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5.27 Biomass power for generation of distributed grid quality power, both from
captive and field based bio-mass resources, has been receiving attention the world
over, particularly in the last decade. The social, economic and environmental benefits
of biomass power are accepted for long term sustainability. The technologies are
progressively getting upgraded, attaining maturity, and reaching commercialisation.
5.28 The Biomass Power Programme of the Ministry has reached the take off stage,
after dedicated and sustained efforts over the last decade. The total potential is
about 19,500 MW, including 3,500 MW of exportable surplus power from bagasse-
based co-generation in sugar
mills, and 16,000 MW of grid
quality power from other
biomass resources. The total
installed capacity in the
country, as of December 31,
2002, is 468 MW, and
projects of capacity 530 MW
are in various stages of
implementation. Year-wise
installation of biomass
power/co-generation
capacity is given in Figure
5.2. A target of 700 MW has
been proposed for the 10th
Five Year Plan (2002-07),
including 450 MW from
bagasse/biomass co-
generation and 250 MW from biomass power.
Objectives
5.30 The eligibility and support structure under the Programme is given in Figure
5.3. The Programme includes the following Components:
5.32 The Ministry had undertaken taluka level biomass resource assessment studies
during the 9th Plan, with a view to assess surplus biomass availability for power
generation in 500 talukas in the country. The Programme was implemented through
a National Focal Point, Five Apex Institutions, and a number of consultants to carry
out field level surveys. 495 studies were taken up in 23 States; 299 studies have
been completed, and the remaining studies are likely to be completed during 2003.
District-level biomass resource assessment studies in six potential States will be
initiated during the year.
5.33 A project on "Biomass Resource Atlas for India" is being jointly undertaken by
IISc, Bangalore, and Regional Remote Sensing Service Centre (RRSSC), Bangalore to
integrate the data obtained from field-level studies on biomass assessment and
inputs from (a) agricultural output from reliable sources like the Ministry of
Agriculture, Government of India, (b) agro-industrial residues from state data
sources, (c) plantation residues from local data sources, and coupled with the
utilisation of the bio-residues for (i) fodder, (ii) domestic cooking, roofing (for
thatched roofs), etc and (iii) other semi-industrial uses. The actual location of the
bio-residue or at least biomass production area is sought to be made available on a
map to help in planning and development of biomass power projects in various
States. RRSSC provides GIS based maps for the identification of cropped areas
across the country. Additional work related to crop identification is being done using
the data on NDVI (Normalised Difference Vegetation Index). Some of these are at
the level of new knowledge and hence what is guaranteed from the maps would be
the cropped area with a probability index attached to the specific crop identified.
5.34 The R&D component of the Programme aims at the development of biomass
conversion technologies, technology application packages; strategic developmental
demonstration pilot projects; improvement in efficiency; reduction in cost; and,
eventual commercialisation and development of biomass power/cogeneration on an
industrial scale. An R&D project on "Strategic Development of Bio-energy" (SDB) is
being implemented, which entails development of technology packages for a variety
of biomass materials for power generation, as well as industrial applications. The
important development relates to producer gas based reciprocating engines.
Experimental work on an industrial natural gas engine of 360 kWe produced 195 kWe
with a gas calorific value of 4.5 MJ/kg. The specific fuel consumption of the engine
was 1.1kg/kWh. Peak output of 214 kWe, with a gas calorific value of 5 MJ/kg, is
likely to be achieved in the field systems with an enhanced design of the reactor,
slightly different from the one used in the laboratory. The modelling of the
reciprocating engine for predicting the pressure-crank angle diagram using fluid
dynamic inputs from three dimensional flow computational tools has been taken to a
logical conclusion in predicting the performance of the engine with varying
compression ratio or ignition timing.
5.40 Advanced Biomass Gasification (ABG) has been identified as a thrust area for
the 10th Plan. Development and application of advanced technologies such as,
Biomass Integrated Gasification-cum-Gas Turbine Combined Cycle (IGCC);
Integrated Pyrolisis Combined Cycle (IPCC); and MW scale reciprocating engines with
very high diesel replacement (exceeding 90%), are proposed to be supported. These
technologies offer a number of advantages, which include higher efficiency of
conversion, and ease of operation, enable cleaner combustion, and are environment
friendly. Limited numbers of demonstration projects are proposed to be supported
during the Plan period. It is also proposed to support captive biomass power projects
through combustion and gasification routes.
