Clean Coal Initiatives of BHEL - carboncap-cleantech.com - Website/DA… · Clean Coal Initiatives...

Clean Coal Initiatives

of

BHEL

(Bharat Heavy Electricals Limited)

Mr. M. Muthukrishnan

General Manager,

R&D and Coal research,

BHEL,Trichy

Conference on Clean Coal and Carbon Capture and

Storage Technologies

Bharat Heavy Electricals Limited

Conference on CCT and CCS 2-3rd December,2013

Overview of BHEL corporation



BHEL – Activity Locations in India

Conference on CCT&CCS

Dec 13



BHEL’s GLOBAL FOOTPRINT



Pulverised Fuel Boilers

Sub critical

•60 MW

•110 MW

•200 MW

•210 MW

•250 MW

•500 MW

•600 MW

Super Critical

•660 MW

•700 MW

•800 MW

•1000 MW

BHEL’s Boiler Range

Fluidised Bed Combustion Boilers

Bubbling Fluidized Bed

•20 MW

•45 MW

•60 MW

•80 MW

•120 MW

Circulating Fluidized Bed

•60 MW

•75 MW

•125 MW

•135 MW

•250 MW



BHEL Corporate – Turn over



BHEL Initiatives towards CCT and CCS



Our Goals on CCT and CCS



Coal Gasification

Coal Characterization Collaborative Research

ScTF CFBC

SFBTF


Research facilities in BHEL Trichy Complex



Coal Research Centre


CRC Equipments

Total = 22 Equipment

Project Outlay Rs 1743 Lakhs


X-Ray Fluorescence Spectrometer

Inductively Coupled Plasma Mass Spectrometer

Microwave Digestor

Mercury Analyser

Portable Flue Gas Analyser

Gas Chromatography

FUEL CHARACTERISATION

THERMAL CHARACTERISATION

MINERAL CHARACTERISATION

PARTICLE CHARACTERISATION

ENVIRONMENTAL LAB

Proximate Analyser

Ultimate Analyser

Bomb Calorimeter

Sulphur Determinator

FTIR Spectrometer

Thermo Gravimetric Analyser

Differential Scanning Calorimeter

High Temperature X-Ray Diffraction Spectrometer

Computer Controlled Scanning Electron Microscope

Low Temperature Asher

Particle Size Analyser

Surface Area And Pore Analyser

Zeta Meter

Gas Pyconometer

PM 10 & PM 2.5 Particle Analyser

Drop Tube

Furnace System



Drop Tube Furnace Test Facility


Key research areas on CCT and CCS

• Increasing efficiency of PF Boilers -Development of AUSC boiler

• Development of CFBC and IGCC of higher capacity

• Biomass Co-firing and Oxy fuel combustion technology

• Technology development for Carbon dioxide capture from flue gas

• Reduction measures for non GHG like NOx through -Over Fire Air compartment

-Bypass Over Fire Air Firing

-SCR development



Plant type with power

rating

Steam Pressure (kg/cm2)

Steam Temperature

(C)

Efficiency (%)

CO2 Emissions (g/kW-hr)

Coal saving for one 800 MW unit

( t/year ) **

Sub Critical

170 540 38-39 900 Base

Super Critical* 247 565 40 830 1,01,000

Ultra Super Critical

250 600 42 784 2,88,000

Advanced Ultra Super Critical

300 700 45 740 5,38,000

* The improvements are with respect to the best units under construction in India ** For the coal HHV of 3500 Kcal/kg • Extension of coal reserves by 11% • Competitive in electricity cost on deployment


Reduction of CO2 emission with increase of

steam parameters


Indian Govt. National Mission for Technology - AUSC

Driven by the government’s National Mission for Technology, the Advanced Ultra Super Critical (AUSC) project ( 300Bar, 710/720°C) is under Development by a joint venture of BHEL, NTPC and the Indira Gandhi Centre for Atomic Research (IGCAR).



