Session VI - Clean Coal Technologies and Electricity-BHEL

Bharat Heavy Electricals Limited, Tiruchirappalli
Coal Fired Boilers

Technologies for Improved Efficiency & Reduced Emissions
C.Jayadevan Bharat Heavy Electriclas Ltd. Tiruchirappalli, India
Clean Coal Technologies - September 2008
Power Generation Options
Hydro Steam Power Plants Boiler + Turbine Oil Coal
Thermal
Nuclear Gas Turbine Based Power Plants
Non Conventional
Gas
Open Cycle (Gas Turbine)
Combined Cycle GT + ST
Pulverised Coal
Fludised Bed Technology
Thermal Power -Market Requirements

Low cost of generation Minimum emission of Pollutants Suitability for different quality of fuel Suitability for differing modes of operation and grid conditions High Reliability & Availability Increased use of IT Low life cycle cost Plant Life Extension & Capacity upgrades Higher size Units Shorter Delivery time
Power Plant Equipment Manufacturers to respond by employing the right technologies

Thermal Power- Choice of fuel

Sustainable, economic power generation thru efficient use of locally available fuels, in an environmentally friendly fashion. India - Coal the desirable choice abundantly available, low cost Coal Based Generation- Emissions/Pollutants minimised 9 Particulates 9 Carbon Dioxide 9 Oxides of Nitrogen 9 Sulfur dioxide to be
Indian Coals Challenges in Boiler Design

Widely varying properties makes equipment selection costly and sub-optimum High Ash with high Quartz; highly abrasive Erosion/wear reduces boiler component life Low Sulphur content - high electrical resistivity of Ash Low Heating Value more coal burnt for the same output
Indian Coals Properties

Range Ash SiO2+ Al2 03 in Ash Moisture Volatile Matter Sulphur Heating Value (HHV) 25 - 50% 80 - 92% 8 - 20% 18 - 30% 0.2 1.0% 2500 - 5000 Kcal/Kg
Indian coal Vs Average International Coals

Coal/Ash Quantity For 500 MW Unit
INDIAN COAL Heat Duty Fuel Fired HHV Quantity of Coal Average Ash Content Quantity of Ash MKcal/h MKcal/h Kcal/Kg t/h % t/h 1080 1250 3800 329 40 132 INT. COAL 1080 1240 6000 207 8 17
The 8 fold increase in the ash passing thru an Indian coal fired boiler, warrants incorporation of special design features for high availability. Clean Coal Technologies - September 2008
Coal Fired Boilers Design for Eco-friendly Power Generation
Towards Eco-friendly use of coal .

Burn less fuel 9 Improve Plant efficiency Minimise generation of pollutants 9 Choice of appropriate combustion system, fuels 9 Choice of boiler technologies like Fluidised Bed combustion Capture pollutants before leaving the boiler 9 Dust Collectors , De-sulfurisation plants, De-Nox plants.
Plant Efficiency Improvement

Efficiency Development of power plants in Europe
175 bar / 540 C / 540 C 55 50 Efficiency, % 45 BHEL CC+ Units 40 35 30 1950 240 - 280 bar evoporator pressure
Efficiency Improvement of Steam power plants
2.0 250 bar / 550 C / 570 C 260 bar / 580 C / 600 C 280 bar / 600 C / 620 C
Turbine Efficiency
1.5 Basis 38 % 7.2 % 0.4 2.0 0.7 0.6
Condenser Pressure Process Optimisation (FWT, feed heater arrangement) Steam Parameters Feed Water Temperature Measures on Steam generator
1960
1970 Year
1980
1990
2000
Source: VGB Power Tech 11/2003

Boiler Side Measures
Designing for Supercritical Steam Parameters Designing for minimum:
RH spray SH spray (if tapped off before feed heaters) Flue gas temperature at AH outlet Excess air at AH outlet Unburnt Carbon loss Fuel oil support for coal flame stabilisation Auxiliary power consumption
Steam Parameters Vs Cycle Efficiency

