cfbc DCPP at a Glance

4X135 MW CAPTIVR POWER PLANT, DONGAMAHUA

RAIGARH (DISTRICT), CHATTISGARH

PROJECT IDEA SHEET

JSPL owns captive mining facility at village Dongamahua in District-Raigarh. Large amount of middling and fines will

be generated during process of yielding washed coal from the un-graded coal mining. Reports and analysis

suggests that yield will be 18%; by the time spin-off middling and fines will be tune of 57%. Precisely, every 01 T

of washed coal yield attributed for generating 03T of middling and fines.

These middling & fines has lower potential and considered as unusable for power generation in general. CFBC

Technology is apt for firing these low GCV coal with high combustion efficiency rate with very low emissions of Nox,

Sox etc.

JSPL initiated a pit-head power plant of 4x135MW Capacity eyeing multiple gains such as best utilization of the

upgraded low GCV coal, negligible fuel handling cost, catering power demand of existing and upcoming plants of

JSPL, Raigarh, evacuating surplus power to power starved Chattisgarh and so on.

General parameters

Coal Property:_____________________________________________________________________________

Proximate Analysis:

Total Moisture : 10% 14 %

Ash : 50% 58%

Volatile matter : 15% - 21%

Fixed Carbon : 13% 20%

GCV Kcal/Kg : 2200 2700

Ultimate Analysis:

Total Moisture : 10% 14 %

Ash : 50% 58%

Carbon (C) : 23% 28%

Hydrogen (H) : 2.3% 3.0%

Nitrogen (N) : 0.7% 0.95%

Sulphur : 0.4% 0.6%

Oxygen (O) by : 4.5% 6.0%

difference

Boiler:

SN Description Unit Value at 100% BMCR Value at 100% TMCR

1 Type Natural Circulation, Single Drum, Water Tube, Balanced Draft, Uncooled type Cyclone

2 Boiler Capacity TPH 460 426

3 Pressure (at SH O/L Header) Kg/cm2(g) 141 135.2

4 MS Temperature at SH O/L 0 C 540+/- 5 540+/- 5

5 FW Temp at Eco I/L 0 C 249 245.5

6 MS Temp at RH O/L 0 C 540+/- 5 540+/- 5

7 Boiler Efficiency % 81.5

Steam Turbine:

SN Description Unit Value at 100% TMCR Value at VWO

1 Type Tandem compound, single Re-Heat, Re-Generative, Condensing, Multi Cylinder (HP&IP, LP) Casing

2 Electrical Power output at Generator Terminal

MW 135 141.373 (at 3% makeup)

3 MS Flow at I/L of HP Turbine TPH 418 447

4 Pressure at HP Turbine I/L Bar (g) 132.4 132.4

5 MS Temperature at HP Turbine I/L 0 C 535 535

6 Condenser Pressure Ata 0.1186 0.1186

7 CW I/L Temperature 0 C 33 33

8 CW O/L Temperature 0 C 42 42

Generator:

SN Description Unit Value at 100% TMCR

1 Rated O/P MW 135

2 MVA Rating MVA 169

3 Power Factor 0.80 Lagging

4 Terminal Voltage KV 13.8

5 No. of Phases 3

6 RPM 3000

7 Frequency HZ 50

8 Type of Cooling (Stator winding, core and rotor) Air

9 Type of excitation Brushless

10 Type of AVR Digital

Light Diesel Oil:

SN Description Unit IS:1593

1 Flash Point 0 C 66

2 Viscosity at 150C max Cst 2.0-7.0

3 Pour point 0 C 12

4 Ash content by weight % Max 0.025

5 Free water content by volume % Max 0.05%

6 Sediments by weight % Max 0.1%

7 Total Sulphur by weight % Max 1.8%

8 Carbon residue (rams bottom) % Wt

9 Approximate GCV Kcal/ Kg In the order of 11000

10 Sp gravity at 150C max 0.81

Ash:

