Mukund Dairy Farm

Sridhar Samudrala President and CEO IECC Partner MDF

June 22, 2011 Manila, Philippines 6th Asia Clean Energy Forum 2011

History
Hyderabad Milk Requirement 25 Laks /Day. Currently
Established in Nov. 2009. 21 Acre Farm - 2 Acres Dairy.

Supply 14-15 Laks/day, milk coming from outside Andhra Pradesh

Invested over 4 Cr. $800,000 (Land,Animals, Sheds, Pasturization Equipment Office and Infrastructure)
farm. Produce over Buffalo 1500. of 150 +

Over 300 buffalos and cows 26 full time staff - reside on

Milk sold to over 6 Major Hotels in City, Retail Customer Base

Current Cost of milk Rs 35-50/Liter and increasing Distribution 3000 ltrs/per day
IECC 2

Activity
Power plant for all electrical needs 30 Kw 4-6

Hrs per day major power cuts in India Milk Processing plant (Paneer, Yogurt, Skim Milk, Ghee) Use heat from wood fired boiler for pasturization C30 Generates electricity Supplements Boiler with hot water. Output 30 65 C saves approximately 50 Kg of wood per day Decrease use of wood convert fully to biogas in 2012 by increasing animals
IECC 3

IECC

IECC

MDF Operation 3-5 hrs/day

3000 Ltr/Day

Animal Waste

Pasteurization 85 C
Pasturezation Machine

Digester

Hot Water for Process & Cleaning 65-75 C

Wood fired /Boiler Capstone C30

300 C output

Packaging Milk, Cream and other products

Ice Bank Tank

Elec. 25 kW

Retail

Wholesale

Compost for Sale

IECC 7

Exhaust Heat Utilization CHP for Pasturization (hot water)

Capstone CHP C30 23 kWe 30 kW Bio gas 5 kWth

2 kW waste

80% average total efficiency 0.15 lb/MWh NOx & 1,540 lb/MWh CO2
IECC 8

COST COMPARISON

Cost of Wood Fired Boiler/Diesel Generator Combination is $ 394,600.

1000 Liters/hr pasteurization plant with a wood fired boiler and Dis Gen set. Wood fired boiler costs $4500 Fuel ($500/mo $6000/Yr). A 30 Kw dis gen. set ($12,000 - it consumes 7 liter/hr $28/day (10,080/yr). Assume the pasteurization plant would operate 3-4 hrs per day.

Over 20 years cost : life span of the diesel generator and wood fired boiler are approximately 7-10 years ($16,500 X 2 = $33,000). (Diesel 20 yrs X $10,080 = $201,600, wood 20 yrs X $6,000 = $120,000). Maintenance is $ 2000/yr = $ 40,000. Total cost is $ $394,600.

Cost of Digester and Capstone C30 Micro-turbine is $ 207,000

The Capstone C30 Micro turbine and digester cost is approximately (Capstone - $61,000, Gas cleaning equip - $10,000, Digester - $15,000,). The C30 - 26 Kw of electricity and exhaust heat is used for pasteurization milk to temperature of 85C.
Over 20 years costs: life span of the Micro turbine is 10 yrs (2 X 61,000 = $ 122,000). Digester life is 30 years ($ 15,000). Maintenance $ 3000/yr = $ 60,000. This total is $ 207,000.

IECC

Cost Comparison over 20 Yrs

IECC

10

Revenue Projections for 3/5/10 kL

No of Ltrs/Day 3000 5000 Rs.25,360,800 10000 INR 44,908,800 $976,278 $551,322 Profits INR Rs.9,621,600 Profits USD $209,165

IECC

11

SUMMARY
Dairy 300 cows - C30 micro turbine 4-6 hours - 45-m3 (1,589-ft3) digester.
Methane 25 times more potent than CO2 and remains in atmosphere upto 15 years. Assume 41 days of operation. Approximately 10,785 m3 of CH4 emitted into

atmosphere - burned to generate electricity and heat. 10,785- m3 will produce approximately 19.4 tonnes of CO2 with a Global Warming Potential (GWP) of 19.
Heat recovery for water inlet temperature of 30C and flow rate of 1.5 l/s to 50-

85C possible under low flow conditions.

Dairy project effective way of controlling climate change. The more that the

microturbines run, more CH4 to electricity/heat.

This is a win win situation for cost and environment
IECC 12

Start small and expand !

THANK YOU & NAMASKAR
ssamudrala@iecc-us.com

Capstone/IECC

13