ESP, MDC AND BAG FILTERS.

 

ESP, MDC, and BAG FILTERS

1. The above-mentioned equipments are pollution control units associated with boiler operation.
2. The present prescribed norms by Pollution control boards the permissible SPM (suspended particulate matter) is limited to 50 ppm in the flue gases passing through stack or chimney.
3. In earlier days the MDC's and bag filters played major parts in arresting particulates from flue gas. but their efficiency was hardly about 85 to 90%.
4. In present condition the ESP'S are unavoidable considering the stringent norms prescribed by PCB. The efficiency of an ESP is 99%. there by meeting the norms prescribed by PCB
5. For small boilers operating on solid fuels such as coal, brickets, bagasse, paddy husk etc MDC is sufficient depending upon the location of the plant
these mechanical dust collectors operates on cycone whirling principles to remove heavier particulates and dischage considerably cleaner flue gas through chimney via I.D.FAN. periodical cleaning of MDC and Checking the condition of cycone cones are important in operation of MDC. A chocked nozzles in the cones circumference and  damaged cyclone cones  are major problem for improper functioning of MDC. A chocked nozzles creates enormous backfire in the furnace and damaged cones fails to arrest the particulates passing through the chimney.
6. The bag filters usually associated with coal fired boilers only. the restriction of flue gas temperature passing through these filters plays important role in the success of this unit. often we experience the damage of bags due to higher flue gas temperature and Mal functioning of solenoid valves because of compressed air which operates these valves. bagasse fired and husk fired boilers generally will not have bag filters due to fire particles in the flue gas which burns the bags. even improved glass filled filter bags which presently fitted in these filters are not pool proof.
7. This left with only ESP'S have to be established with high pressure higher capacity boilers used in many industries as a captive power plant which caters both steam and power requirements. the highest efficiency of atleast 99% is more reliable in boiler operation. however the operation and maintenance costs of ESP are sufficiently higher than MDC and bag filters. Ash conditioning unit is necessary with ESP to avoid spreading of fly ash to the surrounding areas of boiler house. A standby MDC is always recommended along with ESP. in case of break downs.
8. Electro static precipitator operates on d.c voltage current to separate the ash particulates from flue gas by ionizing it into positive and negative ions which are attracted by positive electrodes and negative plates provoded in the ESP. the collected ash are  removed by giving hammer blows or otherwise. ash handling unit is connected with it.

For further information one can always reach me by email or phone given below

K GOPALAN
9420663740/9108956202
kgopalan1956@gmail.com

Grate area, Furnace area and Furnace volume

 

grate area, Furnace area and Furnace volume in boiler operation and performance.

1. we know that the fuel is to be burned in the boiler furnace to generate steam for process and power generation.
2. As such where the fuel has to be burned is called grate and this grate area plays very important role in boiler operation and its performance.
3. The grate area should be sufficient enough to burn the required quantity of fuel continuously to liberate heat for steam generation. lesser the area then sufficient amount of fuel cannot be burned resulting in less steam generation. more the area the flue gas velocity gets reduced such that heat transfer will be erratic thereby influencing its performance.
4. stationary grate, traveling grate, pulsating grate, dumping grate, fluidised bed are types of grates normally used in boilers.
5.The Furnace area will be little more than grate area and the function is to transfer radiant or direct heat transfer to water wall tubes and is part of total heating surface of boiler comprising water wall tubes, inbeded tubes in FBC boilers.
6. Furnace volume is the complete volume of the Furnace consisting Furnace area, water wall refractory area, screen tube area, super heater zone, etc primarily almost all heat transfer areas included in upto total height of the Furnace. the larger the volume, burning of fuel more efficient, better heat transfer, more efficient burning of volatiles and reducing unburnt fuel. proper circulation of flue gases through all heating surface and better control of flue gas temperature.

Thus grate area, Furnace area and Furnace volume are plays more important roles in optimization of boiler operation and its performance. proper care must be taken to check these parameters proportional to boiler capacity before we place order for boiler.

