gasifier study-2-125.pdf

ITCOT

CONTENTS

A. ACKNOWLEDGEMENT

B. CONTENT TABLE

C. LIST OF TABLES

D. LIST OF FIGURES

E. CHAPTERS

Chapter # DESCRIPTION PAGE #

1 Introduction 1

2 Methodology 2

3 Performance Of Ten Select Gasifier Installations

9

4 Vendor Capability And Technology Penetration

58

5 Barriers To Gasifier Programme And Policy Issues

68

6 Case Studies Of Successful Installations 75

7 Conclusion 115

F. ANNEXURES

G. ENCLOSURES

H. PHOTOGRAPHS

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LIST OF TABLES

S.NO. DESCRIPTION PAGE #

1 Letters from BERI 2

2 List of State Nodal Agencies Contacted 3

3 List of Vendors Contacted 4

4 List of installation visited 6

5 Design Vs Actual Performance (PEC) 15

6 Project Cost of Chottomollakhali Installation

23

7 Three Year Performance of Chottomollokhali Installation

24

8 Total Project Cost of PSG College Installation

29

9 Operation & Manual Parameters of PSG College of Technology

33

10 Actual operation of PSG College of Technology Gasifier System

33

11 Performance during April ’04 – March ’05 of Odanthurai Installation

43

12 Cost of Energy Generation at Odanthurai Panchayat

45

13 Nellithurai Plant Performance during August 2004 to March 2005

46

14 Vendors Supplying Gasifiers 58

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15 Ankur Gasifier – Technical Specifications 59

16 Vendor Capability in supplying the system 60

17 Typical Technical Data of an IISc.- Netpro Biomass Gasification Plant

60

18 Data Table – Associated Engineering – Electrical / Power Application

62

19 Grain Processing Industries (India) Pvt. Ltd. – Technical Specifications

63

20

List of Installations with 100% Producer Gas Engine

64

21 List of Installations with Dual Fuel Engine 65

22 Cost of Biomass at Various Installations 70

23 Performance of VCC for the period July 2004 to March 2005

80

24 Design Vs. Actual Performance of VCC, Kovilpatti

83

25 Performance of Gosaba Installation – Design Vs. Actual

97

26 MVIT – Plant Performance 104

27 Design Vs. Actual Performance of MVIT 108

28 Plant Performance of Bagavathi Bio 110

29 Plant Generation and Consumption Details 111

30 Cost of Production at Bagavathi Bio Energy Ltd.

113

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LIST OF ANNEXURES

S.NO. DESCRIPTION

1 Detailed list of gasifier collected along with vendor name

2 Detailed Questionnaire

3 Site visit details

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LIST OF ENCLOSURES

S.NO. DESCRIPTION

I Copy of plant layout drawing of MVIT

II Performance Data of Odanthurai Panchayat system from July 2003 to March 2005

III Performance Data of Bagavathy Bio Power Ltd. the system till March 2005

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LIST OF PHOTOGRAPHS

DESCRIPTION

1. BIOMASS STORAGE YARD AT MVIT, BANGALORE

2. BIOMASS PROCESSING SHED AT MVIT, BANGALORE

3. GASIFIERS INSTALLED IN CHOTUMULAKHALLI

4. 200 kW BIOMASS GASIFICATION PLANT LAYOUT IN PMCTW,

VALLAM

5. STORAGE YARD AT VALLI CHLORATE COMPANY, KOVILPATTI

6. 100% PRODUCER GAS BASED CUMMINS ENGINE AT VCC,

KOVILPATTI

7. DISCUSSION WITH MEDA OFFICIAL, PUNE, MAHARASHTRA

8. 1 X 500 GASIFIER INSTALLATION AT JAGAT ALLOYS PVT.

LTD., KHOPOLI, MAHARASHTRA

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LIST OF FIGURES

S.NO. DESCRIPTION PAGE #

1 PEC Gasifier Performance Analysis 12

2 PEC – Specific Fuel Consumption Vs Gasifier Loading

13

3 PEC Gasifier – Dual Fuel mode Power Generation Cost Breakup

14

4 PEC – Performance Comparison – Design Vs Actual

16

5 Electrical Schematic Diagram of Chottomollakhali Installation

22

6 PSG College of Technology – Performance Data from 3.7.2004 to 30.10.2004

30

7 Cost of Power Generation at PSG College of Technology (From 3.7.2004 to 30.10.2004)

32

8 Performance of Jagat Alloys Private Ltd. 39

9 Performance of Odanthurai Panchayat System

44

10 Cost of Production at Odanthurai Panchayat 45

11 Performance Valuation of Nellithurai Panchayat

47

12 Unit Generation – Breakup Cost at VIT in % 51

13 Layout of Valli Chlorate Company 76

14 VCC Gasifier Average Plant Load Factor and 80

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Overall Gasifier Conversion Efficiency

15 VCC –Biomass Gasifier Plant Performance Data – 2002 to 2004

81

16 Energy Generation and Consumption Details of VCC

81

17 Unit Generation – Breakup Cost in % at VCC 82

18 Electrical Schematic Diagram of Gosaba Installation

88

19 Gosaba Gasifier Plant Performance data – August 1997 – March 1998

92

20 Gosaba Island March Operating Data 94

21 Gosaba Island Power generation cost breakup

96

22 Gosaba Biomass Gasifier Plant Performance – Design Vs Actual

98

23 MVIT Gasifier Average Plant Load Factor and Overall Gasifier Conversion Efficiency

105

24 MVIT Gasifier plant performance data – 2002 to 2005

105

25 Energy Generation and Consumption details of MVIT

106

26 Unit Generation Break up Cost in % at MVIT 107

27 Performance of Bagavathi Bio Energy 112

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CHAPTER 1 INTRODUCTION

1.1 Background

Government of Karnataka (GoK), has signed an agreement with International

Funding agencies – UNDP (United Nations Development Program), ICEF (India -

Canada Environment Facility) and Ministry of Non Conventional Energy Sources

(MNES), Government of India (GOI) to implement the project “India: Biomass Energy for Rural India (PMU - BERI)” in Tumkur district.

In this connection, it has been planned to set up biomass – gasifier decentralized

power generation units in rural areas under the project. To have an appreciation

of technical and financial issues for setting up the project, BERI has initiated to

take up a study on the performance of Biomass Gasifier based power generation

systems in Southern India and Sunderbunds in West Bengal.

1.2 Consultancy BERI has appointed ITCOT Consultancy and Services Limited, Chennai vide their

letter no: PMU/BERI/34/Enc/2004/1809 dated 8th February 2005, to carry out the

study on Biomass Gasifier based Power Generating Systems in Southern India

and Sunderbunds. Accordingly, ITCOT conducted the study and submits this

report on the performance of the gasifiers

1.3 Structure of the Report The report has the following structure:

Chapter 1 details the introduction of the project followed by methodology in

Chapter 2. Performance of nine selected gasifier units is detailed in Chapter 3.

Vendors available in Indian market for supplying gasifier and the technology

penetration are detailed in Chapter 4. Chapter 5 details barriers to gasifier

programmes and policy issues. Successful implementations and case studies of 4

units are detailed in Chapter 6 and Chapter 7 concludes the report.

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CHAPTER 2 METHODOLOGY

2.1 Methodology The methodology adopted for carrying out the study is as follows:

2.1.1 Letters to Nodal Agencies and Vendors ITCOT drafted letters for Ministry of Non Conventional Energy Sources (MNES),

State Nodal Agencies and vendors, and submitted to BERI. BERI forwarded the

letters to various agencies through letters as indicated in the Table 1 below:

Table 1

Letters from BERI

S. No Name of the Organisation

Letter No Date

1 Ministry of Non

Conventional Energy

Sources, New Delhi

BERI/34/ENE/2004/1882

and

BERI/34/En/2004/1917

March 1, 2005

and

March 17, 2005

2 State Nodal Agencies in

Southern India

BERI 34 ENE 2004 /

1856

February 22,

2005

3 Gasifier Vendors /

Suppliers

BERI 34 ENE 2004 /

1855

February 22,

2005

2.1.2 Preparation of complete list of gasifiers The complete list of gasifier installed in South India, West Bengal and

Maharashtra, from the beginning of Ninth Five Year Plan i.e., between 1997 – to

till date was collected along with year of installation, location, capacity,

application and present status. The list of gasifiers was obtained from the State

Nodal Agencies as detailed in Table 2 and from Vendors as detailed in Table 3

below:

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Table 2

List of State Nodal Agencies Contacted

No Letter Date from

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Name of the Organisation Contacted

Letter Received vide No. and Date (if any)

1 March 14,

2005

Agency for Non Conventional

Energy and Rural Technology

(ANERT), Trivandrum, Kerala

-

2. March 14,

2005

Karnataka Renewable Energy

Development Limited (KREDL),

Bangalore, Karnataka

-

3. March 14,

2005 and

April 26,

2005

Maharashtra Energy

Development Agency, Pune,

Maharashtra

BERI 34 ENE 2004/57

dated 21st April 2005

enclosed with MEDA

letter No. REN/BMS

002/2004-05/1686 dated

11th April 2005

4. March 14,

2005

Non Conventional Energy

Development Corporation of

Andhra Pradesh (NEDCAP)

Ltd., Hyderabad, Andhra

Pradesh

NEDCAP/PD/BG/3552/03-

04 dated 28th February

2005

5. March 14,

2005

Tamilnadu Energy

Development Agency (TEDA),

Chennai, Tamilnadu

-

6. March 14,

2005

West Bengal Renewable

Energy Development Agency

(WBREDA), Kolkata, West

Bengal

-

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Table 3

List of Vendors Contacted

No Letter Date from ITCOT

Name of the Organisation Contacted

Letter Received vide No. and

Date

1 February 24,

2005

Ankur Scientific Energy

Technologies private Limited,

Baroda, Gujarat

Replied via email

dated February 25,

2005 and March

10, 2005

2 February 24,

2005

Ankur Scientific Energy

Technologies private Limited,

Regional Office, Kolkata, West

Bengal

Replied via email

dated February 25,

2005 and March

10, 2005

3 February 23,

2005 and

Email on March

14, 2005

Centre for Gasification and

Propulsion Laboratory (CGPL),

Indian Institute of Science,

Bangalore, Karnataka

Letter dated 16th

March 2005

4 February 24,

2005

Associated Engineering Works

(AEW), Hyderabad, Andhra

Pradesh

5 February 24,

2005

Netpro Renewable Energy (India)

Limited, Bangalore, Karnataka

6 February 24,

2005

Grain Processing Industries

(India) Private Limited, Kolkata,

West Bengal

7 February 24,

2005

Cosmo Powertech Private

Limited, Raipur, Chhattisgarh

8 February 24,

2005

Energreen Power Limited,

Chennai, Tamilnadu

The detailed list of gasifier installations collected along with vendor name and

capacity is enclosed in Annexure 1.

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2.1.3 Preparation of Questionnaire The detailed questionnaire including Technical and Financial Parameters required

for carrying out the study was prepared and sent to BERI for clarifications/

correction vide letter No. ENERGY/DV/2005 dated February 21, 2005.

The questionnaire with clarifications was received from BERI vide letter No. BERI

34 ENE 004 / 1889 dated March 3, 2005 and the same was used for survey of

gasifier installations across Southern India, West Bengal and Maharashtra. The

detailed questionnaire is enclosed as Annexure 2.

2.1.4 Selection of Gasifier systems for study As mentioned in Para 2.1.1, the complete list of gasifiers was analyzed and

letters were sent to all the units detailed in Annexure 1 for carrying out site visits

Gasifier systems of various capacities on electrical mode, spread over various

locations were selected for carrying out the study.

Following are the units under various categories selected for the field study.

a. Educational Institutions – 6 Installations

b. Gram Panchayat – 2 Installations

c. Industrial Units – 4 Installations

d. Island under Village Electrification – 2 Installations

2.1.5 Site Visit After receiving the consent of BERI for the units selected, ITCOT Consultants

carried out the site visits. The details visits undertaken along with the date are

enclosed in Annexure 3 and an extract of the same for ready reference is

detailed in Table 4 below.

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Table 4

List of Installation visited (in the order visited)

S. No Name of the Gasifier Installation State

1 M. Vishveswaraiah Institute of Technology, Bangalore Karnataka

2 WBREDA Installation of Chotamulakalli West Bengal

3 WBREDA Installation of Gosaba West Bengal

4 Odanthurai Panchayat, Coimbatore District Tamilnadu

5 Nellithurai Panchayat, Coimbatore District Tamilnadu

6 PSG Institute of Technology, Coimbatore District Tamilnadu

7 Bagavathi Bio Private Limited, Coimbatore District Tamilnadu

8 Pondicherry Engineering College Pondicherry

9 Valli Chlorate Company, Kovilpatti Tamilnadu

10 Periyar Maniammai College of Technology for

Women, Vallam (Phase I and Phase II)

Tamilnadu

11 GB Food Oils Limited, Pudupatty Tamilnadu

12 Jagat Alloys Private Limited, Savroli Village, Khopoli Maharashtra

13 Vellore Institute of Technology, Vellore Tamilnadu

Of these 14 installations, 9 installations are discussed in Chapter 3, while the

balance 4 units are discussed in Chapter 6 under successful Case Studies. Four

installations have been chosen for successful case studies and are detailed

below.

1. Valli Chlorate Company at Kovilpatti, Tamil Nadu Valli Chlorate Company has been chosen as a successful case study for the

reason that it has revived itself from closure by installing 100% producer gas

based gasifier. The company has also increased its profitability by installing

the gasifier by reducing cost of energy purchased from TNEB.

2. Gosaba Island Installation, Sunderbunds Gosaba Island installation has been as a successful case study for the reason

that the energy generated from gasifier has turned the socio economic status

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of the Island along with community development. Even when the cost of

energy generation is high, the energy generated from gasifier has played a

pivotal role in improving the life style of the rural masses of Sunderbunds,

where grid penetration is impossible in the near future.

3. M. Vishveswaraiah Institute of Technology installation at Bangalore In the educational institutions category, MVIT is the oldest gasifier unit

operating successfully for the last three years. The unit also operates for

longer period in a year and has generated more units when compared to

other units.

4. Bagavathi Bio Energy Limited installation at Coimbatore In the industry sector, the unit that is successful in implementing the gasifier

program is Bagavathi Bio Energy installation at Mettupalayam. The company

has successfully been running as a separate entity to serve the energy

demand of a Textile bleaching unit by installing the system in their premises

without any major problem.

Though other units covered by the study were also operating the gasifiers, the

data available from the units other than the above four is scanty and further,

units were also not willing to share the real performance of the gasifiers. Some

units found the operation not economical on dual mode due to high cost of

diesel, and hence, gasifiers are not run.

2.1.6 Limitation of the Study

Most of the units observed that the data questionnaire was very exhaustive and

the units do not have the classified data. Units in general are very reluctant to

share the actual field data especially the financials and absence of the

authentication letter from MNES added to the cause. Thus, ITCOT consultants

based on the discussions, observations and log sheets filled the data

questionnaire. Some units refused to share any details in the absence of MNES

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letter. This resulted in a considerable delay in the unit visit scheduling and data

collection.

Thus, the study is based only on the data collected during the site visit and not

furnished by the unit.

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CHAPTER 3

PERFORMANCE OF GASIFIERS AT NINE SELECTED INSTALLATIONS 3.1 Name of Installation: Pondicherry Engineering College, Pondicherry

A. Project Background Objective District Rural Development Agency (DRDA), Pondicherry through Ministry of Non-

Conventional Energy Sources (MNES) New Delhi implemented the 1x 100kW

biomass gasifier on electrical mode at the Pondicherry Engineering College (PEC)

campus, to promote gasifier system based academic research projects.

Year of Installation The plant is installed in June 1, 2004

Location The engineering college is located at a distance of 10 km from Pondicherry town

Plant lay out Size 5m X15m

Type Woody biomass down draft gasifier with batch feeding

B. Technical Specifications

Gasifier (supplier - Associated Engineering works (AEW), Tanuku, Andhra Pradesh)

i) Capacity: 100 kW (250 m3/h)

ii) Biomass fuel consumption: 100kg/h

iii) Biomass fuel size: 15 mm~75mm

iv) Moisture: < 20%

v) Hopper holding capacity: 500kg

vi) Loading of biomass: manual feeding and intermittent

vii) Gasifier starting: By hand blower

viii) Diesel replacement: average: 70%

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ix) Gas cooling and cleaning of tar removal, particulates: Water spray

cooler, scrubber, 4 nos. of centrifugal tar removing pumps, service filter

(fabric), additional filter with pebbles

x) Gas flaring provision before service filter

xi) Height of reactor 12 ft.

xii) Auxiliary power: 12 hp includes wood cutter of 3 hp, water circulation

pump, and make up water pump, scrubber and centrifugal tar removal

pumps (4 nos).

xiii) Water circulation: 250 litres per minute.

xiv) Recommended biomass fuels: Casuarina, eucalyptus, Subabul, Neem,

Cashew, Coconut shells and any hardwood

xv) Gasifier material of construction: Stainless Steel for nozzle and throat

and MS for Hopper, body and pipe line

xvi) Life of Gasifier: 20 years

xvii) Turn down ratio: 30%

xviii) Starting time from cold start: 30 minutes

Engine (make - Ashok Leyland) • Capacity 151 hp

• Manual starting system with battery

Alternator (Make – Kirloskar) • KVA: 125, Speed rpm: 1500, Voltage: 415 V

• Load: 175 Ampere

• Frequency: 50Hz

• Power factor: 0.8

• Continuous duty, S1 IS: 4722-1992

Electrical panels The plant is designed to operate on stand alone mode and the gasifier power is

transferred to the college for captive consumption after switching off the state

electricity board supply and by providing suitable interlocks to avoid parallel

operation with the grid. Electrical control panel of 200 Ampere rating is provided

with Molded Case Circuit Breaker (MCCB) of 175 A rating with built in protections

of under voltage, over voltage, over current and earth fault protection. The

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college has provided 125 A feeder for supplying auxiliary power for starting of

gasifier plant auxiliaries. The power generated from the Gasifier is transferred by

way of change over switch of 400 A rating in the college electrical control. The

main loading point is administrative block but provision is there is to supplement

the loading in other areas.