• To conduct experiments at Supercritical (SC)/ Ultra Supercritical (USC) conditions of steam

• Know why generation for establishing SC & USC boiler technology

Objective

• Rs. 12 cr. Investment

• Pressure - 400 bar

• Temperature - 700 Deg.C

• Heat flux - 1000 kW/m2

Capabilities

• Commissioned in Dec. 2008

• Experiments under progress Status

World Class



NTPC/ BARH II STPP – 2 x 660 MW

Coal Fuel

568 / 596 oC Temperature

255/54.65 kg/cm2 (g) Pressure

2120/1708.2 t/h. Steam Flow

31.03.2008 Zero Date

U6/1700 & U6/1701 Contract No.

Not in SG Package Dust Collector

2 Nos. SAF 42.5/26.6-1, Axial

Reaction-TLT ID Fan

2 Nos. PAF 19/10.6 – 2, Axial

Reaction-TLT PA Fan

2 Nos. FAF 25/11.2 – 1, Axial

Reaction-TLT FD Fan

PAH - 2 Nos. 28.5 VI 58 (70)MR,2NOS

31.5 VI 70 (82)MR ALSTOM Supply Airheater

9 Nos. Bowl Mill, HP 1103 Mill

Major Auxiliaries

Parameters at SHO / RHO

BARH II – 2 x 660 MW Project

National Thermal Power Corporation Customer



APPDCL / Sri Damodaram Sanjeevaiah

TPS 2 x 800 MW

Blended Coal ( 70 % Indian Washed Coal, 30

% Imported Coal) Fuel

568 / 596 oC Temperature

255/57.9 kg/cm2 (g) Pressure

2600 / 2052 t/h. Steam Flow

25.07.2008

Zero Date

1800, 1801 Contract No.

4 Nos. FAA-8x45M-2x112150-2 Dust Collector

2 Nos. SAF – 40/ 21-1, Axial Reaction ID Fan

2 Nos. PAF 20/12.5-2, Axial Reaction PA Fan

2 Nos. SAF 27.3/12.2-1, Axial Reaction FD Fan

2 Nos. TRI-SECTOR, 34.5 VI 94, Airheater

6 Nos. Bowl Mill, HP 1203 Mill

Major Auxiliaries

Parameters at SHO / RHO

Sri Damodaram Sanjeevaiah T P S –2 x

800 MW Project

APPDCL Customer



Integrated Gasification Combined Cycle

Heat Flow Diagram

Efficiency – 42%

74%

35%

18%

10

%

HRS

G

GT Exh

100%

Loss-2%

Loss-2%

Stack Loss Condenser

Loss

Misc Loss-

3%

Steam

Coal 25

%

47%

17%

33%

Loss - 8%



Coal Gasification – CCDP 6.2 MWe



Corp. R&D,

Hyderabad

18

TPD

(PEDU)

6.2 MW

CCDP

182 MW

IGCC

Tiruchy

Scale up:

Geometrical - 1:1.14

Capacity - 1: 1.21

Pressure - 1:0.9

Scale up:

Geometrical - 1: 3.3

Capacity - 1: 9.33

Pressure - 1:1.2

1.2

TPD

(APFBG)

Corp R&D

Hyderabad

Dia 0.2 m

Press 2.0 ata

Scale up:


Capacity - 1: 15

Pressure - 1:5

125 MW

IGCC

Concept Design

Scale up:


Capacity - 1: 11.1

Pressure - 1:3

APGENCO

Vijaywada

450- 650 MW

IGCC

Future Commercial Scale IGCC Plant



Milestones in BHEL’s IGCC Development

Role of CFBC in CCT

• High fuel flexibility

• Can burn coal of high moisture content (Lignite)

• Low SOx emission due to absorption of SOx in lime bed

• Because of lower bed temperature, it generates less amount of NOx.

• Efficiency is comparable with PCC of same capacity.



