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ENERGY CONCLAVE 2006
TECHNOLOGY FRONTIERS AND MODERNISATION
ENERGY R&DBHEL ROLE & CONTRIBUTION
PRESENTATIONBY
RAVI KUMARDIRECTOR (POWER)
BHEL, NEW DELHI
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R&D – WORLD STATUS
Expenditure on R&D per capita(IN US $)
INDIA - 5.5 CHINA - 11.7 S. KOREA - 241 AUSTRALIA - 285 UK - 460 USA - 705 JAPAN - 978
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R&D – BHEL
TARGETS
2006-07 2005-06
EXPENDITURE ON R&D RS. 150 CR. RS. 125 CR.
NO. OF PATENTS TO BE FILED
55 NOS. 45 NOS.
COMMERCIALISATION OF IN HOUSE DEVELOPED PROJECTS
RS. 700 CR. RS. 650 CR.
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BHEL-R&D EXPENDITURE AS % OF T.O.
History of R & D Expenditure as % of T.O.
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
1992-93
1993-94
1994-95
1995-96
1996-97
1997-98
1998-99
1999-00
2000-01
2001-02
2002-03
2003-04
2004-05
2005-06
Year
R &
D E
xpen
dit
ure
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Lower Cost of Generation
Environment Friendly
Higher Efficiency
Higher Reliability
Compatible to Local Conditions
TECHNOLOGY TRENDS
POWER SECTOR
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Center Of Excellence For Simulators
Center Of Excellence For Computational
Fluid Dynamics
Center Of Excellence For Permanent
Magnet Machines
CENTRE OF EXCELLENCE SETUP BY BHEL
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Low Nox Oil/ Gas Burners
Large Capacity Atmospheric FBC
High Efficiency Pelton Turbine
Controlled Shunt Reactor (CSR)
Flexible AC Transmission System (FACTS)
Space Grade Solar PV Panels
Phase Shift Transformer
145 KV Gas Insulated Switchgear
India’s Largest Vertical AC Motor (6 MW, 6.6 KV)
Micro Controller Based Flame Scanner
Performance Analysis, Diagnostics and Optimization (PADO) Package
91 Ton/hr BHEL 280 Bowl Mill
STATE OF ART TECHNOLOGIES / PRODUCTS INTRODUCED BY BHEL
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TECHNOLOGIES SUBSTANTIALLY DEVELOPED
Supercritical Thermal Power Plants
Circulating Fluidised Bed Combustion
Coal Based Combined Cycle Plants
IGCC
PFBC
Nuclear Power Generation with Fast Breeder
Technologies
Fuel Cells
Solar Photo Voltaic
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The supercritical cycle offers a ‘burn less fuel for the same output’ approach
Involves economical use of energy resources resulting in higher efficiency and low emissions
BHEL is equipped to supply Supercritical Power Plants upto 1000 MW
SUPERCRITICAL THERMAL POWER PLANTS
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Cycle Efficiency benefits of supercritical units are derived from higher pressures and temperatures of steam
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Super Critical R&D Projects
Areas identified R&D Actions Taken
Heat Transfer Correlations Joint Project with
IIT-ChennaiDNB, Tube Dry-out
Flow Instability
Spiral to Vertical Transition Piece Joint Project with AU FRG
Load Transfer Attachment
Dynamics, Temperature Control BHEL Corp R&D
Ripple Effect BHEL In-House Chemical Lab
FW Oxygenated Treatment
Low NOx Burner BHEL In-House
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CFBC TECHNOLOGY
Burns low grade fuels like lignite No pulverising Low NOx & Low SOx emissions Higher efficiency BHEL commissioned 2x390 TPH
boilers for Surat Lignite Power Project
Number of 125 MW CFBC based power plants are under execution
Order received for 2x250 MW NLC, the largest CFBC technology based power plant in the country
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ENVIRNOMENTAL ASPECTS – ROAD MAP
Development of low NOx wall fired coal burner - 2006Establishment of SCR demo plant - 2007Commercialisation of wall burner - 2008Commercialisation of SCR system - 2010
Area of focus - NOx control in pulverized coal fired boilers
Unit capacity, MW fuel NOx emission, ppm at 3.0 % O2
500 gas 73
500 oil 129 to165
500 coal 271 to 434
250 coal 266 to 322
210 coal 247 to 478
210 lignite 242 to 280
120 coal 389
NOx emission scenario of Indian plants while firing different fuels:
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6.2 MW IGCC Pilot Plant at its Trichy Complex.
