S51_AlokMathur

8/2/2019 S51_AlokMathur

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EnergyEfficiencyinPowerSectoEnergyEfficiencyinPowerSectoAlokMathurAlokMathur

GeneralManager(ARP)GeneralManager(ARP)BHELNewDelhiBHELNewDelhi

3rd India3rd IndiaJapan Energy ForumJapan Energy Forum

1515--16 February 201016 February 2010


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ImportanceofIncreasingEfficiencyinPowerSector Less

fuel

burnt

per

unit

LessCO2 andotherpollutantsperunit

Conservesnonrenewablefuel

Reducescostofgeneration

Reducesrequirementoffreshcapacityaddition


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PredominanceofCoal Coalispredominantsourceofenergyforpower

generation 40%inworld

70%inIndia

Coallikely

to

remain

mainstay

of

India's

electricity

generationfornexttwentyfiveyears

Withexplosivegrowthinenergydemand,the

consumption

of

coal

is

slated

to

increase

many

fold


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StrategiestoImproveEfficiencyinPowerSector Multiprongedstrategyhastobeadopted:

Improvementsinexistingtechnologiessuchassubcritical powerplantsandhydropowerplants

R&Mofagedpowerplants

Introductionofsupercriticalandultrasupercriticalpowerplants

Introduction

of

advanced

technologies

such

as

IntegratedGasificationCombinedCycle(IGCC)

Reducelossesinpowertransmission


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ImprovementsinSteamTurbines Forevery1kcal/kWhreductioninTGcycleheatrate,coal

consumptionper

year

reduces

by

300tonnes for210MWsets 700tonnes for500MWsets

Since1977,heatrateofBHELs steamturbineshasreduced

210MW

by

5.4%

500MWby3.1%

Efficiencyofsteamturbinesisbeingimprovedby Moreefficientaerodynamicbladeprofiles

Redesigning

inlet

and

outlet

sections

Reductionofprimaryandsecondaryheatlosses Effectiveinterstagesealing Usinghighersteamparametersespeciallyreheatsteam

temperature


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New500MWSteamTurbine Newvariantof500MWsteamturbineintroducedby

BHEL

Reheatsteamtemperatureraisedfrom537Cto565C

FlowpathsofHP,IPandLPturbinesredesigned

Advancedclass

blade

profiles

Reductionofheatrateby10kcal/kWhr

Thermalperformance0.6%betterthanconventionalcycle

NewcycleadoptedforNTPCDadri,Simhadri,Ennore,Aravali,etc.


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NewRatingof600MW Newunitratingof600MWdeveloped

Usesexisting

HP

and

IP

turbine

modules

of

500

MW

LPturbinechangedfromN302x10.0toN304x6.3(twoLPturbinesof250MW)

Twoalternatives

6heater

cycle

and

537

C

reheat

temperature

7heatercycleand565Creheattemperature

LowercostperMW Onepercentimprovementinheatrateoverconventional500

MW Savingof24,000tonnes ofcoalperyear First600MWplantbeinginstalledatNorthChennai,witha7

heatercycle


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AuxiliaryPowerConsumption AerofoilbladedPAfans,withinletguidevanecontrolin

placeof

damper

control,

has

helped

reduce

fan

losses

Replacementofwormgearbyplanetarygearinpulverisershasimprovedenergyefficiency.

Efficiencyofboilerfeedpumpsbeingenhancedbyonepercent

through

thermo

hydraulic

re

design

UseofvariablespeeddriveswithIDfansandBFPs canreduceenergylossesatpartloads

Useof

efficient

motors

such

as

H

compact

can

increase

driveefficiencyby0.6%


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Control&Instrumentation Moderndistributedcontrolsystemshelptorunall

powerplant

equipment

at

close

to

their

optimum

operatingpoints

PADO(PerformanceAnalysis,Diagnosisand

Optimisation)software

provides

online

guidance

to

runtheplantwithminimumlossesanddowntime

Smartwallblowingsystemcanoptimise steam

blowingcycle

for

soot

blowers

Improvingtheheatabsorptioninboilersurfaces

Reducingtheconsumptionofauxiliarysteam


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SupercriticalPowerPlants Powerplantcycleabovecriticalpressure(221.2bar)

Offersadvantageofburnlessfuelforthesameoutput andlowemissions

Currentsteam

parameters

in

India:

250

bar,

568

C

mainsteamand593Chotreheattemperature

Steamparametersareexpectedtoberaisedfurther,in

linewith

global

trends

Duringthe12thFiveYearPlan,over50%ofthecapacityexpansionwillbethroughsupercritical

powerplants


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UltraSupercriticalPowerPlants Worldwide,UltraSupercritical(USC)plantswith

steamparameters

up

to

280

bar

and

620

OChave

been

setup

Development

of

USC

plants

with

steam

parameters

of

300barand700OCisinprogress

Thefirstsuchplantisexpectedby2015


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IndiaalsoplanstoshifttoUSCsteamparametersoverthe

next

few

years

IndiaalsoplanstodevelopUSCtechnologywith300barand700OC

Thekeychallenges

Developmentofsuitablematerials

Developmentof

an

optimum

thermodynamic

cycle

Developmentofmajorequipmentsuchassteamgenerators,steamturbinesandtheirauxiliaries