C. Financial Parameters

Building and civil works (Comprising of fuel storage yard, biomass sizing, gasifier system with DG set,

control panel, water storage tank with filtration) Rs. 6.82 lakhs For Gasifier system with DG set

DRDA: Rs .21.45 lakhs MNES subsidy: Rs. 1.50 lakhs Total Project cost: Rs. 29.77 lakhs D. Project Status

The plant was commissioned on June 1, 2004 and was under trial operation from

October 2004 to December 2004 by the supplier, for establishing the guaranteed

performance. On completion of the same the project was accepted by DRDA for

handing over to PEC. It was noted that discussions are underway between DRDA

and PEC on official handing over for subsequent plant operation and

maintenance. The plant has not been functional since January 2005.

E. Plant Performance Summary for the monitored Period (8 weeks in November 2004 and December 2004)

• Gross Power Generation: 15,995 kWh

• Average kW loading: 63.42

• Total biomass consumption: 22,630 Kgs

• Total diesel consumption: 1,780 litres

• No. of Operating Hours: 252 hours

• Average diesel replacement: 54%

• Average cost of gross power generation: Rs.5.40/kWh

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• Average PLF: 49.98 %

• Average specific biomass consumption: 1.46 kg/kWh

• Average specific diesel consumption: 0.12 litre/ kWh

The auxiliary consumption data is not provided and hence, not indicated in

the summary.

F. Plant Performance Analysis

(a) The plant performance in terms of following indices has been discussed in

the chart given below:

a. Average Gasifier system kW loading

b. Gasifier system overall conversion efficiency %

c. % Diesel replacement

d. Gross power generation cost Rs/kWhr

FIGURE – 1 Pondicherry Engineering College

Gasifier Performance Analysis

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13

Observations: i. The highest average kW loading which has been recorded is 83.38 kW in the

fifth week of the monitored period

ii. The highest loading shows the best diesel replacement at 67% with optimum

power generation cost per kWh ie. Rs. 3.97/kWh

iii. The overall gasifier system conversion efficiency (including gasifier, engine,

Alternator) is also highest in the 5th week due to improved loading over the

previous weeks. This index is arrived based on the following assumptions;

GCV of HSD – 10,000 kCal/Kg GCV of biomass @ 20% moisture while feeding gasifier – 3,500 kCal/Kg GCV of 1 kWh = 860 kCal

iv. The chart indicates poor performance indices due to fluctuations in loading in

the 3rd week of monitored period.

(b) Specific fuel consumption with respect to gasifier system loading is presented in the following chart.

FIGURE 2 Pondicherry Engineering College Specific fuel consumption Vs Gasifier loading

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Observations: i. As stated earlier, 5th week of monitored period has shown best

performance indices with highest PLF at 70.88 %.

ii. PLF is arrived at considering the installed capacity of 100 kW, with daily

operating hours of 8 and 5 days a week

iii. The specific fuel consumption of biomass is 1.08 kg/kWh and for diesel is

0.08 litre/kWh

G. Cost of Production The breakup cost for gross power generation is given in the chart below:

FIGURE 3 Pondicherry Engineering College Gasifier – Dual fuel mode Power Generation

Cost Break Up Cost (Rs./kWh)

Biomass co st Rs/kWh

14

Observations:

i. In the dual fuel mode of operation the impact of diesel cost is well noticed

in the above pie chart. 65% of the average power generation cost is due to

diesel at an average diesel replacement of 54%.

Operators cost Rs/kWh

0.193%

Diesel Cost Rs/kWh 3.46

1.75 65%

32%

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ii. The share of diesel could be reduced further at higher % of diesel

replacement with the improved loading, as average PLF in the monitored

period is low at 49.98%.

iii. One operator with one helper is considered here and their contribution is

negligible at 3% of the total cost. Based on the discussion, the operator

salary is assumed at Rs. 3,500 per month and salary for the helper is

Rs.1,500 per month.

iv. Repairs and maintenance cost is not considered as the plant is new and it

was conveyed that it is covered under 2 years equipment guarantee with

the supplier for replacement of defective items for the entire gasifier

system.

H. Performance: Design Vs Actual

Table 5

Design Vs Actual Performance of Pondicherry Engineering College

S. No Performance

indicator Unit Design Actual

1 Average kW loading KW 100 63.42

2

Average Specific

Biomass

consumption

Kg/kWh 1 1.46

3 Average Diesel

consumption Litre/kWh 0.06 0.12

4 Average % diesel

replacement Percentage 70 54

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FIGURE 4 - Pondicherry Engineering College (1 x 100 kW)

Performance Comparison design Vs actual

16

• The design value is considered at 100 % loading and is compared with

actual performance in the monitored period.

• The loading in trial operation is lesser compared to the design value and

hence, the performance could not be better at par with design.

• The plant has been operated only for eight weeks and is yet to commence

its commercial operation in full swing. Hence, it is expected to achieve a

better performance in loading, specific fuel consumption and better diesel

replacement with optimum constant loading of 80% and above in future.

1.6 1201.46

1.4 100 100

kg/k

Wh

and

litre

/kW

h

1.2 1

kW a

nd p

erce

ntag

e

801 70

63.42

0.8

0.12 0.06

54 60

0.6 40

0.4 20

0.2

0 0Design Actual

Average Diesel consumption Litre/kWh Average Specific Biomass consumption Kg/kWh

Average kW loading Average % diesel replacement Percentage

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I. Summary of notes of discussion with PEC and DRDA: • Both DRDA and PEC conveyed that plant operation in the monitored

period was satisfactory

• During the trials the supplier has introduced a fine filter made of pebble

stones after the service filter and before air and gas mixer, for achieving

the desired quality of gas

• The power generation was fed to college administrative block, which has

an average load of 65 KW. The administrative block comprises load points

of A/C’s, lighting, computers etc. The load test was carried out from 9.00

am to 5.00 pm in 5 days a week.

• The entire gasifier system has been delivered at site in a month time

• The supplier has offered 2 years guarantee for equipment against

manufacturing defects

• The college has plans to operate the system for academic research

projects under M. Tech, Energy technology programme

• The best wood suggested by DRDA is pencil wood

• The college has done an analysis on generated Charcoal and is given

below:

Volatile matter – 19.11% Ash – 22.87% Fixed Carbon – 58.02%

J. Issues

• The college has a contract demand of 500 kVA from the state electricity

board and the average power cost per kWh is Rs.2.10 (inclusive of

demand charges). The college needs to pay a fixed demand cost of 75%

of contracted demand. The average cost of power per kWh from the

gasifier is Rs.5.40 and is higher when compared to state electricity board

tariff. Hence, the college management is exploring the ways and means of

operating the system not for the purpose of captive power alone but also

for academic research projects under M. Tech energy technology

programme.

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• The college has expressed its inability to allocate a dedicated team for

operating the gasifier installation and discussions are underway between

DRDA and PEC in launching a tendering process to operate the system

through private operator on O&M basis. However, consumables like diesel,

wood, lubricating oils etc. have to be arranged by DRDA/PEC through

Pondicherry Government. The entire process is yet to be finalized and

hence the system is non-functional since January 2005.

K. General Issues on site operations

It was observed that the following parameters, which have affected the gasifier

performance, have never been tested at the site:

• Moisture of biomass fuels at gasifier feeding point

• Emission of tar and particulates level

• Effectiveness of cooling and gas cleaning system and Producer gas quality

– Calorific value

• Vibration and noise levels of the installation

L. Operating Problems: • In dual fuel mode the problems of filters – coarse and fine filters, block

the producer gas line very often and creates reduced producer gas flow

and lead to poor quality, resulting in increased diesel consumption for the

same load.

• The coarse and fine filters filled with dry wood dust of different grading

often demands cleaning and changing due to frequent choking.

• The fabric filter cloth choking problem is experienced frequently in the

installations

• Due to the prevailing dusty atmosphere and poor filtering of gas, often

creates choking of air cooled after cooler in engine. The performance of

water based after cooler, is better in maintenance when compared to air

cooled system, as the fins require more cleaning in these dusty

atmosphere.

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3.2 Name of Installation: Chotamulakalli Island, 24 Parganas District, West Bengal

A. Project Background Objective West Bengal Renewable Energy Development Agency (WBREDA) in association

with MNES, Government of India, Sunderbunds Development Department, Forest

Department, and South 24 Parganas Zilla Parisad decided to install a 500 kW (4

x 125 kW) biomass based power plant and Chotamulakalli has been identified by

the WBREDA as a probable location for setting up the woody biomass based

power plant. This place is situated in Gosaba Block of 24 Parganas District of

West Bengal. This has been selected, as it is one of the Gateways to the

interiors of Sunderbunds.

The locality has a population of 28,000 with a good market where people from

interior areas come for buying and selling products. This market is a good

commercial Centre in the Sunderbunds area. With the availability of electricity,

many small scale entrepreneurs could develop small industries like mini rice mills,

ice plants, pumping /irrigation and water supply, saw mill, cold storage etc.,

where it is almost impossible to extend the conventional power grid line. The

prime objective of this power plant is to improve socio economic condition of the

local people in Chotamulakalli Island.

This power plant may also be utilized for supplying power to the adjacent areas

of Chotamulakalli by installing 11 kV sub-transmission systems and the areas,

which may get the benefit of electric supply, are mentioned below:

a. Tara Nagar

b. Boro Mullakhali

c. Kachukhalli

d. Hetalbari

e. Kalidaspur

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Year of Installation The 500 kW woody biomass based power plant was commissioned on 19th

October 2001 Plant lay out Size 2000 sq. ft



Gasifier (supplier – Ankur Scientific Energy Technologies, Baroda) 1. Model: WBG –120

2. Capacity: 125 kW

3. Rated gas flow: 300 m3/h

4. Average gas Calorific value: > 1,000 kCal/m3

5. Biomass fuel consumption: 96 ~ 120kg/h

6. Gasification temperature: 1050 ~ 1100 deg. C

7. Indicative gasification efficiency:

Hot gas mode: > 85%

Cold gas mode: > 75%

8. Temperature at gasifier outlet: 250 ~ 400 deg. C

9. Biomass fuel size:

Minimum diameter 10 mm and length 10 mm

Maximum diameter 60 mm and length 75 mm

10. Moisture: < 20% on wet basis

11. Hopper holding capacity: 500kg

12. Loading of biomass: intermittent manual feeding per hour

13. Ash removal: Continuous through proprietary control and water seal

14. Gasifier starting: Through scrubber pump/blower

15. Specific fuel consumption: 250 ml/kWh – full diesel mode

16. Indicative diesel replacement: average 65 ~ 75% depending on

operating load

17. Engine conversion efficiency: 25%

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21

18. Gas cooling and cleaning of tar removal, particulates: Venturi scrubber

with water re-circulation and ultra clean gas for power generation

mode through proprietary and fine filters

19. Gas flaring provision before service filter

20. Height of reactor 4 ft.

21. Auxiliary power: 8 kW

22. Water circulation: 250 litres per minute.

23. Recommended biomass fuels: Casuarina, eucalyptus, subabul, Neem,


24. Gasifier material of construction: Stainless Steel for nozzle and throat


25. Life of Gasifier: 5 years

26. Turn down ratio: 30%

27. Starting time from cold start: 30 minutes

28. Maximum permissible particulate: 50 mg/m3

29. Typical producer gas composition (%)

CO=19 +/- 3% N2 – 50%

CO2=10 +/- 3% H2=18 +/- 2% CH4=up to 3%

Engine (make - Greaves) • Capacity 160 kVA

• Mechanical B1 class governor


Alternator (Make – Crompton Greaves) • KVA: 160, Speed rpm: 1500, Voltage: 415 V

• Load: 222 Ampere, Frequency: 50Hz



Electrical Systems

Chotamulakalli Island was an un-electrified village until this project was

commissioned, and the plant was designed to operate on stand alone mode for

village electrification purpose, as extension of the conventional grid power is

impossible.

ITCOT

FIGURE 5 - Electrical Schematic Diagram

Feeder 1

The power generated from the five DG’s can be synchronized at the 415 V bus

and is taken through feeders 1 with a step up transformer of 315 kVA for power

distribution at 11 kV. The existing 11 kV distribution circuit comprises of 1 km,

and 415 V distribution circuit comprises of 5 km. The 415 V distributions has 1

no of 100 kVA and 1 no of 63 kVA step down transformers located at various

load ends. During the discussion it was informed that distribution loss has been

estimated at 8%. The plant has been provided with a bay for second 315-kVA-

distribution transformer. WBREDA has approached MNES for second phase grid

extension of 15 km.

Electrical control panel of 2000 Ampere capacity rating and each DG set is

provided with Molded Case Circuit Breaker (MCCB) of 300 A rating with built in

protections for under voltage, over voltage, over current, earth fault protection

and reverse power. The synchronizing panel has synchroscope and the operators

check synchronizing relay and synchronizing operation manually. The outgoing

feeder and bus coupler is provided with 630 A ACB. The distribution panel is

Provision given for future expansion

415 V bus

Bus coupler

DG sets 1, 2, 3 and 4

22

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23

provided with Enercon make EM 3360 – 2 nos for registering power at the feeder

levels.


Table 6

Project Cost of Chottomollokhali Installation

S. No Items Unit Cost Rs lakh

1 Land 1 acre

2 Fuel storage yard 2,500 sq ft

3 Gasifier system with DG 7,000 sq ft

4 Power evacuation

system

315 kVA transformer,

100 kVA and 63 kVA

distribution transformers

associated electrical

system

150.00

Total project cost: Rs.150 lakhs Source of funds: 75% of the project cost from MNES 25% of the project from West Bengal State Government

Power evacuation cost: Cost for 11 kV (HT) distribution: Rs 2.5 lakhs/km

Cost for 415 V (LT) distribution: Rs 1.5 lakhs/km

The plant has 5km of LT line and 1 km of HT line. WBREDA has planned to

expand the distribution network by another 10 km with the support of MNES in

second phase.

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24

Consumers and Tariff structure The island has an area of 25 sq km with a population of 15,000. It was informed

that around 350 consumers are availing this power supply and are grouped as

below.

• Domestic: Rs.4.00/kWh

• Commercial: Rs 4.50/kWh

• Hospital: Rs.4.50/kWh

• Ice factory: Rs 5.00/kWh

• Small industries like band saw mill and others: Rs 5.00/kWh

Deposit fees towards service connection @ Rs 500/consumer and Rs 20/month

as meter rent is charged from the consumers. The above are flat tariff charges

without taxes. Around 95% of the customers are coming under domestic group.

Operation and Maintenance cost Based on the discussion with WBREDA, the past operating data is summarized

below in Table 7:

Table 7

Three Year Performance of Chottomollokhali Installation

S. No Items 2002 2003 2004

1 Average Processed biomass fuel tonnes 120 144 180

2 Average fuel cost Rs/kg 1.00 1.00 1.00

3 Average Diesel in Kilo litres 12 15 18

4 Average Diesel price Rs/litre 15 20 29

5 No. of operators 9 9 9

6 Average Operators salary/annum Rs lakh 2.40 2.40 2.40

7 Electricity generation cost Rs/kWhr 2.75 3.50 4.50

8 Total revenue generated Rs lakh 4.20 6.00 7.20

9 Total expenditure Rs lakh 5.20 7.30 9.00

10 Net deficit Rs lakh 1.00 1.30 1.80

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25

D. Chotamulakalli Power Plant Operation The power plant though, has an installed capacity of 4 x 125 kW, but presently

one system is operated, due to the non-completion of grid extension network.

The power plant is starts at 5.30 pm and stops at 11.00 pm, and the peak

loading is around 110kW at 8.30 pm, and after 6.30 pm the loading drastically

reduces to 60%.

Society for plant operation Eight member beneficiary committee comprising of personnel from Panchayat

head, Panchayat Samithi, WBREDA, political party, consumer representative,

Sunderbunds development board and state government, manage the power

plant..

Diesel replacement The plant operating data was not provided by WBREDA and the plant was not in

operation during the site visit of ITCOT Consultants (Visit was made at 2.30 pm)

and hence, no reading was taken from logbook. WBREDA informed that at peak

load of 110 kW in one gasifier, following would be the consumption levels, as

experienced by them:

• Total diesel consumption at peak: 10 litres/hour

• Total biomass consumption at peak: 100 kg/hour

• Total diesel consumption on diesel mode: 26 litres/hour

• Diesel replacement at peak load of 88%: 62%

E. General Issues • It was informed that fluctuating demand was a main attribute for the poor

performance of the gasifier. The load points are predominantly lighting

(domestic, commercial, and street) fans, irrigation pumps, commercial

establishment like education institutions and hospital. Before this power

plant, consumers were using SPV for lighting systems and fans.