External Assistance
5.41 The Project Brief on UNDP / GEF / MNES Project on "Removal of Barriers to Bio-
mass Power Generation in India" was approved during the year. The objective of this
two part project is to remove barriers to the increased use of bio-mass energy
sources for generating electricity for own consumption and / or export to the grid,
and accelerate adoption of environmentally sustainable bio-mass power and
cogeneration technologies in India. It will promote combustion, gasification and
cogeneration technologies for electricity generation using different types of captive
and distributed bio-mass resources. The project will focus on bio-mass power
projects to be undertaken in three specific scenarios, viz. co-operative sugar mills,
agro-processors / bio-mass producers and distributed bio-mass. Apart from the
Technical Assistance component for removing the remaining technical, regulatory
and institutional barriers, the project will provide investment support to model
investment projects in the focused sectors in candidate States for risk mitigation.
The project is expected to become operational in April / May 2003.
An important milestone reached during the year was the commissioning of the 17
MW co-generation power project set up by M/s Kakatiya Cement Sugar & Industries
Ltd., at Peruvancha village, Kallur Mandal, Khammam District, Andhra Pradesh. The
project is the first of its kind for a sugar mill. A high pressure boiler of 87 ata./515
deg C has been installed, which ensures high energy efficiency & better utilisation of
bagasse resulting in more steam and hence more electricity.
The project envisages generation of power to meet captive sugar plant requirements,
cement plant requirements and export of about 10.85 MW of surplus power during
season and 14.70 MW during off-season, to the State grid. The project uses bagasse
generated from the crushing operations of the sugar mill during season, and stored
bagasse, cane trash & coal during off-season.
The project was completed in a record period of 18 months and has already supplied
about 84.90 million units to the State grid. It has achieved a PLF of around 90% in
the very first year. The cost of the co-generation project was Rs.50.17 crore. IREDA
has extended a term loan of Rs.36.60 Crore under ADB line of credit and MNES
provided an interest subsidy of Rs.4.09 Crore. The technology used was indigenous,
except for the turbo-generator, which was imported. The project has generated
direct employment opportunities to about 100 persons and has also contributed to
economic development of the area.
The 8 MW Biomass based Power Project with export of 7.20 MW of surplus power
after meeting 0.80 MW for in-house auxiliary consumption has been set up at
Patancheru in Medak District of Andhra Pradesh. The project utilises a variety of
agricultural wastes and industrial wastes for generation of power, such as sugar cane
trash, coffee shells, toor dal stalks, corn cobs, ground nut shells, poultry manure,
jowar husk, waste crops, juliflora, eucalyptus, cotton stalks, saw dust, wood husk,
rice husk and bagasse.
The project was commissioned in February 2002 and in a record period of 11 months
and has already supplied 38.43 million units to the State grid. A PLF of 90% has
been achieved in the first full year of commercial operation. The technology used is
totally indigenous with the Boiler supplied by M/s Walchandnagar Industries Limited.
The company has tied up with M/s AP Forest Development Corporation Limited for
developing fast growing clonal euclayptus plantations in about 500 acres of barren
land for fuel supply to the plant. The Plant has generated direct employment to over
110 persons, and has also contributed to the economic development of the region.
5.44 Biomass gasifiers convert solid biomass (woody and non-woody) materials such
as wood, agricultural residues and agro-industrial wastes etc. into producer gas
through thermo-chemical gasification process. The producer gas could be either
burnt directly for thermal applications, or used for replacing diesel oil in dual-fuel
engines for mechanical and electrical applications. Biomass gasifier systems from 3
kW up to 500 kW unit capacity which use wood, non-woody and powdery biomass,
have been developed indigenously. Conversion of dual-fuel engines to 100%
producer gas engines has also been achieved under R&D Projects. A total of 1806
biomass gasifier systems aggregating to 53.16 MW have been commissioned in 22
States and UTs of the country.
5.45 The programme has been restructured and modified to promote and encourage
development of viable application packages; deployment of gasifier systems for
different end-use applications and higher capacity utilisation; and to bring about
greater market orientation and commercialisation. Additional features that have been
included in the programme include demonstration of indigenous 100% producer gas
engines coupled with gasifiers for power generation, and retrofitting of existing diesel
based power plants in the North Eastern Region with biomass gasifiers for power
generation.
Objectives:
5.46 The objectives of the Programme in the 10th Plan, which commenced in 2002-
03, are given below:
5.48 The Gasifier Action Research Projects (GARPs), supported at Indian Institute of
Technology (IIT), Delhi; IIT, Mumbai; Indian Institute of Science (IISc), Bangalore;
Madurai Kamaraj University (MKU), Madurai; and, at Sardar Patel Renewable Energy
Research Institute (SPRERI), Vallabh Vidyanagar, were completed during the year.