It is very sad to say the commercial minds of manufacturers dominating their engineering brain in order to survive in the present competitive environment as such we are forced to face operational problems.

For more information one can always contact me by mail or phone given below

K GOPALAN
kgopalan1956@gmail.com
9420663740/9108956202.

APH AND ECONOMISER ROLE IN BOILER OPERATION.

 

Role of APH and Economiser in boiler operation and performance.

1. Both APH and Economiser are used as heat recovery units to recover heat from flue gases thereby reducing the temperature of flue gases thus reducing heat loss going into atmosphere.
2, APH air preheater is used to recover the heat from flue gas and transfer the same to cool atmospheric air before going into furnace.
3. heated primary and secondary air is always advantage for good combustion of fuel in the furnace. a reduction of 22 degree in flue gas reduces the fuel by 1%.
thereby increasing the boiler efficiency.
4.Apart from heat recovery unit this APH also act as pollution control unit to lesser extent. The present norms of 50 ppm of suspended particulate matter (SPM) Prescribed by POLLUTION CONTROL BOARDS plays an important role in selecting suitable design of APH.
5. Heat transfer in APH is mainly by convextion process. The design of passing air through the tubes and flue gases from out side is always desirable for better maintenance and easy cleaning.
6. Presently designers of APH are prefering carton stell tubes for cold end and carbon steel for hot end to minimize cold end corrosion of tunes. but my recommendation is to go with carton steel tubes only for both cold and hot sides as it gives longer life and replacement will be less.
7.Economiser is another important heat recovery unit in boiler design. It unimaginable to have boiler with out economiser. feed water is heated in the economiser before feeding it into the boiler drum. Feed water temperature nearer to the saturation temperature of steam is always recommended before feeding into boiler drum.As the flue gas temperature is higher after leaving bank tubes Economiser is placed first and APH after it. also heat transfer from gas to water always more efficient than transfer of heat from gas to air. therefore Economiser's efficiency is always more than that of APH. more over Economiser is considered as pressure part integral with boiler pressure parts and needs IBR Approval. whereas APH is non pressure part and IBR approval is not necessary. as as a rule every 6 degree rise in feed water temperature 1% fuel is saved. thus Economiser saves alot of fuel and increases boiler efficiency considerably.
7. Another important equipment in boiler system is deareter where the dissoved oxygen and other gases are removed from from feed water by heating the water minimum 105 degree and more depending upon boiler working pressure and temperature of super heated steam . this removal of oxygen and other gases is necessary to protect the tubes from pitting and erosion. but this areator is not a heat recovery unit.

For further information one can always reach me by email or phone given below

K GOPALAN.
Kgopalan1956@gmail.com
9420663740/9108956202.

Quality of fuels used in boilers

 

quality of fuels used in boilers.

In boiler operation and performance the quality of fuels play an important role.  

1. Normally we uses solid, liquid and gas  as fuels in operating the boilers.
2.The solid fuels are coal, wood, brickets, bagasse, paddy husk etc.
2. The liquid fuels are furnace oil, LDO, HSD, concentrated liquors from process plants,  etc
3. Gaseous fuels are CNG, BIOGAS, PRODUCER GAS etc.
4.Since Gaseous fuels are very clean we may not experience much of operational problems.
5. Liquid fuels barring furnace oil are also clean as such operational problems are less but furnace oil fired boilers face lot of problems .
6.Solid fuels boilers are one which normally encounter lot of problems. we will focus more on solid fired boilers particularly coal fired boilers.

