Power Plant
Power Plant
Power Plant
596
Power plant
Investment potential on
energy saving projects Rs. 5000 Million (US $ 1000 Million)
INTRODUCTION
As per the recent projections by CEA, The total generating capacity which is today at about
1,07,000 MW is expected to reach 2,15,000 MW by 2012. The share of various sources in
meeting this requirement is shown in Table-1.
Installed Capacity
as on Feb 2003 63800 11560 2720 26760 2800 107644
Additional Capacity
to be increased
(2003-2012) 50690 19860 8380 27050 2170 108150
Total Capacity
by 2012 114490 31420 11100 53810 4970 215800
Source: CEA
Economic growth in India crucially depends on the long-term availability of energy in increasing
quantities from sources that are dependable, safe and environmentally friendly.
India, like many other developing countries, is a net importer of energy, 20 per cent of primary
energy needs being met through imports mainly in the form of crude oil and natural gas.
Currently, thermal power plants accounts for major share of about 70%. Coal is the mainstay
fuel in India for power generation. With total coal reserve around 220 billion tones, of which
84.4 billion tonnes are proven, coal will continue to be an assured energy source for the next
century and beyond.
Though coal based plants account for major share in power generation, recently there is an
increasing trend in going for gas-based power plants also, particularly in the private sector.
The industrial sector is the highest consumer of electricity (34 percent) followed by agriculture
(30 percent) and domestic (18 percent) sector.
But, energy intensity, which is energy consumption per unit of GDP, is one of the highest in
comparison to other developed and developing countries. For example, it is 3.7 times that of
Japan, 1.55 times of the USA and 1.5 times of the World average. This signifies that there
is tremendous scope for energy conservation in the country.
There are about 85 major thermal power plants installed in India. The eastern belt being coal
abundant, major plants are located in that region.
(Info: http://www.osc.edu/research/pcrm/emissions/thermalemissions)
Apart from private and public utilities and IPP’s, most of the industries have there own captive
generation.
The installation of captive generation plants has been either to supplement the electricity
purchased from the Utilities or for emergency use in case of power outages or for producing
energy from by-product of the industrial process (e.g., Sugar Plants).
Table 3 shows sector wise captive power plant installed in the country.
Installed Percentage of
Sl.No. Name of Industry Capacity TotalInstalled
(MW) Capacity
7 Sugar 7862.66
8 Paper 5994.06
11 Automobiles 2311.13
Source: CEA
India has a total capacity of 2500 MW thermal based Independent power plants (IPP’s)
CHAPTER II
As the unit ratings grew, the boiler parameters supplying steam to such turbines have also
increased. Following table 4 shows the trends in super heater outlet pressures and temperatures
for various unit sizes.
30 MW 150 63 490
Source: BHEL
The over all efficiencies of power plants with sub critical parameters fall in the range of 35-
39 percent which can be improved to 45 percent using supercritical parameters with conventional
steam turbines. Using combined cycle mode, the maximum efficiency that can be attained is
about 50 percent.
Table 5 shows the heat rate for various capacities of turbines achieved in power plants.
Power plants are adopting several latest technologies to improve the efficiency and operating
practices. Some of the power plants are installed with multi fuel capabilities by design for the
following benefits.
Clean coal technologies for power generation that posses the potential to contain pollutants
either at the combustion or pre-combustion stage will be the technologies that would eventually
replace the conventional PC firing.
India’s experience in clean coal technology started with the development of AFBC (Atmospheric
Fluidized Bed Combustion) for high ash coals. CFBC (Circulating Fluidized Bed Combustion)
was later introduced to cater to higher capacity power plants and to realize higher efficiency.
It has been a challenge for the Indian power plants to adopt several measures to bring down
the ash disposal and to meet the stringent environmental regulations, some of which are
shown below
• Importing high grade coal
• Lower emission technologies
• Improving efficiency of equipment
Power plants are also exploring various possibilities to utilize the fly ash as by-product for
some processes like
• Utilising in cement preparation as substitute for clinker
• Manufacturing of Flyash bricks
• Technology is suitable to burn a wide range of fuels (high ash coal, high sulphur coal,
lignite, pet, coke, anthracite clum, wood paste, etc.)
• Auxiliary power consumption of these boilers is relatively lower (do not require high pressure
blowers)
Supercritical units normally operate around pressure of 240-250 ata. The main steam temperature
& reheat temperature for these units are normally in the range of 535-565oC. Boilers with
steam pressures and temperatures beyond 250 ata/565oC are termed as ultra supercritical
boilers.
• Reduced emissions
Old power plants are modernized to keep up the operation of the equipment and its efficiencies.
