CLEAN COAL TECHNOLOGIES FOR SUSTAINABLE POWER DEVELOPMENT

Dr. V. K. SETHI Prof. & Head RGPV Bhopal

WORLD SUMMIT ON SUSTAINABLE DEVELOPMENT

PRIORITIES ON ENERGY GENERATION SECTOR: Increased use of Advanced Fossil Fuel Technology.

Promote CCT in countries where coal is main stay fuel for Power Generation. Reduce Atmospheric Pollution from Energy Generating Systems. Enhance productivity through Advanced Fossil Fuel Technology.

POWER SCENARIO IN INDIA

Installed capacity in utilities

(March 31, 2002) 73,274 mw 25,574 mw 2,860 mw 1,427 mw 1,03,135 mw

Thermal Hydro Nuclear Wind Total

Total energy generation 383 billion kwh Per Capita Energy Consumption -400 kwh

DEMAND PROJECTION
YEAR 2012 CAPACITY ADDITION BY SECTORS Central 46,500 MW State & IPP 41,800 MW NCES 10,700 MW Nuclear 6,400 MW Total 105,400 MW YEAR 2020 MIX OF GENERATION Thermal Renewable & Hydro Nuclear Total

326,000MW 104,000 MW 20,000 MW 450,000 MW

CLEAN COAL TECHNOLOGIES

Mining

Management & Practices (Reduction of Extraneous material) Process after mining to improve inherent & Extraneous material (washing & beneficiation) Supercritical, PFBC and IGCC

Coal Preparation

Conversion Technologies

Post combustion cleaning

Particulate and gaseous pollutants removal (Environmental requirement)

VISION 2020 PROGRAM

Gasification using + fluidized bed, moving bed or Entrained bed Gasifiers In-combustion Clean-up Fluidized bed combustion (CFBC, PFBC, AFBC)
Post combustion Clean-upDesulfurization (FGC systems) Supercritical

Pre combustion Cleanup beneficiation/washing

CLEAN COAL TECHNOLOGIES

Technologies for utilization of Coal for Power Generation with minimal pollutants discharged to the atmosphere (Reduced CO2, Sox, Nox, SPM) at high conversion efficiency.World Coal Institute.

Clean

Coal Technologies (CCTs) are defined as technologies designed to enhance:

Efficiency

CLEAN COAL TECHNOLOGIES

of conversion

Environmental

acceptability of coal extraction, preparation and use.

COAL FOR POWER GENERATION

China

and India are projected to account for30% of the worlds increase in energy consumption between 2000-2020 and 92% of increase in coal use. key environmental challenges facing the coal industry are related to :

The

Coal Mining Particulate emission Disturbance land me Acid rain Ozone and Waste disposal

INDIA AMONGST TOP SIX EMITTERS OF CO2

Country of Total emission (Million Tonnes of CO2) USA China Russian Federation Japan Germany India 5470 3121 1456 1173 884 881 Percentage world emission 24% 14% 6% 5% 4% 4%

Note : Green House inventory for India for Energy Sector (Million Tonnes of CO2)
Energy Sector CO2 CO2 equivalent (CO2+CH4+NOx) Total Emission 508 565 (58% of total) (64% of total)

Source : IAE : 1999

PER CAPITA EMISSIONS OF CO2

Top 6 Polluters
World Developed countries Developing Countries Parties (Tonnes of CO2 per (Tonnes of CO2 per capita) capita) USA 20.50 Luxemboury 20.42 Australia 16.52 Canada 15.76 Finland 12.47 Estonia 12.47 Qatar 44.08 Bahrain 35.23 U.A.E. 30.11 Kuwait 25.01 Singapore 23.47 Saudi Arabia 13.27

Qatar 44.08 Bahrain 35.23 UAE 30.11 Kuwait 25.01 Singapore 23.47 U.S.A 20.50

Note : Per capita CO2 equivalent emissions for India in 1990 are estimated to be 1.194 tonnes or 325 kg of Carbon per capita. This contribution 58% of National Emissions and 4% of global emission.
Source : IEA 1999 & UNDP 1998.

COST OF VARIOUS CO2 MITIGATION OPTIONS FOR INDIAN POWER SECTOR

Potential Technologies Green house gas emission reduction (kg/kWh)
1.50 0.96 0.18 0.23 0.18 0.125

COST (Rs/Tonnes CO2)

.

