EnergyEfficiencyinPowerSector

AlokMathur GeneralManager(ARP) BHELNewDelhi

3rd India Japan Energy Forum 15-16 February 2010

ImportanceofIncreasingEfficiencyin PowerSector
Lessfuelburntperunit LessCO2 andotherpollutantsperunit Conservesnonrenewablefuel Reducescostofgeneration Reducesrequirementoffreshcapacityaddition

PredominanceofCoal
Coalispredominantsourceofenergyforpower generation 40%inworld 70%inIndia CoallikelytoremainmainstayofIndia'selectricity generationfornexttwentyfiveyears Withexplosivegrowthinenergydemand,the consumptionofcoalisslatedtoincreasemanyfold

StrategiestoImproveEfficiencyin PowerSector
Multiprongedstrategyhastobeadopted:
Improvementsinexistingtechnologiessuchas subcritical powerplantsandhydropowerplants R&Mofagedpowerplants Introductionofsupercriticalandultrasupercritical powerplants Introductionofadvancedtechnologiessuchas IntegratedGasificationCombinedCycle(IGCC) Reducelossesinpowertransmission

ImprovementsinSteamTurbines
Forevery1kcal/kWhreductioninTGcycleheatrate,coal consumptionperyearreducesby 300tonnes for210MWsets 700tonnes for500MWsets Since1977,heatrateofBHELs steamturbineshasreduced 210MWby5.4% 500MWby3.1% Efficiencyofsteamturbinesisbeingimprovedby Moreefficientaerodynamicbladeprofiles Redesigninginletandoutletsections Reductionofprimaryandsecondaryheatlosses Effectiveinterstagesealing Usinghighersteamparametersespeciallyreheatsteam temperature

New500MWSteamTurbine
Newvariantof500MWsteamturbineintroducedby BHEL Reheatsteamtemperatureraisedfrom537Cto565C FlowpathsofHP,IPandLPturbinesredesigned Advancedclassbladeprofiles Reductionofheatrateby10kcal/kWhr Thermalperformance0.6%betterthanconventional cycle NewcycleadoptedforNTPCDadri,Simhadri, Ennore,Aravali,etc.

NewRatingof600MW
Newunitratingof600MWdeveloped UsesexistingHPandIPturbinemodulesof500MW LPturbinechangedfromN302x10.0toN304x6.3(twoLP turbinesof250MW) Twoalternatives 6heatercycleand537Creheattemperature 7heatercycleand565Creheattemperature LowercostperMW Onepercentimprovementinheatrateoverconventional500 MW Savingof24,000tonnes ofcoalperyear First600MWplantbeinginstalledatNorthChennai,witha7 heatercycle

AuxiliaryPowerConsumption
AerofoilbladedPAfans,withinletguidevanecontrolin placeofdampercontrol,hashelpedreducefanlosses Replacementofwormgearbyplanetarygearinpulverisers hasimprovedenergyefficiency. Efficiencyofboilerfeedpumpsbeingenhancedbyone percentthroughthermohydraulicredesign UseofvariablespeeddriveswithIDfansandBFPs can reduceenergylossesatpartloads UseofefficientmotorssuchasHcompactcanincrease driveefficiencyby0.6%

Control&Instrumentation
Moderndistributedcontrolsystemshelptorunall powerplantequipmentatclosetotheiroptimum operatingpoints PADO(PerformanceAnalysis,Diagnosisand Optimisation)softwareprovidesonlineguidanceto runtheplantwithminimumlossesanddowntime Smartwallblowingsystemcanoptimise steam blowingcycleforsootblowers Improvingtheheatabsorptioninboilersurfaces Reducingtheconsumptionofauxiliarysteam

SupercriticalPowerPlants
Powerplantcycleabovecriticalpressure(221.2bar) Offersadvantageofburnlessfuelforthesame output andlowemissions CurrentsteamparametersinIndia:250bar,568C mainsteamand593Chotreheattemperature Steamparametersareexpectedtoberaisedfurther,in linewithglobaltrends Duringthe12thFiveYearPlan,over50%ofthe capacityexpansionwillbethroughsupercritical powerplants

UltraSupercriticalPowerPlants
Worldwide,UltraSupercritical(USC)plantswith steamparametersupto280barand620OChavebeen setup DevelopmentofUSCplantswithsteamparametersof 300barand700OCisinprogress Thefirstsuchplantisexpectedby2015

USCTechnologyinIndia
IndiaalsoplanstoshifttoUSCsteamparametersover thenextfewyears IndiaalsoplanstodevelopUSCtechnologywith300 barand700OC Thekeychallenges
Developmentofsuitablematerials Developmentofanoptimumthermodynamiccycle Developmentofmajorequipmentsuchassteam generators,steamturbinesandtheirauxiliaries