The quality of coal play major part for operational problems in a boiler. There are many grades of coal available which can be classified from GRADE A to GRADE H.
grade A is good quality and grade H be the worst quality. normally grade A  and B are used in large scale power plants and the normal process industries will uses mostly grade C are lower. There are imported coal are used in boilers. The main problem in the Indian coal is high percentage of ash content. The medium scale process industries normally use high ash content coal because it is cheaper than imported coal in which ash content is significantly less. This high ash percentage will poses major problems in boiler operation. This ash get deposited in outer surface of boiler tubes in water tube boilers and inside in smoke tube boilers. this ash deposit over tubes reduces heat transfer and thereby boiler efficiency. though soot blowing  and air lancing operations removes most ashes from tube surfaces, still will not remove all. For this reason we will take periodical cleaning of boilers.The other solid fuels such as bagasse, husk are also create this problems but to lower extent. Though we know the problem of ash, we don't have any other options considering the economic in operating the industries. sulphur is another content in coal which creates corrosion problems in furnace grate, flue gas passages, ducting, and chimney. flue gas desulfuricatipn (FDG) is remedy for this problem but not viable for its high costs.
Calorific Value of fuel namely NCV net Calorific value of fuel plays on boiler performance and not GCV. since GCV gross Calorific value is includes hydrogen heating value which is not useful for heat transfer in boilers.
Boiler Manufacturers always shows efficiency based on GCV rather than NCV.
to show higher figures.
Preparation of coal for boiler such as screening, sizing, segregation improves boiler performance.
Don't get fooled by c.v.figure of coal coal suppliers. it is the figure of dried coal and the as supplied which we use in boilers normally.
further information one can always contact me by mail or phone given below.

K GOPALAN.
Kgopalan1956@gmail.com
9429663740/9208956202

Importance of combustion in boiler operations

 

Importance of combustion in boiler operation and performance.

combustion is the process of releasing the heat in the fuel with the help of oxygen available in the air to produce steam for process and power requirements of a process industry. there are many fuels available in the form of solid, liquid and gas. In any fuel the percentage of available carbon is counted for combustion in the boiler furnace.

carbon + oxygen = carbon di oxide

C+O2=CO2 ,molecular weight of carbon is12 and that of oxygen is 16
there fore, we have

12+2×16= 12+32= 44
12 ÷12 + 32÷12= 44÷12
1+8÷3 =11÷3
1+2.67=3.67

That is one kg of carbon requires 2.67 kg of oxygen for sticometric combustion of fuel. but in practical sticometric ratio of fuel to air will not provide complete combustion. therefore such amount of excess air is always necessary to achieve complete combustion of fuel.
1 kg of air consists 0.23 kg of oxygen. therefore for 2.67 kg of oxygen will require
2.67÷0.23 =11.61kg of air. for burning 1 kg of carbon we require 11.67 kg of air for combustion. other than carbon the fuel will consist of hydrogen, sulphur and other organic materials in some small quantities  as such air is required for burning those components as well. apart from this some quantity of excess air ranging from 10%to 50% be required additionally. so the F.D fan  must designed for this requirement of air for smooth and proper combustion of fuel in the furnace. the furnace grate area is  also must have sufficient to burn this much quantity of fuel. by having sufficient fan capacities and furnace area the combustion will be proper and the performance of boiler operation will be quite good.

for further information one can always be contacted by email or phone given below.

K GOPALAN.
kgopalan1956@gmail.com
9420663740/9108956202.

Importance of draught fans in boiler operation

 

Importance of draught in boiler operation and performance.

In the boiler operation we normally have three types of draught fans. they are 1. forced draught fan. 2. induced draught fan and 3. secondary air fan.

The functions of these fans are primarily to maintain sufficient Furnace draught in order to make the combustion of the fuel in grate such that the release of heat is maximum for steam generation.

more often we experience problems in combustion of fuel such as black smoke emissions through chimney, unburnt fuel in the ash, fouling of tubes ( water tubes and superheater tubes) etc, because of improper functioning of draught fans . we now look into this fans functioning.

