Substitution of Petroleum Fuel with Green Fuel In Mechanised Laundry Unit, IndoreCurrent Status:

Boiler is running on High Speed Diesel having an hourly consumption of 39.5 litres (info as provided by CDO). The boiler is running for about 22 hrs per day , thus consuming more than 800 litres per day. With the increase in the bulk diesel price the cost of running the boiler per day is close to Rs 55000. Along with this the laundry unit also consumes 60 Kw of power per day costing Rs 6.25 per unit.Technical Specifications of Boiler

Steam Pressure: 10.54/15 kg per sqcm

Fuel Consumption (HSD kg/hr) 34.8

Electric Supply: 3 Phase/440 V/50 Hz

Total Load: 59 Kw

Operations: 20-22 hrs per day

Why Change?

Green House Effect

The current electricity consumption is about 40000 units per month, taking into consideration the transmission and distribution losses, each unit consumed at the users end requires 2 units to be generated at the thermal power plant. Thus in all, a total of 60 thousand generated units are used in a month.Each unit which is generated results in an emission of 1.02 Kg of CO2. Thus consuming 60 Kw per hour results in an emission of about 60 tonnes of CO2 per month. Thus changing to green power would not only reduce the emissions due to the electricity used by the railways but would reduce emissions by upto two times that amount due to the reduction in the transmission and distribution loss.Savings on Imported Fuel:The switch from petroleum based fuels to locally sourced Biomass would result in the creation of employment opportunities in rural areas. Thus dependency on imported fuels would decrease and wealth would flow in rural areas.Economy: The switch to biomass based power would also result in monetary savings as the change from diesel whose cost is increasing day by day to biomass based gasification technology would guarantee savings of 10% over HSD.

Corporate Social Responsibility: Apart from having environmental and monetary benefits, switching to biomass based technology also has social benefits. To maintain a guaranteed supply of Biomass fuel, we are setting up ABPC (Agri Biomass Processing Centre) in villages. These centres would be managed and run by our NGO arm Stree Shakti Sansthan. The processing centres would include charring kilns, threshers and chippers for processing of biomass which is available locally. Each ABPC requires an acre of wasteland in rural areas which would be given by the local government. The land is mostly needed for charring and drying of the biomass with just a small area required for briquetting machine and storage.

Training is provided to beneficiaries to operate the machines and also charring. Charring is a great source of additional income for rural women as it requires less work and helps them earn 150-200 Rs per day.

Each briquetting press is supported by at least 40-50 kilns to ensure regular supply of char and ensure a daily production capacity of 8-10 M.T. per day.

Requirements of ABPC Wasteland: one acre Shed: 1000 sq ft Briquetting press: one Muller Mixer: one Charring Kilns: 20-25 Threshers/ Chipper: according to Biomass Training and Awareness StaffWe would want Indian Railways to support such initiatives by setting up infrastructure in rural areas, through their CSR initiatives, as they not only support green power but also help create employment in rural areas.ABPC in Berasia, Bhopal

Technical Specificationsa) Biomass Gasifier SystemThe gasifier is a down draft system that thermally cracks biomass of specified size

and moisture content into a combustible low BTU gas. The system includes a thermal reactor, open top feed system, automatic moving auger for ash removal, coarse & fine gas filtration system, gas cooler and other associated blowers and piping. The thermal reactor is a bottom supported cylindrical metallic construction with suitable ceramic/insulation internal lining to withstand the thermal load as well contain the heat generated within the reactor system. The top of the reactor also acts as fuel storage and drying zone so as to reduce the intervals between fuel feeds. The ash removal system is a positive displacement system that consists of a rotating auger and is designed to discharge ash/charcoal of less than 1/2" size.

The gas cleaning system includes a hot cyclone followed by a coarse filter and a fine filter.

The gas cooling system has two coolers. The initial cooling by a indirect type wet scrubber

followed by a dry radiator cooler. The gas pumping system is designed to evacuate hot raw gas from the reactor and deliver cold and filtered producer gas to the gas engine at the required pressure.Connected Load Detail

SNoDescriptionQtyLoad in KwConsumption in Kw

1Gas Blower11.751.5

2Biomass Agitator1.75.5

3Ash Auger1.75.5

4Cooling Fan2.5.4

5Water Pump1.75.55

Total4.52.95

List of mandatory spares & consumables

01. High temperature grease (upto 250 Deg C grade)

02. Asbestos tape 50 mm wide x 6 mm thick

03. Gas Filter

b) Biomass Generators

S.NoParticularSpecs

1Rated Power 30 (24)

2Rated Current42

3Dimensions(cm)200 x 70 x 125

4Dry Weight1125

5Power at 1500 rpm (BHP)38

6 No of Cylinders4

7Bore x Stroke110 x 120

8Swept Volume(lts)4561

Legend

1. Gasifier2. Drain Tub3. Distance Piece4. Scrubber5. Drain Box

6. Coarse Filter7. Fine Filter I8. Fine Filter II

9. Safety Filter10. Control Valve

11. Blower12. Flare13. Shut off Valve14. Seperation Box15. Genset

SCOPE OF SUPPLY:

1. Thermal Gasifier Reactor with Fuel feed hopper

2. Ash removal system & Bottom water trough with water pumping system

3. Gas scrubbing and pumping system complete with piping and motors4. Fuel feeding System, Platform with ladders for fuel feeding

5. Gas Filter & Coolers

6. 100% producer gas Engine Generator set complete with accessories and control panel as per detailed offer

Financial Offer:The overall system cost for 60 KW biomass gasification based power system would be Rs 30,00,000 . The project can be either bought out or build operate and maintain the plant. The following components would be supplied and commissioned.SNoItemQty

1Biomass Gasifier System

Suitable for 60 Kw power and supporting boiler for steam

1

2Producer Gas Genset 30KVA1

3Producer Gas Genset

40 KVA1

4Packaging and Forwarding

5 Erection and commissioning

6Training

The fuel cost for running the plant would come up to be Rs 4 per unit . This would ensure a savings on overall electricity cost by atleast 5 % after taking into account the maintenance and manpower cost.Boiler Modification from HSD to Biomass The overall cost of conversion of boiler from HSD to biomass would come up to be Rs 1.34 cr. The fuel cost for running the plant would come up to be Rs 10,000 per day after commissioning. Thus ensuring a reduction in cost by 50% in 24 months. As daily expenditure on HSD is close to Rs 55000 per day.

Terms of Payment:

We would seek a work order with a mobilizing advance of 3 Months i.e. Rs 45 Lakhs(2 months and 1 months operating cost).