NTPC KAHALGAON OVERVIEW

LOCATION: Kahalgaon, Dist. Bhagalpur, Coal Pit-head station

INSTALLED CAPACITY: St-1: 4x210MW, St-2: 3x500 MW, Total: 2340 MW
FUEL SOURCE: ECL- Rajmahal , LALMATIA , ECL Group of Mines

POWER EVACUATION: Total 400kv 12 Lines , : Farakka (4), Maithon (2),

Barh (2), Patna (2), Banka (2)
132 KV : 3 Lines (Sabour, Kahalgaon & Lalmatia)
MAJOR BENEFICIARIES: St-1: Bihar (42%), Odhisha (16%), NR (31%)
St-2: NR (56%), WR (37%), Bihar (5%), Odhisha (4.5%)
 Ash CALCULATION (T/Hr)
Ash in Total Ash Bottom ECO + APH Fly Ash ESP Ash per
Ash (5%)
COAL Coal Produced Ash (15%) (80%) Pass

Time 420 40% 168 25.20 8.40 134.40 33.60

24 10080 40% 4032 604.80 201.60 3225.60 806.40

3
30240 12096 1814.4 604.8 9676.8
UNIT
2419.2 4838
7257
 RW
CW BD AWRS
 WATER INTAKE FROM (AWRS/RW)
Drive Rated flow flow @85% No. running Run hour Total
flow/day
BALP 775 697.5 1 12 8370
BAHP 425 382.5 1 19 7267.5
FAHP 620 558 3 24 40176
FWP 1560 1404 1 0.5 702
SMP 1660 1494 1 0.5 747
Vacuum Pump 8 6.8 15 24 2448
seal water
HPSWP 22 18.7 1 24 448.8
LPSWP 45 38.25 1 24 918
TRENCH
FLUSHING P/P
620 558 1 24 13392
TOTAL WATER INTAKE FROM AWRS/DAY 74469.3

Ash-water ratio wet mode 6.15

Ash-water ratio Dry mode 10.26
 132KV

Tie
To ST # 3 Tie
80 MVA, To
SC/SE 132/11kv
SD/SF

UA SA Board SB Board UB
11KV 11KV

U
GE 21 /11kv
N
T

400KV
Sl No. Equipment kw Total i/s HR. current voltage Total MW
1 Ash Slurry Series pump 330 5 2 24 144 3300 1.4008
2 TRANSPORT AIR COMPRESSOR 400 9 6 24 60 3300 1.7510
3 HP SEAL WATER PUMP 18 2 1 24 23 415 0.0141
4 LP SEAL WATER PUMP 20 2 1 24 25 415 0.0153
5 FAHP WATER PUMP 132 4 3 24 198 415 0.3633
6 BAHP WATER PUMP 110 3 1 19 166 415 0.1015
7 BALP WATER PUMP 75 4 1 12 107 415 0.0654
8 SUMP MAKE UP WATER PUMP 75 2 1 0.5 120 415 0.0734
9 TRENCH FLUSHING PUPM 132 1 1 24 165 415 0.1009
10 FLUSHING WATER PUMP 75 2 2 0.5 110 415 0.1346
11 SLUDGE PUMP 5.5 2 2 0 7 415 0.0086
12 SUMP DRAINAGE PUMP 7.5 2 2 5 10 415 0.0122
13 INSTRUMENT AIR COMPRESSOR 55 5 5 24 80 415 0.2447
14 INSTRUMENT AIR DRYER 15 5 5 24 18 415 0.0551
15 TRANSPORT AIR DRYER 10 9 6 24 15 415 0.0551
16 VACUUM PUMP 75 30 15 24 110 415 1.0093
17 CLINKER GRINDER 11 12 2 24 15 415 0.0184
18 EPS FLUIDISING AIR BLOWER 4.5 6 3 24 5 415 0.0092
19 ESP FLUIDISING AIR BLOWER HEATER 3.7 6 3 18 4 415 0.0073
BUFFER HOPPER FLUDISING AIR
20
BLOWER 4.5 6 3 24 5 415 0.0092
BUFFER HOPPER FLUIDISING AIR
21
BLOWER HEATER 3.7 6 3 18 4 415 0.0073
22 BA OVER FLOW WATER PUMP 50 2 2 0 75 415 0.0918
23 SILO VENT FAN 22 3 3 24 32 415 0.0587
24 SILO DRAIN PUMP 18 2 1 12 24 415 0.0147
25 SILO FLUDISING AIR BLOWER 18 4 2 18 15 415 0.0184
26 SILO FLUDISING AIR BLOWER HEATER 9 4 2 12 9 415 0.0110
27 HDC WATER PUMP 7.5 4 1 0 9 415 0.0055

TOTAL POWER /DAY 5.66

ECO & APH HOPPER
 S TAC K
Boiler 1st pass Boiler
2nd pass ESP
APH

Eco Ash
APH Ash ESP Ash-80%
Bottom Ash-20%
Qty. of Bottom Qty. of Ash Ash per
Coal Total Ash Ash Entering Entering ESP pass
fired Ash in Coal Produced (20%) (80) Analysis of Fly Ash % by
420 40% 168 33.6 134.4 33.60
weight
Field No % of Ash Ash T/hr common pass Less than 10 microns 32
1 64 21.50 5.38
2 20.3 6.82 1.71
10-20 microns 24
3 8.3 2.79 7.08
4 3.9 1.31
20-30 microns 14
5 1.8 0.60
6 0.85 0.29
7 0.45 0.15
30-40 microns 10
8 0.24 0.08
9 0.107 0.04
Greater than 40 20
10 0.054 0.02 microns
33.60
 Wet Ash Evacuation Process
Water from
A2 A1 FAHP

ESP Wetting head

Hoppers Water from
FAHP

Water
from
FAHP
Vac.
Air washer
p/p
unit Air washer
unit
Collector Tank
Water from Collector Tank
Water
FAHP
from
FAHP

ASH INTAKE
V/V

AIR INTAKE V/V

TO TRENCH
 Advantage of Dry Ash Disposal System
* Less Requirement of Land
* Less Water Requirement
* Eliminates Underground Water And Surrounding Waterways Pollution
* Facilitate Large Scale Utilization of Ash.
 ASH DYKE
LOACTION AREA CAPACITY
LAGOON II 443 ACRE 113 LM3
LAGOON III A&B 435 ACRE 111 LM3
LAGOON IIIC 176 ACRE 45 LM3
IIID- 2 LAGOON IIID 214 ACRE 55 LM3
70 Acres Overflow+ N Nallah 127 ACRE ---
Spill Way

LAGOON-IIID-1 Dyke filled

150 Acres
AWRS
Aqua Duct

LAGOON-II
540 Acres 2nd Raising started
DISCHARGE CHANNEL since 01.03.13
TO KOA NADI

132KV POWER LINE

Starter Dyke Road upto Ekchari

 STRATEGY FOR MORE ASH TRANSPORTATION
LOADING OF JUMBO BAGS
Loading of rakes for
transportation

Shifting of bagged ash at

unloading point.

Closed container

Fly Ash Bricks

Transportation of Pond Ash
for Road / Fly over Construction
 OPERATION DEPARTMENT

DRY ASH EXTRACTED (IN MT)

700000.00 658267.13

600000.00

500000.00 446529.00
403820.00
400000.00

300000.00

200000.00

100000.00

0.00