1. F.D. Fan(forced draught fan). The function of this fan is to supply sufficient amount of  primary air (oxygen) to burn the fuel in furnace, also should be able to supply certain amont of excess air for complete combustion. The design of F.D fan is such that sufficient amount of air to be supplied with sufficient pressure ( draught). if proper care was not taken in volume and pressure requirements then it would create more problems. Most of the time boiler manufacturers provide fans with best design options thereby it will perform well when experiences worst conditions. more over boiler may use multi fuels sometimes for which this fans may not sufficient to supply required air. Therefore carefull consideration will be given in selection when we place order for boiler. most of the times the end user are forced to change the fan to higher capacity  after experience more difficulties while operating. Therefore one must consider the F.D fan size for worst fuel and operating conditions likely used so that it can takes care of best fuel and operating conditions. as a thump rule a 10% more in pressure and 25% more in capacity is ideal for the selection.

2. I.D.Fan.(induced draught fan). The primary function of this fan to suck the hot combustion gases from boiler furnace through no of heat exchangers such as furnace tubes, super heater tubes, boiler bank tubes, economiser tubes, air preheater tubes, M.D.C, ESP etc keeping sufficient draught in respective zones. modern boiler employes balanced draught design thereby keeping negative draught of -2mm to -5mmwc. Any under capacity fan will result back firing, fouling of tubes more unburnts black smoke emissions which drastically effect boiler operation and performance. therefore care must be taken before order of boiler as explained in F.D.fan case. most common problems are fan become unbalanced, more vibrations, bearing failures, erosion of fan blades, and ducts etc.

3. S.A.fans (secondary air fan).  In normal conditions the problems within S.A fans are neglible. it function is to burn volatiles and carbon left after primary combustion.

for more information one easily approach me by mail or phone given below.

K GOPALAN.
Kgopalan1956@gmail.com
9420663740/9208956202.

Boiler feed water quality

 

BOILER OPERATION AND PERFORMANCE

Boilers in any process plants is considered as a heart to its continuous operations, any unwanted stoppage or breakdowns leads to heavy loss to the plants. Therefore good performance of boiler is necessary to any process plants. We now discuss what are various parameters which can affect its performance and efficiency.

1. FEED Water Quality
2. F.D, I.D, and S.A. Fans.
3. Combustion
4. Quality of fuels used.
5. Grate area, Furnace area and Furnace volume.
6. Heat recovery units such as APH and Economiser.
7. pollution control units such as MDS and ESP.

In this post we will discuss the feed water quality

for maximum failure cases in boiler operation and its performance is because of poor quality of feed water. high pressure boilers and turbine house are integrated parts of distilleriey plants. poor quality water leads to scaling of tubes, drum inner side, drum internals and feed pipes. The scaling of boiler pressure parts affects its operational efficiency to large extent. it affects heat transfer from fuel to water, lower quantity and quality of steam generation which leads to more consumption of fuel and thereby lesser efficiency. The first and foremost point to consider is therefore the feed water quality.
Hence to have good quality of feed water one must have good water treatment plant
A simple soft water plant is sufficient for a small low pressure boilers used in chemical process plants with out steam turbine. however for a distilleriey plants which requires high pressure boilers with steam turbine one has to consider a D.M.plant  in series with softener plant.
the idea to have a softener plant before D.M plant is to have longer life of D.M Plant
and to some extent lesser times of regeneration cycles of D.M plant. Apart from having water treatment plant  one must have deareter to increase the water temperature 105 degrees and above to remove dissolved oxygen and other unwanted gases from feed water to keep heating surfaces clean and reduce erosion.
we hereby conclude water quality topic
for boiler operations.
For draught fans topic we will consider in the next post.
For any further information one can always contact me by mail or phone given below.

K GOPALAN
kgopalan1956@gmail.com
9420663740/9108956202.

Professional consultancy to industries

 

Other professional consultancy provided

1. Running or recently commissioned distilleriey plants facing any engineering problems.
2. Any operational and maintenance problems of boilers and its auxiliary plants and machineries.
3. Improvements in performance of boilers and distilleriey plant machineries and equipments.
4. Identification of bottle necks in such as undersized machineries while initial project planning and commissioned. 
5. Any process plants facing recurring problems can be identified and proper suggestions are provided for over come such problems at once.
6. Any process plants and distilleries facing operational and maintenance problems can approach us for solutions.

