1

ENERGY EFFICIENCY IMPROVEMENT ENERGY EFFICIENCY IMPROVEMENT IN THE POWER SECTORIN THE POWER SECTOR

PresentationPresentationby by

BHEL - Corporate Engineering &BHEL - Corporate Engineering &Product DevelopmentProduct Development

5 June 20085 June 2008

2

Improvements in existing technologies such as sub-critical power plants and hydro power plants.

Introduction of supercritical and ultra supercritical power plants.

Introduction of advanced technologies such as Integrated Gasification Combined Cycle plants or IGCC.

ENERGY EFFICIENCY IMPROVEMENT IN THE POWER SECTORENERGY EFFICIENCY IMPROVEMENT IN THE POWER SECTOR

3

Initiative - New materials and availability of advanced engineering techniques such as FEM, CFD, Simulation, etc., running on faster and cheaper computers .

Development of more efficient aerodynamic blade profiles and re-designing the inlet and outlet sections using modern CFD techniques.

Improved cycle introduced - increasing steam parameters like main steam pressure, main steam temperature and hot reheat temperature or improving the internal efficiency by reducing losses in the steam turbines

ENERGY EFFICIENCY IMPROVEMENT IN THE POWER SECTORENERGY EFFICIENCY IMPROVEMENT IN THE POWER SECTOR

Improvements in existing technologiesSteam Power Cycle

1 kcal/ kWh reduction in TG cycle heat rate, coal consumption reduces by 300 and 700 tonnes per year for 210 and 500 MW sets.

4

Losses restricted by employing more effective inter-stage sealing and shaft sealing by keeping radial clearances to the minimum.

New Rating Developed - A new cost effective and thermodynamically efficient plant with a unit rating of 600 MW.

ENERGY EFFICIENCY IMPROVEMENT IN THE POWER SECTORENERGY EFFICIENCY IMPROVEMENT IN THE POWER SECTOR

Improvements in existing technologiesSteam Power Cycle

5

Use of aerofoil bladed PA fans, with inlet guide vane control in place of damper control - reduced fan losses. Replacement of worm gear by planetary gear in pulverisers has improved their energy efficiency.

Efficiency of boiler feed pumps - Enhanced by one percent through thermo hydraulic re-design

Use of variable speed drives with ID fans and BFPs - reduced energy losses at part loads.

ENERGY EFFICIENCY IMPROVEMENT IN THE POWER SECTORENERGY EFFICIENCY IMPROVEMENT IN THE POWER SECTOR

Improvements in existing technologies

Auxillary power consumption

6

PADO (Performance Analysis, Diagnosis and Optimisation) can provide online guidance to operators to run the plant with minimum losses and downtime

Smart wall blowing system - Optimises the steam blowing cycle for soot blowers, thus improving the heat absorption in boiler surfaces and reducing the consumption of auxiliary steam.

ENERGY EFFICIENCY IMPROVEMENT IN THE POWER SECTORENERGY EFFICIENCY IMPROVEMENT IN THE POWER SECTOR

Improvements in existing technologies

Control and Instrumentation

7

Washing of coal, or beneficiation, to maintain ash content to 30-35%

The benefits are: Coal quality becomes consistent wrt ash %age Economical design of Boiler, less space, fewer pulverisers,

reduced size of Auxiliaries – Lower capital cost Low operational costs Better efficiency Lower particulate emissions

ENERGY EFFICIENCY IMPROVEMENT IN THE POWER SECTORENERGY EFFICIENCY IMPROVEMENT IN THE POWER SECTOR

Improvements in existing technologies

Coal Washeries

Establishment of coal washeries needs to given a high priority.

8

The station heat rate is 3% lower than with the conventional sub-critical cycle.

Power plant cycles operating above the critical pressure 221.2 bar. Supercritical cycle’s advantage - ‘burn less fuel for the same output’

and low emissions. Steam parameters like 250 bar pressure, 568 C main steam

temperature and 600 C hot reheat temperature are commonly used World-wide R & D efforts are focused on development of power

plants with ultra-supercritical steam parameters of 350 bar, 700 C main steam and reheat steam temperatures and net efficiency of 50% by the year 2015.

ENERGY EFFICIENCY IMPROVEMENT IN THE POWER SECTORENERGY EFFICIENCY IMPROVEMENT IN THE POWER SECTOR

Introduction of supercritical power plants

BHEL is associated with 660 MW Barh Super critical Project

9

GAS CLEAN-UP

GAS

TURBINE H R S G

STEAM

TURBINE

GT POWER STACK ST POWER

2 BLOCKS IN COAL GASIFICATION PLANT

CLEAN FUEL GAS

3 BLOCKS IN COMBINED CYCLE POWER PLANT

STEAMGASEXHAUST

WHAT IS IGCC

NGOIL

COAL

GASIFICATION

10

IGCC Advantage

Conventional Coal plant* IGCC Plant

NOx 350 ppm <25 ppm

SOx 600 ppm 245 ppm

SPM 50 mg/Nm3 2 mg/Nm3

CO2 Emission High 10% Less

Fuel consumption High 7% less

Water consumption High 40% Less

* Typical 500MW thermal plant

Low Emission, High Efficiency

Power Generation Technology

11

Reduce adverse impact of fossil fuel combustion on environment

Acid rain Suspended Particulate Matter in atmosphere Green House Effect

WHY IGCC ?

Uses Low Grade fuels

Environment Friendly Power Generation

12

BHEL has worked for more than 2 decades on development of IGCC

1st ever plant of 6.2 MW set up in 1988 at Trichy

Feasibility of scale up of the 6.2 MW to ~100 MW is established by BHEL

High powered R&D committee set up under chairmanship of scientific advisor has recommended for scaling up to 100 MW site rating plant

BHEL has signed an MOU with APGENCO on 10th May08 for IGCC Plant at Vijaywada

BHEL has contracted more than 60 FBC and 17 CFBC boilers

• Largest in operation : 125 MW : Under construction : 250MW

Next Step - Basic Engineering for 400 MW IGCC completed

BHEL’s Gasification & IGCC Development Program

1st Largest size 125MW IGCC Plant order expected from APGENCO in 2-3 months.

13

ENERGY EFFICIENCY IMPROVEMENT IN THE POWER SECTORENERGY EFFICIENCY IMPROVEMENT IN THE POWER SECTOR

Introduction of advanced technologies

Transmission and distribution of Power

AC Transmission – 400 kV, 765 kV DC Transmission – 500, 800 1200 kV AC Transmission – Transformer, Disc Insulators,

Switchgears, CT, CVT HVDC

14