• Though three gasifiers were replaced with new gasifiers in 2002 (Gasifier

1,3 and 5), it was informed that gasifier three has still problems in the

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26

coarse & fine filters, often leading to pressure build up and reduced flow

of producer gas. Other two units also have intermittent problems related

to filters.

• Fabric filter, which exists before the air fuel mixture, also has similar

problems of choking in all the working gasifiers.

• WBREDA has conveyed that the whole system of gas cleaning and cooling

needs a thorough study on the system design and actual performance. It

was also conveyed that vendor had never checked the performance

indicators like gas quality, tar and particulate emissions at a specified

loading, vibration levels, and wear & tear of the engine on poor gas

quality.

• Due to the frequent problems in the filters and resultant poor gas quality,

operators were forced to operate on diesel to maintain the same load.

• The entire operation of DG set and gasifier is manual; hence, if producer

gas generation is of poor quality then it warrants more attention in

operating the DG set on diesel mode, as more operator intervention is

required. . This could result in increased cost of power generation.

• The operating nature is such that any fall in the gas flow due to filter

choking will throw an impact on the sudden reduction of frequency and

this has to be immediately attended to by the operator to increase the

diesel flow to maintain loading. Hence, gasifier operation with frequent

filter problems poses a great challenge to operators.

• The problems faced in the coarse and fine filter is due to the sizing of

sawdust, which is used as filter medium for removal of tar and other

particulate. Incorrect sizing could lead to blockage of sawdust at the mesh

pores and reduction in gas flow.

• Engine after-cooler has a direct impact on the engine efficiency and one

DG set at Gosaba has air-cooled-after-cooler and due to dusty atmosphere

with biomass fines, air-cooled-after-cooler fins are found to be choked

very often and demand cleaning of filter once a week.

• R&D on gasifier reactor and material thickness should be conducted.

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27

3.3 Name of Installation: PSG College of Technology, Coimbatore, Tamilnadu

A. Project Background

Objective PSG college of Technology, Coimbatore through Ministry of Non-Conventional

Energy Sources (MNES) New Delhi implemented a 1x 100kW biomass gasifier on

electrical mode at the PSG foundry campus, Neelambur to partially meet the

foundry electrical energy requirement and also to promote gasifier system based

academic research projects at the college.

Year of commissioning The plant is commissioned in 30th July 2004.

Location The gasifier is located in PSG foundry unit at a distance of 10 km from

Coimbatore town.

Plant lay out Size 12.1 m X 9.0 m

Type Open top, down draft solid biomass gasifier.


Gasifier (Supplier – Netpro Renewable Energy (India) Pvt Ltd, Bangalore)

1. Capacity: 100 kW

2. Biomass fuel consumption: 135 kg/hr

3. Specific fuel consumption: 1.25 kg/kW +/_ 0.1

4. Bulk density of fuel: 250kg/m3

5. Biomass fuel size: 20mm x 20mm x 60 mm (max). Small particles

(10mm x 10mm x 15mm) could be added but limited to maximum of

5 %.

6. Gas quality with ‘standard biomass’

7. Moisture: < 15%

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28

8. Gas cooling: Cold & Chilled Water spray -180 lpm (10 – 15 °C)

9. Tar & Particulate matter removal by: Cyclone separators, scrubber,

chillers & fabric filter (Non – woven polyester cloth which retain dust

particles up to 5 micron size- Fabric filter is approximately 4 m2)

10. Chilled water spray: 150 lpm

11. Moisture removal: Moisture traps-2nos

12. Gas flaring provision before fabric filter

13. Height of reactor: 5.5 m

14. Auxiliary power: 18 kW includes raw water 3 HP- 3nos, 2 HP- 3 no,

Blower -2HP, Screw conveyor for ash removal- 1HP, ETP- 2HP CT fan

2HP -2nos,

15. Recommended biomass fuels: Besaram (Ipoemia), coconut shell,

Casuarina (Equistifolia), Eucalyptus, Mulberry stalk, Lantana camara,

Silver oak, Jungle wood, saw dust briquettes

16. Gasifier material of construction: high temperature ceramic and stain

Engine (make – Cummins India) • Capacity: 140 kVA

• Governing system: Hydraulic governor with manual air fuel adjustment

and using Battery operated starting system

Alternator (Make – Stamford) • KVA: 140

• Speed rpm: 1500

• Voltage: 415 V +/-2.5 %

• Frequency: 50Hz


• Self excited, self regulated brush less design

Type of circuit breaker: Molded case circuit breaker

Protection system: Earth leakage relay with CBCT

The system is provided with voltage, current and energy meter.

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29

C. Financial Parameters The system is installed in the PSG foundry campus itself and hence, land value is

taken as nil. The unit does not have Biomass sizing unit as the unit is purchasing

processed biomass. The break up cost of the system is given below in Table 8.

Table 8

Total Project Cost of PSG College Installation

S. No System Area Cost in Rs. lakhs

1 Gasifier & auxiliaries 5m x 5m x 7.5m 14.500

2 Gas engine, Alternator &

auxiliaries

5.3m x 9.0m x 7.5 m 15.500

3 Power distribution system - 1.500

4 Effluent treatment system - 0.350

5 Pumps - 0.386

Total 32.286

MNES subsidy on item 1 & 2 50 %

D. Project Status The plant was commissioned on July 30, 2004 and put under operation

intermittently. The system was not operational during the site visit due to

problems in the engine in taking load.

E. Plant Performance Summary available for the Period (3/7/2004 to

30/10/2004) The operating performance of the system as on 30/10/2004 is given below.

• Engine Operating Hours: 263 Hrs.

• Gasifier Operating Hours: 128 Hrs.

• Total units generated: 4,363 units

• Total biomass consumption: 14,562 kgs.

• Average plant load, based on operating hours of the engine: 35.6%

ITCOT

• Average cost of gross power generation as reported in the questionnaire:

Rs.3.25/ kWh


(a) The plant performance in terms of following indices has been discussed in

the chart given below:

1. Specific fuel consumption- kg/kW

2. Gasifier system overall conversion efficiency %

3. % Loading of the system

4. Cost of generation Rs/kWh

FIGURE 6 - PSG College of Technology

Performance Data from 3.7.2004 to 30.10.2004

30

10.0 60.0Date

2.0

2.8

2.2 2.3 2.2

1.8

3.2

2.6

2.0 2.0

1.7

3.8

2.3

1.8

2.5

1.9

3.0

34.0 35.2 36.3

30.0 25.9

44.341.9

27.2

34.0

38.5

46.2 45.8

23.4

43.2

50.8 50.047.2

Spec

ifc

fuel

con

sum

ptio

n-k

g/kW

% o

f loa

ding

& O

vera

ll

37.4 40.0

effic

ienc

y 30.0

20.0

13 13 141412 11 12 12

10 1111 119 10.0

8 98 6

1.0 0.0 Date

Specific consumption kg/kW %of loading Overall efficiency

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31

Observations: 1. Loading plays an important role in the viability of the system

2. The highest operating kW, which has been recorded is 50.8 kW, while the

average operating load is 37%

3. The average auxiliary consumption is around 43 % of the total gross

generation, which in high due to low operating load

4. The average biomass consumption is 2.4 kg/kW, which is much higher

compared to the design value of 1.3 kg/kW, which may be due to low

operating load and high down time of the engine

5. Though the reported average power generation cost per kWh is Rs. 3.25,

the actual power generation cost estimated during the above operating

period is Rs.5.84/kWh

6. The overall gasifier system conversion efficiency (including gasifier,

engine, Alternator) is also in the range of 8-14%, which is also low due to

poor loading

7. The chart indicates poor performance indices due to fluctuations in

loading

G. Cost of Power Generation Cost of power generation with respect to gasifier system loading is presented in

the following chart.

ITCOT

FIGURE 7 - PSG College of Technology Cost of Power Generation

(From 3.7.2004 to 30.10.2004)

32

R &M 0.5 8%Man

Power 0.14 2%

Fuel 5.84 90%

Fuel Manpower R & M

Observations: • The fuel component of cost of generation based on the operating data of

log book is very high due to low loading and operating period of the

gasifier system though the data provided in the questionnaire is Rs 2.5

/kWh based on the specific consumption of Biomass of 1.43 kg/kW at the

rate of Rs.1.75 per kg

• The break up details of R & M is not provided and taken as Rs.0.5 /kWh,

based on the questionnaire

• The cost of manpower is very less as one operator and supervisor is in

charge of the project and their contribution to cost of unit operation is

negligible at 2% of the total cost. Based on the discussion, the operator

salary is taken at Rs. 1000 per month and supervisor at Rs.2500 per

month

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33

H. Technical performance data Operator’s manual has been referred for typical operating design pressure at

various sections of the system during normal operation and the details are given

below in Table 9 and Table 10.

Table 9

Operation & Manual Parameters of PSG College of Technology

Pressure in mm of H2O

Load (kW)

Biomass consum

ption Kg

Gas flow rate- g/s

Across Venturi in

mm

Reactor (P1) in

mm

Inlet to R.W.

Cooler (P2) in

mm

Outlet to Chilled

cooler in mm

50 55 +/- 5 38 +/- 5 30 +/- 10% 60 +/- 10 20+/- 10% 100+/-10%

70 80+/-5 50+/-5 55+/-10% 70+/-10 25+/-10% 85+/-10%

85 90+/- 65+/-5 80+/-10% 80+/-10 30+/-10% 80+/-10%

100 110+/-5 75+/-5 110+/-10% 90+/-10 35+/-10% 80+/-10%

110 121+/-5 85+/-5 135+/-10% 100+/-10 40+/-10% 85+/-10%

120 132+/-5 90+/-5 160+/-10% 110+/-10 45+/-10% 85+/-10%Gas flow g/s: Venturi constant x sq. root of pressure drop at Venturi

Based on the logbook, the following actual operating data is noted for a typical

day (13/7/2004) is given below.

Table 10

Actual Operation of PSG College of Technology Gasifier System

S. No Parameter Unit Value/Range

Load KW 11 ~ 73

1 Gas flow (Based on Venturimeter) g/sec 32 ~ 84

2 Differential pressure across Venturimeter Mm H2O 25~ 175

3 Reactor exit P1 Mm H2O 10 ~ 30

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34

Table 10 Contd..

S. No Parameter Unit Value/Range

4 Raw Water Cooler outlet P2 Mm H2O 20 ~ 60

5 Chiller outlet Mm H2O 55 ~115

6 Reactor exit temperature °C 258 ~ 586

7 Moisture Trap exit temperature °C 14~ 21

8 Charcoal Kg/day 6~10

9 O2 % 0~1

10 Voltage Volts 415~ 420

11 Currents Amps 25~ 120

12 Frequency Hz 47~ 51.5

13 Water Temperature °C 60~ 75

14 Oil Temperature °C 60~ 80

15 Oil pressure Psi 40

16 Exhaust Temperature °C 360 ~ 450

17 Speed Rpm 1400 ~1500

I. Issues: i. The gasifier with 100 % producer gas engine from Cummins is the first of

its kind and the system is yet to get stabilized.

ii. The load connected to the engine is foundry (Sand blasting -35 kW,

Lighting load-20 kW, Auxiliary of gasifier system -20 kW) and facing

fluctuating load predominantly due to sand blasting (For every 8 minutes,

blower will be on for 3 sec.) and during overload, the gas quantity is not

sufficient to meet the demand and hence, the engine trips. It was observed

that engine could not take load more than 40kW often. The following are

some of the problems encountered during the period.

a) Screw conveyor for ash removal was getting choked often, which may be

due to frequent on/off of the gasifier system

b) Fabric filter is getting blocked often

c) Biomass size is reduced from 30 mm x 20 mm to 20mm x 20mm

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35

d) It was noted that the management was trying to synchronize the system

with Electricity Board recently with the technical input of PSG technology

but could not succeed

e) It was observed that no trained man power is available for operating the

system and PSG technology was providing technical support as and when

required

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36

3.4 Name of Installation: Jagat Alloys Private Limited, Khopoli, Maharashtra


Objective Jagat Alloys Private Limited (JAPL), Savroli Village, Khopoli planned to set up 2 x

500 kW gasifier for captive consumption. JAPL has set up only 1 x 500 kW

gasifier to meet the load of Ferro Alloy Plant.

Year of commissioning The plant is commissioned on July 4, 2001.

Location The unit is located in Savroli Village 120 km from Pune.

Type Open top, down draft solid biomass gasifier


Gasifier (Supplier – Cosmo Powertech Private Limited, Raipur) 1. Capacity: 500 kW

2. Rated Gas Output: 1250 Nm3 / h

3. Calorific Value of Gas: 1000 – 1200 kCal/ Nm3

4. Biomass to gas conversion Efficiency: 70%

5. Biomass fuel consumption: 400 kg/hr

6. Specific fuel consumption: 0.8 to 1.2 kg/kW

7. Bulk density of fuel: 250kg/m3 on dry basis

8. Biomass fuel size: Minimum 100 mm and Maximum 150mm of any shape

9. Moisture: < 20%

10. Water required: 300 – 350 litres per hour

11. Turn Down Ratio: 1:2

12. Contaminants in clean gas: Less than 100 mg/Nm3

13. Height of reactor: 10 feet

14. Auxiliary power: 10 units per hour

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37

15. Recommended biomass fuels: Any woody biomass or low ash biomass

briquettes

16. Gasifier material of construction: Reactor with 5mm thick MS plate and

lower part made of 8mm thick MS Plate with air nozzle of SS make.

17. Hopper Capacity: 1500 – 2000 kg of biomass

Engine (make – Yanmar) • Model No: T – 220 – ST

• D1 Water Cooled

• TCIC 6 Cylinder Engine

• Speed 750 rpm

• Compression Ratio: 13:1

• Injection System Make and Model: Diesel KIKI – DL 90S03N75

• Period of Operation:

• Diesel Mode: 1500 Hours

• Dual Fuel Mode: 1000 Hours

• Rate of Lubricating Oil Consumption: 500 CC per hour

Alternator (Make – Taiyo) • Rating: 560 kW

• Type: FE – 45 E - S

• Speed rpm: 1500

• Voltage: 450 V

• Current: 898 Amps

• Frequency: 50Hz


C. Financial Parameters Building and civil works The system is installed in the rear side of the unit and the cost of building and

civil works is taken as nil.

The unit does not have Biomass sizing unit as the unit is purchasing processed

biomass.

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38

For Gasifier system with DG set Total Cost: Rs. 268.68 Lakhs Equity: JAPL: Rs.67.17 lakhs Loan from Banks including MNES Subsidy: Rs. 201.51 Lakhs

MNES subsidy: Rs. 20.40 lakhs (Source MNES Letter to MEDA) a) Gasifier Subsidy: Rs. 8.5 Lakhs

b) Instrumentation: Rs. 0.15 Lakhs

c) Cooling and Cleaning System: 2.50 Lakhs

d) Automation Subsidy: 1 Lakh

e) Others (Pre processing Effluent treatment): 2 Lakhs

f) Dual Fuel DG Set: 6.25 Lakhs

D. Project Status

The plant was commissioned on July 4, 2001 and put under operation

intermittently. The system is not in operation for the past two years.

E. Plant Performance Summary available for the Period (1/8/2001 to

10/09/2001)

• Gross Power Generation 1,57,334 kWh

• Average kW loading: 47.96%

• Total biomass consumption: 1,87,935 Kgs

• Total diesel consumption: 19,010 litres


• Average diesel replacement: 58%




• Average specific diesel consumption: 0.12 litre/ kWh

ITCOT


The plant performance in terms of following indices has been discussed in the

chart given below:

1. Biomass consumption in kg.

2. Diesel consumption in litres and

3. Energy generated in kWh

FIGURE 8Performance of Jagat Alloys Private Limited

0

1000

2000

3000

4000

5000

6000

7000

8000

8/1/0

1

8/3/0

1

8/5/0

1

8/7/0

1

8/9/0

1

8/11/0

1

8/13/0

1

8/15/0

1

8/17/0

1

8/19/0

1

8/21/0

1

8/23/0

1

8/25/0

1

8/27/0

1

8/29/0

1

8/31/0

1

9/2/0

1

9/4/0

1

9/6/0

1

9/8/0

1

9/10/0

1Ener

gy G

ener

ated

an

d B

iom

ass

Con

sum

ptio

n in

kg

s

0

100

200

300

400

500

600

700

Biomass Consumption in Kgs Energy Generated in kWhDiesel Consumption in Litres

Observations: 1. In the figure it could be seen that fuel replacement for unit generation

follows the same pattern with respect to biomass consumption.

2. The highest loading has taken place on 3rd of September 2001.

3. The average biomass consumption is 1.19 kg/kW, which is almost the

same to design value.

39

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40

4. Though the reported average power generation cost per kWh is 3.25, the

actual power generation cost estimated during the above operating period

is Rs.4.6/kWh and this mainly because of diesel price.

G. Issues: JAPL for setting up 2 x 500 kW gasifier based power generating system has

approached Consultant to prepare Detailed Project Report (DPR) for submitting

the same to MEDA, MNES and Development Credit bank limited. Central Financial

Assistance (CFA) of 40.80 lakhs was approved by MNES for the year 2000 – 01.

