part 1: overview of cogeneration and its status in asia - Fire

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68 Part II: Cogeneration experiences in Asia and elsewhere undisturbed operation of several power consumers in the plant during any unexpected tripping by drawing power automatically as and when required up to the extent of 17.6 MVA. Considering longer outage of the cogeneration plant during major overhauls or during the recommended inspections, it was decided to include an additional captive power generation capacity of 20 MW to guarantee power supply without depending on the public utility grid. Similarly, to avoid the problem of steam shortage during the outage of heat recovery steam generators, an additional boiler was included as a spare unit. This would also take care of the start-up constraint of the gas cracker plant when greater amount of steam was required than during normal operating conditions. Lean gas was considered as the sole fuel for operating the cogeneration unit. The results of the economic analysis, considering the prevailing costs of equipment, fuel, O&M, manpower, etc., are summarized in Table 2.1. The cogeneration case has a clear edge over the existing case as it helps to reduce the energy bill by 36 per cent and improves the reliability of the production process. Table 2.1 Economic analysis of cogeneration in the gas cracker complex Existing Situation: Process steam from conventional boiler and power purchase from utility grid Description Annual Cost Investment: Boilers (2 x 136 tons/hour of steam) Operating & Maintenance Costs: (US$/year) 3,780.00 Electricity purchased from the grid (50 MW) 40,832.00 Fuel gas (6,626 tons/hour) 4,529.00 Other utilities 2,479.00 Maintenance & Chemicals 315.00 Manpower 336.00 Total Costs (existing situation) 52,271.00 Steam cost (US$/ton) 15.37 Power cost (US$/MWh) Cogeneration Case: 102.08 Power and heat from the cogeneration plant, minimum demand contract with utility grid Investment: Boilers (3 x 136 tons/hour of steam) Gas turbine generators (3 x 20.7 MW) Steam turbine generator (25 MW) Operating & Maintenance Costs: 18,267.00 Demand contract with the grid (17.6 MVA) 754.00 Fuel gas (15.148 tons/hour) 10,355.00 Other utilities 1,862.00 Maintenance & Chemicals 1,720.00 Manpower 504.00 Total Costs (cogeneration case) Steam cost (US$/ton) Power cost (US$/MWh) 33,462.00 12.30 51.64
Examples of cogeneration projects implemented in Asia 69 Annual cost with the existing case Annual cost with the cogeneration case Net annual saving Percentage annual saving Estimated Savings with the Cogeneration Case 52,271.00 33,462.00 18,809.00 36 per cent Based on the preliminary analysis, further optimization studies were conducted by considering nine different cases involving different capacities and numbers of major equipment. The most optimum scheme retained for actual implementation is shown in Figure 2.1. It consists of 3 gas turbines (including one spare), each with an ISO rating of 25 MW; a double-extraction condensing steam turbine for producing medium and low pressure steam; and 3 heat recovery steam generators (including one spare), each with a capacity to generate 136 ton of steam per hour at 105 Bar and 510°C. Air HSD/Gas Air HSD/Gas Air HSD/Gas SM SL G GT-1 GT-2 GT-3 STG C G G G Atmosphere FD Fan Atmosphere FD Fan Air Atmosphere SVH To deaerator PRDS FD Fan Air PRDS SVH to process plant HRSG -1 Gas/LSHS/HSD/PG HRSG-2 Gas/LSHS/HSD/PG HRSG-3 Gas/LSHS/HSD/PG PRDS Atmosphere SVH: 108 bar SH: 42 bar SM: 19 bar SL: 3.5 bar Figure 2.1 Cogeneration scheme implemented at the petrochemical complex SH
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PART 1: OVERVIEW OF COGENERATION AN
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4 Part I: Overview of cogeneration
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State of art review of cogeneration
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Page 46 and 47: Cogeneration in Asia today 49 1.1 I
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Sample case study in a pulp and pap
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Summary of country study - Banglade
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Summary of country study - Viet Nam
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