Mete BAYSAL İLTEKNO A.Ş. / MAKİNA YÜKSEK MÜHENDİSİ A highly efficient application of diesel cogeneration power plant in Anatolia: BIRKO ENERGY Having founded in the mids of Anatolia Plateau in BorNigde, BIRKO produces wool yarn, wool yarn tor carpet production and weaves carpets brand named Koyunlu Hali. Over two thousand and five hundred shareholders, most of who are inhabitants of the small village called Koyunlu near to where BIRKO premises is founded, have succeeded, by means of their longlasting and constant efforts, creating a company which is one of the leading exporters of yarn and carpet in Turkey while the total sales of annual export is reaching to 20 million US $. To improve their competitiveness further and to protect themselves from the ongoing brown-outs and upcoming black-outs of the national grid, BIRKO has decided to install a heavy fuel burning diesel cogeneration power plant, to generate uninterrupted and quality electricity as well as enjoying the high total efficiency of the plant exploiting the heat, which is recovered from the exhaust stream and cooling circuits of the engines, inside their existing production facilities. There have installed two MAN B&W 12V 32/40 diesel gen-sets, each generating 5.590 kWe together with 4 tones of saturated steam and 150 tones of hot water circulation of 85/65 °c. The total efficiency of the power plant is ■ BIRKO is a genuine example tor the overall performances of diesel cogeneration projects. ■ slightly over 63% while the net electrical efficiency of the power plant is 40.4%. The steady-state demand of the BIRKO production facilities is 8 to 9 MWe, so the surplus capacity of the plant, which is around 2 to 3 MWe, is fed to the grid. BIRKO will increase the capacity of yarn production within 2001 and so they will invest extension of the existing yarn milis. This will bring additional demand of electricity and therefore they are also planning to expand the capacity of the plant by installing the third engine of same size. The plant is operational tor over halt a year and BIRKO has already harvested the benefits of the cogeneration plant. They are not affected from the fluctuations of the grid, because in case it occurs that the voltage of the grid is outside the band of preset min. / max. limits, the plant puts itself automatically to "island operation" to stili supply stably uninterrupted electricity to the factory. The power plant will also prevent the factory from the outages of the grid continuing feeding electricity to the factory again in "island operation". Besides, BIRKO also saves out of energy bills thanks to the efficient production of both electricity and heat and the ability of diesel engines to run uninterruptedly and successfully with low viscosity but cheap heavy fuels. The payback period of the total project capital investment will be within 2.5 to 3 years on the base of actual operational conditions, which is slightly higher compared to the result of feasibility studies carried out by the company before they started implementation because of unexpectedly higher prices of heavy fuel as the reflection of steep increase in crude oil price worldwide. BIRKO is a genuine example tor the overall performances of diesel cogeneration projects. Provided that the pre technical, logistical and economical studies are conducted in fairly objective way first analyzing the actual needs of electricity and heat demands of installed power and consumed electricity of the existing production facility, and determining the best combination of fuel and prime mover technology to accomplish the highest total efficiency of the cogeneration system and ensuring the lowest-cos possible fuel available for continuous supply to the location, the achievement tor the technical performance and economical return is inevitable, even some important parameters are affected infavourably. COGENERATlotl WORLD & Renewoble Energy �
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