Philippine Test Case # 1201: What would you recommend as a Power Plant

A MetroManila-based Paper Mill converting "Scrap Paper" into various customer-specified grades of paper (Newsprint, Writing Paper, Book Paper, Kraft Paper, etc) has a 24x7 CHP System in place - to operate PM-1, PM-2, PM-3, PM-4. Its HEAT requirement is supplied by Boiler-1A producing 6MT/hr of STEAM (@ 5-Bar PRESSURE / @ 350-degreeF TEMPERATURE) and fueled by 12-13MT of Coal every 24hrs. Its supply of Coal (5-6K BTU) costs about P3,500/MT. The Factory has an existing "standby" bunker-fired Boiler-1B operated whenever Boiler-1A is on periodic Maintenance. Its POWER Requirement (costing about P5 million/month @ present FX rate of P42:U$1 and @ P6.87/KWh and supplied by the Electric Utility Distributor in the area - MERALCO) is about 0.8MWh/month - to run all the Electric Motors: (1st) for existing PM-1, PM-2, PM-3, PM-4; (2nd) for drawing-up 8hrs/day from its own underground WaterWell; (3rd) for the Factory's in-house Maintenance Machine Shop; AND to provide Lighting for the entire 3-hectare Factory Site. MERALCO-supplied Grid Electricity is 33.5KV fed into the Factory's Sub-Station (2 Transformers) supplying 440-480V @ 60Hz Frequency @ 96% Power Factor. This Paper Mill uses up every day 120,000 gal of "Process Water" - turning out 20% as WasteWater treated and discharged to the Public Drains. Fresh-Water Spray-System is soon to be installed to re-cycle WasteWater - hopefully reducing Discharge WasteWater down to 10%. Solid Waste volume is considered insignificant @ about 1MT/month - of various kinds of "Scrap Plastics", etc.

This Paper Mill is undergoing Plant Expansion (additional 2 lines: PM-5 & PM-6) with a Target Completion Date Mar2012 - or earlier. When all Lines (PM-1 to PM-6) would be operational, this Paper Mill would need an upgraded CHP System estimated at about 3x to 4x its present requirement. Towards this end, Boiler-2 (Output STEAM of 6MT/hr) and Boiler-3 (Output STEAM of 4MT/hr) are now being installed. The 16MT/hr combined STEAM Output (Boiler-1 + Boiler-2 + Boiler-3) has already elicited an Offer-to-Supply a STEAM Turbine from a Manila-based Supplier. Land Space (allocated for the envisioned CHP Facility inside the 3-hec Factory Site) is 4000 sq meters.