SN Description Abb. IS:1593

1 Silica Silica Sio2 58-62

2 Alumina Al2o3 23-26

3 Iron Oxide Fe2o3 7-10

4 Titaneum Oxide Tio2 0.15-3

5 Calcium Oxide CaO 3-5

6 Magnesium Oxide MgO 1.5-3

7 Sulphuric Anhydride SO3 0.15-0.4

8 Manganese Mn 0.02-0.04

9 Potassium pentoxide P2O5 Traces

10 Alkalis & undermined Remaining

POWER STATION BASICS

STEAM CYCLE THEORY AND CYCLE CONSTRAINTS

Over the years, and particularly the last three decades the size and terminal conditions of generating plants

has continuously increased at a remarkable rate as shown in table below:-

Steam Pressure

Main Steam Temperature

Reheat Steam

Conditions

Type Design Efficiency of Power Plant

Size of plant

Bar Deg C Deg C % MW

41.4 462 27.5 30

62.1 482 30.5 60

103.4 566 33.7 100

103.4 538 538 Reheat + Regeneration 35.7 120

162 566 538 Reheat + Regeneration 37.3 200




241.3 593 566 Supercritical 39.0 375


The main incentive to keep striving for bigger and better plant is that one expects the thermal efficiency to improve

with size and capital cost per MW decreases with the increase of size.

It can be seen that steam temperatures have increased at quite a slow rate. This is because increasing steam

temperature is intimately bound up with metallurgical advances and such advantages are painfully slow. On the

other hand, by increasing the steam pressure, introducing reheat and rapidly increasing output it has been possible

to reduce the cost per MW of installed plant considerably.

Increased output is normally associated with increasing pressure and temperature conditions. This is because:-

1. The higher cost of high temperature components is partly affected by a reduction in the number of

components per MW.

2. Losses become proportionately smaller in the large machine.

3. High density steam must be associated with large flows to give reasonably sized H.P. blades.

Rankine Cycle

The Rankine cycle is the simplest theoretical cycle using vapour as the working medium. The basic arrangement of

this, the simplest of all vapour cycles is shown in fig 1 (Scheme) and Fig 2 (TS Diagram).

Fig 1 Schematic representation of power plant

Fig 2 Rankine cycle on T-S diagram

Temperature Entropy Diagram (T-S Diagram)

The temperature (T-S) diagram is probably the most useful diagram of all illustrating certain fundamental

points about steam cycles. Ideal condition for a unit on a T-S diagram is indicated in fig-3 mentioned. The unit uses

steam at a pressure of 100 bar absolute, temp. 566 oC (839 o K) and rejects it to the condenser at 30m bar abs.

(saturation temp. 24.1 o C).

At point A the condensate is at boiling temperature corresponding to the back (condenser) pressure. Heat

(sensible) is added to this water to raise its temperature and pressure. At the point B it reaches its saturation temp.

(310.961oC obtainable from steam table) at a pressure of 100 bar. Evaporation beings at the pt. B. Heat (latent-

because no rise in temperature between B & C, as evident from the diagram) addition continues. At C all the water

evaporates and superheating commences. This shown by the curve CD and at D and superheated steam

temperature is 566oC.

Fig 3 Sensible, Latent and Superheat, 100 bar, 566 oC Cycle on T-S Diagram

Steam then expands isentropically i.e. enters the turbine and rotates it, as shown by the line DEF. At point

E there is no superheat left in the steam and so from E to F there is increasing wetness. At F and steam is at a

pressure of 30 m bar abs. Steam is then passed out of turbine to the condenser and condensation of steam takes

place as represented by the line FA. At point A the steam has all been condensed and condensate is at boiling

temperature ready to begin another cycle.

To summaries the above,

AB Heating of feed water (i.e. sensible heat addition)

BC evaporation of water in boiler (i.e. latent heat addition)

CD superheating of steam (i.e. superheat addition)

DF expansion of steam in turbine point E denotes and demarcation between superheated and wet steam.

FA condensation of steam in the condenser

An important basic fact to remember is that heat is product of absolute temperature and change of

entropy. In other words the heat is represented by the area under the curve.

Sensible heat addition

In fig above the heat added is represented by the area AB. At A the temperature is 24.1 oC and at B it is 311oC.

Now amount of sensible heat addition can be found as:

Sensible heat at A = 101 kJ/Kg and Sensible heat at B = 1408 kJ/Kg (Both the values taken from the steam table)

So, sensible heat added = B A = 1408 101 = 1307KJ/Kg

It should be noted that increasing pressure in boiler to get more output in turbo alternator (i.e. more MW) means

more sensible heat per kilogram. Fig 2 also presents it graphically. As maximum sensible heat is supplied in feed

heaters and economizers, number of feed heaters or area of feed heating surface shall increases with increase of

steam condition. Table below, shows the increase of sensible heat with corresponding pressure.