For further information one can always contact us by mail or phone given below.

K GOPALAN.
9420663740/9108956202.
kgopalan1956@gmail.com.

Approximate project cost (section wise)

 

approximate cost (section wise)
considering 100 klpd ethanol/ena plants.

1. Grain silos & millsection =6cr (4.3%)
2. Liquefaction & Fermentation =15cr (10.71%)
3 .Distillation &Evoppration=28cr(20%)
4.DDGS Drier(1no)=8cr(5.71%)
5. WTP &ETP=5.5cr(3.93%)
6. Fire fighting systems =5cr(3.57%)
7. Boiler with ESP & Fuel handling plant =10cr(7.15%)
8. steam turbine =5cr(3.57%)
9. Decanters 3nos=2cr(1.43%)
10. Receivers & Storage tanks =6cr(4.3%)
11. Electrical motors & Pumps =5cr(3.57%)
12. pipelines & fittings =3cr(2.15%)
13. Structural materials =12cr(8.57%)
14. civil works =15cr(10.71%)
15. Fabrication, Erection & Commissioning =5cr(3.21%)
16. Electrical motors, panels, pumps =5cr(3.57%)
17. Admin office, store section & Toilet block =4cr(2.85%)
18. Structural painting & wall painting =3cr(2.15%)

It should be noted that 18% GST & Transportation costs are extra as applicable at the time of delivery.

For further information one can always contact me by mail or phone given below.

K GOPALAN
9420663740/9108956202.
kgopalan1956@gmail.com.

Tentative project cost

 

Tentative project cost.

Again we consider for 100 klpd plant.
The following are assumptions.

1. We consider only ss 304 m.o.c only for process plant equipments and storage tanks. (shell side)
2. All the tubes for heat exchangers and process columns are of ss316 m.o.c only.
3. All the process piping and  fittings are ss316, sch40 only.
4. All the water piping are m.s. C class heavy duty only.
5. All the steam and condensate piping are  c.s. A 106 grade only.
6. All the process pumps are fully CF8M construction only. and for water it is C.S.
7. All the electrical motors are squrel cage with F class insulation NFP/FP and 2 pole/4pole/6pole as per requirement.
8. All process and control valves are CF8M,
and class 150 only. All flanges are also of class 150 only.
9. All structural materials such as angles/Channels/Beams etc are medium duty class only.
10. All civil works are included.
11. All erection and commissioning jobs are considered.
12. The selection of thickness for  plates and tubes are as our customers requirement only.
13. The total project time from concept to commissioning will require a minimum of 18 months to 24 months.
19. The cost of getting DPR , EC, CFE, CFO, and other government licenses from various departments are not included in this proposal.
20. Similarly the Working capital also not considered in this proposal.
21. With above considerations the one can always rest assured the trouble free operation for minimum of 10 years barring normal wear and tear.

FINANCIAL COST FOR THE PROJECT IS COMES AROUND 1.3cr to 1.4cr per klpd of plant capacity.

For further information one can always contact me by mail or phone given below

K GOPALAN.
9420663740/9108956202.
kgopalan1956@gmail.com.

Raw materials and by products

 

raw materials and by products of grain based ethanol plant.
we again consider 100 klpd plant.

1. Grain based ethanol can be produced from various raw materials such as broken rice, maize, jawar, wheat, bazra etc.
2. Presently we consider only broken rice and maize only.
3. We can use broken rice and maize individually or combination of both.
4. When using broken rice only, it must consist of minimum 66% of starch. The yield will be around 470 ltrs of ethanol per ton of broken rice. When using maize only, it must consist of minimum 60% starch. the yield will be around 380 ltrs of ethanol for every ton of Maine.

5. We can use both maize and broken rice with various percentage of combinations. example 70%rice & 30%maize etc. The yield will be depending upon expertise how we operate the process plant.
6. The by products are mainly the DDGS/DDWS. That is either dry or wet sludge which can be marketed as cattle feed. The other by product is carbon di oxide CO2. Which can marketed as co2 liquid gas for industries.