Increase of efficiency [%] 10 9 8 7 6 5 4 3 2 1 0 300
Pressure [bar]
Heat Rate Improvement
6.77 5.74 4.81 4.26 3.37 2.64 2.42 1.78 0

241 175 538 / 538
5.79 3.74 2.76
3.44 1.47
600 / 620
0.75
566 / 566 538 / 566
580 / 600
HP / RH outlet temperature [deg. C]
Cycleefficiency efficiencywith with:: Cycle 175bar barand and538/ 538/538 538C C= =38.0 38.0% %(BASE) (BASE) 175 241bar barand and538/ 538/566 566C C= =38.0 38.0x x1.0264 1.0264= =39% 39% 241 Clean Coal Technologies - September 2008
Supercritical Cycles
Steam Power plant efficiency increases with increase in steam pressure and temperature. Power plant Cycles operating above critical pressure (221.2 bar) are classified as Supercritical cycles With higher cycle efficiency, the supercritical cycle offers the advantage of emission. burn less fuel for the same output and lower
Lesser Pollutants SOX , NOX & CO2

Steam Parameters - Global Trends

Country Denmark Germany Japan Year
1991 1997 1995 1999 1991 1995 2000
Pressure(bar)
250 290 285 270 246 246 246
Temp C
540 / 540 580 / 580 / 580 545 / 560 580 / 600 538 / 566 566 / 593 593 / 593
255 bar 568/596 Deg C commonly used presently Ultra super critical units (parameters up to 375 bar & 700 C) with plant efficiency approaching combined cycle plants (50%+) are in development stage with parallel development in Materials Clean Coal Technologies - September 2008
Steam Parameters - Trends in India

300 SHO Steam Pressure 250 200 150 100 50 1970 1975 1980 1985 1990 Year 1995 2000 2005 139 ata 96ata 179 ata 156 ata
Steam Generators Design Parameters

PARAMETER
Main Steam Pressure Main Steam Temp Main Steam Flow Reheat Pressure Reheat Temperature Reheat Flow Cold Reheat Pressure Cold Reheat Temp FinalL FW Temp BMCR
UNIT
ata
O
500 MW
170 537 1515 40.5 537 1335 45 336 253 1625
800 MW
247 565 2400 54 593 1990 60 343 290 2575
t/h ata
O
t/h ata
O O
C C
t/h
Environmental Benefits
Station Cap (
Supercritical Units
Units
(No.x MW)
MS Pressure
(kg/cm2)
MS/RH Temp 0C 538/538 566/593
Efficiency (%) 38.6 40.24
Coal Consumption (MMT/Yr)* 15.61 14.98
CO2 Emissions
(MMT/Yr)
4000 4000
8x500 5x800
169 246
22.90 21.97
Savings Savingsin incoal coalconsumed consumed::0.63 0.63MMT/Yr MMT/Yr(about (about4% 4%Saving) Saving) Savings 2 emissions Savingsin inCO CO emissions ::0.93 0.93MMT/Yr MMT/Yr
2
Source : CEA Clean Coal Technologies - September 2008
Boiler Design for Supercritical Steam Parameters
Subcritical Drum Type boiler

Supercritical Once thru Boiler
Supercritical Boilers
Once thru Boiler technology facilitates adoption of Supercritical parameters Higher pressure & temperature stress the boiler components at a high level New materials in use/trial operation to withstand the demanding service conditions 9 T 91/P91 9 T 92/P92 9 T 23/T24 9 TP347HFG 9 Esshete 1250
Well established, mature technology Availability on par with subcritical boilers
Plant Efficiency Improvement - Boiler Side Measures Flue Gas Temperature at Boiler outlet
EFFICIENCY %
GAS TEMP. LEAVING AH Deg.C
89 88 87
86
175 150 125 0 1980s 2000
Plant Efficiency Improvement Boiler Side Measures