Absolute pressure (bar) Saturation Temperature (oC) Sensible Heat (kj/kg)

50 100

150 200

221.2

263.9 311.0

342.1 365.7

374.15

1154.5 1408.0

1611.0 1826.5

2107.4

Fig 4 Sensible heat at Saturation Temperature at Various Pressures

Latent Heat addition

As stated before almost all-sensible heat is supplied in the feed heaters and economizer. Water entering

the boiler water wall tubes is almost at boiling temperature, fast bit of sensible heat is added to water at lower part

of water wall tubes and thereafter latent heat addition starts taking place.

As there is no change in temperatures (line BC in fig3 indicates so) the water/ steam mixture is about

constant temperature from the bottom to top of the tubes. The area nBCl represents the latent heat added. It

amounts can be calculated in the following way:

Latent heat required = T (S2- S1)

Where, T=temp. of boiler water at B=311degC=584.15K

S2=Entropy at C=5.6198Kj/Kg.K

S1=Entropy at B=1319.7Kj/Kg deg. K

It should be noted that unlike sensible heat at amount of latent heat required to convert boiling water to dry

saturated steam reduces with increase of pressure. At critical pressure of 221.2 bar absolute it is zero.

Fig 5 Latent heat at various pressures

Table -II Latent heat at Saturation Temperature

Absolute Pressure Saturation temp.(deg C) Latent heat(Kj/Kg)

50 100

150 200

221.2

263.9 311.0

342.1 365.7

374.15

1639.7 1319.7

1004.0 591.9

0

Superheat addition: -

The curve CD shows the process of steam being superheated at a constant pressure of 100 bars from the state of

dry saturated steam at 311 deg C to the designed stop valve temp. of 566 deg C.The area plCD represents the

amount of superheat. The amount of heat required by deducting the total heat at C from total heat at D and is

equal to 811.6 Kj/Kg. Quantity of heat required to superheat steam to a given temperature varies with pressure.

Table3 Variation of superheat for different pressure (final temp 570 deg C)

Pressure Bar absolute Superheat required KJ/Kg

50

100 150

200

800.9

821.5 885.4

1033.2

Thermal Efficiency of the cycle:-

Useful heat Thermal efficiency =

Total heat

Useful heat means that part of total heat which is used in rotating the turbine i.e. when the steam expand

adiabatically(adiabatic expansion means no heat accepted or rejected during the process; all work done by steam

at the expense of its internal energy) in the turbine represented by line DEF fig - 6. Expansion of steam takes place

up to a pressure of 30 m bar (24.1 deg C). The condensation takes place at a constant temp. as indicated by line

FA, until all latent heat is removed.

Heat removed from steam or useless heat is shown or useless heat is shown by rectangular pmAF. Amount of this

rejected can be calculated as follows:

FIG- 6: Basic Ideal Cycle showing useful rejected heat components

Heat rejected = T x (S2 S1) where,

T = Absolute temperature of FA = (24.1 + 273.15) = 297.25oK

S2 = Entropy at F = 6.803 kJ/kg

S1 = Entropy at A = 0.3455kJ/kgK

So, Rejected heat = 297.25 X (6.8043 0.3544) = 1917.2kJ/kg

Now, total heat = Sensible heat + latent heat + superheat

= 1307 + 1319.7 + 811.6 = 3438.3kJ/kg

Useful heat = Total heat Rejected heat

So, Thermal Efficiency = Total heat Heat rejected

Total heat

Q = 1 - Rejected Heat = 1 - 1917.2

Total heat 3438.2

= 0.4423 or 44.23%

This is the highest possible efficiency for a basic Rankine Cycle with steam at 100 bar absolute, 566oC and

backpressure is 30m bar. Ofcourse, in practice a turbine operating under this cycle will be less efficient. It can also

be noted that how superheating of steam adds to efficiency. If steam is not superheated the total amount of heat

in this cycle will be addition of sensible heat and latent heat only i.e.1307 + 1319.7 = 2626.7kJ/kg

So, Thermal efficiency= 1 Rejected heat = 1 - 1917.2 Total heat 2626.7

= 0.2701 or 27.1%

Hence, efficiency of basic Rankine Cycle can be improved by increasing the superheat. But this scope becomes limited due to limitations of materials, which can withstand very high temperature and the cost associated

with it.

REHEATING To increase the heat available compared to the heat rejected is to increase the superheated steam

temperature. Unfortunately this is only possible to a very small degree because of metallurgical limitations. Thus

there is very little scope in this direction. Therefore the alternative is to probably expand the steam in the turbine to some suitable intermediate condition and then pass it back to the boiler to be reheated to some high temperature.

It is then piped back to the turbine to continue expansion.