For further information one can always contact me in the following email address and phone numbers

K GOPALAN
9420663740/9108956202
kgopalan1956@gmail.com

Utilities requirements.

 Utilities requirements. 

consider 100 klpd ethanol/ena plants. 

Water, Steam, Cooling towers, Copressed air, WTP/ETP are common utilities required for any process plants for its operation. Let us discuss each of these. 

1. Water is required for boiler operation, Cooling tower make up, process operation such as slurry preparation, product washing to get required quality and purity. As per E.C. norm the water consumption should be around 4.5 ltrs per ltr of spirit produced. however the ground reality is it may required 7 ltrs/ ltr of spirit produced. this is fresh water requirement. we should be having an ETP to recover around 65 of water consumed. So for a 100 klpd plant we require 7 lakh liters of fresh water. there fore it is utmost importance to know the source of raw water requirements before stepping into project planning. 

2. Steam required for captive power plant and process plants such as liquefaction, distillation, evaporation and driers. The average consumption of the steam is around 4 to 5 kg/ltr of spirit produced depending upon the product  I.e ENA/ETHANOL/or both. The steam requirement for electrical power generation (captive power plant) is around 11 to 12 % of total steam generation, remaining 88 % is used for process. Depending upon the capacity of the plant the steam turbine may be back pressure type or extraction cum condensate type turbine. without the captive power plant the distilleriey project is not viable considering high cost of electricity from state electricity boards. 35tph boiler @ 45 bar pressure and 450 degree super heat temperature and 3.5MW turbine is sufficient for a 100 klpd plant. 

3. Cooling tower is one more essential part of utilities which cools the warm water from heat exchangers before circulating back to heat exchangers. The cooling towers may be counter flow type or cross flow type with induced fan arrangements. it consumes 1 to 1.5% of total flow of water as make up to compensate evaporation, drift and blow down losses. For a 100 klpd plant a total of 5500 TR with  8 degrees delta T is required for a typical 100 klpd plant. 

4. compressor air is primarily used to operate different types of control valves and actuators installed. 100 to 120 CFM @7 bar pressure with suitable driers is sufficient for 100 klpd plant. It should be noted that a standby unit is absolutely necessary. 

5. WTP AND ETP. 

WTP the water treatment plant is necessary to treat the raw water to reduce its hardness and tds before proceeding to use in the process and boiler. this treatment is necessary to avoid unnecessary scaling and fouling of healing surfaces which may reduce the effectiveness of respective heat exchangers. softener, reverse osmosis and demineralising plants are normally used as WTP. 700 to 800 cu m. perday capacity is required keeping in mind for back washing and regeneration. 

ETP Effluents generated from process plant and process condensate are required to treat in ETP to recover 65%water for reuse.

Land requirement

 

Land requirement for ethanol plant.

For the time being let us consider a 100 klpd plant.

Having discussed in the earlier post about the details of statuary requirements for land selected for distilleriey plant we now know the area of land required to set up a 100 klpd plant.

1. The total build up area requirements is around 20 to 25 acres.
2. Out of which 33% should be left as green belt, a mandatory requirement to get the environmental clearance. That comes around  7 to 8 acres.
3. Internal roads require around 10%of total build up area. That is around 2 to 2.5 acres.
4. Parking area for vehicles consumes around 10%of total build up area.This again consumes around 2 to 2.5 acres.
5.The remaining 47% will be utilized for plant building. This includes plant and machineries for process plant, boiler and turbine house, ware house for final product storage, loading station, administrative office, raw materials godown, engg stores and mechanical workshop, toilet block, WTP and ETP,  electrical substation, coal yard etc which comes around 9.5 to 11.5.acres.

this is a minimum requirement in order to  set up a 100 klpd distilleriey project. anything more can be always had advantages particularly when we look for capacity expansion.

For further information any time one can contact me in the contact numbers and/or mail address given below.

