S C. Natu Sr. Vice President (Power Division) MITCON Consultancy & Engineering Services Ltd.

S C. Natu Sr. Vice President (Power Division)

MITCON Consultancy & Engineering Services Ltd.

All India potential, 7000 MW (650 sugar mills) Achievements as of September 30, 2012, 2250

MW (200 projects) Under construction, 750 MW (50 projects) Total, 3000 MW (250 projects), 43% penetration Private sector leading in States like UP, Tamil

Nadu, Karnataka & Andhra Pradesh

Co-operatives leading in Maharashtra & Tamil Nadu

Own investment & BOOT models established Conducive CERC / SERC orders, CDM, REC &

power trade, the key drivers Results of promotional measures, mainly by

MNRE

Conventional rankine cycle technology Own / saved bagasse, biomass & coal used as

primary fuels, during season & off season of the sugar mills

Travel grate type boilers designed for multi-fuel operations

High pressure / temperature steam generated and expanded through back pressure or double extraction cum condensing TG set

Medium pressure steam at 8 kg/cm2 pressure used for HP heater & process requirements

Back pressure steam at 1.5 kg/cm2 pressure used for process requirements & de-aerator

Balance steam condensed through the condenser

Power generated during season used for cogen plant auxiliaries, sugar / by-product process & balance exported to the grid

Power generated during off season used for cogen plant auxiliaries, by-products, colony & balance exported to grid

Steam to fuel ratios range from 2.4 kg/kg to 2.65 kg/kg

Steam to power ratios range from 5.2 – 5.6 kg/kw during season & 3.6 – 4.0 kg/kw during off season

PLF, 55 – 60% during season & 90% during off season

Boiler efficiencies, 68-72% on bagasse & 80% on coal

TG efficiency of 90% Station heat rates, 3600 – 3800 kcal/kwh Capex, Rs. 5.25 crore / MW for cogen power

plant & Rs. 1.0 – 1.5 crore / MW for concurrent sugar factory modernization

O&M, 3-5%

Main packages Boiler & auxiliaries Turbine, generator & auxiliaries Cooling tower or ACC Fuel & ash handling Electrical distribution / evacuation Water treatment plant Civil works

Main packages (contd.) Plant DCS EOT crane AC & ventilation system Air compressor DG set Interface HP / MP / LP steam, cooling water, DM

water & compressed air piping Fire fighting

COND.G.S.C.

Kg/Cm 2 Kcal/Kg

FLOWTPH

TEMP.°C

BFP

PRESSURE

LEGEND :-

ENTHALPY

CEP

124.5

116

115

154

98DEAERATOR

124.59.7

4

HEATERHP

22098

659

150

2.5

4.85

SJAE

BLOW DOWN1 TPH226150

BAGASSE

BOILER36.60 TPH

828110

97 540

8

249

704.5

15.51

HOTWELL

TURBINE GEN.

61.92 150407.452.5 659

0.1 580

20 MWSTEAM

18.65 MW

FLASH RECOVERY 0.5 TPH

0.49 TPHTO GSC & SJAE

SUGAR FACTORYL.P. STEAM TO

58.33 150

2.5 659

7.94 TPH

8

249

704.5

9.7

100 TPH

ETHANOL PLANTM.P. STEAM TO

0.49 TPH

FROM SJAE & GSC

110 Kg/Cm540°C

2

8

180

700.5

6

B B

G.S.C. - GLAND STEAM COOLERSJAE - STEAM JET AIR EJECTORCEP - CONDENSATE EXTRACTION PUMP

MP - MEDIUM PRESSURELP - LOW PRESSURE

CW - COOLING WATERTPH - TONNES PER HOUR

LEGENDS :-

- PRESSURE CONTROL VALVE

BFP - BOILER FEED PUMP

MA

KE

UP

9.42

4

33

33

SUGAR FACTORY 55.4 TPH, 95°C

CONDENSATE RETURN FROM

DM

WA

TE

R FEED WATER

TANK

64.82 TPH

TRANSFER PUMP

25

359

748

11.64

-

222

228

11.64

NO 1

HEATERHP

NO 2

16698

169152

826.3

535

105

96.51

CONDENSER

CW OUTLET

CW INLET

SURFACE

40600

- 40

32600

- 32

A

J

1.26 TPH

I0.19 TPH

4

1.26 J115

116

115I

10

0.19

116

COND.G.S.C.

Kg/Cm 2 Kcal/Kg

FLOWTPH

TEMP.°C

BFP

PRESSURE

LEGEND :-

ENTHALPY

CEP

124.5

116

115

154

82.8DEAERATOR

124.58.2

4

HEATERHP

22082.8

659

150

2.5

5.74

SJAE

BLOW DOWN0.8 TPH

226150

BAGASSE

BOILER30.94 TPH

828110

82 540

8

249

704.5

13.92

HOTWELL

TURBINE GEN.

