64/88
SPB 106 65
WCPM 64 64
TNPL 64 64
* : Planned
3
Existing HP Cogen Scenerio in SPB
Captive Power Plant [CPP1]
• Boiler # 10 [106 kg/cm² /510˚C AFBC ] &
21MW Double extraction condensing steam turbo‐
generator
‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐
Captive Power Plant [CPP2]
• Boiler # 11 [65 kg/cm² /465˚C CRB] &
16 MW Extraction back pressure steam turbo‐generator
4
SPECIFICATIONS OF THE 2 HP COGEN UNITS
CPP Chemical Recovery Cogen
Steam Pressure (kg/cm2) 106 65
• Boiler 10 operating at economic load (85%) with Imported
coal as fuel
• Boiler 11 designed for Phase‐1 ( 60 %) &
Phase ‐ 2 ( 100 % ) operation with Black
liquor solids firing in CRB
7
Turbine Extraction‐Exhaust Steam Range
Condensing 25‐50 TPH X
8
ENERGY DISTRIBUTION ACROSS 16 MW STG
9
POST MDP – [PHASE – I] – FLOW CHART
Weak Black Liquor from
Pulp Mill
.
Falling Film
Evaporator
GRID
IMPORT
. Strong Black
Liquor 70% 586 tpd CPP/CFB
Concentration
AFBC#10
106 kg/cm2
B#11 CRB
65 kg/cm2 95 tph
73 tph
EBP DEC
16MW STG 21MW STG
8.7 MW 15.6 MW
8 tph 22 tph
65 tph 42 tph
31 tph
0.1 MW
11 kg/cm2 4 kg/cm2 CW
Steam Header Steam Header
• 16 MW STG is designed for both the phases of operating
loads( 60 % to 100%)
• Hence extraction stage ( nozzle) is designed by BHEL to
commensurate with rated steaming conditions at the
header for Process(11 kg/cm2)
• Obviously at lower loads of operation, higher turbine
nozzle steam temperatures are unavoidable
11
.
16 MW STG E1 flow Vs Nozzle steam temperature
400
350
300
250
Temp (Deg c)
200
Tnoz
150 Tsat
100
50
0
0 5 10 15 20 25 30 35 40 45
E1 (TPH)
.
16MW STG E1 flow Vs Enthalpy differential
30
25
20
ΔH (Kcal/Kg)
15
10
0
0 5 10 15 20 25 30 35 40 45
E1 (TPH)
.
250
16MW STG E2 flow Vs Nozzle steam temperature
200
Temp (Deg C)
150
Tnoz
100
Tsat
50
0
0 20 40 60 80 100 120 140
E2 (TPH)
.
16MW STG E2 flow Vs Enthalpy differential
16
14
12
10
Δh (Kcal/Kg)
0
0 20 40 60 80 100 120 140
E2 (TPH)
Available Energy for Conversion from Thermal
‐16 MW Steam turbo‐generator
• 1.5 MW (th) each from turbine nozzles of both E1 & E2
upto saturation are available
• Equivalent to 15 to 20 % of total energy through reduction
of steam temperature through desuperheating alone.
16
RECOMMENDATIONS
• Splitting E 1 ( M.P. steam extraction) flows between the 2
steam turbines to be minimized.
• Ensure entire E 1 flow through one of the 2 STGs
• Accordingly split E2 (L.P. steam extraction) flow between
the 2 steam turbines
• Maximize combined cycle efficiency in power with either of
the turbines acting as slave.
17
POWER GENERATION ENHANCEMENT SCHEME [PES]
Through shifting of E1 flows to one STG ( instead of splitting of flows)
Extraction Steam flows – Actual & Potential [TPH]
1 of 2
2010 E1 E1 E1 E2 E1 E2 C
18
Power generation enhancement (estimated)
2 of 2
19
Gains from Power enhancement scheme
• Higher electrical power generation with lowering of
extraction(E1) steam temperature at turbine nozzle
• Equivalent to 0. 3 MW on a continuous basis.
• Reduction in spray quantity required for desuperheating
ensures better steam quality for process use.
X Counteracted by marginal reduction in LP steam generation
through desuperheating
20
Contribution to Power enhancement by
Energy efficient main steam pipe‐line
• Recommended to go in for high level pipe‐line
insulation for a design temperature drop across main
steam line connecting boiler to steam turbine from
8°C to 4°C.
• Through the above scheme in place, power
generation increment of 0.3 MW shall be ensured
for the case under study during Phase‐1 operation.
21
CONCLUSIONS & WAY FORWARD
22
Conserve
.
.
Energy
Green the
Mother
Earth
23