Let us consider the same 100bar cycle, now with reheat. Fig - 7 below shows the cycle. Steam as usually starts expanding after being superheated. At the point G when the pressure had dropped to 20 bar the steam is

taken out of turbine and reheated to 566oC as shown by the line GH. It is then fed to the LP turbine where it expands to the condenser pressure.

The efficiency of the cycle is determined in a similar manner to the previous cases and works out to be 46.09%.

So, reheating had improved efficiency from 44.23% to 46.23% to 46.09%. A further advantage of

reheating is that the wetness of the exhaust steam is reduced considerably.

Fig 7 Modified Basic Cycle to incorporate reheat

REGENERATIVE FEED HEATING

Steam in a thermal cycle will normally reject heat in two ways. Firstly the heat rejected can go to waste via the

condenser cooling water and secondly, the steam can reject heat to the feed water by means of feed heaters. In

the second case, all the heat is kept within the cycle and not lost. The more steam which can be prevented from

going to the condenser, the more heat will be saved from rejection to waste. Consequently, if the steam is allowed

to expand to a certain extent in the turbine and perform useful work before it is allowed to transfer its remaining

heat to feed water, then the quantity of work is obtained without any condenser loss and the efficiency is improved.

In modern design of high capacity units the bled steam has been used for turbine driven feed pump and its exhaust

used for feed water heating in addition to the conventional extractions.

Let us see the previous 100 bar cycle, this time with regenerative feed heating (Fig 7). The steam

expands isentropically in the turbine until the temperature is 250oC after which the steam is bled to an infinite

number of feed heaters. The result is quantity of heat represented by area under the curve KL is transferred to the

water side shown by the area LFpr has been given to feed water whereas before it would have been rejected in the

condenser. The heat represented by the area LKF has also been transferred to feed water, where as formerly it

would have done some useful work in turbine, so there is some loss of work too. Yes, but on the balance its is

better to loss the power from the triangle LKF to save the heat represented by large rectangle LFpr that would have

been wasted.

Regenerative feed heating elevates the condensate temperature represented along the boiling water line to

M and the remaining sensible heat is supplied in the economizer and boiler to point B.

Let us find the efficiency with reheat;

Total heat supplied = sensible heat from M to B + Latent heat + superheat

Amount of latent heat and superheat in this cycle are same on the previous cycle with superheat and eual; to

1319.7kJ/kg and 811.6kJ/kg respectively.

Now, sensible heat = Total heat at B total heat at M = 322.2 kJ/kg

So, total heat supplied = 322.2 + 1319.7 + 811.6 = 243.5 kJ/kg

Heat rejected = Area under ALRM = 1192.2kJ/kg

So, efficiency = 1 - Rejected Heat = 1 - 1192.2 Total Heat 2453.5

= 0 .514 or 51.4%

Hence you find how efficiency of Rankine cycle changes with reheating and feed heating.

Basic efficiency (Fig 6) = 44.23%

Reheat efficiency (Fig 7) = 46.09%

Feed heating cycle efficiency (Fig 8) = 51.4%

A combination of reheating and feed heating will give higher ideal cycle efficiency.

Fig 8 Modified Basic Cycle to incorporate feed heating

The main factors affecting the cost of plant are:

1) The improvement in thermal efficiency permits a reduction in the size of boiler as it has less heat input to do

for a given load.

2) The increased amount of steam tapped for feed heating increases the cost of the feed heaters and the steam

piping between turbine and heaters.

3) The increase in the total steam consumption increases the cost of the steam piping between the boiler and

the turbine, the cost of high pressure end of the turbine and that of feed piping and feed pumps.

4) The decrease in the amount of steam flowing through the low-pressure end of the turbine and the amount of

steam to be condensed. It decreases the cost of low-pressure end of the turbine and the cost of condensing

plant, C.W. culverts, etc.

5) The higher feed temperature consequent upon the use of extensive regenerative feed heating would cause

the flue gases to leave the boiler economizer at a higher temperature, thus inevitably reducing the boiler

efficiency to an extent which could largely counter balance the increase in turbine thermal efficiency. For this

reason it is necessary to employ a further regenerator in the form of an air heater in which the heat of the

flue gases is transferred to the combustion air supplied to the furnace.

Another consideration with respect to boiler design is that the feed temperature at the economizer inlet must be

higher than the due point of the boiler flue gases, but not high enough to cause steaming in the economizer also,

the temperature of feed water in the economizer outlet must be less than the saturation temperature of water at

that particular pressure, normally difference shall be 20oC.