1. 2. 3. 4. 5. 6.

Co-generation Combined Cycle PFBC IGCC Supercritical Coal Washing

480 2600 24000 16000 16000 8500

Source: ADP 1998

Zero Emission Technology (ZET)

This technology combines and forms a part of : Clean Coal Technologies Solid to liquid fuel technology GHG mitigation technology Clean Development Mechanism for power sector Non-CFC Refrigerant and Non-CFC Aerosol Propellant Technology Clean Aviation Fuel or ATF for aircraft Substitute LPG for domestic use.

Measures to achieve Sustainable Development

Promoting

CCTs, including carbon sequestration is essential to a balanced cost effective climate change response
Developing

countries where coal combustion efficiencies are low CCT promotion a need of the day.

Super Critical PC Power Plant (15 oC Amb.) 60 Super Critical PC Power Plant (Indian Condition) IGCC (15 o Amb) C IGCC (Indian Condition) Sub Critical PC Power Plant (Indian Condition) 1500 oC 1300o C 623 o C oC 600

Net Thermal Efficiency (%)

55

50
45 566 oC

40
1184o C

650o C
540oC

Ceramic gas turbine

35 30 1990

1995

2000

2005

2010

Year of commercial use

EFFICIENCY IMPROVEMENT FORECAST

CONVENTIONAL Vs IGCC ( Courtesy BHEL)

POLLUTANT GENERATION FROM PC PLANTS

150
MMT

128 85 13.3 20
1997 2002 1997 2002

100 50 0

No Change Scenario Specific Coal Consumption

15

ASH

=0.75 KG/KWH
Coal Ash : 43% 0.6%

10

MMT

10 5 0 2.8 4.3

6.6

Sulphur :
1997 2002 1997 2002

SO2
600 500 400
MMT

570

Ideal Scenario Specific Coal Consumption

384 256

380

=0.35 KG/KWH
Coal Ash : 15% 3%

300 200 100 0

1997 2002

1997

2002

Sulphur :

CO2

RELATIVE EMMISSION
PERCENTAGE OF PC PLANTS
120 110 100 90 80 70 60 50 40 30 20 10 0

PC PC+FGD PFBC IGCC

SOx

NOx Particulates

SUPER CRITICAL UNITS

Standardized Unit Size 660 MW, 246 ata, 537 oC Station Size 2x660 MW (Minimum) Common Off site facility o o FW Temperature 270 C 275 C with 6 Heaters.

Total Capacity Planned Number of Units

14,560 MW * 22 Units

* Includes 6x720 MW and 2x500 MW Imported sets.

Main advantages of Super-Critical Steam Cycle

Reduced fuel cost due to improved thermal efficiency

Reduction of CO2 emissions by 15% per unit of Power

generated compared to sub-critical

Very good part load efficiencies Plant costs are comparable with sub-critical units

Current State-of-Art
Super-critical Steam Power Generation Plants Pressure 300 bar Temperature 600oC Efficiency 45% (LHV Basis)
Nickel based alloys allows up 650oC By the year 2005 620 oC By the year 2020 650-700 oC Cycle Efficiency 50-55%

R&D IN SUPERCRITICAL TECHNOLOGY

Main Thrust Areas :

Materials & Metallurgy for components of boiler & turbine subjected to high temperature and high pressure. Supercritical cycle optimization -incremental heat rate improvement Retrofit of supercritical boiler to subcritical PC boiler Fluidized bed supercritical steam cycles Once through HRSGs with supercritical parameters Multi-reheat supercritical boilers with double/triple reheater.

SUPER CRITICAL SCENARIO

EXPECTED BENEFITS:

Coal Saving
Co2 Emission Reduction

1,565,200
1,909,544

Tonnes

SO2 Emission Reduction

Ash Reduction

11,648
661,752

COAL BASED COMBINED CYCLE PLANT

Routes Combustion Hot Flue gas under pressure drives the G.T. Gasification Pressurized gasification process produces fuel for G.T. Options Available Moving BED Fluidized BED Entrained BED

Pressurized Fluidized BED Combustor (PFBC)

COAL BASED COMBINED CYCLE POWER GENERATION

Offers Plant efficiency over 44% with advanced GT

Has Lower emission of gaseous and solid pollutants

Accept Inferior and varying quality of coals

Lower water requirement

Capability of phased construction and retrofitting

IGCC TECHNOLOGY ...