5.63 1505452.212.5 659

0.14 580

20 MWSTEAM

20 MW

FLASH RECOVERY 0.4 TPH

0.41 TPHTO GSC & SJAE

52.62 TPH

8

249

704.5

8.2

100 TPH

ETHANOL PLANTM.P. STEAM TO

0.41 TPH

FROM SJAE & GSC

110 Kg/Cm

540°C

2

8

180

700.5

6

B B

G.S.C. - GLAND STEAM COOLERSJAE - STEAM JET AIR EJECTOR

CEP - CONDENSATE EXTRACTION PUMP

MP - MEDIUM PRESSURELP - LOW PRESSURE

CW - COOLING WATERTPH - TONNES PER HOUR

LEGENDS :-

- PRESSURE CONTROL VALVE

BFP - BOILER FEED PUMP

MA

KE

UP

6.4

4

33

33

SUGAR FACTORY 0 TPH, 95°C

CONDENSATE RETURN FROM

DM

WA

TE

R FEED WATER

TANK

6.4 TPH

TRANSFER PUMP

25

359

748

9.84

-

222

228

9.84

NO 1

HEATERHP

NO 2

16682.8

169152

826.3

535

105

81.59

CONDENSER

CW OUTLET

CW INLET

SURFACE

404300

- 40

324300

- 32

A

J

0.11 TPH

4

0.11 J115

116

I

0.28 TPH

I

4

0.28 115

116

Extra high pressure boiler (87 kg/cm2 pressure & 110 kg/cm2 pressure), commercialized

Matching back pressure, single / double extraction cum condensing type TG sets, commercialized

Air cooled condensers and RO type water treatment plants for overcoming water quality and availability issues, commercialized

Plant DCS, VFDs, ACVFD drives, grid synchronization, etc. technologies, commercialized

Extended off season by utilization of cane trash & other biomass materials, getting progressively commercialized

Equipment, technology & services available indigenously

All India potential, 18000 MW from agro waste materials (excluding sugar mills)

Potential will explode with energy plantation on waste lands for power generation

Achievements as of September 30, 2012, 1250 MW (160 projects) & under construction, 250 MW (20 projects), only 8% penetration

Conducive CERC / SERC orders, CDM, REC & power trade, the key drivers

Results of promotional measures, mainly by MNRE

Conventional rankine cycle technology, similar to bagasse cogen

Extra high pressure boiler (67 kg/cm2 pressure & 87 kg/cm2 pressure), commercialized

Variety of biomass materials established, although fuel linkage difficult

Equipment, technology & services available indigenously Independent biomass power plant models established,

yet captive power plants in industries through biomass in experimental stages

Continuation of MNRE / MoF fiscal & financial support Rationalization of tariffs, other provisions of ERC orders

& adequate hikes due to rise in capital & operating costs Consideration capex for essential sugar mill

modernization for tariff determination Demonstration & commercialization of fuel linkage

mechanisms & energy plantation models Capacity building & information Dissemination Technology development / demonstration, difficult

biomass materials like paddy straw, mustard husk Level playing field for CDM, REC & power trade

Engineering / consultancy services

Technology transfer & equipment / EPC supply

O&M contracts

Financing, equity & debt

Capacity building

Information dissemination

Consultancy / engineering company, established in 1982 Central / State Government stakeholders, 59.5% of shares &

Private shareholders, 40.5% shares Profit making & IS/ISO 9001:2008 certified company Sugar & Power, infrastructure, energy & carbon,

environment, agri business, finance & market research, biotechnology, main consultancy / engineering divisions

Latest infrastructure & experienced manpower (totaling to 225, engineering about 100)

Offices in Pune, Mumbai, New Delhi, Ahmedabad, Chennai & Nagpur


To become a ‘One Stop’ service provider for decentralized Power Projects on any fuel, from concept to successful commissioning & establish at the National & International Levels


Vision

Services (Sugar, Power & Ethanol Projects) Pre-investment (Feasibility study, fuel / biomass / cane survey, bankable

DPR, loan syndication, lender engineering, approval services, MNRE capital grant & excise duty exemption certificates, project developer interface services, etc. )

Pre-contract Engineering (Basic / detailed design engineering, plant layouts,

specifications and drawings, EPC / packaged bid documents, bidding / bid evaluation / recommendations, pre-contract discussions, assistance in signing EPC / package contracts & manpower planning )


Post-contract Engineering / Project Management (Kick start meetings with vendors / EPC contractors,

PERT / CPM networks, inspection / expediting, vendor drawling services and approvals, site supervision, monitoring of erection / commissioning, plant stabilization & plant MIS development)

Post-commissioning (Witnessing PG tests, trouble shooting, plant MIS,

contract to compliance reports, etc. )


Macro Assignments & Training

◦Macro and Policy Studies for biomass, bagasse, natural gas, fossil fuel based industrial captive / cogen power for sugar, distillery & ethanol sectors

◦Organized number of regional / national / international business meets, interaction meets, workshops, seminars, training and skill up-gradation programs


Experience

National & International experience of two decades, private, public sector & co-operative sector clients

Micro level services to over 200 sugar factories, several biomass & fossil fuel based industrial cogen / captive power projects & distilleries / ethanol plants

A dedicated team of qualified and experienced in-house staff and associate experts at various offices

State-of-the-art engineering design / drawing equipment


Experience (contd.)

