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8/7/2019 Coal efficiency

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APEC Workshop on Options to Reduce CO2

EmissionsS.C. Deo Sharma

Centre for Power Efficiency and Environmental Protection (CenPEEP)

National Thermal Power Corporation (NTPC) Limited, India16th February, 2004

"Coal-fired Power Plant Heat Rate and

Efficiency Improvement in India"


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Coverage

1. NTPC: A Snapshot

2. NTPC USAID Partnership

3. Indian Power Scenario

4. CenPEEP Strategies

5. CenPEEP Experience

6. Future Options & Govt. Initiatives


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Present Commissioned Capacity -- 21749 MW

(Coal based: 17480 MW Gas based: 3955, JV: 314)

Projects Under Construction --- 5300 MW

Capacity Addition of over 9370 MW planned for Xth Planand 11210 MW planned for XI th Plan

Ambitious growth plan to become a 56000 MW company by

2017

NTPC:A SNAPSHOTNTPC:A SNAPSHOT

PLF of NTPC Stations in 2002-03: 83.6%

Turnover: Billion $ 4.129Net Profit: Million $ 745

National Thermal Power Corporation Ltd. a Govt. of India

Enterprise, set up in 1975 is the largest power utility inIndia.


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NTPC USAID Partnership

Greenhouse Gas Pollution Prevention ProjectGEP Project Aim:

Environmental protection in energy sector by reducing

emissions of greenhouse gases Project outputs: demo of advanced efficient

generation techniques for coal fired power plants.

Ministry of Power

(GOI)

NTPCNTPC USDOEUSDOE

US Agency for International

Development


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Protocol of Intent signed between Govt. of India, Govt. ofUSA and NTPC to implement GEP Project in 1994.

Center for Power Efficiency & EnvironmentalProtection (CenPEEP) established by NTPC in 1994 toimplement GEP Project.

US Department of Energy (USDOE) & USAID supportingCenPEEP through technical assistance & transfer of

advanced leading edge technology for performance

improvement

Initially Project Assistance Completion Date was March,2002;

Project extended till March 31, 2005 and September 30, 2008

in Sept. 1999 and 2003 respectively

Formation of CenPEEP


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Development of an Institution in power sector in India:

To reduce GHG emission from coal fired power plants by

performance optimization in terms of efficiency, availability& reliability .

Technology acquisition with USAID assistance for GHG

reduction Institutionalization of cooperation for technology transfer.

To become a National Resource Centre for performance

optimization and climate change options

To become a Service Provider in power sector

GOALS OF CenPEEP


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Awards & RecognitionsAwards & RecognitionsAwards & Recognitions

CTICTIs Worlds World

ClimateClimateTechnologyTechnology

Award 2002Award 2002

USEPAUSEPA

CLIMATECLIMATE

PROTECTIONPROTECTION

AWARD 2003AWARD 2003


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Coverage

1. NTPC: A Snapshot


3.Indian Power Scenario





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Per Capita Electricity Consumption(IEA: Key World Energy Stat 2003)

We have a long way to go

Per Capita Energy Cons & CO2 emission

408

12896

0

2000

40006000

8000

10000

12000

14000

Wo

rld

USA

Japan

France

Germany

U

K

Korea

USSR

Malaysia

Bra

zil

China

India

Country

PerCapitaEnergyCon

0

5

10

15

20

25

PerCapitaCO2Emission

Per Capita Energy Cons

Per Capita CO2 Emission


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109868

101661

66003

97386

28448

12957

46531712

0

20000

40000

60000

80000

100000

120000

1950

'60-'61

'68-'69

'79-'80

'90-'91

'99-'00

00-01

'2003

Ins

tall

edC

apac

ityx

x(M

W)

Years

India: Growth of Installed CapacitiesIndia: Growth of Installed Capacities

Generation in the country risen from 5 Billion units in 1950 to531.43 Billion units in 2002-03.

Generation recorded average yearly growth rate of + 8%.