IntegratedGasificationCombinedCycle (IGCC)
Importanttechnologyinthecontextofclimatechange EmissionofCO2 perMWlessthanforconventional plants Potentialefficiency(~45%)higherthanthatofsubcritical (~37%)andsupercritical(~40%) CaptureofCO2 iseasierinthecaseofIGCC LowNOx andSOx emissions Lowwaterconsumption Fuelflexibility:coalaswellasrefineryresidues Syn Gascanbeusedforconversiontooil,chemicals, fertiliser andhydrogen

IGCCvs.ConventionalCoalPlant
ConventionalCoalPlant Plant NOx 350ppm SOx 600ppm SPM 50mg/Nm3 CO2 Emission High CO2 captureready No Fuelconsumption High less Waterconsumption High <25ppm <245ppm <2mg/Nm3 10%Less Yes 7% 40%Less IGCC

BHELs ExperienceinIGCC
BHELhasbeendevelopingIGCCtechnologysincethe earlyeighties BHELhasgainedalotofexperienceinthe developmentandoperationofapilot6.2MWIGCC plantatTrichy BHELnowwellpoisedtosetupa182MWIGCC DemonstrationProjectwithAPGENCOatVijaywada UsesPressurised Fluidised BedGasification(PFBG) technology,mostsuitedforIndiancoals

MilestonesinIGCCDevelopment
Scale up: Geometrical - 1:1.14 Capacity - 1: 1.21 Pressure - 1:0.9

450- 650 MW IGCC 182 MW IGCC

APGENCO Vijaywada

Scale up: Geometrical - 1: 2.91 Capacity - 1: 11.1 Pressure - 1:3

Scale up: Geometrical - 1: 3.3 Capacity - 1: 9.33 Pressure - 1:1.2 Scale up: Geometrical - 1: 2.25 Capacity - 1: 15 Pressure - 1:5 Dia 0.2 m Press 2.0 ata
1.2 TPD (APFBG)

Future Commercial Scale IGCC Plant

125 MW
IGCC
6.2 MW CCDP Concept Design

18 TPD (PEDU)

Tiruchy

Corp. R&D, Hyderabad

Corp R&D Hyderabad

BHELs IGCCDevelopment
6.2 Mwe IGCC with moving bed gasifier Process & Equipment Developme nt (PEDU) pilot plant based on PFBG 6.2 Mwe IGCC retrofitted with PFBG
Start July 1983 Commg Mar 1988 Developmental testing Compln Sep 1992

To gain experience in gasification and IGCC plant operation Design and fabrication of major equipmt and development of PFBG technology Data for scale-up of gasifier and its integration with CC

Start May 1986

Commg May 1988

Developmental testing Compln Jan 1997

Start Sep 1993

Commg Jan 1996

Extensive testing carried out

6.2 MW IGCC Pilot Plant at Trichy

6.2 MW IGCC Pilot Plant at Trichy

182MWIGCCProject
Rating182MW Gasifier 2265tpd coalcapacityusingPressurised Fluidised BedGasification(PFBG)technology Gasifier Pressure:28kg/cm2,Temperature:1025C Ashcontent:3642%(Ashupto50%canbeaccepted) Gascleanupsystemincludingbarrierfiltersandwet scrubbers Frame9EGasTurbine:102MW HeatRecoverySteamGenerator(Twopressure) Steamturbine:80MW Grossefficiency:>40% Coal&ashhandlingsystem Switchyard

FutureDirectionsinIGCC
450650MWcapacitycommercialplant Advancedclassgasturbine Oxygenenrichedgasification Lowcostoxygenseparationtechnology Hotgascleanuptechnology Greaterdegreeofintegration CO2 capture Hydrogenfiringingasturbines Integrationwithfuelcells

PowerTransmission
FlexibleACTransmissionSystems(FACTS),havebeen developedandintroduced Canbeusedintransmissionnetworkstoreducesystem losses Thyristor ControlledSeriesCompensation(TCSC)systems enableincreasedpowerflowinexistinglines ControlledShuntReactor(CSR)developedtoreplace fixed shuntreactors Fixedshuntreactorscausecontinuouspowerlosses CSRcomesintothecircuitonlywhenrequired Installed50MVARCSRinPGCILsubstationatItarsi in 2001 Excellentoperationalfeedback MAHAGENCOhasplacedordersfortwosetsofCSRs for differentlocations

HVDC
HighVoltageDirectCurrent(HVDC)isalso employedtoreducetransmissionlossesinlong distancepowerflow. Advantages:lowerlosses,completecontrolofpower flowontheHVDCline,reducedrequirementofright ofway,etc. HVDCcanalsobeusedtointerconnectelectrical gridsoperatingatdifferentfrequencies Surpluspowerfromoneregioncanbetransmittedtoa powerdeficitregion Moreefficientandeffectiveutilizationofresources

Conclusion
Indiaispoisedtoexpanditspowersectorinabigway Newtechnologiesarebeingintroducedtoenhance energyefficiency Internationalcooperationwouldbegreatlywelcome intheseareas