ADVANCES IN HIGH PRESSURE COGENERATION

BATTERY IN SESHASAYEE PAPER PLANT

T. G. Sundara Raman &
R. Thirumurugan
Seshasayee Paper and Boards Limited

COMPANY PROFILE

Established in the year 1961

Started with a production of 20,000 tonnes of paper/year

SPB produces now ~1,20,000 tonnes of paper/ year

2 High Pressure Cogeneration Plants with state of the

art technology

Present Gross turnover is about Rs 5000 million

An ISO-9001 / ISO-14001 / OHSAS organisation

Two projects are under DVR Stage for CDM/VCS

9th ENERGY EFFICIENCY SUMMIT 2010

EnCon in Thermal Systems
CII
Chennai
4 Sep. 2010

CHOICE OF HIGH PRESSURE STEAM

High pressure Steam (105 bar)
Impact of Steam Pressure on SSC

Low Specific Steam

Consumption - SSC
(in other words, more
power generation per
unit ton of steam)
Flexibility to produce
more steam or more
power

8
SSC (Te/Mwh)

7
6

High cycle efficiency

Low cost of total energy

generation & conversion

7.1

Reduced dependence on
grid power

5.4
4.6

5
4

4.2

3.8

3.5

3
2

Flexibility in operation depending on steam & power

needs during all time of the year

1
0
21

MERITS OF HIGH PRESSURE

COGENERATION

32

44

63

87

Steam Pressure (bar)

105

Quality steam
requirement

at

desired

levels

for

process

SPECIFICATIONS OF THE 2 HP COGEN UNITS

H.P. COGENERATION

CPP

Pulp & Paper Industries

Sugar Plants
Petrochemical Industries
Fertilizer Units

Parameter

AFBC Boiler

Type

Boiler #11
Chemical Recovery Boiler

117 TPH

Rated Steam Evaporation

83TPH(Phase1) I140TPH(Phase2)

106 kg/cm

SOP

65 kg/cm

510C

SOT

465C

135C

Feed inlet temperature

135C

Fuel

Black liquor
@ 70% solids concn.

Imported coal

Chemical Industries

Chemical Recovery Cogen

Boiler #10

21 MW- DEC

STG

16 MW- EBP

10.5/4.0 kg/cm

E1/E2

10.5/4.5 kg/cm

0.09 ata

Condensing

--

20.4 MW

Capacity

10MW(Phase1) / 16 MW(Phase2)

POST MDP [PHASE I] FLOW CHART

Wea k Bla ck Liquor
from Pulp Mill

Falling Film
Evapo rato r

GRID
IMPORT

Strong Bla ck
Liquor 70%
Concen tr ation

58 6 tpd

CPP
AFB C# 10
10 6 kg/c m2

New C R B
65 kg/c m 2

95 tph

70 tph

DEC
DEC
21MW
21MW STG
STG

EBP
EBP
16MW
16MW STG
STG
8 MW

6.5 tph

17.5 MW

22 tph
42 tph

64 tph

0.1 at a
0.5 MW

11 kg/c m 2
Stea m H e ader

Station
Consu mption

To Proce ss

4 kg/c m2
Stea m H e ader

Station
Consu mption

CW

To Proce ss

Total Power : 26 MW

Efficient Turbo Generators

BHEL STEAM TURBINES

117 TPH AFBC High Pressure BOILER

Atmospheric Bubbling Fluidised

Bed Combustion Boiler with
economizer & flue gas air heater

High pressure (106 bar) steam unit

117 TPH Steam Generation

510C Steam Temperature

Enviro Coal as Fuel

High Bed Temperature :950- 970C

135C Feed water Temperature

Highest Efficiency (~ 84% on GCV)

3 Field ESP ( SPM <20 mg/Nm3)

Lower N2O (GHG) for a FBC unit

CPP- COGEN LADDER CHART

92 MW

21 MW

16 MW

Type

Double Extraction
Condensing

Extraction Back
Pressure

Design

97.6 %

97.7 %

Actual

97.9 %

98.1 %

Gain

0.07 MW

0.06 MW

FUEL (COAL)