K GOPALAN.
9420663740/9108956202.
kgopalan1956@gmail.com

Project site should not have

 

The proposed site for ethanol project should not have

1. Any defence installations within 10km radius.
2. Any archeological important place within 10km radius.
3. Any critically/severely polluted area within 10km radius.
4. Any Ecological sensitive zone within 10km radius.
5. Any reserved forest/protected forest/National parks/ wildlife sanctuary etc within 10km radius.
6.Any airports within 10km radius

The above points are taken into consideration before finalizing any project site proposal for ethanol projects.

for any further information one can always can contact me.

K GOPALAN
9420663740/9108956202

kgopalan1956@gmail.com.

Govt help in setting up ethanol projects.

 

Government's help in setting up ethanol projects.

1. Ethanol industry is expected to grow upto 500% by the end of 2025-26.
2. Financial assistance schemes by ministry of consumer affairs through DFPD. That is department of food and public distribution.
3. Interest subvention schemes upto 50% or maximum of 6% of interest applicable by financial institutions which ever is high.
4. Long term agreement to buy the ethanol produced by OMCS. That is oil manufacturing companies. there by eliminating the marketing problems.
5. Reducing the GST on ethanol from 14% to 5%.
6. Government also provides the following
a. tax breaks.
b. grants
c. easy loans and speedy approvals.
d. provides loan guarantees to deserved entrepreneurs.

Further India being an agricultural based country has sufficient land resources to produce likes of sugar cane, rice, maize, and other cereals from which one can easily produce ethanol.

Ethanol supply increased from mere 38 cr.liters in the year 2013-14 to 1380 cr.litrers in the financial year 2023-24.
Further the demand for ethanol will continue to only increase in the coming year as well. As India is committed to self resilient in all the front particularly in energy needs any to reduce the cost of importing crude oils. In this noble ambitions of our nation we will be doing our best to come up with atmanirbhar to promote our own formers income and their respect. 

Further information any body can always approach me on the following.

kgopalan1956@gmail.com.
9420663740/9108956202.

Out line of EBP Program

 

The outline of EBP Program

a) Reducing the lmport of crude oils from oil rich countries thereby reducing the revenue spent on import cost.
b) self dependence on our country natural resourse that is agriculture and there by improving the our formers income and their own confidence.
c)By setting up new ethanol plant there will be employment opportunities thereby reducing unemployment and bringing cheers in the youths.
d)Mixing ethanol upto 20 % by end of 2026
originally it was planned by 2030. ambitions to encourage new projects to meet the targets at the earliest and giving motivation to work towards the goal.
e)With this EBP Program, ethanol being a cleaner fuel and less pollutive, can reduce the CO2 Emissions and thereby protecting the environment from pollution.
f) With this program one can always show that we are self resilient and more successful in achieving energy security as ethanol is less costlier than other conventional products such as petrol, diesel, AFT etc.
g) Formers satisfaction as they move forward from annadata to urjadata.

For more information one can always reach me by mail or phone.

K GOPALAN
kgopalan1956@gmail.com
9420663740 / 9108956203

Why ethanol project now?

 

Why to go for ethanol projects now?

India is one of the major consumers of petroleum products such as petrol, diesel, AFT, etc which are produced from crude oils. since crude oil availability and production in India is very less say around 13% of total requirements. as such we are forced to import crude oil from gulf and other oil rich countries.

Thus we are spending a lot of revenue for oil imports. again not only spending a lot of money but also depending on other countries.

To overcome these problems government of India brought up self resilient program
called ethanol blended with petrol (EBP).
in this program though initiated way back in 2002-03, but really focused from 2015 onwards only. The Blending of Ethanol was hardly 1.5% in 2013-14 to it increased up to 12% in 3023-23. The target is to blend up 20 % by the end of 2026.

To achieve the set target the union government  encouraging to set up the ethanol production plants by giving incentives for loan interest and speedy approvals for necessary permissions.

The outline of this EBP Program and and its benefits and how government helping in this project will be shared in next post.

however for anything about this project one can easily approach me.

