Team ARMEC recently came back from a co-gen plant of a private sugar plant in western Maharashtra region.
They have an existing co-gen plant with following specification:-
Capacity = 15 MW-17 MW
Steam flow = 52.8 ton/hr (Approx)
Turbine = Extraction cum Condensing
Condenser steam flow=23.3 ton/hr
Cooling water flow ~1600 m3/hr
Typical Problem: Even In Winter Months
- Condenser cannot be loaded with full steam flow.
- Cooling tower fills keep falling in basin & block the strainer/ pipeline.
- Typical cooling tower performance with practical observation in winter months.
- Condenser steam load = 18.7 ton/hr.
- Power generated = 14 MW.
- Condenser inlet (Cooling tower cold water) = 48°
- Condenser outlet (Hot water to cooling) =55°
- With reduced steam flow to condenser = 8 ton/hr, Power operation = 9.3 MW, Hot water=44°c, Cold water=39°
The Mill wants to go for augmentation
Cooling tower capacity, post expansion = 3000 m3/hr.
Additional condenser + existing condenser steam loading = 40 ton/hr
Max power generation design = 25.5 MW.
- Existing pipeline is combination of 650 mm to 450 mm.
- No Space for additional cooling tower.
- The new cooling tower location (within given constraints) is surrounded by obstacles/ buildings.
It was interesting to see very casual approach towards over all the aspects of fan cooling tower performance, operations & almost “FAT ACCOMPLI” kind of attitude with existing MONEY HUNGRY + POWER HUNGRY + MAINTENANCE HUNGRY FAN COOLING TOWER TECHNOLOGY.