50% of 40.80 lakhs i.e. 20.40 lakhs was sent to MEDA from MNES for granting

the subsidy. JAPL has mobilized equity through shares for their plant expansion

& gasifier installation and arranged loans other than MNES subsidy through

Development Credit bank limited.

JAPL has installed 1 x 500 kW gasifier and received 50% grant from 20.40 lakhs

i.e., 10.20 lakhs from MEDA. JAPL has commissioned 1st Phase 500 kW and

provided Rs. 8 lakhs as advance to Gasifier Supplier Cosmo power tech for

installing second phase.

However, MNES has asked for bank guarantee from JAPL to pay the final 50%

for 1st Phase and as bank guarantee could not be provided by JAPL though

nationalized bank (as Development Credit bank were their bankers – a non

Nationalized bank) the second payment got delayed. This has forced the

company into financial crunch. Further to it, MNES after installation has

requested for type certificate of Cosmo power tech gasifier, adding further delay

in receiving the subsidy.

After receiving the type certificate, MNES has requested IIT Mumbai to provide

common performance report (CPR) on gasifier performance. During trial, the

replacement of diesel was 58%. The reason indicated for lesser diesel

replacement was the wetness prevailed in the biomass used as the trial was

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41

taken during rainy season and hence CPR submitted by GARP, IIT was rejected

by MNES and added further delay. Then final trial run was conducted on 2nd April

2002 and diesel replacement was achieved around 71%.

MNES has sanctioned the remaining subsidy for 1st Phase; however, JAPL has

given up 2nd Phase and then requested MNES to cancel the second phase grant

for another 500 kW, due to their own financial crunch and other hiccups in

receiving the grant.

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42

3.5 Name of Installation: Community Based Gasifier Project, Odanthurai, Coimbatore District


The project is commissioned to meet the energy requirement of raw water

pumping station of Odanthurai Municipality. The Gasifier system of 9kW is

supplied by Ankur. The system is self-regulated and excited engine supplied by

DIPCO and later replaced with Field Marshall as the engine could generate 7HP

and the matching Compton Greaves Alternator.

The project cost is as follows

• The project cost is Rs.3.71lakhs

• Panchayat contribution-Rs. 1.75 lakhs

• MNES subsidy-Rs. 1.35 lakhs

B. Technical Specifications Gasifier (Supplier – Ankur Scientific Energy Technologies Private

Limited, Baroda) 1. Model – Ankur Gas – 9 WBG – 15

2. Biomass Consumption: 13 kg./ hr.

3. Fuel: Hard Woody Biomass

4. Calorific Value of gas: 1100 – 1300 kCal/ Nm3

Alternator (Make – Crompton Greaves pf:0.8) • Rating: 15 kVA Alternator

C. Financial Parameters The project cost is as follows:

• The project cost is Rs.3.71 lakhs

• Panchayat contribution: Rs.1.75 lakhs

• MNES Subsidy – Rs.1.35 Lakhs

ITCOT

D. Plant Performance

The project is commissioned on 5th April 2004 and the performance data of the

system till 29th March 2005 is given in Enclosure II, and the consolidated data

is given below in Table 11.

Table 11

Performance during April ‘04 – March ‘05 of Odanthurai Installation

Month Biomass

consumption -kgs

Power consumption-

kWhr

Specific biomass

consumption Kg/kWh

No of operating hrs of the

system

Apr-04 660 344 1.92 57.50

May-04 1,223 587 2.08 116.20

Jun-04 787 395 1.99 78.45

Jul-04 1,070 535 2.00 102.00

Aug-04 876 473 1.85 80.30

Sep-04 850 506 1.68 90.80

Oct-04 360 201 1.79 35.50

Nov-04 650 346 1.88 67.60

Dec-04 403 198 2.04 39.75

Jan-05 390 341 1.14 34.50

Feb-05 621 341 1.82 62.25

Mar-05 755 569 1.33 74.90

Total 8645 4835 840

The above data on the performance is given in a graph shown below.

43

ITCOT

FIGURE 9 - Odanthurai Performance of Odanthurai System

P e r fo r m a n c e o f s y s t e m

A p r - 0 4 M a y -0 4

J u n - 0 4 J u l- 0 4 A u g -0 4

S e p -0 4

O c t - 0 4 N o v -0 4

D e c -0 4

J a n - 0 5 F e b - 0 5 M a r - 0 5

M o n t h

Woo

d co

nsum

ptio

n ,

Pow

er g

ener

atio

n

-

0 . 5 0

1 . 0 0

1 . 5 0

2 . 0 0

2 . 5 0

Spec

ific

biom

ass

cons

umpt

ion

W o o d c o n s u m p t i o n P o w e r g e n e r a t i o n S p e c i f i c b i o m a s s c o n s u m p t i o n

• The above table indicates that specific biomass consumption decreases over

the period of time

• The power generation is low during the period of October & December which

may be due to low operating days which may be due to weather conditions

• The power generation is low with high specific biomass consumption during

summer and low during winter seasons

E. Cost of Production The cost of production before implementing the project and after biomass

gasifier system is given below in Table 12.

44

ITCOT

Table 12

Cost of Energy Generation at Odanthurai Panchayat

No Before Gasifier system After Gasifier system

1. Electricity

charges

Rs.3.5 per kWh Biomass cost Rs.0.450*

2. Labour Rs.0.446 per kWh Labour Rs.0.664

3. Maintenance Rs.0.071 per kWh Maintenance Rs.0.281

Total Rs.4.017 Total Rs.1.395

Savings: 65%

* Biomass consumption is @[email protected] per ton

The breakup of cost of production is given below.

Figure 10 – Cost of Production at Odanthurai Panchayat

20% 32%

48%

Biomass cost Labour Maintenance

• It is observed that the labour cost contribute maximum in the cost of

production, while maintenance cost is the lowest

• The raw material cost is low as the biomass is being collected and sized

locally using self-help group.

45

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46

3.6 Name of Installation: Community Based Gasifier Project, Nellithurai, Coimbatore District

A. Project Background Location: Nellithurai, Coimbatore district The project is commissioned to meet the energy requirement of the raw water

pumping station at Nellithurai Municipality and the lighting of the surrounding

area. The total power requirement is 3 HP and 2 HP for water pumps and a

lighting load of 3 kW.

B. Technical Specifications The Gasifier system supplied by Ankur . The system is 10kW self regulated &

excited engine of DIPCO with matching Alternator.

C. Financial Parameters Financial parameters not provided.

D. Performance

The project was commissioned in August 2004 and the performance data of the

system till March 2005 is given in Enclosure III and the consolidated data is

given below in Table 13.

Table 13

Nellithurai Plant Performance during August 2004 to March 2005

No Month No of days

Biomass UnitsHrs of

generator

Specific Biomass consumption-

kg/kW

1 Aug.04 13 645 436 10,383 1.48

2 Sep.04 9 250 172 9,980 1.45

3 Oct.04 20 250 215 37,204 1.16

4 Nov.04 28 580 193 9,980 3.01

ITCOT

5 Dec.04 19 870 555 45,398 1.57

6 Jan.05 19 640 560 37,204 1.14

7 Feb.05 18 1,230 573 26,787 2.15

8 Mar.05 30 3,500 1123 3.12

Total 156 7,965 3,827 176,936

The above data is represented in the graphical form below.

FIGURE 11 – Performance Valuation of Nellithurai Panchayat

Performance Valuation

4000 3.50

P

ower

gen

erat

ion

un

its

in k

Wh

3500 3.00

B

iom

ass

con

sum

ptio

n-k

g &

3000 2.50

consu

mption

-kg/kW

2500

Specific biomass

2.002000

1.501500

1.001000

0.50500

0 -

Jan.05 Mar.05 Aug.04 Nov.04 Oct.04 Feb.05 Sep.04 Dec.04

Month & YearBiomass Units specific Biomass consumption

47

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48

The above graph indicates the following.

• The biomass consumption is lower for the initial period due to low loading.

• The power generation and biomass consumption is higher for December

to March period.

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49

3.7 Name of Installation: Vellore Institute of Technology, Vellore

A. Project Background Objective Vellore Institute of Technology (VIT) has installed a 90 kWe Gasifier for

generating power for captive consumption in the hostels and to carryout R & D

activities in the field of Renewable Energy.

Year of Installation The unit was installed during 2003.

Location VIT is located at Vellore, which is 145 Kms from Chennai.

Plant lay out Size The total plant area is 2,100 Sq feet covering 400 sq feet for fuel processing yard

and 600 sq feet for Gasifier System and DG Set


B. Technical Specifications Gasifier (supplier – Netpro Renewable Energy Private Limited)

iii. Capacity: 100 kW

iv. Biomass fuel consumption: 135kg/h

v. Biomass fuel size: 50 mm~50mm

vi. Moisture: < 15%

vii. Loading of biomass: manual feeding and intermittent

viii. Gasifier starting: Manual

ix. Diesel replacement: average: 75 - 85%

x. Gas cooling and cleaning of tar removal, particulates: Water spray

cooler, cyclone separator, scrubber, sand (coarse and fine) filter, fabric

filter, 2°C output - water chiller

xi. Gas flaring provision before gas entry into engine

xii. Height of reactor: 2.9m

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50

xiii. Recommended biomass fuels: Casuarinas, eucalyptus, Julia flora and

any hardwood

xiv. Gasifier material of construction: Stainless Steel for nozzle and throat

and SS 304 for Hopper, body and pipe line

xv. Life of Gasifier: 10 years

xvi. Turn down ratio: 1:3

xvii. Starting time from cold start: 15 - 30 minutes

xviii. Conversion Efficiency (Fuel to Producer Gas): 92%

xix. Conversion Efficiency (Engine): 30%

xx. Auxiliary Consumption: 32 HP for pumps

Engine • Make: Kirloskar

• Capacity: 90 kW

Alternator • Make: Kirloskar

• Capacity: 125 kVA, Speed: 1500 rpm, Voltage: 415 V

• Frequency: 50 Hz, Power Factor: 0.8, Insulation: Class H

• Voltage Regulation: Automatic

C. Financial Parameters Building and civil works The college has allotted land for installing gasifier. For Gasifier system with DG set Capital Subsidy: Rs. 1.35 Lakhs

Total Project cost: Rs. 42.00 lakhs

D. Project Status The plant was commissioned in 2003 and is in operation since then continuously

for 300 days in a year.

ITCOT

E. Plant Performance Summary for the monitored Period

♠ Average gross power generation per month: 24,000 kWh

♠ Average auxiliary power consumption per month: 3,500 kWh

♠ Average biomass consumption per month: 22,080 Kgs

♠ Average diesel consumption per month: 792 Litres

♠ Operating hours/day: 24 hours

♠ Average cost of gross power generation: Rs.3.22/kWh

♠ Average specific biomass consumption: 0.92 kg/kWh

♠ Average specific diesel consumption: 0.033 litres/kWh

F. Cost of Production The unit cost breakup of gross power generation is given in Figure 12 below.

Figure 12 –Unit Generation – Breakup Cost at VIT in %

30%

40%

3%27%

Diesel Cost Biomass Cost AMC Labour

Observations: • Diesel cost plays a vital role in power generation cost.

51

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52

• Manpower is required for fuel sizing of non-processed wood. The salary for

operators (Totaling fourteen in number for 3 shifts operation) is around Rs.

60 per day per person.

• Repairs and maintenance cost is considered at 3% of the production cost G. Summary of notes of discussion with VIT

About Fuel • Julia flora is the fuel used and the calorific value is around 3500 kCal/ kg

• The size of the fuel is 1.5 inches in diameter and 3 inches in length

• The moisture in the fuel is less than 15% at the feeding point of gasifier

• Average replacement of diesel achieved – 87 % (Max: 88% and Min: 70%)

Water Utilisation • The makeup water of 1000 litres is used for every two days.

Load Pattern A section of hostel load is connected to the gasifier system and it provides a

fairly constant demand of 50~60 kW.

Waste Heat Recovery (WHR) VIT has installed a WHR at engine exhaust for drying biomass with 1,600 kg of

drier holding capacity and it was informed as very effective.

H. Issues

Gas cooling and filter systems for gas cleaning have been highlighted as the

problem prone area, which have been rectified by VIT themselves. However, the

technical details on the modifications carried out have not been disclosed.

VIT conveyed that overall performance of the gasifier was satisfactory.

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3.8 Name of Installation: Periyar Maniammai College of Technology for Women

A. Project Background Objective

Periyar Maniammai College of Technology for Women (PMCTW) has installed 100

kW Dual Fuel Mode Gasifier system during 2001 and later installed 200 kW 100%

producer gas based Gasifier system during 2004. The college has installed the

gasifiers for captive consumption and for carrying out R&D activities in the field

of renewable energy.

Year of Installation The dual fuel based gasifier plant was installed during 2001 and the 100%

producer gas based plant was installed on 24th June 2004.

Location Periyar Maniammai College of Technology for Women is located at Vallam, and is

accessible from Thanjavur by road at a distance of 20 Kms.

Plant lay out Size 5m X15m



The College has provided technical details for 200 kW system alone. Gasifier (Supplier – Ankur Scientific Energy Technologies Private

Limited, Baroda) i) Capacity: 200 kW

ii) Biomass fuel consumption: 300 kg/h

iii) Moisture: < 20%

iv) Loading of biomass: Automatic

v) Gasifier starting: Manual

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vi) Gas cooling and cleaning of tar removal, particulates: Cyclone

Separator, 4 Nos. of active and passive coarse filters, fine filters

with sawdust.

vii) Gas flaring provision before engine entry

viii) Height of reactor 10 ft.

ix) Auxiliary power: 20 kW includes pumps in cooling tower, pumps in

gasifier, pumps in engine and blower

x) Recommended biomass fuels: Casuarinas, eucalyptus, Julia flora

and any hardwood

xi) Gasifier material of construction: Stainless Steel for nozzle and

throat and MS for Hopper, body and pipe line

xii) Life of Gasifier: 5 years

xiii) Turn down ratio: 30%

xiv) Starting time from cold start: 15 minutes

Engine (make - Cummins) • Model: GTA – 1710 – G

• Starting system: Battery

Alternator (Make – Stamford) • KVA: 320, Speed rpm: 1500

• Voltage: 415 V, Amps: 445 Ampere, Frequency, 50Hz

• Power factor 0.8, Continuous rating

• DC Excitation 38 V: 2 A, Star Connected, Enclosure: IP 23

• Insulation: Class H

Electrical panels The plant is designed to operate in stand-alone mode and the gasifier power is

fed to six changeover points in the college. The panel is provided with over

voltage, over current and over speed protection. The panel reads voltage,

current and energy online.


Not Provided

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D. Project Status The plant was on run from July 2 2004 and is in operation without any trouble

since then. The plant operates for 12 to 14 hours a day for 6 days a week.

E. Average Plant Performance

• Gross Power Generation: 50,000 kWh per month

• Auxiliary Power Consumption: 5,000 kWh per month


• Total biomass consumption: 300 kgs per hour

• Average cost of gross power generation: Rs.2.25/kWh without

depreciation and interest on loan

F. Overall Observations

• Personnel required for loading the gasifier is eliminated in Ankur Scientific

System since lift is used for loading the Gasifier; as the manual operation is

not required, the cost of labour is only for processing the fuel; and hence,

taken as Rs.0.10 per kg of fuel used.

• Repairs and maintenance cost is not considered, as the plant is new.

• The gasifier system has an improved version when compared to Valli Chlorate

system (as it is the first gasifier) in gas distribution and governing.

• The system is provided with gas controlled pneumatic systems.

• Producer gas is fed into the engine through valve control and depending

upon the load, gas is provided with these valve controls.

G. Summary of notes on discussion with PMCTW • PMCTW gasifier is of Ankur Scientific Make with Cummins engine of 200 kW

with a capital subsidy of Rs. 30 lakhs from MNES, New Delhi

• There are 6 change over points (load points) connected to the gasifier.

• Main building, computer building, Hostel 1, Hostel 2, Hospital and Farms are

the six load points

• EB tariff for the college is Rs. 4.80 per kWh and for the farm alone is Rs. 6

per kWh.

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56

• The gasifier fuel is Julia flora and Eucalyptus and fed at an interval of 2 hours

in its 14-hour operation, which is acquired through Self Help Groups (SHG)

and local villagers.

• During each interval 240 kgs of wood is fed into the gasifier and the cost of

biomass is Rs. 1200 per ton.

• Average unit generated is Rs. 50,000 units per month and the auxiliary

consumption is around 10% and the net export is Rs. 45,000 per month.

• Auxiliary loads are as follows:

a. The water cooling system for gasifier is served with three pumps (2 x 3

HP + 1 x 2 HP) – 7 HP

b. Water cooling system for engine with two pumps (1 x 3 HP and 1 x 2 HP)

– 5 HP

c. Engine Cooler Pumps – 1 HP

d. Blower – 12.5 HP

• The live load pattern taken up from control panel on 11th April 2005 is as

follows:

a. Amps: 153 A

b. KW: 125 kW

c. Voltage: 414 V

d. Frequency: 49.5 to 50.4 Hz

H. Issues Since the college has been operating the system for the last two years, no major

issues were highlighted during discussion.

I. General Issues on site operations There are no major reported issues though constant loading is a problem. The

college observed that, due to changing loads, it would not be possible for the

system to be synchronized with the grid, due to changing frequency.

