Power Co-generation

Generating Electric Power for in-house Use

Kakira is in the fortunate position being able to generate its own electricity so that its factory is self-sufficient.

Bagasse (the fibrous residue left after sugar-cane crushing) is burnt in boilers to produce high-pressure steam. This high pressure steam is then:

• Used to turn the factory mill turbines, etc.
• Passed through turbo-generators to produce electric power, after which.
• The low-pressure steam is used in the sugar manufacturing process.

The electric power used in Kakira is hence generated from a renewable biomass energy source.

In 2005, Kakira had two 20 bar steam-driven turbo-generators (3 MW + 1.5 MW) in addition to 5 diesel standby generators.

2004-2008 Expansion to Generate Electricity for Grid Supply

As part of its 2004-08 expansion, KSW installed :

• Two new boilers of 50 tonnes per hour steam capacity at 45 bar-gauge pressure, with all necessary ancillaries such as an Ash Handling System, a Feed water System and Air Pollution Controls (such as wet scrubbers and a 40m high chimney).
• A complete Bagasse Handling system
• A new 16+ MW 11KV double extraction condensing Turbo-alternator of type along with a cooling tower,
• A new switch yard at Kakira with the necessary transformers and switch gear to supply power to the Kakira complex as well as the Ugandan grid
• A dedicated new 14 km distribution line for grid supply at 33 KV.

The capacity of Kakira's expanded co-generation not only meets the entire increased needs of KSW's factory and infrastructure on a 24hr per day basis but also supplies up to 12 - 14 MW of electricity to the National Grid.

This project not only diversified the scope of the company's business, but also augmented its substantial contribution to the economy of South Busoga and, indeed, of Uganda.

Planned Further Expansion 2010-2012

There is a continuing deficit in electricity generation in Uganda and the national utility has undertaken emergency measures to supplement generation using diesel and heavy-fuel oil. Moreover, there is a growing demand for power in the country for development. 

Considering this situation and the need to increase the renewable energy supply whilst conserving fossil fuels and reducing carbon emissions, the Madhvani Group has decided to expand its electricity co-generation capacity.

The Kakira co-generation expansion envisages installing:

• A new 160 TPH 67 bara(a) boiler
• A new 30 MW double-extraction-condensing turbo-alternator
• A new switch-yard for power distribution
• An additional new 14 km distribution line for grid supply at 33 KV.

The large new boiler will effectively replace the five 20 bar(a) boilers (which will be placed on stand-by for any emergency or new system break-down).  Hence the bagasse burning efficiency will improve to generate steam at a pressure that is more than 3 times higher, thereby increasing its electricity generation potential.

All of the new equipment will be procured shortly and the expanded co-generation project is expected to be commissioned by July 2012, after which Kakira will supply around 32 MW electricity to the grid for 24h/d for at least 305 days each year.