Familiarization of Boiler and Turbine system at DCPP

Boiler:

Shanghai Boiler Works Ltd. (SEC/SBWL) has supplied JINDAL STEEL & POWER LIMITED four sets of 460TPH CFB

boiler. The boiler mainly consists of drum, membrane water wall furnace, thermal insulation cyclone separator, U -

type seal pot and back-pass convective heating surface.

1. Steam and water system: The steam and water system consists of economizer, drum, evaporative

heating surface (furnace water wall and evaporate panels), superheater panels, back-pass superheater, final

superheater and re-heater.

The feed water enters low temperature economizer from one side of the pack-pass and then high temperature

economizer. The heated water then enters the drum through 2 connecting pipes. The water in the drum flows

to the furnace water wall through 4 large diameter downcomers, and 02 to the evaporate panels through

downcomers. Then the saturated steam is lead to the drum through link tubes.

The saturated steam is lead to back-pass superheater from drum through 2 connecting pipes. The superheat

steam flows through back-pass superheater, low temperature superheater panels, first-stage de-superheater,

high temperature superheater panels, secondary-stage de-superheater and final superheater.

2. Gas and air system: The boiler is of balanced draft. Zero pressure point is set at the inlet duct of cyclone

separator. The air is send into the air pre-heater by fans (include primary air fan and secondary air fan). The

hot primary air enters wind box arranged under the furnace and flows through the nozzles on the grate and

fluidizes the materials inside the furnace. The hot secondary air is send into the furnace through secondary

nozzles. The high pressure fluidizing air is used as greasing air of seal pot and fluidizing air of ash cooler.

3. Coal & Ash circulation system: Fuel, sorbent and bed materials are fluidized in the furnace by the primary

air. Fuel particles, high temperature materials and sorbent particles are mixed sufficiently. Combustion process

is completed in the dense-phase area, however small particles are carried out by the gas, which are separated

in the cyclone as the heavy particles drop down and the light fly ash are carried by the gas to the back-pass.

Two thermal insulation cyclone separators are arranged between furnace and back-pass. A U type seal pot is

arranged under each separator. Fluidizing nozzles are arranged at the bottom of the seal pot, which fluidizes

the material and send it back to the furnace.

4. Ash drain system: Ash generation will be tune of 50% of the coal firing rate, in which, Fly ash and bed ash

ration is 55:45. Bottom ash is drained from the furnace bottom. The temperature of bed ash is about 800 Deg

C. The bottom ash will drag to ash coolers that will be cooled to as low as 120 Deg. Fly ash is drained from the

back-pass and ESP.

Details of Coal Bunker, feeder, fans & motors:

Coal bunker Capacity:

No Item Unit Value

1 No of coal bunkers for each boiler Set 2

2 Volume per bunker m3 1150

3 Effective volume m3 977.5

4 Bulk Density T/ m3 0.85

5 Effective Stacking capacity Tons 830

6 Plant operation time without filling coal Hrs 12 (6 Hrs x 2 Bunkers)

Gravimetric Coal Feeder

No Item Unit Value

1 Type - Gravimetric

2 Max O/P TPH 60

3 No. per Boiler Set 6

Primary Air Fan

No Item Unit Value

1 Type - Centrifugal

2 Inlet air capacity 0C 27

3 Capacity m3/ Hr 165486

4 Static pressure rising mmwc 2345

5 Flow control device - IGV

6 Motor rated power KW 1200

7 Voltage V 6600

8 No for each boiler Set 2

Secondary Air Fan

No Item Unit Value

1 Type - Centrifugal




5 Flow control device - IGV


7 Voltage V 6600


Induced Draft Fan

No Item Unit Value

1 Type - Double suction inlet

Centrifugal

2 Inlet air capacity 0C 139.5



5 Flow control device - Hyd Coupling


7 Voltage V 6600


High Pressure Blower

No Item Unit Value

1 Type - Constant volume

(displacement type)





6 Voltage V 6600


Electrostatic Precipitator

No Item Unit Value

1 Type - Double chambers and

eight fields

2 Inlet flue gas temperature 0C 154.6

3 Flow of gas m3/ Hr 962280

4 Flow area m2 333

5 Pressure drop mmwc 99.97

7 Dust emission at ESP Outlet Mg/ m3

Reheat Condensing Steam Turbine

Shanghai Turbine Co. Ltd. (SEC/STC) has manufactured more than 200 turbine units of 135MW capacity so far.