The advantages of Renovation & modernization are
• Capacity augmentation
Some of the renovation and retrofitting techniques that are followed by the power plants are
1. Steam turbine retrofitting (blades replacement and improvement of the labyrinths’ operation
and turbine control system, etc)
3. Implementation of techniques for further reduction of the Nox emissions and for the flue gas
de-sulphurization
5. Optimization of the existing fuel drying system or implementation of new effective drying
techniques
7. Supplementary heat exchange surfaces for further heat recovery from flue gas
CHAPTER III
The auxiliary consumption in general varies between 3 to 6% for larger plants and close to 10
% for smaller captive power plants.
CII studies indicate that the energy saving potential in small size power plants (CPP’s & IPP’s)
varies between 6% - 10% of auxiliary consumption. It is estimated that the saving potential is
150 MW of power amounting to Rs.300 crores annually.
CII study also indicates that the investment potential for energy efficiency in small size
power plants is Rs.500 crores. This does not include saving potential in utility plants.
These projects apply to IPP’s & CPP’s and can be easily implemented. Some of these
projects are equally applicable in utility power plants.
A) Boilers
1. Install online O2 analyser and improve combustion efficiency of the boilers
2. Arrest air infiltration in boiler flue gas path, particularly economiser and air preheater section
3. Install water heating system for preheating gas through waste heat recovery from Boiler
exhaust
5. Install flash vessels for heat recovery from hot condensate vapours
6. Replace electric heaters with LP steam heaters for RFO tracing lines
C) Electrical Areas
1. Install delta to star converters for lightly loaded motors
5. Install CFL’s for lighting in non-critical areas, such as, toilets, corridors, canteens etc.
D) Miscellaneous
1. Replace Aluminium blades with FRP blades in cooling tower fans
2. Install temperature indicator controller (TIC) for optimising cooling tower fan operation,
based on ambient conditions
6. Reduce system pressure of the compressed air system close to operating pressure of
the users
7. Install variable frequency drive for hot well makeup water pump
8. Install Variable Frequency Drive (VFD) for cooling tower make up pump with water level
control feed back
10. Close Suction Dampers at Stand-By Equipment and Reduce RPM of Dust Extraction
Blowers in the Coal Handling Plant
11. Install the next lower size impeller for the chilled water pumps
12. Avoid idle flow of cooling water in stand by DG sets and compressors
13. Install chlorine dosing and HCL dosing for circulating water
A) Boilers
1. Install economiser/air preheater for boilers
2. Install high temperature deaerator (120°C to 140°C) with suitable boiler feed water pump
to enhance cogeneration
5. Segregate Intermediate Pressure & High Pressure Boiler Feed Water Pump
6. Install Variable Frequency Drive (VFD) for CCW pump and operate in closed loop control,
based on the discharge header pressure.
7. Reduce Heat rate of gas turbines by optimizing NOx water injection and arresting of
leakages through bypass dampers
8. Install Turbine inlet air cooling to increase power output of gas turbines
10. Reduce one stage of feed water pump or install variable frequency drive with feed back
control to exactly match with the system pressure
11. Install lower head fan for power plant boiler ID fan
4. Install Variable Fluid Coupling or variable frequency drive for condensate extraction pump
5. Utilise flash steam from boiler blow down for deaerator heating
4. Replace conventional ballast with high efficiency electronic ballasts in all discharge lamps
5. Install Sodium vapour lamps instead of MV lamps for Yard, Street and General Lighting
9. Minimise overall distribution losses, by proper cable sizing and addition of capacitor banks
11. Replace heater - purge type air dryer with heat of compression (HOC) dryer for
compressed air requirement above 500 cfm
12. Replace old and inefficient compressors with screw or centrifugal compressors
4. Install steam driven equipment to prevent HP steam flow through pressure reducing valves
8. Install Distributed control system (DCS) for Power Plant Operation and monitoring
Case Study: 1
Background
In the older power plants, the boilers are the conventional stoker boilers.
The latest trend has been to install the fluidised bed boilers or conversion of the existing chain
/ spreader stocker boilers, which have the following advantages:
• Coal having high ash content/ low calorific value can be used
Hence, the older plants are also in a phased manner, converting their old stoker-fired boilers
to fluidised bed boilers. This case study describes one such project implemented.
Previous Status
A power plant had four numbers of spreader stoker boilers, operating to meet steam
requirements of the plant. These spreader stoker boilers, were designed for high calorific value
coal (4780 kCal/kg) with low ash content.
Due to non-availability of this type of coal, these boilers had to be fired with coal of low calorific
value and high ash content. This resulted in the capacity down-gradation and loss in efficiency.
The steam generation was only 14 TPH, as against the design rating of 30 TPH. The boiler
efficiency achieved was only 65%.