Program partner & lead program partner of MNRE, Govt. of India

Macro level assignments and promotional work with IREDA, Winrock International India, USAID, UNDP, financial institutions & banks

International exposure & events participation Founder member of World Alliance for Decentralized

Energy (WADE) and patron member of Cogeneration Association of India (Cogen India)


International

Pure Diet Mocambique Limitada, Mozambique Sugar Corporation of Uganda Ltd., Uganda Alliance Tire Co. Ltd., Israel Delta Energy Inc, UK Sindicatum Carbon Capital, Singapore Charter Oak Energy, Renova Engineering PC & Nitash Inc, USA NUCON Energy Corporation, USA Ratnala, Behl & Co., USA Entech Energy Consultants Ltd., UK UNDP-GEF USAID Winrock International India Swiss Development Corporation


Coverage

Sectoral

Power Biomass Sugar Chemical Steel Ethanol Paper Rice Mills Infrastructure Waste Heat Recovery

Geographic

Maharashtra Tamil Nadu Bihar UP / Uttarakhand Karnataka Andhra Pradesh Goa Gujarat Madhya Pradesh Punjab Rajasthan


Coverage

Services (End of Pipe, Concept to Commissioning)

Pre-investment Engineering Project Management Macro Assignments Events / Training

Fuel Types

Biomass Bagasse Coal Natural gas Waste heat recovery

Size Range

1 MW to 600 MW


Micro Level

Establishment in private, public, co-operative & other sectors, across India at the national level

Fuel assessment / DPRs / TEV studies / appraisals / loan syndication / lender engineering for public, private & co-operative sector clients & banks / FIs

Owner Engineering / Consultancy Services for biomass power, bagasse cogen along with concurrent sugar factory modernization / expansion & coal fired power plants


Micro Level (contd.)

EPC consultancy services for TANGEDCO / Govt. of TN, 12 cogen power plants along with concurrent sugar factory modernization projects (installed capacity 183 MW), in advance stages of construction & expected to commission in Sept – Dec, 2012)

EPC consultancy services for HPCL Bio Fuels Ltd., integrated sugar expansion / modernization (3500 TCD), cogen power plants (20 MW) & ethanol plants (60 KLPD) at Lauriya & Sugauli in Bihar


Micro Level (contd.)

Consultant to Urjankur Trust for Shri Datta SSKL & Shri Tatyasaheb Kore Warana SSKL, DPR preparation & EPC consultancy for concurrent sugar factory modernization projects

Appointment as LIE by PNB, 2X600 MW imported coal based power plant of ITPCL at Cuddalore, Tamil Nadu

Project developer interface, consultancy & engineering services for BOOT projects for IREL, BPCL & DCM

Pre-investment & engineering services for existing / new sugar plants & ethanol plants


Micro Level (contd.) Engineering services for first 67 Kg/cm2 pressure

bagasse cogen power plant (Mula SSKL, 2006), first 87 Kg/cm2 pressure (YM Krishna SSKL, 2010) & first 110 Kg/cm2 pressure (Shankar SSKL, 2011) in Maharashtra

Engineering services for biomass, bagasse, coal based power plants, 412 MW commissioned capacity (31 projects) & 470 MW under erection (18 projects)

Approved TEV consultants & lender engineers for large no. of banks & financial institutions


Macro Level All India Bagasse Cogen Study for IREDA, New Delhi Program Partner & Lead Program Partner of MNRE Member Secretary, Cogen India & Vice Chairman,

WADE Cane Cogen Handbook of USAID / WII (Partner) Assessment, Strategy & Action Plan for Non Sugar

Cogen Market Development Initiative for USAID / Nexant

Guidelines for Captive Cogen – A handbook for Govt. of Maharashtra, Department of Energy

UNDP-GEF-MNRE project, Removal of Barriers to Biomass Power Generation in India

Renewable Energy Certificates MITCON Consultancy & Engineering Services Ltd.

S. C. NatuSr. Vice President (Power Division)MITCON Consultancy & Engineering Services Ltd.1st Floor, Kubera ChambersShivajinagar, Pune - 411 005Tel : (020) 25534322 / 3309, 66289136 (D), 09822684102 Fax : (020) 25533206E-mail : [email protected]


S C. Natu Sr. Vice President (Power Division) MITCON Consultancy & Engineering Services Ltd.

Documents

commercialized slide

mnre slide

grid slide

vision slide

fighting slide

rec power trade slide

kgcm2 pressure

power ratios