8/7/2019 Coal efficiency
1/32
APEC Workshop on Options to Reduce CO2
EmissionsS.C. Deo Sharma
Centre for Power Efficiency and Environmental Protection (CenPEEP)
National Thermal Power Corporation (NTPC) Limited, India16th February, 2004
"Coal-fired Power Plant Heat Rate and
Efficiency Improvement in India"
8/7/2019 Coal efficiency
2/32
Coverage
1. NTPC: A Snapshot
2. NTPC USAID Partnership
3. Indian Power Scenario
4. CenPEEP Strategies
5. CenPEEP Experience
6. Future Options & Govt. Initiatives
8/7/2019 Coal efficiency
3/32
Present Commissioned Capacity -- 21749 MW
(Coal based: 17480 MW Gas based: 3955, JV: 314)
Projects Under Construction --- 5300 MW
Capacity Addition of over 9370 MW planned for Xth Planand 11210 MW planned for XI th Plan
Ambitious growth plan to become a 56000 MW company by
2017
NTPC:A SNAPSHOTNTPC:A SNAPSHOT
PLF of NTPC Stations in 2002-03: 83.6%
Turnover: Billion $ 4.129Net Profit: Million $ 745
National Thermal Power Corporation Ltd. a Govt. of India
Enterprise, set up in 1975 is the largest power utility inIndia.
8/7/2019 Coal efficiency
4/32
NTPC USAID Partnership
Greenhouse Gas Pollution Prevention ProjectGEP Project Aim:
Environmental protection in energy sector by reducing
emissions of greenhouse gases Project outputs: demo of advanced efficient
generation techniques for coal fired power plants.
Ministry of Power
(GOI)
NTPCNTPC USDOEUSDOE
US Agency for International
Development
8/7/2019 Coal efficiency
5/32
Protocol of Intent signed between Govt. of India, Govt. ofUSA and NTPC to implement GEP Project in 1994.
Center for Power Efficiency & EnvironmentalProtection (CenPEEP) established by NTPC in 1994 toimplement GEP Project.
US Department of Energy (USDOE) & USAID supportingCenPEEP through technical assistance & transfer of
advanced leading edge technology for performance
improvement
Initially Project Assistance Completion Date was March,2002;
Project extended till March 31, 2005 and September 30, 2008
in Sept. 1999 and 2003 respectively
Formation of CenPEEP
8/7/2019 Coal efficiency
6/32
Development of an Institution in power sector in India:
To reduce GHG emission from coal fired power plants by
performance optimization in terms of efficiency, availability& reliability .
Technology acquisition with USAID assistance for GHG
reduction Institutionalization of cooperation for technology transfer.
To become a National Resource Centre for performance
optimization and climate change options
To become a Service Provider in power sector
GOALS OF CenPEEP
8/7/2019 Coal efficiency
7/32
Awards & RecognitionsAwards & RecognitionsAwards & Recognitions
CTICTIs Worlds World
ClimateClimateTechnologyTechnology
Award 2002Award 2002
USEPAUSEPA
CLIMATECLIMATE
PROTECTIONPROTECTION
AWARD 2003AWARD 2003
8/7/2019 Coal efficiency
8/32
Coverage
1. NTPC: A Snapshot
2. NTPC USAID Partnership
3.Indian Power Scenario
4. CenPEEP Strategies
5. CenPEEP Experience
6. Future Options & Govt. Initiatives
8/7/2019 Coal efficiency
9/32
Per Capita Electricity Consumption(IEA: Key World Energy Stat 2003)
We have a long way to go
Per Capita Energy Cons & CO2 emission
408
12896
0
2000
40006000
8000
10000
12000
14000
Wo
rld
USA
Japan
France
Germany
U
K
Korea
USSR
Malaysia
Bra
zil
China
India
Country
PerCapitaEnergyCon
0
5
10
15
20
25
PerCapitaCO2Emission
Per Capita Energy Cons
Per Capita CO2 Emission
8/7/2019 Coal efficiency
10/32
109868
101661
66003
97386
28448
12957
46531712
0
20000
40000
60000
80000
100000
120000
1950
'60-'61
'68-'69
'79-'80
'90-'91
'99-'00
00-01
'2003
Ins
tall
edC
apac
ityx
x(M
W)
Years
India: Growth of Installed CapacitiesIndia: Growth of Installed Capacities
Generation in the country risen from 5 Billion units in 1950 to531.43 Billion units in 2002-03.