Their brand-new D151 type turbine unit is developed on basis of MHIs technique. This steam turbine is a super

high-pressure reheat unit of reaction condensing type with double exhaust arrangement. Its features are combined

HP and IP cylinder and inverted flow path arrangement, as main steam flow and reheated inlet flow are gathered at

the middle part of HP-IP cylinder. The LP cylinder is radial diffusing type with double exhausts, reducing axial

length of turbine and lowering exhaust resistance by the greatest extend.

The HP-IP cylinder is a single-shell casing, with a single-row control stage and 13 pressure stages in the HP section.

The reheated steam enters the combined reheat valve which is controlled by 2 oil-relays in left-right arrangement

via two pipes, and then goes into the IP section via two rigid admission pipes. The IP section has 13 pressure

stages. The upper half of IP exhaust section is designed upright to lead the exhaust steam into the LP cylinder via

two flexible IP and LP crossover pipes. The LP cylinder is double-flow and double-exhaust type.

Performance evaluation of Power Station

Evaluation of power station performance shall be pronounced as performance of boiler and TG as boiler receives

energy from outside so as to produce steam while Turbine attributed to electricity generation.

Power station output or capacity mentioned in terms of MW in general. Kilo-Watt-Hour or KWh is the basic unit of

electricity.

Heat rate:

Heat rate is a significant indicator of power station performance. Heat rate defined as Heat Input (Kcal or KJ) per

Unit electricity generation (KWh). Lower the heat rate, higher the plant efficiency.

1. Turbine Heat Rate: Turbine heat rate is defined as heat input to turbine (in Kcal) per unit generation. At

DCPP, guaranteed turbine heat rate is 2042 Kcal/ KWh.

2. Unit heat rate: Turbine heat rate divided by boiler efficiency leads unit heat rate. For DCPP, guaranteed

boiler efficiency is 82.7% and their by unit heat rate will be 2469 Kcal/ KWhr. (NB: 2042/.827= 2469)

3. Station / Plant heat rate: Auxiliary power consumption of Thermal power plant is considered at 10% of

the plant total capacity. So, the power output can be calculated as 90% of total generation and the station

heat rate will be 2743 Kcal/ KWhr.(NB:2469/.90=2743)

Boiler efficiency:

Efficiency of boiler can be calculated in two ways viz; direct method and indirect method.

Direst method: Direct method is simple Output / Input method.

Efficiency: Main Steam Flow (TPH) X 1000 X (hs- hf) + RH Flow (hhrhs hcrhs)

Coal fired / Hr in Kg x GCV of coal in Kcal/ Kg

Indirect method: Indirect method counts various losses and their by considered as more accurate than

direct method of finding efficiency. However, blow down loss is omitted in indirect method. There are

reference standards for Boiler testing at site using indirect method namely British Standard BS 845: 1987

and US standard ASME PTC-4-1 Power test code steam generating units. Indirect method is also called

heat loss method, covers various losses such as

Heat loss due to dry flue gas

Heat loss due to moisture in fuel

Heat loss due to moisture in combustion air

Heat loss due to hydrogen in fuel

Heat loss due to radiation

Heat loss due to Unburnt in fly ash

Heat loss due to Unburnt in bed ash

Station costing model (tentatively given for understanding concepts)

Estimated project Cost of 4 x 135 MW Captive Power Plant is Rs.2259.00 Crores. The CPP will cater to ever

increasing power demand of not only the existing but also the upcoming Steel complex at Raigarh.

The Project is financed in two phases.

The total project cost and financing plan for Phase I & II is as under:-

Sl. Description Project cost

Phase I Phase II

1 Total Project Cost Rs.1179.00 Crores Rs.1080.00

Cost calculation sheet (combined for Phase I & II)

Generation

Item Unit Quantity Remark

Turbine Maximum Continuous rating (TMCR) MW 135.00 Per Hour generation in Million Units

Maximum Generation per day MU 3.24

Average achievable generation per day MU 2.92 at 90% PLF

Auxiliary power consumption per day MU 0.29 at 10% of generation

Net saleable units per day MU 2.62 Average generation - Aux Power

Per day revenue (Rs in Crores) Rs in Cr 1.14 at Rs 4.35 / Unit (i.e. KWhr)