Optimum design of furnace, Reheater & Superheater minimises the spray for maintaining rated SH&RH steam temperature Optimum design of combustion chamber, pulverising system, firing equipment - minimises the need for high excess air at boiler outlet & reduces the unburnt carbon in fuel. Coal specific design of firing equipment reduces the quantum of fuel oil support for coal flame stabilisation
Plant Efficiency Improvement - Boiler Side Measures Auxiliary Power Consumption Reduction
Use of High efficiency Boiler Auxiliaries Axial Reaction fans Bowl Mills ESP with Intelligent operating systems Use of High Efficiency Drives like VFD Reduction in the duty of the auxiliaries by system design optimisation
Towards Eco-friendly use of coal

NOx generation reduced by: Use of Fluidised bed combustion Technology Use of Low NOx Burners/ firing systems Use of techniques like air staging/fuel staging/ re-burning Separate Over Fire Air (SOFA) system Capturing the NOx in DeNOX plants located at tail end of the boiler
Fluidised Bed Combustion Boilers

Technologies in vogue: Bubbling Fluidised Bed Combustion (BFBC) Circulating Fluidised Bed Combustion (CFBC)
9 Ideally suited for Low Grade fuels, Lignite, Pet coke 9 Does not need coal pulverisation system 9 Keeps SOx & NOx emissions low
Integrated Gasification Combined Cycle (IGCC)

The emerging technology to utilise coal with the maximum efficiency
6.2 MWe capacity coal based combined cycle demonstration facility at BHEL, Trichy BHEL is now setting up a 125 MW plant jointly with a customer
Integrated Gasification Combined Cycle (IGCC) SynGas

Combustor
Coal Gasifier
Air HRSG
Air
FETF, a fire side boiler simulator for study of complex interrelated effect of fuel characteristics. Rated for heat input of 756,000 kcal/h (880 KW).
Fuel evaluation test facility
Solid Fuel Burning Test Facility
SFBTF of 10 Mkcal/h capacity is used for coal burner/nozzle development, evaluation of flame stability, combustion efficiency & turndown.
Existing Existing Power Power Plants Plants Performance Performance Improvement Improvement
Focus area for improvement in existing plants :

Availability Reliability Output Efficiency Environment
Availability & Reliability improved by

Adoption of appropriate Operation & maintenance practices special focus on tube failure prevention, maintaining proper combustion regime Use of early warning systems:
Tube leak detection system, Operator alarms
9 Sophisticated Controls & Instrumentation 9 Vibration monitoring systems for high speed equipment 9 Equipment trip provisions
Operator Training Renovation of Boilers Use of well proven equipment Redundancy for Critical equipment
&
design
practices,
Results in lesser number of plant outages, start ups Minimises fuel oil consumption
Boiler Operating Modes for Improved Efficiency

Base Load Cycling Two-shift Sliding pressure Trip to house load Designing to operate in different modes : - Improves part-load efficiency - Less number of plant start ups - Quicker plant start-ups Minimises fuel oil consumption
IT for Power Plant Applications

Increasingly used for :
Performance Optimisation Residual Life Assessment Emission analysis Operator Training Expert systems & Root cause analysis Maintenance
IT for Boiler Performance Improvement

Introduction of smart systems:
Performance Analysis, Diagnostics, Optimisation(PADO) System - provides operator guidance for optimised performance Smart wall blowing system improves heat rate, minimises steam erosion Emission analysis Expert systems & Root cause analysis
Performance Improvement Optimised Operation

Improved Plant Efficiency by maintaining : 9 Minimum spray in Superheater/Reheater- use temperature control mechanisms 9 Rated steam parameters 9 Optimised combustion regime 9 Rated pulverised coal fineness 9 Minimum/zero oil support for coal flame stabilisation Minimum Auxiliary Power consumption: 9 Optimum number of mills in service 9 Prevent air ingress into boiler Minimise Down time: 9 Boiler maintenance techniques plan for shortest time 9 Reduce plant start up time Minimise Emissions: 9 Maintain appropriate combustion air regimes 9 Flue gas conditioning for reduced emissions
Renovation & Modernisation of boilers