Generation recorded average yearly growth rate of + 8%.
Peak energy shortages are approx 11%
8/7/2019 Coal efficiency
11/32
POWER SCENARIO of INDIAPOWER SCENARIO of INDIA
Thermal generation share: consistently increasingPeak: 84% in year 2002-03
35%
Hydro
65%65%Thermal
29%
Hydro
69%69%
ThermalThermal
2% Nuclear
70%70%
ThermalThermal
5 % Nuclear & Others
Ist PLAN VIIth PLAN(03/56) (03/90) 2003
25 %
Hydro
8/7/2019 Coal efficiency
12/32
India: Capacity Addition Programme
(Projected for next 10 years- by 2012)
A. Capacity Addition :
Hydro 36597 MW
Thermal 65339 MW
Nuclear 7215 MWTotal 109151 MW
Coal is going to remain the dominant fuel
8/7/2019 Coal efficiency
13/32
Coal Based Power Generation-Issues
Important Issues: Peak power and energy shortages; focus on PLF
Deterioration in coal quality
Deterioration in equipments performance
Approx 40% of power plants less than 200MW
Old plants and equipments - lower rated efficiency
Poor C&I in old plants
Poor maintenance;low performance recovery
Need of R&M: but resource constraint
Coal - mainstay of power generation in India
(abundant reserve, low cost and energy security reasons)
8/7/2019 Coal efficiency
14/32
Environmental issues in coal based power generation :
Greenhouse gas (CO2) emission
Particulate mission
SOx and NOx emission Poor coal quality
Coal haulage over long distance
Ash management / large ash quantity and large land &water requirement, leachates possibilities
Fugitive emission Effluents
Environmental Issues
With accelerated capacity addition program, theseissues would be further aggravated.
Hence appropriate measures need to be taken early.
8/7/2019 Coal efficiency
15/32
Why Power Plant Efficiency is Important?
Increased efficiency implies:
Same MW / Electricity from less quantity of coal
1% efficiency improvement implies:
~3% reduction in coal consumption and
~3% reduction CO2/GHG & particulate emission
Generation efficiency: percentage energy content of thefuel being converted into electrical energy.
Focus needed on technology options to improve
generation efficiency of existing & new power stations.
Efficiency of modern coal power plant = 34-36%
Efficiency of old power plant = 20-30%
8/7/2019 Coal efficiency
16/32
Coverage
1. NTPC: A Snapshot
2. NTPC USAID Partnership
3. Indian Power Scenario
4. CenPEEP Strategies5. CenPEEP Experience
6. Future Options & Govt. Initiatives
8/7/2019 Coal efficiency
17/32
WIN-WIN STRATEGY
EnvironmentImprovement
Plant Productivity
Improvement
GHG emission reductionParticulate emissionreduction
Sox / Nox emission
reductionEffluents reduction
Improved ash
managementImprovement in global
climate
Efficiency increase
Availabilityimprovement
Reduction in O&M
costsLess capacity addition,
less resource required
Increased profitability
Sustainable growthDual focus: PLF& Eff.