5.50 GARP, IIT, Mumbai, laid emphasis on formulation and updating of the Test
Procedures, Standards and Methodology Protocols for biomass gasifiers up to 500 kW
unit size. Application specific two-stage and single-stage premixed producer gas
burners developed awaits commercialisation. A non-throat type downdraft rice husk
gasification unit with rotating grate type and an up-draft biomass flexible throat-less
designs have already been commercialised. 100% Spark Ignition Producer Gas
Engine has been developed. A State-of-art Report on Biomass Gasification (SAROBG)
with updated information on the technology and Indian achievements was prepared.
5.51 At MKU, Madurai, efforts were concentrated on developing and testing a 120
kW thermal gasifier for use in high temperature applications particularly ceramic
industries, with novel features of tapered hopper and air nozzles that promotes
efficient firing. A gasifier based continuous zigzag Ceramic Kiln (CZZ) has been
designed, and is being tested for commercial use. Fast-firing kilns have been
developed, along with rubber combustion gasification of old used tyres. Development
of cardamom drier to dry 50 kg. per run was developed, designed, fabricated and
tested as per the field conditions, with encouraging results. Development and
fabrication of 100 kW (equivalent) thermal gasifier using long sticks, avoiding cutting
expenses and fuel loss while cutting, has also been undertaken.
5.52 SPRERI, Vallabh Vidyanagar designed and tested a 125,000 kcal/hr thermal
open core gasifier using groundnut shells and their briquettes. Powdered groundnut
shells were successfully briquetted in a modified punch and die unit. Gasification
efficiency levels of 60-70% were achieved. A one million kcal/hr thermal gasifier
using groundnut shells was installed in a ceramic industry in Morbi to test and
demonstrate the feasibility of replacement of LDO/kerosene oil with producer gas for
firing the kilns with encouraging results. SPRERI's gasifier-based community
cookstove was demonstrated to 16 owners of roadside food stalls and
representatives of seven NGOs engaged in relief and rehabilitation work in
earthquake-affected Bhuj District of Gujarat. Nominees of the seven NGOs were
trained in the operation and maintenance of the cookstoves. Ten such community
cookstoves were supplied to the NGOs for cooking food in different relief camps.
5.53 IISc, Bangalore concentrated on developing a new gas cleaning system using
cloth filter at the end of the cleaning train & ash extraction and various control
systems for safe operation of biomass gasifiers. A 500 kWe biomass gasifier system
was developed and commissioned at M/s. Senapati Whitely, Ramanagaram.
Modifications of natural gas based engines to 100% producer gas engines in unit
sizes up to 250 kWe was achieved. These engines will now be taken up for
demonstration and field trials.
5.54 Innovative R&D projects covering applied, associated and other strategic
industry-wise sectoral studies on scientific, technical, engineering, management,
financing and evaluation aspects, were supported at various research institutions and
universities. Progress made in these projects is given below:
5.55 1.870 MW capacity was commissioned under ten projects in the States of
Chhattisgarh, Kerala, Tamil Nadu, Uttar Pradesh and West Bengal during 2002-03.
The State-wise details are given in Table-5.14.
5.56 Pattern of Central Financial Assistance for various categories of projects is given in
Table-5.15 (I-IV). Other promotional features include support for preparation of DPRs,
awareness creation, applied R&D, service centres, and other professional /technical
services.
5.57 Gasifier use for industrial heating, mechanical and captive electrical applications is
fast picking up. During the year, special emphasis was given for electrification of remote
un-electrified villages. Another special feature of the Programme during the current year
is retrofitting of biomass gasifier systems to existing diesel power stations in the North-
Eastern States. In order to encourage the use of indigenous 100% producer gas
technology in the country, demonstration of 100% producer gas engines has been taken
up.
IIT Mumbai designed and developed an industrial package for a Steel Re-rolling Mill in
Raipur, Chhattisgarh State, producing 50 T/day of re-rolled steel. The mill was
consuming 2800 litres of furnace oil on an average shift of 10 hrs per day. The target
was to replace 50% of furnace oil by producer gas. An updraft gasifier of 12,50,000
kcal/hr. capacity was designed using 500 kg per hr of wood or 700 Kg of rice husk as
the input biomass and along with specially designed and developed producer gas
burners of fully premixed type.
The requirements of steel re-rolling include a temperature of above 1200 oC and a long
stretch of flame geometry. The gasifier- retrofitted mill works on dual-fuel mode with
50% of the thermal energy supplied by producer gas. The retrofitted re-rolling furnace
has successfully logged over 1000 hours of proving trials. 50% furnace oil substitution
by producer gas implies annual conservation of 400 tonnes of furnace oil, saving 25%
in the energy cost of steel re-rolling. At present costs, the payback period for the
package works out to less than one year.