Thursday , Nov 21st, 2013

A Maharatna Company

Advanced Technologies and Best Practices for SC TPPs

A Presentation by: D.K. Dubey General Manager (PE- Mech/SG, WS) NTPC Limited

NTPC Plan for improvement

of Power Plant Efficiency

New Delhi

Contents

NTPC’s Efficiency Approach 1

Supercritical as the central idea 2

Forays into advanced energy conversion 3

Experience Based deployment strategy 4

Contents

NTPC’s Efficiency Approach 1

Coal forms the edifice of Indian power story

Source: CEA, excluding captive capacity

Total Installed Capacity ~ 229 GW*

12% 17%

59% 9%

Hydro

Coal

RES

Gas

(134+ GW)

*as on 31.10.2013

Of the total installed capacity of 41,794 MW for NTPC 35,889 MW is based on coal

NTPC’s Efficiency focus over the years

New

Technology

Induction

Plant Efficiency

control

Stack Emissions

control

41000 + MW

Contents

Supercritical as the central idea 2

Supercritical Technology a natural choice

0.40-0.30

0.65-0.60

0.75-0.70

0.80-0.75

0.85-0.80

0.90-0.85

NGCC

IGCC +FC

IGCC

USC

Super critical

PC Subcritical

0% 20% 40% 60%

46-58%

> 50%

45-49%

>41.5

39.3-40.5%

37.9-38.5%

Specific CO2

emission * Efficiency

%

CO

2 e

mis

sio

n r

edu

ctio

n

po

ten

tial

Tech

no

logy

Mat

uri

ty

* Figure in kg/KWh

Supercritical is central to NTPC’s posturing

Ultra supercritical technology with temperature upto 600 °C/ 600 °C introduced in

North Karanpura Project.

2018

42%

2020

46%

2025 2006

38.9%

500MW

Sub-Critical 565RH

2011

39.5%

SC

247 537/565

2013

40.8%

SC

247 565/593

USC

270 600/620

Adv-USC

310 710/720

1st Unit

AUSC AUSC

Fleet 1st Unit

USC

Barh-II

onwards Sipat-I Simh-II

46%

1998

38.6%

Rihand-II

500MW

Sub-Critical Mod.

Indian Adv-USC Program

Adv-USC

Collaboration between NTPC, BHEL and IGCAR

Time schedule 7 years (2½ R&D & 4½ yrs plant Const.)

Objective: 800 MWe Adv-USC Plant having 310 ksc pr/ 710°C MS/ 720°C RH Temp

Status Update

•Pre-project R&D for Boilers started

Test loops utilizing indigenously developed advanced materials, to be deployed for high temp applications, shall be installed at NTPC, Dadri for hot

corrosion tests.

Characterization of two Adv-USC materials in

advanced stages.

•Plant Design Memorandum (PDM) finalized

•Pre Project R&D for design & Devpt. of turbine blade

profiles for HPT for Adv-USC parameters started

•Other projects like design and development of thick

walled header for SH, HPT bypass valve are being planned.

Project Implementation Mode

Research

Development

Demonstration

Deployment

No global reference at present

Target efficiency of 46% as against 38% in sub-critical plants resulting in ~ 20% reduction in carbon emissions

Contents

Forays into advanced energy conversion 3

Gas Turbine- the key building block

2014

J class

1600 °C

Improvements in Gas Turbine Technology will boost gasification based technology adoption

IGCC- the promising option

IGCC offers Better Coal Utilization

•Potential for higher efficiency due to GT use

•Cheaper dedusting & deSOx- low syngas volumes

•Low Nox- low reactor temperatures

PC

SCP

C

NG

CC

P

FBC

IGC

C

0

10

20

30

40

50

60

70

80

The

rmal

Eff

icie

ncy

(%)

Current Possible Future

CCT Efficiency Comparison

0

100

200

300

400

500

600

700

0

10

20

30

40

50

60

70

GT

Ca

pa

cit

y (

MW

)

CC

PP

E

ffic

ien

cy (

%)

Time Line

GT Technology Status Market Introduction: 463 MW Class h = 62% by 2014

2013

NTPC IGCC Program Update

IGCC

Set up 100 MWe Net capacity IGCC demo Plant

Plant Location: NTPC Dadri

Fluidized bed Technology

Tech. Specs Phase-I finalized

• Establish the gasification process for Indian coals.

• Establish design for Gasification Island and other key equipment.

• Establish the IGCC process package.

• Establish in-house Engineering capability for IGCC plants

• Establish O&M systems for IGCC plant

• Establish commercial viability with non recourse funding

Technology Demo Project Benefits

Contents

Experience Based deployment strategy 4

Knowledge based Efficiency program Deployment

Technology scans

OEM dialogues

Visits for 1st hand exposure

Global Operation feedback

International experts inputs

Supercritical induction

IGCC Strategy

Background studies

Coal Testing in Gasifier

Industry experience capture

International experts inputs

International experience

capture

Efficiency Increase Program Deployment Strategy

• Availability analysis and failure scan

• Contemporary Indian industry experience

• Technology selection as per Indian fuel & MRO

(maintenance-repair-overhaul) situation

•Pilot tests, demo project testing

• Developmental work space within EPC contract

• Demo project R&D Plan

The presenter may be contacted at: dkdubey@ntpceoc.co.in