Briquette fired Boiler

An initiative towards Minimizing

Carbon foot print at Coca-Cola

Our CSR Vision is ingrained in the Companys Manifesto

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 Planet: Three Global Destinations
Water Stewardship

- Water efficiency improvement at

operations
- Rainwater harvesting and
National & Community
Priorities
watersheds management.
- Increase access to clean drinking
water
Unique
Assets Business
& Relevance 2. Sustainable Packaging
Capabilities
- Lead PET recycling programs
- Implement new packaging practices

3. Initiatives related to energy and

environment
- Energy Conservation
- Greenhouse gas reduction.
- CFC free refrigerators at Market place

Agro-waste Briquettes
An alternative to fuel oil in steam generation

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 Outline

Energy Scenario world

Energy usage Coca-Cola Bottling

Energy Scenario India

Alternate Energy Sources

Why Agro-waste briquettes ?

Briquette Social angle
Briquette Environmental angle
Briquette - Commercial Angle

Briquette based boiler Technical considerations

Energy Scenario- World

Neuclear Other
Hydroelectric Expected Life of Fossil Fuel
energy Renew able
6%
6% 1% 250
200
Oil 200

37% 150
Years

100 65
Coal 45
50
26%
0
Oil Gas Coal
Natural Gas
Fuel
24%
Source : Bureau of Energy Efficiency India

More than 90 % world energy comes from Finite, Non-Renewable energy sources.

Less than 8 % of energy comes from Clean , green Renewable sources for example
wind, Hydroelectric and Biomass.

Oil and Gas , relatively cleaner , most widely used energy source in the world
is predicted to become extinct in coming 70 years.

Renewable energy source are not tapped adequately

World is looking forward to Renewable energy source for future energy demand

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 Outline

Energy Scenario world

Energy usage Coca-Cola Bottling

Energy Scenario India

Alternate Energy Sources

Why Agro-waste briquettes ?

Briquette Social angle
Briquette Environmental angle
Briquette - Commercial Angle

Briquette based boiler Technical considerations

Energy Usage - HCCB

HCCB Energy consumption in Kcal (2006 -07)
Electrical
Steam energy from
generation grid
(from Furnace 28%
Oil)
57%

Own
Electricity
Generation
(from Diesel)
15%

More than 99 % of energy consumed by HCCB in manufacturing comes

From Non-renewable energy source.

57 % energy consumption in manufacturing of HCCB is for steam generation

Energy Consumption Pattern for HCCB is Not very different than the World

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 Outline

Energy Scenario world

Energy usage HCCB

Energy Scenario India

Alternate Energy Sources

Why Agro-waste briquettes ?

Briquette Social angle
Briquette Environmental angle
Briquette - Commercial Angle

Briquette based boiler Technical considerations

Energy Scenario - India

Oil demand - supply Status - India Furance Oil Wholesale Price Index (WPI)
6 Variation

400
MM barrel /day

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WPI Variation

300
2
200
92 %
0 57 % 85 % 100
1997 2010 2020
0
years
93 -94 00 -01 01-02 02 -03 03 -04 04 -05 05 -06
Net Import Domestic Production
Year

Source : Bureau of Energy Efficiency India Source : Ministry of Petroleum Website , India

India Imports about 75 % of its annual oil requirement.

World oil resources are depleting
HCCB uses furnace oil as fuel for steam generation.
Furnace Oil price have increased over 3.5 times in last 13 years.

Energy security is business necessity in Cost competitive Indian Market

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 Outline
Energy Scenario world

Energy usage HCCB

Energy Scenario India

Alternate Energy Sources

Why Agro-waste briquettes ?

Briquette Social angle
Briquette Environmental angle
Briquette - Commercial Angle

Briquette based boiler Technical considerations

Coal or Biomass ???