BOILER 10
76

STGin

POWER
15 MW

73 MW

STG
MP

18

21

LP

MP

~G

LP C EXH

ENERGY DISTRIBUTION ACROSS 16 MW STG

CPP II [Recovery] COGEN LADDER CHART

108 MWt

Black Liquor Solids

Boiler 11
65
MSH
65

8 MW

50

LP

MP

MP

LP
14

POWER ENHANCEMENT SCHEME

-First of its kind

Turbine Extraction-Exhaust Steam Range

ZONE

21 MW STG

16 MW STG
With reduction in E1 steam extraction flows ( as related to
design flow ), the te mperature at turbine nozzle increases

E1 [ MP]

0-30 TPH

0-60 TPH

relating to lower Electrical Power conversion and higher

de-superheating

E2 [LP]

0-60 TPH

30-130 TPH

Hence Splitting E 1 ( M.P. steam extraction ) flows between

the 2 steam turbine s to be minimized to the extent
practicable.

Condensing

25-50 TPH

X
15

16

E1 Nozzle Steam vs Saturation

Temperatures
.

E1 [MP Steam]Steam]- Energy in Steam to DSH

2.5
2
1.5
Low Load,MW

High Load,MW

0.5
0
-

E2 Nozzle Steam vs Saturation

Temperature
.

16
TPH

25
TPH

40
TPH

E2 [LPSteam
[LPSteam]]-Energy in Steam to DSH
1.2
1
0.8
Low Load MWt

0.6

High Load MWt

.

0.4
0.2
0
48TPH

72TPH

130TPH

POWER ENHANCEMENT SCHEME

[PES]

POWER ENHANCEMENT SCHEME

CONCEPT
Splitting E 1 ( M.P. steam extraction) flows between the
2 ste am turbines to be minimized.
Objective is to ensure entire E 1 flow through one of the

E 1 ( M.P. steam extraction) flow had been reduced in

16 MW steam turbine from 21 TPH to 6 TPH as of now ;
this flow had been added in E1 of 21 M W steam turbine.

2 STGs
Accordingly E2 (L.P. steam extraction) flow is being
Accordingly split E2 (L.P. steam extraction) flow between

adjusted between the 2 steam turbines.

the 2 steam turbines

In case of E2 , there is hardly any impact ; hence the above
philosophy of splitting is not taken up.

Thus the overall MP and LP steam flow rates are left

undisturbed.

21

22

COGENERATION BATTERY

POWER ENHANCEMENT

COMBINED STEAM & POWER GENERATION RECORD

OPERATIONAL COMPARISON

2010

H.P.Steam
Te

Power Gen.
MU

Spec. Steam
Consn.
Te/MW

2010

Spec. Steam
Consn.
Te/MW

Power equiv.
000 units

E1-equiv.
E1TPD

Apr

109800

16045

6.83

Apr

6.83

Base

Base

May

113660

16950

6.69

May

6.69

309

-19

July

113218

16906

6.70

July

6.70

329

-20

Aug

114296

17160

6.66
Aug*[1
[1--28]

6.66

458

-30

23

24

GHG Reduction through PES

Power equiv.
000 units

CO2 [equiv.]
Te

Apr

Base

Base

May

309

263

July

329

280

Aug

458

390

2010

Advanced Steam Pipe Insulation

[5C reduction]
[5
0.3

POWER ENHANCEMENT & GHG REDUCTION

{ BaseBase -line : April 2010 }
500
450
400
350
300
250
200
150
100
50
0
-50

Power'000 units
CO2 eq. T
E1 TPD

April

May

July

August

RECOMMENDATIONS & CONCLUSIONS

Maximize combined cycle efficiency in electrical power
with either of the turbines acting as slave using Power
enhance ment sche me [PES].

0.25
0.2
0.15
Energy MWt

0.1
0.05
0
60
TPH

80
TPH

100
TPH

120
TPH

Main steam te mperature drop from Boiler to turbine to be

minimal ( through quality and adequate insulation)
say 5 to 6C.
The resultant saving in heat in HP steam shall be gainfully
converted to Power at no extra fuel input.
With PES in place, GHG reduction would be of the order of
5000 Te CO2 equiv.
28