K GOPALAN
kgopalan1956 @gmail.com
9420663740/9108956202

Basic requirements to establish a new ethanol plant.

 

Basic requirements to establish a new ethanol plant.

1. Make sure that sufficient N.A.Land is available to establish a plant.
2. It should be noted that 33% of the available land is to set aside as green field.
3. E.I.A. that is environmental impact assessment authorization is required from E C. to show that the proposed project meets the environmental  .
4.Land documents with  clear title is must before proceeding with any kind of project proposal. 
Once the above points are taken care, we will be proceeding to next steps for obtaining necessary certification and licenses as described below.
a) State Excise license for ethanol production. proceeding
b) Certificate of Incorporation and Business commencement from Registrar of companies of respective state to establish legality and operational status of business.
c)NOC From fire and safety department.
d)Memorandum and Articles of association which is legal document outlines the structure and purpose of the company.
e) Certificate from CPCB and SPCB for granting necessary permission.
f) IEM that is Industrial Entrepreneur Memorandum license from sugar, cogen and ethanol to demonstrate compliance with industrial regulations.
g) Water lifting permission from respective waterboards for water requirements to production process .
h) NOC's from local body authorities such as district and village bodies.
i)State Electricity Board permission for power supply during establishment and further requirements.
j) License from petroleum explosive safety organization (PESO) for storage of Ethanol in bulk storage tanks.
k) A well designed plant layout for proposed site.
for further information one can always contact me by mail or phone given below
kgopalan1956@gmail.com
9420663740/ 9108956202.

Why choose customized design for ethanol plants?

Difference between standard design in ethanol/ena plants supplied by plant suppliers and by customers design/requirements as per their operational experience while operating in such type of Organizations.

1. The selection of m.o.c 's and their specifications regarding their make, material composition and thickness etc really matters the life of the plant and its continuous operation with out any unnecessary breakdowns.
2. The selection of equipments with respect to their capacities with respect to diameter, height, etc and their auxiliaries such as heat exchangers, condensors, pumps and motors as a units also make lots of difference.
3. The selection of utilities such as cooling towers, steam requirements, electrical power requirements, water requirements and their treatment systems, effluent generation and its treatment systems along with water recycling systems are greater role to play with respect towards success and selection of plant capacities.
4. Selection of process and utility pipelines with respect to m.o.c, their sizes, their schedule selection also play major lmpact for successful and continuous operations of the plant.
5. In practice where project proponents are more dependent on turnkey projects by suppliers shall be facing more operational issues than when they engage more technically competent personnel from the beginning of the project until its commissioning.
6. While it is more important taking a view in cost of the project but it is equally important to look into the post commissioning benefits it offers by its continuous operational time and less unforeseen outages. The quality and quantity of the products thus produced will definitely offsets the little premium injected in the initial project costs.

For further information, one can always reach me by phone number and email address given.
Email: kgopalan1956@gmail.com, Phone: 9420663740/9108956202.

Customized ethanol plant commissioning

While in my previous organisation, we had successfully commissioned two new projects 100 klpd ENA/ethanol plant and 65 klpd RS to ethanol plant. Both the plants are in continuous operation to produce fuel ethanol as a small contribution to GOI's prestigious EBP Blending program.

Most probably this may be first projects to be established as customized projects as per client's requirements and specifications. In this project, we have established 55 tph, 65 bar, 510 super heat boiler with full fledged ESP and standby MDC. A 7 MW extraction cum condensate steam turbine also established as captive power plant catering the full power requirements for the distilleriey.

The  beauty of this project is that other than distillation, evaporation and driers rest of other plant equipments and machineries such as mill section, grain silo systems with material handling systems, liquefaction,  fermentation, WTP/ETP/DM Plants, captive power plant with fuel handling systems, cooling towers for process and power plant, receiver and  bulk storage tanks, full fledged fire fighting systems etc are designed, fabricated and established at site under my guidance.

For any project proponents with such requirements can approach me at kgopalan1956@gmail.com and 9108956202/9420663740