Peak energy shortages are approx 11%


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POWER SCENARIO of INDIAPOWER SCENARIO of INDIA

Thermal generation share: consistently increasingPeak: 84% in year 2002-03

35%

Hydro

65%65%Thermal

29%

Hydro

69%69%

ThermalThermal

2% Nuclear

70%70%

ThermalThermal

5 % Nuclear & Others

Ist PLAN VIIth PLAN(03/56) (03/90) 2003

25 %

Hydro


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India: Capacity Addition Programme

(Projected for next 10 years- by 2012)

A. Capacity Addition :

Hydro 36597 MW

Thermal 65339 MW

Nuclear 7215 MWTotal 109151 MW

Coal is going to remain the dominant fuel


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Coal Based Power Generation-Issues

Important Issues: Peak power and energy shortages; focus on PLF

Deterioration in coal quality

Deterioration in equipments performance

Approx 40% of power plants less than 200MW

Old plants and equipments - lower rated efficiency

Poor C&I in old plants

Poor maintenance;low performance recovery

Need of R&M: but resource constraint

Coal - mainstay of power generation in India

(abundant reserve, low cost and energy security reasons)


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Environmental issues in coal based power generation :

Greenhouse gas (CO2) emission

Particulate mission

SOx and NOx emission Poor coal quality

Coal haulage over long distance

Ash management / large ash quantity and large land &water requirement, leachates possibilities

Fugitive emission Effluents

Environmental Issues

With accelerated capacity addition program, theseissues would be further aggravated.

Hence appropriate measures need to be taken early.


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Why Power Plant Efficiency is Important?

Increased efficiency implies:

Same MW / Electricity from less quantity of coal

1% efficiency improvement implies:

~3% reduction in coal consumption and

~3% reduction CO2/GHG & particulate emission

Generation efficiency: percentage energy content of thefuel being converted into electrical energy.

Focus needed on technology options to improve

generation efficiency of existing & new power stations.

Efficiency of modern coal power plant = 34-36%

Efficiency of old power plant = 20-30%


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Coverage

1. NTPC: A Snapshot



4. CenPEEP Strategies5. CenPEEP Experience



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WIN-WIN STRATEGY

EnvironmentImprovement

Plant Productivity

Improvement

GHG emission reductionParticulate emissionreduction

Sox / Nox emission

reductionEffluents reduction

Improved ash

managementImprovement in global

climate

Efficiency increase

Availabilityimprovement

Reduction in O&M

costsLess capacity addition,

less resource required

Increased profitability

Sustainable growthDual focus: PLF& Eff.

Global Concerns Utility Concerns

CenPEEP


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Focus AreasFocus Areas

Low CostLow CostHigh returnHigh return ESPESPOptimizationOptimizationAvailabilityAvailabilityImprovementImprovement

Turbine CycleTurbine Cycle

OptimizationOptimizationBoiler CycleBoiler Cycle

OptimizationOptimization

Technology DisseminationService Provider in selected areas

Coal Beneficiation Studies to promote washed coal usageAdvanced power generation technologiesAsh haulback

CenPEEP: TARGET AREAS


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TechnologyDissemination

Workshop/ News Letters

/ Web Site

TechnologyDemonstration

Wide spreadTraining

Technology Selection &Acquisition

CENPEEP ModelState-of-the art technologies & practices for GHG reduction

from existing coal fired power stations

and

Pursuit of new technologies & options forpower generation & GHG mitigation

State-of-the art technologies & practices for GHG reductionfrom existing coal fired power stations

and

Pursuit of new technologies & options forpower generation & GHG mitigation

Sustainability Through implementation ofSystems / Procedures / Guidelines

CenPEEP MethodologyCenPEEP Methodology

Technology Transfer


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Typical Steps in Technology Transfer

1. Identification of cost effective technique practiced in

US Utilities for performance improvement

2. Training to CenPEEP / NTPC personnel at US

Utilities

3. Training & demo by US experts in Indian Utilities

(NTPC state run utilities both)

4. Demo by CenPEEP in Indian Utilities

CenPEEP: Methodologies

To start performance improvement activities, set of

instruments and equipments were provided by USAID


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Typical Steps in Technology Demonstration