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3.9 Name of Installation: G B Food Oils Private Limited, Pudupatty

G. B. Food Oils has installed a 1x100 kW Gasifier supplied by Netpro Renewable

Energy (India) Limited, Bangalore, Karnataka. The project is on a test run and

highlights of the system are detailed below:

• Netpro Renewable Energy (India) Limited, Bangalore, Karnataka and G. B.

Food Oils Limited have 50 – 50 share in gasifier supply.

• 1 x 100 kW gasifier is installed in G. B. Food Oils, Pudupatty and 1 x 100 kW

gasifier is installed in GB Enterprises, Trichy.

• These two gasifiers are test run gasifiers.

• Gasifier at G. B. Food Oils is operated for 20 days in Dual Fuel Mode during

December 2003 connected to one 125-kVA engine. The energy generation

through engine was struck due to problems in engine and hence stopped

operating diesel engine.

• The unit has two engines of 125 and 63 kVA and the total load of the unit is

400 HP. The unit is connected to HT line at the rate of Rs. 4.80 per unit.

• The unit has ordered for Greaves 300 kVA LPG based engine modified to

100% producer gas engine for Rs. 16 lakhs and Rs. 10 lakhs grant was

agreed by MNES, New Delhi.

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CHAPTER 4 VENDOR CAPABILITY AND TECHNOLOGY PENETRATION

4.1 Vendors

There are only a few technology suppliers and manufacturers in India and to

obtain the status of technology and capability of Gasifier and Engine suppliers, a

detailed questionnaire was sent to the manufacturers of Gasifier systems for

their feed back on their capabilities and list of Installations. The vendor list as

follows:

Table 14

Vendors supplying Gasifiers

S. No Name of the Gasifier Supplier/ Technology Provider

1 Netpro Renewable Energy (India) Limited, Bangalore, Karnataka

2 Ankur Scientific Energy Technologies Private Limited, Baroda

3 Energreen Power Limited, Chennai, Tamilnadu

4 Cosmo Powertech Private Limited, Raipur, Chhattisgarh

5 Centre for Gasification and Propulsion Laboratory (CGPL), Indian

Institute of Science, Bangalore, Karnataka

6 Grain Processing Industries (India) Private Limited, Kolkata, West

Bengal

7 Associated Engineering Works (AEW), Hyderabad, Andhra Pradesh

Out of the above Ankur, Grain Processing, AEW and Cosmo have their own

technologies, while the others use the technology developed by IISc.

The feed back from the manufacturers was poor in that only one vendor

responded with the filled in questionnaire, and ITCOT had one to one discussions

with the following vendors after receiving their concurrence

a. Ankur Scientific Energy Technologies private Limited, Regional office at

Kolkata

b. Netpro Renewable Energy (India) Limited, Bangalore, Karnataka

c. Grain Processing Industries (India) Private Limited, Kolkata, West Bengal

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4.1.1 Gasifier Type All vendors supply downdraft gasifiers except Grain Processing Private Limited.

Woody biomass gasifier, fine biomass gasifier and gas based biomass gasifier are

the different types supplied by the vendors.

4.1.2 Vendor Capability on Capacity Ankur Scientific Energy Technologies Ltd The company is in operation for more than 15 years with many awards from

Research institutions and Government, and is one of the MNES approved

vendors. They are having the manufacturing capability to produce gasifier

systems for both thermal and electrical applications based on both woody (WBG)

and fine biomass (FBG). The highlights of technical specifications are given

below as Table 15.

Table 15

Ankur Gasifier – Technical Specifications

Parameters FBG Series WBG

Gasifier Modes FBG-40, 60, 80, 100, 120, 150,

200, 250, 300, 335

WBG; 40, 60, 80, 100,

120, 150, 205, 250, 300,

400, 500

Type Down Draft - do -

Size – Min. &

Max.

2 mm on cylindrical diameter

Diameter: 3mm, L: 20 mm

D: 10 mm; L: 10 mm

Moisture 10% (max.) < 20%

Gasification

Temp. ° C

900-100 1,050-1,100

Efficiency- Hot

Gas mode

65 to 75 > 85%

Efficiency - Cold

Gas mode

60 to 65 > 75%

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60

The capability of the vendor in supplying the system as provided in the

questionnaire is given below as Table 16.

Table 16

Vendor capability in supplying the system

S. No Type Model Capability

1 Woody Biomass WBG-5 to WBG-850

2 Fine Biomass FBG-40 to FBG-400

3 Combo Combo-150 to 350

4 100% producer gas based

power pack systems

Gas-4 to 425

Can manufacture at

least 500 systems of

small ratings and

another 300

systems of higher

ratings

NETPRO Renewable Energy (India) Pvt. Ltd. (NETPRO) The company was established in 1994 to design and manufacture biomass

gasification plants in association with IISc, Bangalore and Dasag Energy

Engineering Ltd., Switzerland. NETPRO’s current focus is on large scale

Commercialisation of biomass gasification plants of various sizes for power

generation as well as thermal applications. Netpro has a technical collaboration

agreement with the Indian Institute of Science (IISc), Bangalore, India, a

premium-engineering institute of the country.

NETPRO undertakes the turnkey execution of power generation facilities with

unit capacities up to 500 kW and tailor made designs for thermal applications. It

has supplied a large number of gasifiers in India, USA, Switzerland and Kenya.

Table 17

Typical Technical Data of an IISc – Netpro Biomass Gasification Plant

Parameter Specification

Ratings of the Gasifier 25 kg/ h to 750 kg/ h of standard biomass

Type Open top, down draft solid biomass gasifier

Feed Stock Any solid biomass with bulk density over 200kg/m3,

moisture content less than 15% cut to a maximum

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61

size of 60 mm x 20 mm x 20 mm

Average Lower Calorific

Value

4.5 + 0.2 Mj/ kg

Typical gas composition (%

by volume)

CO: 20 + 1%: CH4 : 3 + 1%, H2 : 20 + 1%, CO2 :

12 + 1%; O2 : 0.1% (max) and rest N2.

Turndown ratio

(max./min.) load

4:1

Avg. specific weight of

producer gas

1.12 kg/ Nm3

Auxiliary plant loads Water pump, Chiller, Suction blower, Chilled water

pump

Application Diesel substitution upto 70 – 80% is expected to

be achieved in dual – fuel mode of operation on

specified diesel engines at or above 75% of the

rated load. The tune to which diesel substitution

could be achieved is sensitive to the moisture

content in the biomass

Gas quantity with

“standard” biomass

Hot end Cold end

Tar: 70 + 30 ppm < 40 + 10 ppm

Particles: 600 + 100 ppm < 30 + 10 ppm Tar

Gasification efficiency with

“standard” biomass

Hot gas: 80 – 85% Cold gas: >75% at high loads

Specific Wood Consumption Depends upon the engine. Typically, with biomass

of 12% moisture content: 1.1+0.1 kg/kWh in dual

fuel mode and 1.3 + 0.1 kg/ kWh in pure gas

mode.

Associated Engineering Works Ltd The vendor is in operation for more than 10 years supplying gasifiers for both

thermal & electrical dual fuel applications. The typical technical specification of

models manufactured by the vendor as per the brochure is given below in Table 18.

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62

Table 18

Data Table - Associated Engineering Works

Electrical / Power Application

MODEL S.NO. SPECIFICATIONS

GE-350 GE 450 GE 600

1 Nominal Rated output to KCal/Hr. 50000 1,00,000 2,50,000

2 Rated Electrical Output (kW) 20 40 100

3 Wood/ Biomass consumption in

Kg./Hr. 20 40 100

4 Moisture content acceptable 5-20% 5-20% 5-20%

5 Hopper holding capacity in Kgs. 100 200 500

6 Aux. Power required (HP) 2 3 5

7 Wood Cutter Motor H.P 1.5 2 3

8 Wood chip size range (Diameter or

length)

1/2" - 1

1/2"

3/4" - 1

1/2" 1" - 2"

9 Typical diesel replacement (Average) 65% 65% 65%

10 Floor space required 8'-8' 10'-15' 10'-20'

Energreen Power Ltd, Chennai The vendor is in operation for more than 5 years supplying Gasifiers system with

technical know how from IISC, Bangalore. Though no details are provided on

their capability or the current operation, based on the discussions, it was

observed the first 1 MW grid connected Gasifier has been supplied by the vendor

though no details could be obtained either from the vendor or from the promoter

M/s. Arasi Hi Tech Bio Power Pvt Ltd, Tamil Nadu. Based on the secondary

survey it is noted that the vendor is capable of supplying the following systems

• Thermal systems: 100kW to 10MW

• Electrical systems: 20kWe to 2 MW

The technical specifications of the systems as per the claim of the vendor are

given below.

• Specific fuel consumption for dual fuel mode: 0.8 to 0.9 kg of

biomass/kwh

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63

• Diesel replacement possible for dual fuel mode: 80%

• Specific fuel consumption for producer gas mode: 1.0 to 1.2 kg of

biomass/1kWh

Grain processing Industries (India) Pvt. Ltd. The vendor is in operational for more than 10 years and the system design is

based on updraft and the various models available are given below in Table 19.

Table 19

Grain Processing Industries (India) Pvt. Ltd. – Technical Specifications

Specifications GP 100 GP 200 GP 500

Max. Electrical output (kW) 100 200 500

Max. Thermal Output (KCal./hr.) 2,50,000 5,00,000 12,50,000

Rated Biomass Consumption

(Kg./hr.) (Including 10-15% diesel

oil)

2,50,000 5,00,000 12,50,000

Min. space required for plant (Sq.

ft.)

40’ x 40’ 50’x40’ 50’x60’

Cosmo Power tech Pvt Ltd The company is in the process of supplying Gasifier systems with dual fuel mode

and is one of the approved vendors of MNES and has supplied 500 kW dual fuel

mode gasifier systems.

4.1.3 Guarantee/Warrantee Provided Though no guarantee is provided on the performance for the system as a whole

by these vendors as characteristics of ‘standard biomass’ vary based on site

conditions, few vendors like Ankur, have provided guarantee to following

equipment supplied by them.

a. Gasifier

b. Burner

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64

c. Dual fuel engine

d. Cutters

e. Filters

f. Skip Charger

g. Wood Dryer

h. Variable Load Control System

4.1.4 Annual Maintenance Contract Annual Maintenance Contract is provided to the equipment under guarantee.

4.2. Engine Various engine manufacturers have supplied engine for producing power from

the gas generated from the gasifiers. Engines specific to 100% producer gas

usage and with dual fuel option (usually Diesel) has been used for generating

power. The vendors supplying 100% producer gas engine and Dual Fuel Engine

for the gasifier system is detailed below.

4.2.1 100% Producer Gas Engine Supply, Erection, Testing and Commissioning of 100% Producer gas engine has

been under the responsibility of Gasifier Suppliers / Vendors. So far for higher

capacity range the engine has been supplied by Cummins. Of the 14 installations

visited following are the systems with 100% producer gas engine.

Table 20

List of Installations with 100% Producer Gas Engine

NO. Name of the Unit

Engine make

Alternator Make

Gasifier Supplier

1 PMCTW, Vallam Cummins Stamford Ankur

2 VCC, Kovilpatti Cummins Stamford Ankur

3 Nellithurai Dipco

replaced with

Field Marshall

Compton

Greaves

Ankur

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65

4 Odanthurai Dipco Crompton

Greaves

Ankur

5 Bagavathi Bio,

Mettupalayam

Cummins Stamford Energreen

6 PSG, Coimbatore Cummins Stamford Netpro

4.2.2 Dual Fuel Engine

Supply, Erection, Testing and Commissioning of Dual Fuel Engine has been the

responsibility of Gasifier Suppliers / Vendors. Gasifier supplier provides the

Guarantee for the engines supplied. The engine for dual fuel mode has been

Kirloskar, Greaves, Ashok Leyland and Yanmar. Of the 14 installations visited

following are the systems with Dual Fuel Engine.

Table 21

List of Installations with Dual Fuel Engine

No. Name of the Unit Engine make

Alternator Make

Gasifier Supplier

1 MVIT, Bangalore Kirloskar

and Greaves

Kirloskar and

Stamford

Netpro

2 VIT, Vellore Netpro

3 Jagat Alloys, Khopoli Yanmar Taiyo Cosmo

4 PMCTW, Vallam Ashok

Leyland

Kirloskar AEW

5 Gosaba Islands Greaves Crompton

Greaves

Ankur

6 Chotamulakalli

Islands

Greaves Crompton

Greaves

Ankur

7 Pondicherry

Engineering College

Ashok

Leyland

Kirloskar AEW

8 G. B. Food Oils

Private Limited

NA NA Netpro

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66

4.3. Technology Penetration Gasifiers have started as a thermal application device and with further

improvements have been extended to electrical applications. Reasonable

technology developments have taken place especially in gas cleaning and cooling

system and in engines to use 100% producer for power generation.

4.4. Improvement Required

Improvement in system performance could be further improved.

Gas Cleaning System Gas Flow Controlling System Engine Cooling System

4.5. Research & Development Indian institute of science, Bangalore is the only institute in India who have

developed laboratory models to commercialized gasifier systems in India and is

actively involved in research and development activities and some of the current

activities are given below

Gas Engine Adaptation • Systematic Procedure – Experiments & Modeling

• Testing of various capacity Engines – 0.5 to 200 kWe ~ at varying CR

• Design of gas circuitry elements ~ Gas Carburetor

• Identify key parameters like the optimum ignition timing and establish

maximum rating in each case

Engines tested in the laboratory and in the field • Kirloskar Oil engine (RB 33) (converted from available diesel engine to gas

engine)

• Greaves 250 kVA producer gas engine

• Cummins G743G and GTA 855G

Test Summary • G 743G & GTA855G adapted for producer gas operations replacing

Natural gas carburetor with Producer gas carburetor

• Engines tested at different ignition timings and optimum identified

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67

• Tested for 75 hours at the laboratory; two 24 hour run – active

participation from Cummins

• Parameters monitored – energy input, power output and emissions

• Engine run smooth with clean gas admitted to the engine

• No deposition found in the Throttle valve, Intake manifold & Cylindrical

Head

• A peak load of 55 kWe (60 kW) recorded in PG against 84 kW in NG

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68

CHAPTER 5

BARRIERS TO GASIFIER PROGRAMME AND POLICY ISSUES

5.1. Barrier Identification Gasifier based power production is under development and has the following

barriers.

5.1.1 Biomass Resource Identification and Logistics in Collection

Ministry of Non Conventional Energy Sources has carried out Biomass Resource

Assessment study in four phases at Taluka level through National Biomass

Resource Assessment Program (NBRAP) with the help of National Focal Point,

Apex Institutions and Consultants. This has been carried out for taluka level and

further extended to the district level. This study, especially in South India focuses

on forest wood, agricultural field level residue, agro industries residue and the

wood traded around in the area concerned. The report gives a broad outline of

biomass availability in the area concerned.

However, this does not provide any clear indication of the biomass quantity and

availability at closer vicinity and at desired price suitable for gasifier operation.

The units however before putting up their individual gasifier unit should assess

the biomass required for operation.

Collecting the biomass from various sources requires better and controlled

logistics. The units in operation consume biomass from traders and brokers. If

the unit handles the collection of biomass themselves, they find it tough to

handle. However, if the biomass is purchased in open market, then the cost,

collection, handling of biomass becomes very sensitive to market changes, which

leads to high landing cost, poor quality of the purchased biomass and un

processed fuel for the gasifier.

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Site-specific conditions with respect to Biomass Resource Identification are

detailed below:

a. M. Vishveswaraiah Institute of Technology, Bangalore, Vellore Institute of Technology, Vellore, PSG Institute of Technology, Coimbatore and Periyar Maniammai College of Technology for Women, Vallam have assessed the requirement of biomass at site and

purchase wood before processing from local traders at a feasible price. Thus,

these units do not have any barrier to biomass resource.

b. Valli Chlorate company, Kovilpatti is gifted with plenty of woody biomass

(as recommended by vendors) in and around the plant site and hence,

resource is not a constraint for smooth operation of the unit.

c. Bagavathi Bio Private Limited, Coimbatore has drafted an agreement

with the local traders for smooth supply of biomass to the unit and hence,

faces no barrier currently on biomass availability.

d. Gosaba Islands and Chotamulakalli Islands enjoy the benefits from

Government of West Bengal, as the fuel (both wood and diesel) is supplied by

the Government. However, if a private entity puts up a unit in these Islands,

then it would not be financially feasible if fuel is purchased. However, private

units would enjoy smooth operation when the wood is from the local Energy

Plantation.

e. Nellithurai Panchayat and Odanthurai Panchayat has a low capacity

gasifier installed and hence the biomass requirement is met through local

self-help groups.

f. Pondicherry Engineering College, Jagat Alloys Private Limited, Khopoli and G. B. Food Oils Private Limited, Pudupatty currently does

not operate the gasifier units.

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5.1.2 Cost of Biomass Biomass cost is a matter of concern before putting up the gasifier unit. The cost

of woody biomass at most of the installations visited was around Rs. 800 to Rs.

850 during the time of installation and has soared up to Rs. 1200 per ton

presently in a span of 2 to 3 years.

The cost is inclusive of

a. Processing the wood either at site or at source

b. Loading and unloading

c. Labour Charges

d. Moisture content in wood

Of the points mentioned above from a to d even if one changes it has a direct

impact on the cost of biomass.