Technical feasibility of upgrading the 6.2 MW Combined Cycle Demonstration Project of BHEL to ~100 MW had been established
Preliminary assessment made for 400 MW IGCC Plant
Plan to set up 125 MW IGCC Demonstration plant
IGCC POWER GENERATION - DEVELOPMENT IN BHEL
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PFBG SCALE - UP
IGCC POWER GENERATION - DEVELOPMENT IN BHEL
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A glimpse of Fuel Cell Developments at BHEL(Inter-disciplinary approach followed for Fuel Cells Development)
Anodes, Cathodes,Membrane Electrode
Assemblies etc(Fuel Cells Lab) Bipolar &
Cooling plates(Fuel Cells Lab)
Stack Hardware& Assembly
(Design Analysis &Value Engg)
Reactants & Coolant Supply
(Turbo MachineryLab)
Stack Heating & Cooling
(Heat TransferLab)
Fuel CellDevelopment
Data Acquisition,display & Controls
(Control Instrumentation Lab)
Inverter System(Pow er
Electronics Lab)
Skid Design (Renewable
Energy SystemsLab)
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Indigenous Fuel Cell R&D - Achievements
Phosphoric Acid Fuel Cells (PAFC)BHEL R&D: 1 kW (1991), 5 kW (1995) & 50 kW (2000, 2 stacks of 25 kW each) - with data acquisition and display system & inverter have been demonstrated.
Performance of a state-of-the-art 200 kW FCPP (PC 25 C, procured from M/s IFC / ONSI / Toshiba) also evaluated, using LPG as fuel.
Polymer Electrolyte Membrane Fuel Cells (PEMFC)Single cells & small stacks for evaluating electro-catalysts. Also tested Direct Methanol FCs – Basic Tech acquired from IISc, B’lore
High Temperature Fuel Cells (SOFC)BHEL R&D & CTI, Bangalore: Materials, processes & components developed. Assembled & tested single cells of planar SOFC.
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BHEL IN PHOTOVOLTAICS
Over two decades experience in Photovoltaics
Manufacturing capacity of 3MW
Single crystalline (mono) cells upto 2.3W (15% efficiency)
PV modules range is from 10W to 160W
PV systems integration capabilities- have supplied PV power plants ranging from 1 KWp to 150 KWp
PV modules internationally certified to IEC 61215 standards
Cumulative shipments from BHEL over 20 MWp
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Future outlook for PV in BHEL
Automatic manufacturing capacity over 30 MW planned Plan for improving solar cell efficiencies to over 18% by
2010 Capability to process both mono & multi crystalline wafers Opportunities for backward integration into silicon wafer
manufacturing Large scale deployment of PV power plants Explore alternate technologies like Thin film cells, multijunction cells etc
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BHEL - R&D
DEVELOPMENT OF 765 KV TRANSMISSION SYSTEM 2006-07 TARGETS
DESIGN & MANUFACTURE OF 765 KV, 500 MVA TRANSFORMER
DESIGN & MATERIAL PROCUREMENT FOR MANUFACTURE OF 765 KV 80MVAr SHUNT REACTOR
DEVELOPMENT OF COMPOSITE INSULATORS FOR TRACTION & TRANSMISSION WITH NANO ADDITIVES
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Power plant consumes nearly 7 to 9% of energy generated
Auxiliary power can be brought down by proper selection of technology, equipments and cycle parameters
Power consumption of BHEL manufactured equipment has been recently reduced from 7% (of total power consumption) to 6.65% for 250 MW & from 4% ( with turbine driven boiler feed pump) to 3.8%
POWER PLANT PERFORMANCE IMPROVEMENTSAUXILIARY POWER CONSUMPTION REDUCTION
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LEADING PLAYER IN R&M AND UPRATING
R&M and LE of Large No. of Units in India and Abroad
Uprating of 110 MW Czech Units to 120 MW- Replaced Internals of HP, MP & LP Turbines with Reaction Type Blading- Boiler Upgrades to Ensure Rated - FlowModernize C&I and Balance of Plant
Improvised Blade Profiles for 210 MW LMW Sets- Reaction Type Blades for HP Turbine yield an additional 2.5 MW- New Monoblock LP Rotor with Reaction Blading Leading to additional 3.7 MW
POWER PLANT RENOVATION & MODERNISATION
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PERFORMANCE OF BHEL THERMAL SETSPerformance Trend
(Thermal sets in India)
50
55
60
65
70
75
80
85
90
year
%
PLF-BHEL
OA-BHEL
PLF-ALL INDIA
PLF-BHEL 55.8 56.6 59 62.8 61.2 63.1 64.6 65.6 65.7 68.3 70.5 71.3 74.1 74.3 75.7 74.9
OA-BHEL 71.7 72.7 74.6 77 77.5 79.9 80.7 79.8 78.9 80.4 81.8 81.7 83.9 83.9 84.3 83.4
PLF-ALL INDIA 53.8 55.3 57.1 61 60 63 64.2 64.7 64.2 66.7 68.5 69.9 72.2 72.7 74.8 73.6
90-91
91-92
92-93
93-94
94-95
95-96
96-97
97-98
98-99
99-00
00-01
01-02
02-03
03-04
04-05
05-06
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THANK YOUTHANK YOU
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