1. Create awareness through training / workshop /

performance optimizers etc2. Walk down of power station to assess the plant

conditions, provide broad recommendations,

3. Formation of POGs groups and identify test ports andnecessary instruments for performance testing

4. Performance testing of the equipments / plants using

high accuracy test instruments5. Recommendation based on the performance testing

6. Sustainability of program by follow up, workshops,

feedback sessions etc

CenPEEP: Methodologies


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Establishes the current level of boiler efficiency

Facilitates combustion optimization

Improves operating efficiency of the boiler Assesses performance degradation, provides inputs to

maintenance for performance restoration

The test comprises of:

Mill testing & performance optimization

Boiler efficiency test

Air preheater testBoiler Furnace Test

Auxiliary power measurement of boiler drives

Boiler Performance Testing


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Turbine & Auxiliaries Testing

Salient Features Establish current level of performance using high

accuracy Instruments

Demo exercises revealed potential of recovering 50- 100 kcal/kWh in HR

Techniques Demonstrated

Performance testing of equipments Water powered cleaners

Condenser air in leak using He leak detector

CW flow measurement using dye dilutiom Induction heating of turbine studs

TurbineTurbine

HRHR

HP / IPHP / IP

EffEff..

CondenserCondenser

HPHPHeatersHeaters

BFPBFP


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The performance optimization techniques:

Establish current level of equipment performance &

best achievable efficiency

Recommend optimal operating regime

Assess performance degradation, provides inputs tomaintenance for performance & capability restoration

Facilitate combustion optimization

Improve operating efficiency

Performance Improvement Activities

CenPEEP undertakes performance improvementactivities through its central & regional set ups.

Use of high accuracy measuring instruments


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Coverage

1. NTPC: A Snapshot







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CenPEEP demonstrated performance improvement in several

NTPC stations and state owned utilities by:

1. Generating awareness for performance improvement

and key areas to be focused upon.

2. Implementing systems for performance evaluation &

performance tracking

3. Adopting best practices & new cost effective techniques

Demonstrated improvement even in best run power plants

CenPEEP Experience / Feedback

CenPEEP awareness program & activities enabled

shift in focus from PLF to Efficiency and PLF both


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Salient findings of CenPEEP activities:

Performance improvements are possible at any plant;

1-2% in many plants. Start small; one or two areas (Condenser, APH) and / orone or two activities (primary indicators / testing)

Full support of plant management required

Detailed plan of activities for improvement ant their

periodical review

HR improvement is continuing process; normal work

activities

Performance improvement to be responsibility of every

one; active involvement of all plant staff


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Typical savings ($/Year for pit head station; 210 MW Unit)

1% HR Improvement: 122,640

1% APH Inlet O2: 36,350

1mm Condenser pressure: 9,958

1C APH exit gas temp: 5,886

1C Main steam temp: 3,140

The demand for CenPEEP services increasingconsistently.

CenPEEP expanded its activities by establishing tworegional CenPEEP Centers; set of instruments /

equipments provided by USAID


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Coverage

1. NTPC: A Snapshot





6. Future Options & Initiatives


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GHG Emission Reduction: Other Options

Setting up advanced technology plants like IGCC,Fuel Cells; their feasibility is being explored

Use of non conventional energy resources;

Reduction of T&D Losses

Energy End Use Efficiency

End use energy efficiency improvement leads to lessenergy consumption, less power requirement for

same usage and hence less GHG emission.

Potential areas includes:1. Efficient motor & pumps for agricultural application

2. Energy efficient equipments / system in industries

3. Efficient lighting, domestic electrical appliances, air

conditioning, building design etc.

I i i l i i i i


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500 MW plants & 660 MW supercritical plants for futurecapacity addition

Establishment of CenPEEP to reduce GHG, SPM and

other pollutant emissions

Accelerated Power Development & Reform Program toprovide support to state utility to reduce T&D losses.

Promulgating Energy Conservation Act and establishingBureau of Energy Efficiency to improve end use energyefficiency

Employing highly efficient pollution control devices Large scale Afforestation

Use of washed coal in plants 1000 Km away from mine

end, in sensitive areas & suburbs

Institutional initiatives


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Thank You

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