If the cost escalates in a unrealistic manner, then the feasibility of the project

would be at stake. Cost of biomass at sites visited is listed below in Table 22.

Table 22

Cost of Biomass at Various Installations

Cost of Biomass in Rs. Per tonS. No Name of the Unit During

Installation Current Cost

1 MVIT, Bangalore 800 1,100

2 PMCTW, Vallam NA NA

3 PSG, Coimbatore 1,000 NA

4 Pondicherry Engineering College 1,100 NA

5 VIT, Vellore 1,200 1,400

6 Gosaba Islands NA NA

7 Chotamulakalli Islands NA NA

8 Valli Chlorate Company, Kovilpatti 800 1,200

9 Bagavathi Bio Energy Limited 800 1,200

10 Jagat Alloys Private Limited 1,200 NA

11 G. B. Food Oils Private Limited NA NA

12 Odanthurai Panchayat NA NA

13 Nellithurai Panchayat NA NA

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5.1.3 Choice of Fuel Restriction Gasifiers installed in various units in southern India use predominantly hardwood

as fuel to the gasifier. Biomass other than woods like straw, stalks, sawdust, coir

pith are not used which are available in plenty.

5.1.4 Soaring Cost of Diesel in Dual Fuel Mode The gasifier units in Dual Fuel Mode operation face the heat on the soaring price

of diesel. The units’ installed three years ago derived the feasibility based on

diesel price of Rs. 18 per litre which is currently at Rs. 30 per litre.

M. Vishveswaraiah Institute of Technology, Bangalore has signed a PPA

with Netpro Renewable, Bangalore on the purchase of Power at Rs. 5 per kWh

escalated with respect to increase in Diesel price. Current purchase price is Rs.

5.70 per KWhr. If this price exceeds KPTCL price of Rs. 6 per kWh, then the

college might opt for KPTCL power and might stop the gasifier operation.

Jagat Alloys Private Limited, Khopoli, Maharashtra has installed gasifier of

500 kW in dual fuel mode but stopped operation by 2002 due to internal financial

problems. Also the hike in Diesel price made the project not financially feasible.

Islands of Sunderbunds enjoy the fuel supply from Government of West

Bengal and hence the cost does not play a vital role as the entire project is for

the community development and for socio economic improvement of these

Islands.

Periyar Maniammai College of Technology for Women, Vallam currently

does not operate 100 kW dual fuel mode based gasifier and uses only 200 kW

100% producer gas based system for energy generation.

G. B. Food Oils Private Limited and Pondicherry Engineering College

currently does not operate the system.

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Vellore Institute of Technology (VIT), is effectively loading the system by

which diesel replacement is by 87% and hence faces no major problem at

present.

All the other units apart from the units mentioned above are 100% producer gas

engine systems, which does not require diesel for their operation.

5.1.5 Technology Although technical feasibility is available for the gasifier-based systems, the

operational problems are found especially in gas cleaning and cooling system.

The technology adopted in filters used in gas cleaning system plays a crucial role

in gasifier operation. Currently coarse sand, fine sand, fabric filters and saw dust

is used in cleaning system. Also chiller based gas cooling has been introduced to

bring down dust and tar levels in the gas.

Cooling tower based Engine-Cooling and Gas-Cooling is costlier in operation. The

desired cooling is also not achieved in these systems.

Islands of Sunderbunds often faces problem in gas cleaning system. The

sawdust used in the filters restricts the flow of gas into engines thus increasing

the consumption of diesel.

M. Vishveswaraiah Institute of Technology, Bangalore, has opted for a

chiller based gas cooling system in their Second phase, which solves the problem

of dust and tar generation.

Valli Chlorate Company, Kovilpatti has shut the plant for four months in the

year 2004 due to high operational cost of cooling towers and has installed coil

based cooling system for engine to reduce cost.

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5.1.6 Delay in Disbursement of Loans and Subsidy Many units currently has adopted gasifier based energy generation system not

only on the basis of adopting renewable energy technology but for availing

subsidies and soft loans from Government to generate energy at a cheaper rate.

If the delay in disbursement persists it might lead to a closure of the parent

company itself.

Jagat Alloys Private Limited (JAPL) is a classical example. JAPL for setting up 2 x 500 kW gasifier based power generating system has

approached Consultant to prepare Detailed Project Report (DPR) for submitting

the same to MEDA, MNES and Development Credit bank limited. Central Financial

Assistance (CFA) of 40.80 lakhs was approved by MNES for the year 2000 – 01.

50% of 40.80 lakhs i.e. 20.40 lakhs was sent to MEDA from MNES for granting

the subsidy. JAPL has mobilized equity through shares for their plant expansion

& gasifier installation and arranged loans other than MNES subsidy through

Development Credit bank limited.

JAPL has installed 1 x 500 kW gasifier and received 50% grant from 20.40 lakhs

i.e., 10.20 lakhs from MEDA. JAPL has commissioned 1st Phase 500 kW and

provided Rs. 8 lakhs as advance to Gasifier Supplier Cosmo power tech for

installing second phase.

However, MNES has asked for bank guarantee from JAPL to pay the final 50%

for 1st Phase and as bank guarantee could not be provided by JAPL though

nationalized bank (as Development Credit bank were their bankers – a non

Nationalized bank) the second payment got delayed. This has forced the

company into financial crunch. Further to it, MNES after installation has

requested for type certificate of Cosmo power tech gasifier, adding further delay

in receiving the subsidy.

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After receiving the type certificate, MNES has requested IIT Mumbai to provide

common performance report (CPR) on gasifier performance. During trial, the

replacement of diesel was 58%. The reason indicated for lesser diesel

replacement was the wetness prevailed in the biomass used as the trial was

taken during rainy season and hence CPR submitted by GARP, IIT was rejected

by MNES and added further delay. Then final trial run was conducted on 2nd April

2002 and diesel replacement was achieved around 71%.

MNES has sanctioned the remaining subsidy for 1st Phase; However JAPL has

given up 2nd Phase and requested MNES to cancel the second phase grant for

another 500 kW.

5.2. Measures to overcome Barriers

Following are some of the measures to overcome the above said barriers.

a. Support from Central and State Governments from scratch to commissioning

of the project.

b. Timely disbursement of loans and grants for smooth functioning in the

commissioning of the project.

c. Approvals of 100% producer gas system alone to prevent diesel playing a

pivot role in the operation of entire system.

d. Better biomass resource assessment

e. Better logistics in biomass trading and handling

f. Technology improvement in Cooling and Cleaning Systems

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CHAPTER 6

CASE STUDIES ON SUCCESSFUL INSTALLATIONS

6.1 Name of Installation: Valli Chlorate Company, Kovilpatti, Tamilnadu

A. Project Background Objective Valli Chlorate Company (VCC), Kovilpatti is in operation from 1989 for producing

potassium chlorate (Kclo3), a major chemical for making matchsticks. The

company has its own matchsticks making factory called Meenakshi Match factory

at Kovilpatti. The company earlier had a High Tension (HT) service connection

from Tamilnadu Electricity Board (TNEB) for a connected load of 500 kVA. The

company uses D.C. Power supply in their operation for producing Potassium

Chlorate. During 1999, when the cost of kWh increased to Rs. 4.20 per kWh,

VCC has decided to shutdown the operations of the potassium chlorate company.

The company disconnected the HT service connection. In the year 2003, the

company planned to use Gasifier and approached an engineering company in

Kerala to modify their DG set into dual fuel mode engine. With the direction of

the engineering company, VCC approached Ankur Scientific, Baroda and revised

the plan of setting up a duel fuel engine to set up 100% producer gas system.

The company thus set up the first 200 kW / 100% producer gas based Gasifier in

Tamilnadu. When the company resumed operation in 2003, it has acquired an LT

connection of 50 HP load for auxiliary consumption. The plant capacity is around

1 ton / day and based on the demand the current production is around 10 tons

per month.

Year of Installation The gasifier was installed on June 23, 2003

Plant layout and Size Total area of 3,000 Square feet

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Location Valli Chlorate Company is located in Uppathur Road, Ovanayakanpatti village,

Sattur Taluka, Virudhunagar District, Tamilnadu. The unit is accessible from

Tirunelveli by road at a distance of 80 Kms via Kovilpatti.

FIGURE 13 – Lay out of Valli Chlorate Company

COIL BASED

COOLER

ALTERNATOR

GAS CLEANING SYSTEM

CONTROL PANEL

GASIFIER AND COOLING SYSTEM

RECTIFIER TRANSFORMER

CUTTING

MACHINES

ENTRANCE

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Gasifier (supplier – Ankur Scientific Energy Technologies Private Limited, Baroda)

(i) Capacity: 200 kW

(ii) Biomass fuel consumption: 300 kg/h

(iii) Moisture: < 20%

(iv) Loading of biomass: Automatic using lift

(v) Gasifier starting: Manual

(vi) Gas cooling and cleaning of tar removal, particulates: Cyclone Separator,

4 Nos. of active and passive coarse filters, fine filters with sawdust.

(vii) Gas flaring provision before engine entry

(viii) Height of reactor 10 ft.

(ix) Auxiliary power: 20 kW includes pumps in cooling tower, pumps in

gasifier, pumps in engine and blower

(x) Recommended biomass fuels: Casuarinas, eucalyptus, Julia flora and

any hardwood

(xi) Gasifier material of construction: Stainless Steel for nozzle and throat


(xii) Life of Gasifier: 5 years

(xiii) Turn down ratio: 30%

(xiv) Starting time from cold start: 15 minutes

Engine (make - Cummins) • Model: GTA – 1710 – G

• Date of Manufacture – 11/10/2001

• S. No: 35020


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Alternator (Make – Stamford) • KVA: 320

• Speed rpm, 1500

• Voltage, 415 V

• Load, 445 Ampere

• Frequency, 50Hz

• Power factor 0.8

• Continuous rating

• DC Excitation 38 V: 2 A

• Star Connected

• Enclosure: IP 23


Rectifier Transformer

• Make: Hind Rectifier (Bombay)

• DC Volt 60 V Current 4000 A

• Phase 3 Ǿ

• Frequency 50 Hz

• Tank 700 kgs

• Resistance 2.099

• Oil 900 kgs

• Rating: Continuous

• Input KVA: 307.22

• Primary: Main ∆ 415 V 427.4 A

• Secondary: 498 – 108 ץ – ג V 1156 x 2 A

Electrical panels

The plant is designed to operate in stand-alone mode and the power generated

from gasifier is fed to rectifier transformer for AC to DC Conversion. Electrical

control panel is provided with Oil Circuit Breaker (OCB) of 400/440 Volts and 400

A rating with built in protections of under voltage, over voltage, over current and

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earth fault protection. The company has an LT connection of 50 HP for supplying

auxiliary power for starting gasifier plant auxiliaries.

C. Financial Parameters Building and civil works The company had land area for gasifier installation and hence spent negligible

amount for installing gasifier. For Gasifier system with DG set Equity: Rs.18.00 lakhs

MNES subsidy: Rs. 30.00 lakhs

Total Project cost: Rs. 48.00 lakhs D. Project Status

The plant was commissioned on June 23, 2003 and was in operation for 9

months till March 31 2004. Due to Generator Breakdown, the operation resumed

from July 2004. The high operational cost of cooling tower has forced the unit to

install coil based cooler for engine, for which the installation period was four

months from November 2004 to March 2005. The gasifier operation was

shutdown during this period. The plant has been functional since then.

E. Plant Performance Summary for the monitored Period (5 months from July 2004 to October 2004 and March 2005)

• Gross Power Generation 1,72,890 kWh

• Auxiliary Power Consumption: 38,868 kWh







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Table 23

Performance of VCC for the period July 2004 to March 2005

Date (Excl. Holidays

Month

From To

Units Generat

ed in KWh

Aux. Cons.

In kWh

Operation Hrs.

Biomass consumption

kgs.

July ‘04 12.704 31.07.04 25,040 5,008 138 37,560

Aug ‘04 2.8.04 31.8.04 40,480 8,070 220 60,870

Sep ‘04 1.9.04 30.9.04 36,000 7,200 200 54,720

Oct ‘04 1.10.04 31.10.04 27,300 5,450 151 41,500

Mar ‘05 1.3.05 31.03.05 44,070 13,140 248 67,710

TOTAL 172,890 38,868 957 262,360

FIGURE 14 – VCC Gasifier Average Plant Load Factor and Overall Gasifier Conversion Efficiency

90.72% 92.00% 90.00% 90.40% 88.85%

38.23%38.64%

38.65%39.07%

39.16%

0.00%

10.00%

20.00%

30.00%

40.00%

50.00%

60.00%

70.00%

80.00%

90.00%

100.00%

July 2004 August 2004 September2004

October 2004 March 2005

Weeks

Per

cen

tag

e %

Avg PLF Overall % Gasifier Conv Efficiency

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FIGURE 15 - VCC, Kovilpatti – 1 x 200 kW Biomass Gasifier Plant Performance Data – 2002 to 2004

1.501.50

1.52

1.54

1.52

25040

40480

27300

44070

36000

1.48

1.49

1.50

1.51

1.52

1.53

1.54

July 2004 August 2004 September2004

October 2004 March 2005

kg/k

Wh

0

5000

10000

15000

20000

25000

30000

35000

40000

45000

50000

kWh

kg/kWh Total Energy Generated in kWh

0

10000

20000

30000

40000

50000

60000

70000

Jul-04 Aug-04 Sep-04 Oct-04 Nov-04 Dec-04 Jan-05 Feb-05 Mar-05

FIGURE 16 - Energy Generation and Consumption Details at VCC, Kovilpatti

Biomass Consumption in kgs Energy Generated in kWhAuxiliary Consumption in kWh

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Observations:

• It could be seen from Figure 14 and 15 that when the Plant Load Factor

(PLF) increases on 100% producer gas mode, the gasifier conversion

efficiency also increases and vice versa.

• It could be seen from Fig.15 that at various energy generation levels fuel

consumption per kWh is 1.50 to 1.52 kg/kWh.

• It could be seen from Figure 16 that Auxiliary consumption is almost the

same throughout the period of operation i.e. around 20%

F. Cost of Production

The cost breakup cost of gross power generation is given below:

FIGURE 17 - Unit Generation - Breakup Cost in %

92%

8%

Fuel Cost Labour Cost

Observations Personnel required for loading the gasifier is eliminated in Ankur Scientific

System since lift is used for loading the Gasifier. As the manual operation is not

required, the cost of labour is only for processing the fuel and hence, taken as

Rs. 0.10 per kg of fuel used. Based on the discussion, the operator salary is Rs.

340 per day for 8-hour operation for 25 days a month and the annual salary is

around Rs. 8,500 per month.

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Repairs and maintenance cost is not considered as the plant is new and it was

conveyed that it is covered under 2 years equipment guarantee with the supplier

for replacement of defect items for the entire gasifier system

G. Performance: Design Vs actual

Table 24

Design Vs Actual Performance of VCC, Kovilpatti

S. No Performance indicator Unit Design Actual

1 Average kW loading KW 200 185

2 Average Specific Biomass Consumption Kg/kWh 1.3 1.51

The design value is considered at 100 % loading and is compared with actual

performance in the monitored period. The loading in operation is lesser

compared to the design value and hence, the performance could not be better or

at par with design.

H. Summary of notes of discussion with VCC

• The company sells Potassium Chlorate at a rate of Rs. 36 per kg. The

production cost with EB Power Supply was around Rs. 34 to 35 per kg results

in a meager profit margin. Due to gasifier installation, the production cost of

Potassium chlorate has come down to Rs. 28 to Rs. 30. This has helped the

plant in improving their profits.

• The power generated is used into their titanium cell chamber by converting it

to DC source by rectifier transformer.

• The operation of the unit is for 8 hours a day and extends some times to 10

hours a day and six days a week.

• Spares, consumables are provided by Ankur as and when required

• No major problem reported apart from generator – cooling system failure and

breakdowns

• Water requirement is met from 36,000 litres common sump, from where

water is pumped to a 12,000 litres an individual sump for Gasifier operation

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• The company has its own lorry with two sintex tanks of 300 litres capacity

each to supply water from their farm.

• The charcoal generation from Gasifier is around 10% of biomass used in a

day and sold in 40 kg bags at Rs.60 per bag.

• The other small particulate residue apart from charcoal is used as manure for

their farms.

• No tar is reported in the Ankur system

I. Issues

Since the company has been operating the system for the last two years, no

major issues was found during the operating period.

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6.2 Name of Installation: Gosaba Island, 24 Parganas District, West Bengal A. Project Background

Objective West Bengal Renewable Energy Development Agency (WBREDA) in association

with MNES, Government of India, Sunderbunds Development Department, Forest

Department, and South 24 Parganas, Zilla Parisad installed a 500 kW (5 x 100

kW) capacity biomass based power plant at Gosaba Island of Sunderbunds

where it is almost impossible to extend the conventional power grid line. The

prime objective of this power plant is to provide socio economic improvement of

the local people in Gosaba Island.

Year of Installation The 500 kW woody biomass based power plant was commissioned in Gosaba on

20th June 1997. Location Gosaba is situated at a distance of about 120 Km. from Kolkata (100 Km by road

and the rest by water transport). The nearest Rail Stations are Howrah &

Sealdah. Road Distance from Sealdah to Sonakhali is 107 Kms. and waterway

distance between Sonakhali and Gosaba is about 10 Kms. Diesel Engine driven

Launches/ Mechanized boats operate between Sonakhali & Gosaba and takes

about 60 meters to reach Gosaba from Sonakhali. Adjacent to Sir Hamilton’s

Estate Geographical co-ordinates: Latitude: 22° 12’ N, Longitude: 88° 48’ N.

