gujarat state electricity corporation limited gujarat

FEASIBILITY STUDY OF LIGNITE DRYING (REPORT )

GUJARAT STATE ELECTRICITY CORPORATION LIMITED

GUJARAT ENERGY RESEARCH &




1ST

Floor, Pandit Deendayal Petroleum University Campus,





Raisan, Gandhinagar


SUBMITTED TO


SUBMITTED



Raisan, Gandhinagar

www.germi.org


SUBMITTED TO


SUBMITTED



Raisan, Gandhinagar

www.germi.org


SUBMITTED TO


SUBMITTED BY

MANAGEMENT INSTITUTE (GERMI)


Raisan, Gandhinagar – 382 007

www.germi.org





382 007





Pag



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97

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Contact Detail

Project Leader (GERMI)

Dr. Sagarkumar M. Agravat (Scientist – E1)

Scientist In-Charge Solar R&D Projects

Cell Phone : +91 90999 50356

Email : [email protected]

Institute’s Address

Gujarat Energy Research & Management Institute (GERMI)

1st Floor, Energy Building, Pandit Deendayal Petroleum University (PDPU) Campus

Raisan, Gandhinagar – 382 007

Gujarat, IN

Phone : +91 79 2327 – 5372

Fax : +91 79 2327 – 5380

Web : www.germi.org

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About the Report

This report is divided into seven chapters with a total no. 97 pages.

Chapter – 1 provides overview of the study site i.e. KLTPS power plant, its basic

operation and different cycles.

Chapter – 2 provides introduction and overview of effect of fuel moisture on

performance / emission.

Chapter – 3 highlights different types of lignite drying technologies, its

function, pros and cons of each one of them.

Chapter – 4 provides experimental details for proximate and ultimate analysis

of lignite samples.

Chapter – 5 provides detailed account of experiments conducted on lignite for

determination of its constituents, moisture content, ash content, fixed carbon,

results and conclusion etc.

Chapter – 6 provides details of energy requirement for drying sample of lignite

and time consumed for direct, indirect and forced convection solar dryer.

Chapter – 7 provides overview of techno-commercial analysis of drying of lignite

through solar energy, flue gas exhaust. It also highlights possibility of tapping

flue gas to convert into useful energy and therby making plant energy efficient.

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EXECUTIVE SUMMARY

Today, considering all types of fossil fuels, coal is the energy rich material

which generates 42% of the world’s electricity. In India, the reserves of lignite

are about 40.91 billion tonnes found in Tamil Nadu, Pondicherry, Kerala,

Gujarat, Rajasthan and Jammu & Kashmir. About 80% reserves are located in

Nevyeli (Tamil Nadu) with about 32.89 billion tonnes. GSECL operates lignite

based thermal power station in Kutch location of Gujarat with source of coal

from adjacent lignite mines of GMDC. The reserves of lignite from GMDC are

almost exhausted and in order to keep the plant running, new source of lignite

need to be identified. Being low grade coal with lots of moisture, transportation

cost of lignite may raise electricity cost.

One of the possible solutions is to make plant energy efficient by drying of

lignite through high temperature exhaust gas / flue gas. GERMI has conducted

laboratory experiments to confirm possibility of drying lignite at higher

temperatures than ambient and also reviewed available technologies across

globe. All these technologies being new and due to lack of sizeable market are

costly at present. It was found that such an initiative is attractive due to

following factors.

1. Higher fuel costs

2. Higher moisture content of lignite

3. Carbon credits

GoI has started taking measures for clean coal technologies. Appropriate

mendate through legislation can also help.

We have recommended following two methods for drying of lignite (Refer

Chapter – 7)

1. Drying of lignite through WTA technology

2. Drying of lignite through use of solar thermal energy

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Alternately, high temperature flue gas can be converted into electricity

generation through Kalina Cycle which is well mature technology used in

geothermal thermal energy exploration and industrial exhaust heat recover.

We believe that cleaning of flue gas through Pneumatic Saturation

Condensation Process for cleaning of flue gas for desalination of water is also a

very good solution for desalination of salty water which may be useful in the

plant operation and also for supply to neighbouring village as part of CSR

activities.

Such projects may have pay-back period of around 20 years without any

financial incentives and carbon revenue, however, with financial support from

UNIDO / UNDP, the returns can be very attractive.

We propose to conduct preparation of Detailed Project Report as next stage.

We take this opportunity to congratulate GSECL management for initiating the

study and providing financial support to GERMI for the study.

Dr. Sagarkumar M. Agravat

20.03.2016

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Contents

About the Report .......................................................................................................................................... 3

(Author)EXECUTIVE SUMMARY .................................................................................................................... 4

EXECUTIVE SUMMARY .................................................................................................................................. 4

CHAPTER-1: OVERVIEW ABOUT KUTCH LIGNITE THERMAL POWER STATION ............................................. 8

Introduction .................................................................................................................................................. 8

The flowchart of the plant is as follows: ..................................................................................................... 10

Water Cycle ................................................................................................................................................. 14

Gas cycle ..................................................................................................................................................... 16

CHAPTER 2: INTRODUCTION ....................................................................................................................... 17

Effect of Fuel moisture on Performance ..................................................................................................... 21

Effect of Fuel moisture on Emission ........................................................................................................... 23

CHAPTER 3: DRYING TECHNOLOGY ............................................................................................................ 25

RWE- WTA Technology ............................................................................................................................... 25

Vantefall PFBD ........................................................................................................................................ 28

Dryfining ...................................................................................................................................................... 29

Rotary Drying .............................................................................................................................................. 30

. Rotary drying .................................................................................................................................... 30

Rotary tubes ........................................................................................................................................ 31

Microwave Technology ............................................................................................................................... 31

Microwave drying ............................................................................................................................... 31

Screw Conveyor Dryer ................................................................................................................................ 32

Hydrothermal dewatering .......................................................................................................................... 33

Integrated Drying ........................................................................................................................................ 33

Solvent Extraction Method ......................................................................................................................... 34

References .................................................................................................................................................. 35

Chapter 4 ..................................................................................................................................................... 37

4.1 Determination of proximate and ultimate analysis of lignite ............................................................... 37

4.1.1 Procedure for proximate analysis ...................................................................................................... 37

4.1.1.1 Moisture content ............................................................................................................................ 37

Observation Table ................................................................................................................................. 39

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Sample 1- ................................................................................................................................................. 39

Calculation .............................................................................................................................................. 39

Scale Requirements .............................................................................................................................. 39

4.1.1.2 Volatile Matter ................................................................................................................................ 42

4.1.1.3 Ash content ..................................................................................................................................... 45

4.1.1.4 Fixed Carbon ................................................................................................................................... 48

4.1.2 Procedure for ultimate analysis ......................................................................................................... 49

4.1.3 Results and Conclusion ...................................................................................................................... 54

CHAPTER-5 .................................................................................................................................................. 56

Experimental study of lignite drying through solar energy ........................................................................ 56

Materials and method ................................................................................................................................ 56

Results and Discussion....................................................................................................................... 67

Analysis ....................................................................................................................................................... 74

CHAPTER – 6: ENERGY ANALYSIS ................................................................................................................ 79

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