CFB Boiler Development

Test Facility installed

Collaboration with

First CFB boiler (175 t/hr ) installed at BILT , Bhigwan

First Utility reheat boiler (2x125 MW) installed at

SLPP, Mangrol

Collaboration with LLB ends 125 MW, RVUNL, Giral

75 MW order received from GEB, Kutch

2 x 135 t/hr M/s Gujarat Ambuja cement

2 x 250 MW order received from Neyveli Lignite

Corporation

2 x 125 MW NLC – Barsingsar

2 x 125 MW repeat order received from SLPP

1 x 135 t/h repeat Order received from GACL

1x120 t/h First Export order received from PT BR, Indonesia

2x135MW order received from KNS,NewCaledonia2x30 MW PT MSW, Indonesia

3 x 275 t/h Petcoke fired units from BORL

125 MW repeat order received from RVUNL, Giral

1990

1991

1992

1993

1994

1995

1996

1997

1998

1999

2000

2001

2002

2003

2004

2005

2006

2007

2008

2009

2010

0 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 850 900

Y

e

a

r

Boiler Capacity in t/hr



27

CFB Product Range

Combustor Wing Wall Non Integral FBHE Integral FBHE Pant Leg

< 30 MW 60-100 MW 60-135 MW 125 MW 250 MW



Project Fuel %S

BILT ,Sinarmas IC 0.35

SLPP, Mangrol L 2.00

GLPP, Giral L 6.00

GACL, Kodinar IC 0.43

KLTP Ext, Kutch L 4.90

BTPP, Barsingsar L 1.70

SLPP Extn, Mangrol L 2.00

BORL, Bina IC P 5.63

PT IBR, Indonesia IC 0.96

KNS, Koniambo AC 0.80

PT MSW, Indonesia IC 0.28

BECL Bhavnagar L 4.00

BHEL CFB – Fuel Summary




CFB Boilers – Capacity & Range

Range Upto 850 t/h (250 MWe ), 545ºC & 172 kg/cm2(g)

Fuels Range Lignite, Petcoke, Coal, Middlings, Washery Rejects

HHV >1800 kcal/kg Ash < 70%wt Total Moisture < 55%wt Sulphur < 6%wt



CFBC capacity status-worldwide



Lignite Potential In India

Lignite Reserves – 39 bill. Tons (Proven in Mill tons) Tamil Nadu 31327 (2831) Rajasthan 4485 ( 561) Gujarat 2663 ( 785) Puduchery 417 ( 0) J&K 28 ( 0) Kerala 10 ( 0) West Bengal 1 ( 0) Total 38931 (4177)

Potential 70 Nos: 250 MW (Approx. 50 mill tons one 250 MW plant)



BHEL 125 MWe CFBC Boilers – SLPP Units

1&2 Units Commissioned in 1999

3&4 Units Commissioned in 2010

One of the best performing lignite power plants



Location : Giral, Barmer Dt , Rajasthan Fuel : Lignite ( 40 % M & 6 %S) Highest in world Design fuel, kcal/kg : HHV – 3000 Start-up : 2007 Availability : 60-90%

RVUNL (Giral) – 2 x 125 MWe CFB Boiler



Location : Barsingsar, Bikaner Dt , Rajasthan

Fuel : Lignite ( 40 % M & 0.8 %S) Unique Palana Lignite

HHV : 1900 - 3300kcal/kg

Start-up : 2010

Availability : 80-90%

NLC BARSINGSAR CFB 2 x 125 MWe



250MW – What’s New • Combustor – Single to Pant Leg

• Cyclones – Two to Four

• Pressure rating – 170 ata vs 130 ata

• FBHE – Integral to Separate

• Airheater – Tubular to Quadsector RAPH



HIGHER CAPACITY CFBC BOILERS ESTABLISHED



Successfully established CFB technology for difficult Lignite Variety available in

Rajasthan

- High Sulphur Content

- with shrinking ash characterisitics

Plants firing lignite from Gujarat & Rajasthan are operating successfull today

The Largest CFB boiler of 250 MW has demonstrated full load capacity firing

Lignite from Neyveli, Tamil Nadu

BHEL has extensive R&D facilities to characterize various fuels and

successfully fired washery rejects of 70% ash content, various coals etc.