Monthly Generation MU 78.73

Monthly revenue Rs in Cr 34.25

Yearly generation MU 944.78 Considering 12 months

Yearly achievable generation MU 866.05 considering 01 Month S/D

Unit Yearly Revenue Rs in Cr 376.73 From one Unit

Plant yearly Revenue Rs in Cr 1506.93 From 04 Units

Coal


Max Coal Consumption per hour BMCR Tones 162 for 460 TPH, 2300 Kcal/ Kg GCV coal

Max Coal Consumption per hour TMCR Tones 145 For 435 TPH, 2042 Kcal/ Kg heat

rate, Boiler efficiency at 82.7%

Avg. Coal consumption per Day Tones 130 At 90% PLF

Coal consumption per day Tones 3120

Specific coal consumption T/MW 1.075

Cost of coal per day Rs in Cr 0.28 at Rs 900/ T of Middling

Cost of coal per month Rs in Cr 8.42

Cost of coal per annum per unit Rs in Cr 92.66 Considered 01 month S/D

Cost of fuel per annum for 04 units Rs in Cr 370.66

Fuel Oil


LDO Consumption (Per light up) T 32.00 Cold startup

LDO Consumption (Per light up) T 12.00 Hot Startup

Total consumption / annum T 336.00 06 cold startup & 12 hot startup

Fuel cost Rs/T 30000.00

Fuel cost per annum Rs in Cr 1.01 One unit

Fuel cost for 04 Units Rs in Cr 4.03

Miscellaneous costs


Maintenance cost and other Misc cost such as

Manpower (staff & operators), Ash transportation,

chemicals, DM Water etc

Rs in Cr 113 5% of capital cost of 2259 Crores

Calculation sheet


Total revenue per annum Rs in Cr 1506.93 From 04 units

Expenditure Rs in Cr 487.69

Net Savings Rs in Cr 1019.24

Simple payback period:-

This is the simplest technique that can be used to appraise a project proposal. The Simple Payback Period can be

defined as the length of the time required for the running total of net saving before depreciation to equal the

capital cost of the project. Shorter the payback period, more attractive the project becomes.

Simple payback period (SPP) : Capital cost of the projects / Net annual saving. SPP (of DCPP) : 2259 / 1019

: 2.21, to say 2 years 03 months

Discounted cash flow methods:-

Even though, SPP is a simplest technique for a quick evaluation, it has a number of major weaknesses as below:

SPP does not consider savings that are accrues after the payback period is finished.

SPP does not consider either interest, inflation etc. Other way, time value for money is not been considered

in SPP Method.

Net present value: NPV method calculates the present value of the all yearly cash flows (i.e. capital costs and

net savings) incurred or accrued throughout the life of a project, and summates them. Costs are represented as

negative value and savings as positive. The sum of all the present value termed as NPV. The higher the NPV, the

more attractive the proposed project.

PV = S x DF; DF = (1+IR/100)-n

PV is the Present Value of S in n years time, S is the value of cash flow in n years time, DF is the discount

factor or simply interest on capital.

Profitability Index: Profitability index termed as sum of the discounted net savings per capital cost.

Net Present Value and Profitability Index for a 10 Year span

Discount factor is nothing but accrues figure of interest, depreciation and inflation. Here, we have considered 10% interest, 10% depreciation and 4% inflation

Net Present Value and Profitability Index for a 10 Year span

Year Discount at 16% (Interest,

inflation and Depreciation)

Capital investment (In

Crores) Net Savings Present Value

0 1 -2259 0 -2259

1 0.862 0 1019 878

2 0.743 0 1019 757

3 0.641 0 1019 653

4 0.552 0 1019 562

5 0.476 0 1019 485

6 0.41 0 1019 418

7 0.354 0 1019 361

8 0.305 0 1019 311

9 0.263 0 1019 268

10 0.227 0 1019 231

NPV 2666

Profitability index 1.18

VARIOUS PACKAGES ALONGWITH VENDORS & THEIR OWNERSHIP

S.N. PACKAGE NAME VENDOR FOR PH-II VENDOR FOR PH-II Owner

1 BTG PACKAGE Shanghai Electric

Company (SEC), China

Shanghai Electric

Company (SEC), China

Boiler: Mr Aravindaran

Turbine: Mr U K Ghosh

2 MAKE-UP WATER

SYSTEM "RAUNAQ International

Ltd "RAUNAQ & Jindal Saw

Pipes Mr Balamurugan / Mr T V

Gopi

3 PTDM Plant TRIVENI TRIVENI Mr Sunil Porwal

4 COOLING TOWER (2

Nos.) "PAHARPUR COOLING

TOWERS LTD." "PAHARPUR COOLING

TOWERS LTD." Mr Sunil Porwal

5 EOT CRANE "CSD,RAIGARH" "CSD,RAIGARH" Mr U K Ghosh

6 CHIMNEY SIMPLEX Infrastructure

Ltd GDC Mr A Kar/ Mr U K Ghosh

7 CIVIL & STRUCTURAL

WORK

SIMPLEX Infrastructure

Ltd GDC Mr A Kar/ Mr U K Ghosh

8 CW & ACW PUMP "WPIL LTD." "WPIL LTD." Mr Sunil Porwal

9 SWITCH YARD (For

10Bay) "Siemens" "Siemens" Mr S K Garai

10 POWER/GENERATOR

TRANSFORMER

"AREVA" T&D LTD.

