Application Power for electrical furnace in Ceramic industry
Engine 125 KVA Cummins
Year 2016
Fuel consumption, hourly in Diesel mode 16 Litres
Fuel Consumption, hourly in Dual fuel mode 11 SCM gas & 5 Litres of Diesel

Application: The DG set is used 8~10 hours daily, to support uninterrupted power requirement of Electric furnace to ensure product quality.

Cost Savings:

  • Cost of operation in 100% diesel: With diesel price at Rs. 60/- per litre and hourly consumption of 16 litres, estimated daily cost of fuel considering 8 hours of operation, was 16 x 8 x 60 = Rs. 7,680/-, approximately. The DG set generates 3.54 units of power per litre of diesel; that is, fuel cost of ~ Rs. 16.95 / Kwh (cost of diesel – Rs. 60 / Kwh generated per litre of diesel – 3.54).
  • Cost of operation in dual fuel: Average cost of fuel per hour = (volume of gas consumed x cost of gas) + (volume of diesel consumed x cost of diesel) = (11 x 34) + (5 x 60) = Rs. 674/-, considering 8 hours of operation, daily cost of fuel = 674 x 18 = Rs. 5,392/- approximately. Fuel cost / Kwh = (674/16)/3.54 = Rs. 11.90 /Kwh.
  • A fuel cost saving of Rs. 2,288 per day (7,680 – 5,392) ~ 30%.

Advantages:

  1. Fuel cost saving of 30%, estimated period of recovery of investment of Dual Fuelling system ~ 155 days.
  2. Reduced frequency of refilling diesel storage system, thus saving manpower & transportation.
  3. Usage of Green fuel – reduction in emissions.
Engine after conversion System Layout