BHEL has solution for firing various fuels of coal & lignite in CFB boilers

BHEL-TRECSTEP EU Project on Demonstration and deployment of

CCT and CCS project

BHEL has initiated the following projects

Pilot scale testing of Oxy fuel combustion

Cofiring of Biomass



Biomass is a Carbon Neutral Fuel



Demonstration of Wood Pellets (20% by wt) Co-firing with Coal in SFBTF to European Union Team

Dr. Rodrigo Ubierna (ROM) Visit

on 12th June 2013 to BHEL

Mr. ARNO SCHAEFER (Head of

Operation, EU Delegation to India) &

Ms. SMITHA SINGH (Project

Manager) VISIT to BHEL on

14.06.2013



Firing with 100% coal

Firing with coal and 20% of Wood pellets

Flame

Photograph from

rear side of the

combustion

chamber

• Studies with wood pellets has been showed good results and temperature profiles, heat

flux values near wall are closely matching with 100% coal test results.

• Better flame stability observed as biomass co-firing proportion increases

• With limited proportion of firing biomass with coal up to 20% by mass

• No slagging, fouling or heavy deposition observed

• Flowability issues observed when biomass proportion is more than 20% by wt

Biomass Co-firing with Coal – Project

Completed




Oxy- combustion Technology in PC Boilers


400 KW Pilot scale – Oxy fuel Combustion Test Facility



• CO2 separation from flue gas and fuel gas by wet scrubbing

with ammonia solvents.

• Ammonia method offers lower solvent cost, lower energy for

regeneration, applicable for retrofits and new plants.

• BHEL has developed the ammonia process for CO2 capture in

bench scale.

CO2 capture and regeneration by Ammonia

absorption process




Pilot scale CO2

capture testing

facility


13.5 13.2 13.6

1.20.6 0.3

0.0

2.0

4.0

6.0

8.0

10.0

12.0

14.0

16.0

3.1% NH3 soln 6.25% NH3 soln

12.5% NH3 soln

% CO2 before absorption % CO2 minimum in absorption


CO2 absorption trend using Ammonia Solution




Bypass Over Fire Air (BOFA)System

Bypass Over Fire Air (BOFA) system

• Cost effective technology among the technologies

available for NOx reduction in pulverised coal fired

thermal power plants.

• Employs deep air staging technique to abate NOx

emission.

• The BOFA system was retrofitted into a 250 MW boiler

supplied by BHEL (Suratgarh).

• The NOx reduction capability around 50%.



Selective Catalytic Reduction

• BHEL has developed Selective Catalytic Reduction

system for NOx reduction in PC fired boilers by injecting

ammonia in to the flue gas in the presence of a catalyst.

• SCR pilot plant has been established at Fuel Evaluation

Test Facility at BHEL Trichy.

• NOx reduction capability of the SCR system was

demonstrated to be in the order of 90-95%.



Selective Catalytic Reduction(SCR) System



Summary BHEL has implemented Supercritical parameters for PF boilers and moving towards USC and AUSC towards Higher Efficiency and Lower Emissions.

Process development for IGCC of higher capacity is completed and is ready for commercialization

CFBC of 250MWe capacity established to handle wide variety of fuels including Lignite

Developed technology for biomass co-firing and oxyfuel combustion technology

Know how on CO2 capture from flue gas is developed and demonstrated on pilot scale

Reduction of non GHG emissions like NOx is commercialized based on need



Clean Coal Initiatives of BHEL - carboncap-cleantech.com - Website/DA… · Clean Coal Initiatives...

Documents

Transcript of Clean Coal Initiatives of BHEL - carboncap-cleantech.com - Website/DA… · Clean Coal Initiatives...