"AREVA" T&D LTD. Mr S K Garai

11 ST & UAT "T & R ltd." "T & R ltd." Mr S K Garai

12 Service Transformer "Crompton Greaves

Ltd."

"Crompton Greaves

Ltd." Mr S K Garai

13 CHP Enviro abrasion

Resistant Ltd.

Enviro abrasion

Resistant Ltd. Mr R Verma

14 AHP "Mecawber Beekay

Ltd." "Mecawber Beekay Ltd." Mr Vinay Krishan

15 BTG Erection &

Commissioning EDAC Engineering Ltd Sunil Hi-Tech

Boiler: Mr Aravindaran

Turbine: Mr U K Ghosh

16 HT Switchgear Siemens Mr S K Garai

17 MISCELLANEOUS PUMPS "WPIL LTD." "WPIL LTD." Mr Sunil Porwal

18 COMPRESSED AIR

SYSTEM "Atlas Copco LTD." Mr Vipin Chaudhary

19 HT POWER CABLE "KEI LTD" Mr S K Garai

20

CW & ACW PIPING

"LLOYD LTD."

Mr Balamurugan / Mr T V Gopi

FUEL OIL SYSTEM Mr Balamurugan / Mr T V

Gopi

21 BATTERY & BATTERY

CHARGER "HBL LTD." "HBL LTD." Mr S K Garai

22 RE JOINT "CORI ENGINEERING

LTD." "CORI ENGINEERING

LTD." Mr U K Ghosh

23 BF VALVE "TYCO VALVE LTD." "TYCO VALVE LTD." Mr Balamurugan / Mr T V

Gopi

24 BUSDUCT "CONTROL &

SWITCHGEAR LTD." "CONTROL &

SWITCHGEAR LTD." Mr S K Garai

25 C & I M/s YOKOGAWA LTD. M/s YOKOGAWA LTD. Mr J Kole

26 FIRE detection and protection system

Tyko fire Tyko fire Mr Sarkar

27 STOP LOG GATES &

SCREENS M/s Macmet India Ltd M/s Macmet India Ltd

Mr Balamurugan / Mr T V Gopi

28 LP PIPING M/s Unitech Machines

Ltd.

M/s Unitech Machines

Ltd. Mr Sarkar

29 BOP ELELCTRICAL M/s UB ENGINEERING

LTD. Mr S K Garai

30 DG SETS M/s STERLING & WILSON Mr Vipin Chaudhary

31 LT switch gear M/s Schneider Electric

India Pvt. Ltd.

M/s Schneider Electric

India Pvt. Ltd. Mr S K Garai

32 Air conditioning M/S VOLTAS LTD Mr Vipin Chaudhary

33 Ventilation M/S SK SYSTEM Mr Vipin Chaudhary

34 Misc crane and hoist M/s Century Crane

Engineers Pvt ltd

M/s Century Crane

Engineers Pvt ltd Mr Sunil Porwal

35 Elevator M/S OMEGA

ELEVATORS

M/S OMEGA

ELEVATORS Mr Aravindaran

36 LT Power Cable M/S KEI Mr S K Garai

37 220 KV Transmission

Line M/s Nirmala Constructions Mr S K Garai

38 Logistics M/s Ruby infra logistic TRANSPORT LTD.

39 Plate type Heat

Exchanger M/s Tranter India Ltd Mr Balamurugan

40 Third Party Inspection in

china M/s Lloyd register Asia ltd.

41 O&M Contract M/s SEC

42 Supervision of

Refractory Application &

Furnace drying

M/s SEC Mr Ravindrakumar

43 33 kV Switchyard M/s Siemens Mr S K Garai

44 33 kV Transformers "AREVA" T&D LTD. Mr S K Garai

45 SCADA Mr S K Garai

46 Effluent Treatment Mr Sunil Porwal

47 Public Address System Mr J Kole

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