Indian Coal Wood

Easy Availability Low ash content

Low sulfur content

High in ash & sulfur content

Deforestation
Low in Calorific value (Adverse
environment
Air Pollution Impact) -Not in
line with TCCC
Difficult to maintain GMP policy
Availability An
Manual handling Not Issue
suitable for food industry

Agro-waste
Easy availability
Environment friendly - Low ash and sulfur content
Opportunity for positive contribution to rural economy

Agro-waste appears to be best alternative to fossil fuel for Indian Operation

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 SWOT Analysis Agro-waste
Weakness
Strength

Sustainable Raw material Low in density - Difficult to

availability handle In Transport & Operation

Environmentally friendly Fuel Availability issue during

monsoon months (4 months)
Minimal price fluctuation

Opportunities Threats

Triple bottom line improvement

Process Re-engineering for
fuel handling and steam
Cost economics
generation
Environment
CSR - Positive Contribution to
Solid waste management
rural economy

Briquetting of the agro-waste could be a solution to weakness and threat in project

Agro-waste Briquettes Manufacturing Process

Briquetting is process of converting loose, high volume, density mass into

compact, high density, low volume lumps by mechanical compression.

Briquettes
Bagasse /
Cotton Stalk / Drying , cutting
Corn Cobs / Grinding and
Ground Nut Shell / Pressing
Saw Dust

Raw Material Process Product

No oil or additive used as binder.

Only possible contamination in the process loose soil from agricultural

operation

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 Briquettes Environmental benefits
Carbon neutral - Green fuel
Carbon neutral Means there is no
net increase in carbon in environment
due to the activity / operation.
With use of biomass as fuel Carbon
released during combustion shall be
adsorbed by replacement plantation.
Reduces operation carbon footprint
for the TCCC

Demonstrate leadership in
environment management by
obtaining Certificate of Emission
Reduction (CER).

Possible to generate about 20000

CER for HCCB operation.

Carbon Cycle
When NET carbon is taken from atmosphere it is carbon positive
When we release NET CO2 is released in atmosphere - it is Carbon negative operation

Replacement of oil with Briquette helps in combating global worming

Briquettes Environmental benefits (cont.)

Reduced Sox emission -estimated

about 650 Tones/ annum) for HCCB
operation.

No increase in particulate emission over

oil.

Boiler Ash can be used in bricks making.

Hence, reduced soil erosion

HCCB can prevent 2000 Tones/ annum

soil excavation through ash recycling in
brick making operation.

Demonstrate leadership in environment

management by registering for carbon
credits.

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 Briquettes Social benefits
Estimated agro-waste generation in India per
annum is about 300 MM tones.

70 % of the Indian population lives country

side depends on agriculture for their lively
hood.

Production of 1 ton briquette generates 1 man-

day employment opportunity.

HCCB can help generating about 25000 man-

days / annum additional employment in rural
India.

Additional Income to farmers An Hectare of

land produces about 2.5 ton of agro-waste

HCCB operation can help farmers generate

about 11.2 MM INR additional income @ rate
of Rs. 500 per / Ton of waste by converting all
its steam generation operation to briquette

Briquettes Commercial benefit

Fuel cost Calorific Value Energy Cost

Fuel Rs / kg Kcal / kg Efficiency Rs/ Kcal
FO 19 10423 82 2223

Coal 4 4200 60 1587

Briquette 3.5 4200 66 1263

Briquette gives about 6 % higher thermal efficiency compared to Coal

Sulfur Content NIL against 4 % in FO.

Possible to reduce flue gas temperature from normal 220 C to 140 C resulting
4 % increase in thermal efficiency
Reduction in thermal loss in ash content about 2 % compared to coal due to less
ash content in the fuel

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 Outline

Energy Scenario world

Energy usage HCCB

Energy Scenario India

Alternate Energy Sources

Why Agro-waste briquettes ?