Regain of lost capacity / Capacity augmentation Reduced forced outages Lesser maintenance requirement and time Enhanced operational Efficiency Improved Boiler Availability & reliabilty Performance improvements State-of-the-art upgrades Reduced support fuel requirement Enhanced life for Wear prone components Reduced emissions
Future Outlook
Coal & Lignite will continue to be main fuels for Power Plants for some more decades Economics will decide the optimum power plant cycle parameters to be adopted. Increasing focus on minimising Emissions, improving efficiencies, fuel flexibility, enhanced Availability & Reliability Pulverized coal firing will continue to be the mainstay, till other technologies mature into commercially viable options Boiler technology will continue the advance towards increased efficiencies.
Bharat Heavy Electricals Limited Tiruchirappalli

Session VI - Clean Coal Technologies and Electricity-BHEL

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Bharat Heavy Electricals Limited, Tiruchirappalli

Coal Fired Boilers

C.Jayadevan Bharat Heavy Electriclas Ltd. Tiruchirappalli, India

Clean Coal Technologies - September 2008

Bharat Heavy Electricals Limited, Tiruchirappalli

Power Generation Options

Hydro Steam Power Plants Boiler + Turbine Oil Coal

Nuclear Gas Turbine Based Power Plants

Open Cycle (Gas Turbine)

Fludised Bed Technology

Clean Coal Technologies - September 2008

Bharat Heavy Electricals Limited, Tiruchirappalli

Thermal Power -Market Requirements

Power Plant Equipment Manufacturers to respond by employing the right technologies

Bharat Heavy Electricals Limited, Tiruchirappalli

Thermal Power- Choice of fuel

Clean Coal Technologies - September 2008

Bharat Heavy Electricals Limited, Tiruchirappalli

Indian Coals Challenges in Boiler Design

Clean Coal Technologies - September 2008

Bharat Heavy Electricals Limited, Tiruchirappalli

Indian Coals Properties

Clean Coal Technologies - September 2008

Bharat Heavy Electricals Limited, Tiruchirappalli

Indian coal Vs Average International Coals

Bharat Heavy Electricals Limited, Tiruchirappalli

Coal Fired Boilers Design for Eco-friendly Power Generation

Clean Coal Technologies - September 2008

Bharat Heavy Electricals Limited, Tiruchirappalli

Towards Eco-friendly use of coal .

Clean Coal Technologies - September 2008

Bharat Heavy Electricals Limited, Tiruchirappalli

Plant Efficiency Improvement

Efficiency Improvement of Steam power plants

1.5 Basis 38 % 7.2 % 0.4 2.0 0.7 0.6

Source: VGB Power Tech 11/2003

Clean Coal Technologies - September 2008

Bharat Heavy Electricals Limited, Tiruchirappalli

Plant Efficiency Improvement

Clean Coal Technologies - September 2008

Bharat Heavy Electricals Limited, Tiruchirappalli

Steam Parameters Vs Cycle Efficiency

Heat Rate Improvement

6.77 5.74 4.81 4.26 3.37 2.64 2.42 1.78 0

5.79 3.74 2.76

HP / RH outlet temperature [deg. C]

Bharat Heavy Electricals Limited, Tiruchirappalli

Lesser Pollutants SOX , NOX & CO2

Bharat Heavy Electricals Limited, Tiruchirappalli

Plant Efficiency Improvement

Steam Parameters - Global Trends

Bharat Heavy Electricals Limited, Tiruchirappalli

Steam Parameters - Trends in India

Plant Efficiency Improvement

Clean Coal Technologies - September 2008

Bharat Heavy Electricals Limited, Tiruchirappalli

Steam Generators Design Parameters

Bharat Heavy Electricals Limited, Tiruchirappalli

MS/RH Temp 0C 538/538 566/593

Efficiency (%) 38.6 40.24

Coal Consumption (MMT/Yr)* 15.61 14.98

Source : CEA Clean Coal Technologies - September 2008

Bharat Heavy Electricals Limited, Tiruchirappalli