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DG Set Combined Heat & Power (CHP) Generation – A successful case study of a Cold Storage

This case study highlights the successful implementation of Combined Heat & Power (CHP) generation in a cold storage facility, resulting in significant energy and cost savings.

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DG Set Combined Heat & Power (CHP) Generation – A successful case study of a Cold Storage

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  1. DG Set Combined Heat & Power (CHP) Generation – A successful case study of a Cold Storage G.Subramanyam Sr.Dy.Director (Energy Management) National Productivity Council 10th Floor, Gagan Vihar M.J.Road, Hyderabad – 500001

  2. Unit Details • The Unit started its operations way back in 1987. • One of the first and commercial De-Humidification Cold Storage unit in the state of AP. • Exclusively designed for high value hybrid seeds, tamarind , chillies etc. • The company has state-of-art pre-cooling facility for export of quick perishables like fruits, vegetables and eggs

  3. Cold Storage

  4. Inside Cold Storage

  5. DG set Details DG set Rating - 320 KVA Avg. Power Requirement - 185 KW Avg. Diesel Consumption - 55-60 lit/hr Spec. oil Cons. - 3.3 kw/lit

  6. Boiler Details

  7. Dehumidification System Make - Bry Air Desiccant - Silicagel Type - Rotary type Hot air Temp. required - 120 0C Air Flow - 1500 CFM Steam Required- 167kg/hr Heat Duty - 3.24,000 Btu/hr (81,818 kcal/hr)

  8. Initial Energy Bill Diesel cons. in DG set - 55 lit/hr Diesel cons. in Boiler - 22 lit/hr Daily Energy Bill - Rs. 31,416/day Annual Energy Bill - Rs. 115 Lakhs

  9. Gassifier Details

  10. Gassifier DG set Module Original Diesel Consumption = 55 litre/hour 0.3 litre/kWh Diesel Consumption = 22 litre/hr (0.12 liter/kWh) Rice Husk : HSD = 60 % : 40 %

  11. Energy Bill after Gassifier Diesel cons. in DG set - 22 lit/hr Diesel cons. in Boiler - 22 lit/hr Rice Husk Cons. - 200 kg/hr Daily Energy Bill - Rs. 21,552/day Annual Energy Bill - Rs. 79 Lakhs Annual Energy Savings - Rs. 36 Lakhs (115 – 79) Investment - Rs. 15 Lakhs Simple Payback Period - 5 months

  12. Heat Balance

  13. Modification

  14. Heat Recovery system – some more clips

  15. Hot Air Temp. Monitoring

  16. Benefit of Heat Recovery system HSD savings - 264 lit/hr Cost Savings - Rs. 33 Lakhs/yr Investment - Rs. 6 Lakhs (Towards Heat exchanger, piping, insulation, fan) Simple Payback Period < 3 months Overall Savings - 69 Lakhs % Savings - 60%

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