A sugar factory is under designing phase, proposed capacity 15,000 tons/day.

Proposed location is in district Badin about 50 KM from coast, national electric grid and main
natural gas supply line is at about 5-8 Km. Electric company is ready to contract for provision
and purchase of power to and from the factory.
Factory operates only for 155 days a year (from Nov to March) on 24 hour basis.
Residential colony for staff has electric load varying from 500 during summer to 1500 kW
during operational period.
Essential/critical electric load for controls (200 kW) and security lights (500 kW).
Max load for sugarcane crushing 30 kW/ton of sugar cane.
Process heating is to be done by steam.

A) What are various options available for meeting the Electric load/consumption, evaluate the
best strategy.
B) What should be most appropriate power generating installed capacity at the Plant?
C) What should be the number, size /ratings of three major equipment of power generation
facility.
D) What should be the stream production rate at plant and fuel consumption?

DATA:

Capacity = 15000 tons/day

Operation days = 155 days (24 hours basis)
Power Requirement:
Residential Colony = 500 kW
During Operational Period = 1500 kW
Load for Controls = 200 kW
Security lights = 500 kW

Max load for Sugarcane crushing = 30 kW/ton

SOLUTION:

Power Requirement for crushing of cane = 15000 * 30 = 450000 kW/day

Lets assume, all other rates are on monthly basis then:
All other power requirement = 500 + 1500 + 200 + 500 = 2700 kW/month
As the process is for 5 months then = 2700 * 5 = 13500 kW
Total power requirement of cane = 450000 * 155 = 69750000 kW
Overall energy requirement = 69750000 + 13500 = 69763500 kW = 69763.5 MW
Energy requirement (per day) = (2700/30) + 450000 = 450090 = 450.09 MW/day
The Major part of power is required in crushing of canes and the other factors contribute very
small amount to it therefore we will neglect the change in those factors during different periods.

Q.1) What are various options available for meeting the Electric load/consumption,
evaluate the best strategy.

A) The electricity rate for industrial sector in Pakistan is 17 Rs./kWh = 17000 Rs/ MWh
Our daily consumption of units will be = 450.09 MW/day * 24 = 10802 MWh/day
Therefore daily cost of electricity if purchased from government institute would be =
17000 Rs/MWh * 10802 MWh/day = 183636720 Rs/day
The cost of electricity would be very high if purchased.

B) Our other option could be installation of gas turbine at the peak times but in our case almost
all the energy being consumed is due to crushing of canes so this approach wouldn’t be much
different either instead will have extra cost of gas turbine and its installation.

C) Our best strategy would be to build a combined cycle power plant. The dried bagasse is burnt
to produce heat which is used to convert water into steam in boiler. The steam at high pressure is
used to rotate a turbine-generator system to produce electricity. The general schematic of any
bio-mass( including bagasse) based power plant is given below:

Our capacity of Sugar cane = 15000 tons/day

1 ton of sugar cane contains 27-28 % bagasse then = 280 Kg Bagasse
Bagasse obtained per day = 15000 tons/day * 280 Kg Bagasse/ton = 4200000 Kg Bagasse/day
23.5 ton Bagasse can produce 100 kWh electricity by use of High Pressure Boiler
We have, 4200 tons of Bagasse
Energy produced with the help of bagasse = 4200 ton * 100 kWh/ 23.5 ton = 9870000 kWh
= 9870 MWh / 24 = 411.25 MW / day
Our daily requirement of Energy is = 450.09 MW
Requirement of energy after use of Bagasse = 450.09 MW – 411.25 MW = 38.84 MW/Day
Requirement of energy met by Bagasse = 411.25/450.09 * 100 = 91.37%

Q.2) What should be most appropriate power generating installed capacity at the Plant?

The most appropriate power generating installed capacity at the plant is combined cycle power
generation plant, the reason is that because Combining two or more thermodynamic cycles
results in improved overall efficiency, reducing fuel costs. In stationary power plants, a widely
used combination is a gas turbine (operating by the Brayton cycle) burning natural gas or
synthesis gas from coal, burning bagasse whose hot exhaust powers a steam power plant
(operating by the Rankine cycle) or vice versa.
Q.3) What should be the number, size /ratings of three major equipment of power
generation facility.

In our proposed scheme, the major equipments of power generation facility would be:
1) Boiler
2) Turbine

(We aren’t taught how to rate furnace or turbines according to industrial practice)

Q.4) What should be the stream production rate at plant and fuel consumption?

Our fuel source is basically the bagasse produced from the sugarcane which helps us meet the
power requirement. Rate of production of bagasse is 4200 tons/day. This bagasse will boil our
water and convert it into high pressure steam which will rotate our turbine.

REFERENCES:

 http://sugarcane.org/sugarcane-products/bioelectricity
 https://www.quora.com/What-is-the-concept-of-a-power-generation-in-sugar-mills
 http://www.fao.org/fileadmin/templates/rap/files/meetings/2014/140723-
d1s3.Bagasse.pdf