Plant lay out Size 2,000 sq. ft.

Type Woody biomass down draft gasifier with batch feeding.

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xv) Gasifier starting: Through scrubber pump/blower

B. Technical Specifications Gasifier (supplier – Ankur Scientific Energy Technologies, Baroda)

i) Model: AG –100

ii) Capacity: 100 kW

iii) Components of gasifier

☼ Hopper

☼ Reactor

☼ Cyclone

☼ Venturi Scrubber

☼ Blower for Coarse filter

☼ Fine filter

☼ Safety Filter

iv) Rated gas flow: 250 m3/h

v) Average gas Calorific value: > 1,000 kCal/m3

vi) Biomass fuel consumption: 80 ~ 100kg/h

vii) Gasification temperature: 1050 ~ 1100 deg. C

viii) Indicative gasification efficiency:

Hot gas mode: > 85%

Cold gas mode: > 75%

ix) Temperature at gasifier outlet: 250 ~ 400 deg. C

x) Biomass fuel size:

Minimum diameter 10 mm and length 10 mm

Maximum diameter 60 mm and length 75 mm

xi) Moisture: < 20% on wet basis

xii) Hopper holding capacity: 500kg

xiii) Loading of biomass: intermittent manual feeding for every hour

xiv) Ash removal: Continuous through proprietary control and water seal

xvi) Specific fuel consumption: 250 ml/kWh – full diesel mode

xvii) Indicative diesel replacement: average 65 ~ 75% depending on

operating load

xviii) Engine conversion efficiency: 25%

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xix) Gas cooling and cleaning of tar removal, particulates: Venturi scrubber

with water re-circulation and ultra clean gas for power generation

mode through proprietary and fine filters

xx) Gas flaring provision before service filter

xxi) Height of reactor 4 ft.

xxii) Auxiliary power: 8 kW

xxiii) Water circulation: 250 litres per minute.

xxiv) Recommended biomass fuels: Casuarina, eucalyptus, subabul, Neem,


xxv) Gasifier material of construction: Stainless Steel for nozzle and throat


xxvi) Life of Gasifier: 5 years

xxvii) Turn down ratio: 30%

xxviii) Starting time from cold start: 30 minutes

xxix) Maximum permissible particulate: 50 mg/m3

xxx) Typical producer gas composition (%)

CO=19 +/- 3% N2 – 50%

CO2=10 +/- 3% H2=18 +/- 2% CH4=up to 3%

Engine (make - Greaves) • Capacity 151 hp


Alternator (Make – Crompton Greaves) • KVA: 125, Speed rpm: 1500

• Voltage: 415 V, Load: 175 Ampere

• Frequency: 50Hz

• Power factor 0.8


Electrical Systems

Gosaba Island was an un-electrified village until this project has been

commissioned and the plant was designed to operate in stand alone mode for

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village electrification purpose, as extension of the conventional grid power is

impossible.

FIGURE 18 - Electrical Schematic Diagram of Gosaba Installation

88

Feeder 1 Feeder 2

415 V bus

Bus coupler

DG sets 1,2,3,4 and 5

The power generated from the five DG’s can be synchronized at the 415 V bus

for parallel operation through a bus coupler and is taken through feeders 1 and

2, with each having a step up transformer of 315 kVA for power distribution at

11 kV. The existing 11 kV distribution circuit is 14 km and 415 V distribution

circuit is 19 km. The 415 V distribution has 5 nos of 100 kVA, step down

transformers located at various load ends. During the discussion it was informed

that distribution loss has been estimated at 8%.

Electrical control panel of 1500 Ampere capacity rating and each DG set is

provided with Molded Case Circuit Breaker (MCCB) of 300 A rating with built in

protections of under voltage, over voltage, over current, earth fault protection

and reverse power protections. The synchronizing panel has synchroscope and

the operators do a check-synchronizing relay and synchronizing operation

manually.

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C. Financial Parameters Land: 3 acres

Building and civil works: Fuel processing yard: 600 sq ft

Fuel storage yard: 2000 sq ft

Gasifier system with DG set: 2000 sq ft

Plant and machinery cost: Rs 85 lakhs Cost for land, buildings, power evacuation, others: Rs 65 lakhs Total project cost: Rs 150 lakhs Source of funds: 75% of the project cost from MNES 25% of the project from West Bengal State Government

Power evacuation cost: Cost for 11 kV distribution: Rs 2.5 lakhs/km

Cost for 415 V distribution: Rs 1.5 lakhs/km

D. Project in brief

Gosaba Island is one of the important islands of Sunderbunds. It is located in

South 24 Parganas District. The island is approximately at a distance of 120 km

from Calcutta with 25 sq. km area and has a population of 25,000 people. Till

May 1997, Gosaba Island did not have any electricity. The entire area used to

become dark after sunset. The local people approached WBREDA in the year

1996 for the provision of electricity from renewable sources of energy,

considering the fact that conventional energy may never come to Gosaba Island

after crossing of large number of creeks and rivers. After a careful survey of the

area, WBREDA decided to set up a 500 kW gasifier based power plant at Gosaba

Island along with energy plantation in wasteland and formation of a rural energy

co-operative with local people.

This project is a fine example of co-operation between MNES, WBREDA,

Sunderbunds Development Department, South 24 Parganas Zilla Parisad and

West Bengal State Electricity Board. The main motive force behind co-ordination

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of various departments and completion of work on schedule is the continued

efforts of WBREDA.

E. Consumers and Tariff structure It was informed that around 1,065 consumers are availing the power supply

through gasifiers and are grouped as below:

Domestic: Rs.5.00/kWh

Commercial: Rs 5.50/kWh

Hospital: Rs.6.00/kWh

There are no charges towards deposit fees and the above are flat tariff charges

with no taxes charged from consumers. Around 95% of the customers are

coming under domestic group.

F. Gosaba plant operation Another very important aspect is that the power plant is being run by a local co-

operative society, viz. Gosaba Rural Energy Co-operative Society, formed for this

purpose. The society comprises of consumers representatives, WBREDA, WSEB,

Sunderbunds Development Board, Forest co-operative department and from

Govt. of West Bengal. The entire operation and maintenance of the plant is the

responsibility of the Co-operative Society. WBREDA is responsible for providing

diesel, biomass, and revenue collection and in rendering necessary assistance in

repair, maintenance and other works from time to time. The salaries for the

operating staff are met from the revenue collection through the prevailing

consumer tariff and the balance of the revenue collection is paid to WBREDA,

which takes care of diesel and biomass supply.

WBREDA is providing all technical and resource backup to the society for running

the plant. The plant has been working smoothly since commissioning.

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Biomass Fuel: Woody biomass available in Sunderbunds is arranged through the society and

following are the different woody fuels that are used in the plant with an average

calorific value at 20 % moisture levels.

Akash – 3,400 kCal/kg

Shirish – 3,300 kCal/kg

Eucalyptus – 3,600 kCal/kg

Subabul – 3000 kCal/kg

Mango – 3,000 kCal/kg

It was informed that moisture level at the time of purchasing will be around 70%

and is dried at the site to reduce to 20% before feeding into gasifier.

Revenue: WBREDA indicated that the income and expenditure of the plant for the year

2003-2004, is as follows.

☼ Income: Rs 30 lakh

☼ Expenditure: Rs 33 lakhs

☼ Deficit: Rs 3 lakhs

Though the operating figure indicates a net deficit, the plant was provided financial support from the West Bengal state government along with the technical guidance from WBREDA. The project model isaimed at providing a socio economic benefit to Gosaba and also indirect benefit to the nearby islands.

Gosaba plant performance in August 1997 ~ March 1998 (Source WBREDA annual report -1996 ~1998) The operation in that period was limited to 6 hrs/day, from 17.00 hrs to 23.00

hrs. Initial demand for power was very low at 60kW and within one year, it grew

sharply to 200 kW. The summary of performance is given below and is expected

to improve further with increase in demand:

• Total energy generated in that period, 77,505 kWh

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• Total diesel consumed, 10,174 litres

• Average specific diesel consumption, 0.13 litre / kWh

• Total biomass consumed, 68,482 kgs

• Average specific biomass consumption kg/kWh: 0.90

• Average diesel replacement - 47%

FIGURE 19 – Gosaba 5 x 100 Gasifier Plant Performance data – August 1997-March 1998

92

Gosaba plant performance in March 1~22, 2005 The plant was operating with 3 gasifiers 1,3 and 5. Gasifiers 2 and 4 were under

replacement with new ones and hence, are not in operating condition. The

gasifiers 1, 3 and 5 were replaced with new gasifier system in 2002.

1.20 14,000

0.16 0.15 0.13 0.12 0.14 0.13 0.12 0.12

1.14 12,485 1.13

12,0001.00

0.85 0.80

0.84

0.76 0.77

0.91 11,337

7,180 7,119

8,415

10,515 9,974

10,00010,480 0.80

kg/k

Wh

and

litre

/kW

h

kWh

8,000

0.60 6,000

0.40 4,000

0.20 2,000

0.00 0August '97 September '97 February'98 March'98 October '97 November '97 December'97 January'98

litres/ kWh Total Energy Generated in kWh kg/ kWh

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93

Present Operating mode: The plant was feeding power to the consumers from 10.00 am to 12.00 pm (say

14 hrs/day). One DG set starts on diesel operating mode at 9.30 am with one

gasifier firing simultaneously with woody biomass, and after the gasifier

stabilization, producer gas is fed into the DG set and DG set is under dual fuel

mode from 10.00 am. One DG set operates till 4.30 pm and the second DG set

with gasifier under dual fuel starts and the third DG set with gasifier starts by

5.00 pm. Thus, three DG sets on dual fuel mode are operated. For meeting the

evening peak load, fourth DG set on diesel mode is started at 6.30 pm and goes

till 8.30 pm. From 8.30 pm to 12.00 pm, only two DG sets are operated.

The plant operating data for the period March 1~22, 2005 was collected from

the operators logbook and following curves were drawn for plant performance

assessment.

Observations: • In that period, three gasifiers and four DG sets were operated to meet the

load requirement

• From the logbook, it was observed that maximum load in Ampere

recorded in a DG set was 150 A (rated 175 Ampere). Two DG sets were

operated in that range, while the third DG set with a load of 110 Ampere

and the fourth DG with a load of 80 Ampere, was operated in the evening.

• The cost of power generation was highest in March 17, 2005 at Rs

8.82/kWh with an average loading of 252 kW and PLF of 63%. The reason

could be the operating problems in the gasifier due to filter choking.

Hence, more diesel was consumed to maintain the load.

• Producer gas from a particular gasifier is used in one or more DG sets in

an operating day, by changing the feed of DG sets, time to time. Hence, it

is difficult to assess the performance of a particular gasifier with a

dedicated DG set, as there is a provision for providing gas from any

gasifier to any DG set by shuffling the flexible hose piping of gas feeding,

in order to overcome operating problems in DG sets/gasifiers

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FIGURE 20 – Gosaba Island 5 x100 KW March Operating Data

300 12

14 13 8 12 8 8 11 10 12 15 1323

17 16 -1

21

-62 1 2 3

15

257 269 270

256 253 252

232 244 244

250 239233 235

190

220214

238

Pow

er Gen

eration C

ost Rs/kW

h

241 240233233 10226

219

8.41 200

repl

acem

ent

88.37 8.35 8.348.82 8.15

64 67 67 64 58 61 60 61 58 59

4855 54

59 58 63 6357 58 60 55 60

7.47 7.57 7.79 7.927.70 7.85 7.73 7.717.62 7.58

150 7.45 7.407.067.02

7.62 7.40 6

100

4

50

20

14 1 2 3 4 5 15 16 17 18 19 20 21 2210 11 12 136 7 8 9

Days-50 0

% Diesel Repl Avg kW Avg PLF Power generation cost Rs/kWh

ITCOT

95

• The availability of only three gasifiers, imminent filter problems (it was

informed that Gasifier 3 has pending filter problem and hence, gasifier

loading has been compared to the other two) and highly fluctuating load

demand, resulted in a poor plant performance. The associated gasifier

problems on power generation have contributed to the high cost of power

generation.

• It was informed that fluctuating load demand was the main attribute for

the poor performance of the gasifiers. The load points are predominantly

lighting (domestic, commercial, street), fans, irrigation pumping,

commercial establishments like education institutions and hospital. Before

this power plant, consumers were using SPV for lighting and fans.

• Though three gasifiers were replaced with new gasifiers in 2002 (Gasifier

1,3 and 5), it was informed that gasifier three has still problems in the

coarse and fine filter, often leading to pressure build up and reduced flow

of producer gas. Other two also have intermittent problems related to

filters.

• The following is the summary of plant performance during the observed

period:

o Total energy generated, 34,866 kWh (this value is summated value of

energy meters at two outgoing feeders with added 10% auxiliary

consumption. It was noted that energy meter for DG 2 was not

working and hence, addition of individual DG energy meters for

comparing with feeder energy meters was not possible)

o Total biomass consumed: 26,733 kgs

o Total Diesel consumed: 7,869 litres

o Average diesel replacement: 10%

o Average loading: 238 kW

o Average PLF: 60%

o Average cost of power generation: Rs 7.79/kWh

o Average Specific diesel consumption: 0.23 litre/kWh

o Average Specific biomass consumption: 0.77 kg/kWh

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96

G. Power generation cost breakup

FIGURE 21 – Sunderbunds Gasifiers Installations – Gosaba 5 x 100 kW – Dual Fuel mode power generation cost breakup (Rs./kWh)

• 86% of the power cost is due to diesel and it warrants immediate detailed

performance evaluation of the gasifier systems

• 10% of the power cost is due to biomass and is higher due to lower

replacement of diesel

• Operator cost and maintenance cost is 3% and 1% respectively, which are

negligible compared to the fuel cost

• List of assumptions on costing, based on the discussions: Biomass fuel cost @ Rs1.00/kg

Diesel cost @ Rs 30/litre

20 operators for the plant @Rs 2500/operator/month

operator cost Rs/kwh, 0.24, 3%

Maintenance Cost

Diesel cost Rs/kWh, 6.77, 86%

Biomass cost Rs/kWh, Rs/kwh, 0.11, 1%

0.77, 10%

Diesel cost Rs/kWh Biomass cost Rs/kWh Maintenance Cost Rs/kwhoperator cost Rs/kwh

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Annual maintenance cost/gasifier: Rs. 20,000

Annual maintenance cost of DG set: Rs 25,000

H. Performance Design Vs Actual

Table 25

Performance of Gosaba Installation - Design Vs Actual

S. No Performance indicator Unit Design Actual

1 Average kW loading kW 500 238

2 Average Specific Biomass

consumption Kg/kWh 1 0.77

3 Average Diesel consumption Litre/kWh 0.06 0.23

4 Average % diesel

replacement Percentage 70 10

Observations:

• The plant has consumed more diesel than the design value, and hence,

biomass consumption has been lower than the design value due to poor and

fluctuating load

• The reasons for the poor performance are problems of gas cooling and gas

cleaning system, engine operating performance and moisture content of

biomass. • The situation demands a thorough study on load demand; operation

performance of gasifiers on a continuous basis, issues related to gas quality

and increased diesel consumption. I. Maintenance

It was informed that no specific Annual Maintenance Contract (AMC) has been

signed with vendors for gasifier and engine system.

Annual maintenance cost/gasifier: Rs. 20,000

Annual maintenance cost of DG set: Rs. 25,000

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98

The above is inclusive of vendor representative site visit fees,

consumables and spares

A nominal charge of Rs 1000/day is charged by the vendors for site

visit

WBREDA is inviting vendors to the site in case of problems faced by

the operator.

FIGURE 22 – Gosaba 5 x 100 kW Biomass Gasifier Plant Performance Design Vs Actual

1.2

Kg/kWh, 1 1

Kg/kWh, 0.770.8

kg/k

Wh

and

litr

e/kW

h

0.6

0.4

Litre/kWh, 0.23

0.2 Litre/kWh, 0.06

0 Kg/kWh Litre/kWh

Actual Design

Following is the maintenance schedule for various systems, as informed by

WBREDA.

Engine ☼ Checking of engine after 10,000 hours of operation

☼ Checking of engine cylinder head, nozzle injectors after 4000 hours

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☼ First filling of lube oil 35 litre and changing of lube oil after 250 hrs. Lube oil

grade – SAE 15W40

☼ Routine checkup for diesel filter, engine and alternator coupling

☼ Battery system weekly once

Gasifier ☼ Generation of charcoal in kgs

☼ Water spraying nozzles for gas cooling

☼ Water pump and blowers motors

☼ Coarse and Fine filter - cleaning of dry wood dust choke once in a week

☼ Fabric cloth in check filter – cleaning once in a week

☼ The life of the filter material is 5,000 hrs and could be reused after washing

and cleaning

WBREDA informed that the overall service rendered by vendors have been

satisfactory.

J. GOSABA Energy plantation There are large areas of foreshore land on the riverbanks of Sunderbunds in

West Bengal. This area in the whole of the Indian part of Sunderbunds is

estimated to be about 0.15 million hectares, out of which 50,000 hectares are

suitable for plantation.