Briquette Social angle
Briquette Environmental angle
Briquette - Commercial Angle

Briquette based boiler Technical considerations

General Arrangement for Briquette firing

To Atmosphere

Ambien
Chimney t Air
I. D. Flue Furnace/
Fan Gas
Duct
Membrane Panel
Preheater Boiler

Pre-heated Air

F. D. Briquette feeding
Fan

It is Possible to covert Existing Oil Fired boiler to Briquette fired boiler

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 Conversion of Boiler operating at 30% - 70% of its capacity

The Conversion is possible by providing an external furnace

Steps
Remove oil burner unit & FD fan
Install external furnace & ducting
Install I. D. Fan with Air Pre-Heater/ Water Pre-
Heater for heat recovery from flue gas

Advantages

Boiler pressure parts are not touched So No permission for Boiler

Regulatory authority required.
No change in Boiler foot print
Conversion at Minimal Cost and minimum shut down ( max. 2 days)

Disadvantage
Re-rates boiler capacity by about 35 %

Conversion of Boiler operating at > 70% of its capacity

For Boilers with > 70% capacity utilization Conversion

requires addition of external surface in terms of water
tubes

Steps involved :
* Riser tubes to enhance heat transfer area.
* Removal of oil burner unit & FD fan
* Installation of external furnace & ducting
* I. D. Fan with Air Pre-Heater / Water Pre-
Heater
Advantages

Steam generation remains same.

Disadvantages
Boiler pressure parts are not touched So No permission for Boiler
Regulatory authority required.
Conversion at Minimal Cost and minimum shut down ( max. 2 days)
Stringent water quality is required to be maintained.

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 Briquette Characteristic and Quality Control

Typical Briquette Characteristics

Appearance :Gray white/Blackish
Nature :Cellulose, Eco-Friendly
Bulk Density :1100 Kg/m3
Carbon :40 42 % By weight
Hydrogen :3%
Sulfur :Nil
Moisture :Less than 5%
G.C.V. :3800 4000 Kcal/Kg
Ash :58%

It is essential for briquettes to have high calorific value and low ash content

It is function of raw material used in briquette and process control

Regular Quality monitoring is essential as briquette making is rural industry

and lakes strict quality control measures

Typical Payback for boiler conversion

Amount of furnace oil consumption as per ABP 2007 444,453

Cost of FO saved as per projected FO price of 18.15/- 8,066,822
Consumption of FO to Briquette ratio per tonne of Steam generation 3.0
Briquette consumption for the w hole year (in Kg) 1,333,359
Cost of Briquette at the current market price 3.20
Cost of operation & maintenance of Briquette fired boiler 0.35
Transportation cost of ash generated from the combustion 0.45
Total cost of operation per Kg of briquette fired in the boiler 4.00
Cost of Briquette fired boiler operation for the entire year 5,333,436
Am ount of m oney saved for the year 2007 2,733,386
Investment for furnace and other necessary attatchments 1,855,600
Civil w orks for storage of solid fuel 1,165,208
Miscelleneous 150,000
Expenditure for removing existing boiler from boiler house 65,000
Total Investm ent required for BRIQUETTE FIRED BOILER 3,235,808
Total Investm ent net of returnable taxes like VAT in furnace 3,060,808

Simple payback period 13.4

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 HCCB - Execution Status

Year 2007

Conversion for one 5 TPH boiler to deliver 3 TPH of

steam completed. (external furnace type)

Conversion of one 4 TPH Boiler to deliver 4 TPH is

process (external water wall type)

Plan 2008

Undertake conversion of boilers at 3 more plants

Initiate process for registering the project for CERs.

Pictures of Briquette Fired

Boiler
HCCBPL, PUNE

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 BRIQUETTE STORAGE

BRIQUETTE STORAGE SHED

Fire safety Fire extinguisher and Reel hose station

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 BRIQUETTE LOADING IN FURNACE

Automation is possible and recommended over 10 TPH boiler

REMOVAL OF ASH

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SPRAYING WATER FOR ASH COOLING

STORAGE AREA FOR ASH

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