Gasification of coal is the cleanest way of utilization of coal, while combined cycle power generation gives the highest efficiency. Integration of these two technologies in IGCC power generation offers the benefits of very low emissions and efficiencies of the order of 44-48%.

The comparative indices show that in case of IGCC, emission of particulate, NOx and SOx are: 7.1%, 20% and 16%, respectively, of the corresponding emissions from PC plant.

IGCC ...

Environmental performance of IGCC plants far exceeds that of conventional and even supercritical plants. Three major areas of technology that will contribute to improvements in IGCC are : hot gas de-sulfurisation hot gas particulate removal advanced turbine systems

DEVELOPMENTAL GOALS FOR IGCC

To utilize Indias low grade coal for power generation with improved plant efficiency. To introduce coal gas in Natural Gas based Combined Cycle Plants in a phased manner. To increase power generation capacity at the level of present emission. To develop state of Art Technology for Indigenous and Export Markets.

IGCC
Gas Clean Up COAL Raw Gas Cooler Steam Air
Gasifier
Booster

Fuel Combustion Chamber

Alternator Comp. Turb.

Ash Steam

Air Alternator
ST

Exhaust Gases Condenser WHB

IGCC DEVELOPMENT PROGRAM IN INDIA

MAJOR MILE STONES:

Choice of gasification for high ash coals by BHEL 6.2 MW IGCC demonstration plant established by BHEL both with Moving Bed and Fluidized Bed.

Coal Characterization by BHEL & IICT for gasification application. Intensive data generated by IICT on oxygen-steam gasification in their

Moving Bed gasifier.

Task force CEA, CSIR, NTPC & BHEL constituted to assess technological maturity & Financial requirement for a green field IGCC plant of 100 MW capacity at Dadri (NTPC).

BHEL, CSIR & NTPC prepared proposal for setting up of this 100 MW IGCC demonstration plant.

Circulating fluidized Bed Combustion

Circulating Fluidized Bed Combustion (CFBC) technology has selectively been applied in India for firing high sulphur refinery residues, lignite, etc.

CFBC Technology is superior to PC Power Plant Technology:

Lower NOx formation and the ability to capture SO2 with limestone injection the furnace.

Circulating fluidized Bed Combustion

Good combustion efficiencies comparable to PC Power Plants. The heat transfer coefficient of the CFB furnace is nearly double that of PC which makes the furnace compact. Fuel Flexibility: The CFB can handle a wide range of fuels such as inferior coal, washery rejects, lignite, anthracite, petroleum coke and agricultural waste with lower heating.

Circulating Fluidised Bed Boiler

Steam to Super Heater

Cyclone Coal Feed Hopper Back-Pass Furnace

ESP

Ash Cooler

External Heat-Exchanger HP Air

CFBC Vs Other Clean Coal Technologies

ITEM Cycle Eff. % Relative Capital Cost/kW Relative O&M Cost/kW CFBC 34.8 1.0 1.0 PF+FGD/SCR 36.7 1.03-1.19 1.49 IGCC 41-42 1.15-1.42 0.8-0.98

At present pulverized fuel firing with FGD are less costly than prevailing IGCC technology. However, firing in CFB Boiler is still more economical when using high sulfur lignite and low-grade coals and rejects.

Renovation & Modernization (R&M) and Life Extension (LE) of old power plants is a costeffective option as compared to adding up green field plant capacities. Growing environmental regulations would force many utilities within the country to go for revamping these polluting old power plants using environmentally benign CFBC technology.

SUMMERY

Sustainable Power Development calls for adoption of Clean Coal Technologies like Supercritical cycles, IGCC and FBC technologies Supercritical Power technologies may selectively be used for Pit Head power generation using washed coal

SUMMERY

IGCC can revolutionize the power generation scenario in India, once the commercial viability of technology with high ash coals is established at the proposed 100 MW plant.

The success of the project will largely depend on maturity of Fluidized bed gasification technology for high ash Indian Coals. CFBC technologies are particularly useful for Boiler Emission reduction through revamping of old polluting plants.