Energy plantation in an area of about 71 hectares was made for supplying woody

biomass to the Gosaba power plant. About 71 hectares of plantation has been

made under the captive energy plantation scheme attached to 500 kW capacity,

Gosaba biomass based power plant. The growth of trees under the schemes

appears to be satisfactory.

Effects of Energy Plantation The biomass gasifiers consume woody biomass, which must be replaced to

maintain ecological balance. The Gosaba Biomass based power plant has been

ITCOT

100

planned in such a manner that the biomass produced by the captive energy

plantation will generate more than the quantity it consumes. So in the long run it

will have a positive impact on the environment and the same time result in

employment generation as mentioned below:

b. Mainly branches and twigs between ½” and 2” will be used in the gasifier

and in most cases the main tree will not be affected much.

c. New plantations are being made to replenish the biomass consumed by

the machine and this quantity produced is much higher than that

consumed.

d. The new plantations are made for running the power plant, otherwise

these plantations would not have come up.

e. A number of people get employment for planting trees and for

maintenance of plantations linked to the power plant.

So, it has positive effect on the environment as well as on employment

generation. The energy plantations will have the following positive effects:

a. It will help generation of employment opportunities in rural area.

b. Impact on rainfall pattern

c. Prevention of soil erosion

d. Preservation of flora and fauna

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6.3 Name of Installation: M Vishveswaraiah Institute of Technology, Bangalore, Karnataka

A. Project Background Objective

M Vishveswaraiah Institute of Technology (MVIT) has sought the assistance of

Netpro Renewable Energy Private Limited, Bangalore to install a Dual Fuel

gasifier-based power plant in their college premises and to supply power to the

college. The cost of gasifier system, operation and maintenance and the other

costs involved are under the scope of Netpro, and MVIT has allocated the land

for installing the gasifier. The power Purchase agreement between them is for 10

years @ Rs. 5 per kWh escalating with hike in diesel price. Current purchasing

price of power by MVIT from Gasifier system is Rs. 5.60 per kWh while the

current Electricity Board rate is Rs. 6 per kWh. The college has installed two 100

kW gasifier systems in phase I and II.

Year of Installation The month and year of installation of two phases are as follows.

Phase I: June 2002

Phase II: November 2002

Location MVIT is located in Hunusumaranahalli, via Yelanka an hour drive from Bangalore.

Plant lay out Size A copy of plant layout drawing is enclosed in Enclosure I. Type Woody biomass down draft gasifier with batch feeding.

B. Technical Specifications Gasifier (supplier – Netpro Renewable Energy Private Limited, Bangalore)

ii Capacity: 100 kW

iii Biomass fuel consumption: 135kg/h

iv Biomass fuel size: 50 mm~50mm

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v Moisture: < 15%

vi Loading of biomass: manual feeding and intermittent

vii Gasifier starting: Manual

viii Diesel replacement: average: 75 - 85%

ix Gas cooling and cleaning of tar removal, particulates: Water spray

cooler, cyclone separator, scrubber, sand (coarse and fine) filter, fabric

filter, 6°C output - water chiller

x Gas flaring provision before gas entry into engine

xi Height of reactor: 2.9m

xii Recommended biomass fuels: Casuarinas, eucalyptus, Julia flora and

any hardwood

xiii Gasifier material of construction: Stainless Steel for nozzle and throat

and SS 304 for Hopper, body and pipe line

xiv Life of Gasifier: 10 years

xv Turn down ratio: 1:3

xvi Starting time from cold start: 15 - 30 minutes

xvii Conversion Efficiency (Fuel to Producer Gas): 75%

xviii Conversion Efficiency (Engine): 30%

xix Auxiliary Consumption: 32 HP for pumps

Engine Phase I

• Make: Kirloskar

• Capacity: 2 x 50 kW

• Governor: Mechanical

Phase II • Make: Greaves

• Capacity: 1 x 100 kW

• Governor: Electronic

Alternator Phase I • Make: Kirloskar

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• Capacity: 2 x 62.5 kVA

• Speed: 1500 rpm

• Voltage: 415 V

• Frequency: 50 Hz

• Power Factor: 0.8



Phase II • Make: Stamford

• Capacity: 1 x 160 kVA

• Speed: 1500 rpm

• Voltage: 415 V

• Frequency: 50 Hz

• Power Factor: 0.8



Electrical panels The plant is designed to operate on stand-alone mode. Electrical control panel is

provided with 100 Amps MCCB for Phase I and with 250 Amps with Phase II. The

panel is provided with under voltage, over voltage, earth fault and over current

protection along with reverse power relay.

C. Financial Parameters Building and civil works The college has allotted land for installing gasifier. For Gasifier system with DG set 50% Equity by Netpro Renewable Energy Private Limited

50% Grant from Dutch Government

Total Project cost: Not disclosed

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D. Project Status The plant was commissioned by November 2002 (both Phase I and Phase II) and

was in operation since then, for 6 and half days a week and all weeks in a year.

E. Plant Performance Summary for the monitored Period

(3 years from June 2002 to December 2004)

• Gross Power Generation: 8,94,928 kWh

• Auxiliary Power Consumption: 1,00,496 kWh


• Total Diesel Consumption: 99,700 Litres

• No. of Operating Hours: 16,680 hours


• Average annual PLF: 21.07 %


• Average specific diesel consumption: 0.11 litres/kWh

The plant performance for the period monitored with energy generation, auxiliary

consumption, operating hours, Biomass consumption and Diesel Consumption, is

given in Table 26 below.

Table 26

MVIT - Plant Performance

Year Units Generated

KWh

Aux. Cons.

In kWh

Operation Hrs.

Biomass consumption kgs.

Diesel Consumption

in KL

2002 63,821 7,650 360 53,790 9,600

2003 393,874 43,580 8,160 410,000 44,100

2004 437,233 49,266 8,160 490,000 46,000

TOTAL 894,928 100,496 16,680 953,790 99,700

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FIGURE 23 - MVIT Gasifier Average Plant Load Factor and Overall Gasifier Conversion Efficiency

11.56

24.8626.79

31.94

32.53

31.41

0

5

10

15

20

25

30

35

2002 2003 2004Weeks

Per

cen

tage

%

Avg PLF Overall % Gasifier Conv Efficiency

FIGURE 24 - MVIT, Bangalore - 2 x 100 kW biomass gasifier plant Performance data - 2002 to 2004

0.15042 0.11196 0.10521

0.84

1.04

1.12

63821

393874

437233

0.00

0.20

0.40

0.60

0.80

1.00

1.20

2002 2003 2004

kg/k

Wh

an

d lit

re/k

Wh

0

50000

100000

150000

200000

250000

300000

350000

400000

450000

500000

kWh

litres/kWh kg/kWh Total Energy Generated in kWh

ITCOT

106

FIGURE 25 - Energy Generation and Consumption Details of MVIT

53970

9600

63821

7650

410000

44100

393874

43580

490000

46000

437233

49266

0

50000

100000

150000

200000

250000

300000

350000

400000

450000

500000

2002 2003 2004

Biomass Consumption in kgs Diesel Consumption in LitresEnergy Generated in kWh Auxiliary Consumption in kWh

Observations: • It could be seen from Figure 23 and 24 that when the Plant Load Factor

(PLF) increases on the dual fuel mode operation, the diesel consumption

gets reduced with more producer gas being taken in for energy generation.

• It could be seen from Figure 25 that Auxiliary consumption is almost the

same throughout the period of operation i.e. 11%

• When annual PLF increases from 11 to 26%, the diesel replacement also

increases from 66% to 78% for the observed period.

• When the biomass consumption increased by 19% in the last two years the

diesel consumption has increased by 5% during the same period. This has

resulted in the generation cost almost to be the same throughout the

observation period even when the cost per litre of diesel has soared from

Rs. 18 to Rs. 30 per litre.

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107

F. Cost of Production The cost breakup for gross power generation per unit is given in Figure 26 below:

FIGURE 26 - Unit Generation Break up Cost in % at MVIT

58%

20%

22%

Diesel Cost Biomass Cost Labour Cost

Observations: • Diesel Cost plays a vital role in unit cost of generation. In the PPA, MVIT and

Netpro have worked out a formula for escalation in purchase price based on

hike in Diesel price. The price of diesel at the time of installation was around

Rs. 18 per litre. Currently it is more than Rs. 30 per litre at site. Manpower

requirement is mainly for non-processed wood. The salary for operators

(Seven in Number) is around Rs. 2 to 3 lakhs a year and for a supervisor it is

around Rs. 0.72 to 0.84 lakhs a year.

• Repairs and maintenance cost is not considered as Netpro runs the plant. G. Performance: Design Vs Actual

The design and actual performance comparison is detailed in the Table 27

below:

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108

Table 27

Design Vs Actual Performance of MVIT

No Performance indicator Unit Design Actual

1 Average kW loading KW 200 185

2 Average Specific Biomass

consumption Kg/kWh 1.1 1.065

Observations: Actual kW loading and specific Biomass Consumption are closer to Design

parameters. All other actual parameters are also in line with design parameters.

H. Summary of notes on discussion with MVIT

About Gasifier • Gasifier installed in Phase II is an improved version of Phase I.

• Cyclone separator and chilled water spraying system have been introduced in

the new version.

• The new phase has cyclone separators before water spraying, to reduce tar

component in the gas. Chiller unit is provided to introduce water spraying at

6°C before fabric filter to further reduce tar and dust content levels.

About Fuel • 80 tons of wet Biomass is purchased every month and after drying 50 tons of

dry biomass is used in the Gasifier

• Size of biomass used is 25 x 40 x 40 or 20 x 50 x 40 mm

• Feeding on the open top is for every 5 minutes minimum and every 15

minutes maximum

• 3000 to 4000 litres of diesel is used per month replacing 20-25% of biomass

in the DG Set

• Average Replacement of Diesel – 81 % (Max: 85% and Min: 70%)

• Waste Heat from DG set is used to dry biomass before feeding into gasifier.

About Energy Generation • 50,000 to 52,000 kWh is generated from gasifier system and 45,000 kWh

(net) is exported to MVIT every month

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109

• Current Energy Selling Price to college is Rs. 5.60 per kWh

• Commercial tariff of KPTCL for the institution is Rs. 6.00 per kWh

Water Utilisation • Water consumption is through the sump of 50,000 litres capacity

• The sump is cleaned every month and raw water of 50,000 litres is filled in

the tank.

• 10 loads of water per month are purchased of 6000 litres per load.

• The makeup water of 1000 litres is used for every two days.

• Water treatment is done while adding the make up water.

• The chemicals used every 1000 litres make up water are

o Non Ferric Alum – 400 grams and

o Poly electrolyte – 20 grams

Load Pattern • Load sharing details are as follows:

o 86% of the college load is met by gasifiers

o 6% by the local DG Set of 30, 20, 10 kVA each

o 8% of the load is met from KPTCL Supply

I. Issues

Since the supplier is operating the gasifiers, no major issues were highlighted

during discussion.

J. General Issues on site operations It was observed that if the diesel price further hikes up, and if the generation

cost using gasifier in dual fuel mode moves above Rs. 6 per kWh, then the

college might opt for power supply from Karnataka Power Transmission

Company Limited (KPTCL) forcing the project to close.

k. Overall performance Netpro is presently successful in providing captive power to the college to the

greatest satisfaction.

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110

6.4 Name of Installation: Bagavathi Bio Power Limited, Mettupalayam

A. Project background M/s. Bagavathi Bio Power is a company, which was formed with the main aim of

generating power from Biomass through gasification and selling the same. A

company was formed and an agreement was made with M/s. United Bleachers

Limited for power purchase and M/s. Bagavathi Bio power will provide the plant

and machinery.

The contract is to supply 250kW/hr. First phase of 120kW/hr plant has been

commissioned and the plant has successfully completed six thousand eight

hundred hours of operation. The technology provider is IISC Bangalore and the

manufacturer is M/s. Energreen Power Ltd, Chennai. The gas engine used is

from Cummins. The engine is 855 GTA coupled with Stanford Alternator. The

maximum engine capacity is 130kW.After internal consumption of 23 kW for the

various plant auxiliaries; 100kW is ready for export to the textile-processing unit.

The plant operates continuously and generates around two thousand units per

day for export. The plant operates for around 26 days in a month. If the load is

constant then the plant operates in a trouble free manner

B. Plant performance summary: 26th July, 2003 to 15th March 2005 The data on the performance of the project from the commencement of the

project was collected and given as Enclosure and based on the analysis, the

highlights of the project performance are given below.

Table 28

Plant Performance of Bagavathi Bio

S. No Parameter Unit Value

1 Total no of days 532

2 Total Biomass

consumption

Tons 753.29

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111

Table 28 Contd..

S. No Parameter Unit Value

3 Total power

generation

Lakh kWh 6.36

4 Power exported Lakh kWh 4.55

5 Total gasifier

operated hours

Hours 6895

6 Total Engine

operated hours

Hours 6637

Based on the above performance, analysis on specific fuel consumption, plant

load factor etc were estimated and highlights of the performance are given

below.

Table 29

Plant Generation and Consumption Details

No Parameter Unit Value

1 Average specific biomass

consumption

Kg/kWh 1.2

2 Auxiliary Power consumption % 28

3 Availability of Gasifier on total

days

% 54

4 Availability of generator on

total days

% 52

5 PLF based on generator

availability

% 78

6 PLF based on total availability

days

% 46

The above table indicates the following

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112

• The average specific biomass consumption is 1.2 kg/kWh, which is higher

than the design value, which may be due to low plant load factor.

• The auxiliary power consumption is higher, which may be due to higher

installed capacity of the auxiliary equipments, which originally was planned

for higher capacity

• Though the plant load factor of the system was 78% based on the actual

available days of generator, the PLF on total days is only 46%, which may be

due to down time of the engine /gasifier system

The performance of the system indicating specific biomass consumption and PLF

is given below.

Figure 27 – Performance of Bagavathi Bio Energy

100 2.00 90 1.80 80 1.60

Plant load factor

70 1.40 S pecific energyconsumption60 1.20 50 1.00 40 0.80 30 0.60

PLF20 0.40 10 0.20

0.00 0 Operating period

Specific biomass consumption

Note: Each operating period is period run before gasifier un loading

C. Cost of production

The cost of production is as follows.

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113

- 1.2 kg of Biomass gives 1 unit of electricity. Assuming raw material cost at

Rs1200/tonne, Cost of processing at Rs 300 per ton- Rs.1500 is the net cost

of raw material.

- The plant requires three people per shift and one technical supervisor. The

engine is serviced at every 750hrs of operation.

Table 30

Cost of Production at Bagavathi Bio Energy Limited

S. No

Parameter Cost/unit-Rs/kWh

1 Raw material cost per unit 1.80

2 Labour and Salary 0.35

3 Maintenance and Repairs 0.35

Net cost before interest and depreciation 2.50

The above breakup of the cost of production is depicted in a graph shown below.

FIGURE 28 – Cost of Production at Bagavathi Bio Limited

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114

The cost of production indicates that the raw material contributes 68% of the

cost and the unit is planning for its own cultivation to optimize the raw material

cost to around Rs.800 /ton.

D. Issues relating to the performance • The plant will be operating continuously for a period of 25 days and the plant

load drops due to carbon deposit in the after cooler of engine. So stopping of

engine is required for cleaning and maintenance.

• As the power is being exported to UBL, the plant will not be operating during

Sundays and also during plant breakdown of UBL, which will be around 2-3

days in a month.

• It is observed that the load of the system is highly fluctuating based on

process requirement like intermittent operation of giggers and FD fans of

Boiler which lead to starving or excess load throw in the engine.

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115

CHAPTER 7 CONCLUSION

• Gasifier based Power Generating systems are technically feasible and

financially more viable, when run on 100% producer gas mode and not on

Dual Fuel Mode.

• The project would be more successful if the availability and cost of biomass

used in the system are kept at constant check. Energy Plantation would be

the most feasible and reliable option for adequate and cheaper biomass

availability.

• Constant Load operation and increased Plant Load Factor (PLF) would further

improve the financial viability of the Project.

• Grid interfacing using gasifiers is very difficult and may not be possible as the

synchronization of grid frequency and the system frequency is not possible.

This is because of uneven flow of gas from the gasifier into the engine.

• Technology available for gasifiers is satisfactory but not adequate. However,

further improvement in Gas Cooling, Cleaning, Ash removal, and Engine

Cooling Systems would increase the system availability and improve the

overall performance of the system.

• Vendors currently do not provide overall performance guarantee to the

system as a whole though some vendors are providing guarantee to some of

the components manufacturers are having tie up with engine manufacturers

who are yet to provide performance guarantee for their engines with 100 %

producer gas applications.

• Though IISC is the sole technology developer and provided solutions for the

operational problems of the gasifiers to a limited extend, most of the

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116

developments /improvements in the field were carried out by the users only

and there is no agency involved in monitoring the performance on a

continuous basis.

• The concept of Annual Maintenance contract is yet to be operational in the

market and after sales service or service back up by the vendors is very

limited as not many vendors are active in this field.

• Well-trained technical manpower is limited in the market, which may affect

the sustained performance of the system.

• Though most of the units are supportive of the capital subsidy scheme,

procedural delays from submission to actual disbursement of subsidy have

extended the time schedule of project implementation.

gasifier study-2-125.pdf

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