USCTechnologyinIndia


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IntegratedGasification

Combined

Cycle

(IGCC)

Important

technology

in

the

context

of

climate

change

EmissionofCO2 perMWlessthanforconventionalplants

Potentialefficiency(~45%)higherthanthatofsubcritical(~37%)

and

super

critical

(~40%)

CaptureofCO2 iseasierinthecaseofIGCC

LowNOx andSOx emissions

Lowwater

consumption

Fuelflexibility:coalaswellasrefineryresidues

Syn Gascanbeusedforconversiontooil,chemicals,fertiliser and

hydrogen


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IGCCvs.ConventionalCoalPlantConventionalCoalPlant IGCC

Plant

NOx 350ppm


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BHELs ExperienceinIGCC BHELhasbeendevelopingIGCCtechnologysincethe

earlyeighties

BHELhasgainedalotofexperienceinthedevelopmentandoperationofapilot6.2MWIGCCplantatTrichy

BHELnowwellpoisedtosetupa182MWIGCC

Demonstration

Project

with

APGENCO

at

Vijaywada UsesPressurised Fluidised BedGasification(PFBG)

technology,mostsuitedforIndiancoals


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Corp. R&D,Hyderabad

18TPD

(PEDU)

6.2 MW

CCDP

182 MWIGCC

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:

Geometrical - 1: 2.25

Capacity - 1: 15Pressure - 1:5

125 MWIGCC

ConceptDesign

Scale up:Geometrical - 1: 2.91

Capacity - 1: 11.1

Pressure - 1:3

APGENCOVijaywada

450- 650 MWIGCC

Future CommercialScale IGCC Plant

MilestonesinIGCCDevelopmentMilestonesinIGCCDevelopment


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6.2 MweIGCC withmovingbedgasifier

Process &Equipment

Development (PEDU)pilot plantbased on

PFBG

6.2 MweIGCC

retrofittedwith PFBG

To gainexperience ingasificationand IGCCplantoperation

Design andfabrication of

majorequipmt anddevelopmentof PFBGtechnology

Data forscale-up ofgasifier andits integrationwith CC

CommgMar 1988

DevelopmentaltestingCompln

Sep 1992Start

July 1983

CommgMay 1988

DevelopmentaltestingComplnJan 1997Start

May 1986

CommgJan 1996

Extensive testing

carried outStartSep 1993

BHELs IGCCDevelopment


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6.2 MW IGCC Pilot Plant at Trichy


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6.2 MW IGCC Pilot Plant at Trichy


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182MWIGCCProject Rating182MW Gasifier 2265tpd coalcapacityusingPressurised

Fluidised BedGasification

(PFBG)

technology

Gasifier Pressure:28kg/cm2,Temperature:1025C Ashcontent:3642%(Ashupto50%canbeaccepted)

Gasclean

up

system

including

barrier

filters

and

wet

scrubbers Frame9EGasTurbine:102MW HeatRecoverySteamGenerator(Twopressure) Steam

turbine:

80

MW

Grossefficiency:>40% Coal&ashhandlingsystem

Switchyard


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FutureDirectionsinIGCC 450650MWcapacitycommercialplant

Advancedclass

gas

turbine

Oxygenenrichedgasification

Lowcostoxygenseparationtechnology

Hotgas

clean

up

technology

Greaterdegreeofintegration

CO2 capture

Hydrogenfiring

in

gas

turbines

Integrationwithfuelcells


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PowerTransmission FlexibleACTransmissionSystems(FACTS),havebeen

developedand

introduced

Canbeusedintransmissionnetworkstoreducesystemlosses

Thyristor ControlledSeriesCompensation(TCSC)systemsenable

increased

power

flow

in

existing

lines

ControlledShuntReactor(CSR)developedtoreplacefixed shuntreactors

Fixed

shunt

reactors

cause

continuous

power

losses

CSRcomesintothecircuitonlywhenrequired Installed50MVARCSRinPGCILsubstationatItarsi in

2001

Excellentoperational

feedback

MAHAGENCOhasplacedordersfortwosetsofCSRs fordifferentlocations


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HVDC

HighVoltageDirectCurrent(HVDC)isalso

employedto

reduce

transmission

losses

in

long

distancepowerflow.

Advantages:lowerlosses,completecontrolofpower

flowon

the

HVDC

line,

reduced

requirement

of

right

ofway,etc.

HVDCcanalsobeusedtointerconnectelectrical

gridsoperating

at

different

frequencies

Surpluspowerfromoneregioncanbetransmittedtoapowerdeficitregion

More

efficient

and

effective

utilization

of

resources


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Conclusion Indiaispoisedtoexpanditspowersectorinabigway

Newtechnologiesarebeingintroducedtoenhanceenergyefficiency

International

cooperation

would

be

greatly

welcome

intheseareas


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