A numerical approach to optimising efficiency in industrial co-generation plants

The global shift toward reducing reliance on fossil fuels, widely used as supplementary fuel in the sugar industry, has intensified the need for improving the efficiency of co-generation plants. Enhanced efficiency reduces fuel consumption while maximising electricity production, crucial for industries such as sugar mills with power purchase agreements during the off-crop season, where coal serves as the primary fuel. This study explores the operational and efficiency optimisation of a sugar mill’s co-generation plant,, focusing on achieving contractual efficiency targets. A comprehensive numerical model of the plant was developed, encompassing boilers, turbines, condensers, and pre-boiler systems, and validated against operational data. Recommendations from a recent boiler inspection and operational audit were incorporated into the model, projecting a 15% increase in the plant's power-to-fuel ratio upon implementation. The model also evaluated cost-effective modifications to the plant, demonstrating its utility in decision-making. This work highlights the critical role of advanced simulation tools in understanding and improving the performance of complex energy systems, aiding industries in meeting operational goals and sustainability targets.