The steam generation capacity increased to 27 TPH and the thermal efficiency improved to
78%, with this modification. The improved thermal efficiency has resulted in an annual coal
saving of 5639 MT. Additionally, the use of saw dust (calorific value of about 3000 kCal/kg) has
resulted in an annual coal savings of 3600 MT.
Finalcial Analysis
The annual benefits achieved were Rs.10.50 million. This required an investment of Rs.27.0
million (for the conversion of two spreader stoker boilers to fluidised bed combustion boilers),
which had a simple payback period of 31 months.
Implementation Strategy
The plant took up implementation of the project after a detailed planning with the EPC contractor.
The modification was taken up during the annual shut down (30 days). The shut down had to
be extended to avoid 30 days to complete the project. The commissioning of the new boiler
took about 4 days and there were no problem during implementation.
Case Study: 2
Background
In a major captive power plant, three irculating fluidised bed combustor (CFBC) were in
operation. Each boiler has two ID fans and three PA fans.
• All these fans had higher capacity & head by design and controlled either by IGV’s or
Dampers to meet the operating requirements.
• The IGV opening of the ID fans varied between 50-60%, resulting in tremendous energy
loss. The measured pressure loss across the damper & IGV was of the order of 40-45%
of the total pressure rise of the fan.
• Also, the operation of a fan operating with IGV or damper control will result in operation of
the fan in an energy inefficient zone on the fan performance curve. Instead the speed of the
fan can be varied to meet the operating condition of the boiler by installing variable frequency
drives.
• The estimated operating efficiency of the fans was in the range of 60% - 65% as against
design efficiency of 80%. It was confirmed that the fans were operating in an energy
inefficient zone.
Implementation Strategy
The VFD’s were installed during the stoppage of the plant for maintenance. The plant personnel
were well trained in operation and maintenance of VSD’s (prior to the installation of VFD) and
therefore no problems were faced with implementation. The inlet guide vanes were kept fully
opened after the VFD was installed.
Energy saving
Financial Analysis
The annual energy savings achieved was Rs 6.0 million and the investment was Rs 10.0
million for installing 15 nos of variable frequency drives, which got paid back in 20 Months.
Replication Potential
Similar projects can be taken up for FD & Secondary air fans also. The project has high
replication potential in majority of the captive power plant and IPPs. For ID, FD, secondary air
and primary air fans
Case Study: 3
Install steam drives to prevent HP steam flow through pressure reducing valves
Background
• In a major captive power plant, the auxiliary steam requirement was at a pressure of 24 kg/
cm2 and 4100C.
• The quantity of process steam requirement was about 11.5 kg/cm2. To meet the process
requirement the steam from extraction was passed through PRDS.
• When steam pressure is reduced by passing through a pressure reducing valve, the enthalpy
of the steam remains constant. But due to pressure loss, the opportunity for converting the
low grade energy (thermal energy) to high grade energy (mechanical energy) is lost.
• The quantity of steam passed through the pressure reducing valve was varied depending
upon the process requirement.
• Instead of dropping the high pressure to low pressure by throttling, the same energy can
be used for power production.
Implementation Methodology
In a captive power plant the modification of the plant on a continuous basis is essential. A
stoppage for replacing the motor with a turbine for drip pump was not possible. Therefore 2
new drip pumps with back pressure turbines (300 kW) each were installed and the system
was hooked up during a maintenance shut down. Though the investment was high the stoppage
of plant could be avoided.
Benefits
The implementation of the project resulted in improving the co-generation potential.
Finalcial Analysis
The annual energy savings achieved was Rs 27.5 million and the investment was Rs 12.5
million for installing back pressure turbines, Generator and steam piping, which had a pay
back of 6 Months.
Case Study: 4
Background
In a captive power plant (of 21 MW capacity) of a large integrated paper plant, certain areas,
viz., the boiler & TG control room, static excitation room, ESP/Ash handling plant control room
and coal handling plant control room required a temperature of 26 ± 2 °C to be maintained.
The total air-conditioning load was 60 TR. Since, this power plant was in the project stage, the
plant team had the option of choosing between a vapour compression system and a vapour
absorption system, for maintaining these conditions. A techno-economic study favoured the
installation of a vapour absorption system.
In this case study, the turbine had the capacity to accept additional 300 kg/hr of low cost low
pressure steam. This gives an excellent spin-off benefit by generating additional power in the
turbine.
Rating TR 60 60
Power consumption kW 60 60
Steam consumption at
Replication Potential
The installation of vapour absorption refrigeration system is in its nascent stage in the Indian
industry. The potential for installation of vapour absorption system in combination with a co-
generation system is tremendous in Indian industry and therefore needs to be pursued.
CHAPTER IV
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3. Thermax Ltd
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