Global Concerns Utility Concerns
CenPEEP
8/7/2019 Coal efficiency
18/32
Focus AreasFocus Areas
Low CostLow CostHigh returnHigh return ESPESPOptimizationOptimizationAvailabilityAvailabilityImprovementImprovement
Turbine CycleTurbine Cycle
OptimizationOptimizationBoiler CycleBoiler Cycle
OptimizationOptimization
Technology DisseminationService Provider in selected areas
Coal Beneficiation Studies to promote washed coal usageAdvanced power generation technologiesAsh haulback
CenPEEP: TARGET AREAS
8/7/2019 Coal efficiency
19/32
TechnologyDissemination
Workshop/ News Letters
/ Web Site
TechnologyDemonstration
Wide spreadTraining
Technology Selection &Acquisition
CENPEEP ModelState-of-the art technologies & practices for GHG reduction
from existing coal fired power stations
and
Pursuit of new technologies & options forpower generation & GHG mitigation
State-of-the art technologies & practices for GHG reductionfrom existing coal fired power stations
and
Pursuit of new technologies & options forpower generation & GHG mitigation
Sustainability Through implementation ofSystems / Procedures / Guidelines
CenPEEP MethodologyCenPEEP Methodology
Technology Transfer
8/7/2019 Coal efficiency
20/32
Typical Steps in Technology Transfer
1. Identification of cost effective technique practiced in
US Utilities for performance improvement
2. Training to CenPEEP / NTPC personnel at US
Utilities
3. Training & demo by US experts in Indian Utilities
(NTPC state run utilities both)
4. Demo by CenPEEP in Indian Utilities
CenPEEP: Methodologies
To start performance improvement activities, set of
instruments and equipments were provided by USAID
8/7/2019 Coal efficiency
21/32
Typical Steps in Technology Demonstration
1. Create awareness through training / workshop /
performance optimizers etc2. Walk down of power station to assess the plant
conditions, provide broad recommendations,
3. Formation of POGs groups and identify test ports andnecessary instruments for performance testing
4. Performance testing of the equipments / plants using
high accuracy test instruments5. Recommendation based on the performance testing
6. Sustainability of program by follow up, workshops,
feedback sessions etc
CenPEEP: Methodologies
8/7/2019 Coal efficiency
22/32
Establishes the current level of boiler efficiency
Facilitates combustion optimization
Improves operating efficiency of the boiler Assesses performance degradation, provides inputs to
maintenance for performance restoration
The test comprises of:
Mill testing & performance optimization
Boiler efficiency test
Air preheater testBoiler Furnace Test
Auxiliary power measurement of boiler drives
Boiler Performance Testing
8/7/2019 Coal efficiency
23/32
Turbine & Auxiliaries Testing
Salient Features Establish current level of performance using high
accuracy Instruments
Demo exercises revealed potential of recovering 50- 100 kcal/kWh in HR
Techniques Demonstrated
Performance testing of equipments Water powered cleaners
Condenser air in leak using He leak detector
CW flow measurement using dye dilutiom Induction heating of turbine studs
TurbineTurbine
HRHR
HP / IPHP / IP
EffEff..
CondenserCondenser
HPHPHeatersHeaters
BFPBFP
8/7/2019 Coal efficiency
24/32
The performance optimization techniques:
Establish current level of equipment performance &
best achievable efficiency
Recommend optimal operating regime
Assess performance degradation, provides inputs tomaintenance for performance & capability restoration
Facilitate combustion optimization
Improve operating efficiency
Performance Improvement Activities
CenPEEP undertakes performance improvementactivities through its central & regional set ups.
Use of high accuracy measuring instruments
8/7/2019 Coal efficiency
25/32
Coverage
1. NTPC: A Snapshot
2. NTPC USAID Partnership
3. Indian Power Scenario
4. CenPEEP Strategies
5. CenPEEP Experience
6. Future Options & Govt. Initiatives
8/7/2019 Coal efficiency
26/32
CenPEEP demonstrated performance improvement in several
NTPC stations and state owned utilities by:
1. Generating awareness for performance improvement
and key areas to be focused upon.
2. Implementing systems for performance evaluation &
performance tracking
3. Adopting best practices & new cost effective techniques
Demonstrated improvement even in best run power plants
CenPEEP Experience / Feedback
CenPEEP awareness program & activities enabled
shift in focus from PLF to Efficiency and PLF both
8/7/2019 Coal efficiency
27/32
CenPEEP Experience / Feedback
Salient findings of CenPEEP activities:
Performance improvements are possible at any plant;
1-2% in many plants. Start small; one or two areas (Condenser, APH) and / orone or two activities (primary indicators / testing)
Full support of plant management required
Detailed plan of activities for improvement ant their
periodical review
HR improvement is continuing process; normal work
activities
Performance improvement to be responsibility of every
one; active involvement of all plant staff
8/7/2019 Coal efficiency
28/32
CenPEEP Experience / Feedback
Typical savings ($/Year for pit head station; 210 MW Unit)
1% HR Improvement: 122,640
1% APH Inlet O2: 36,350
1mm Condenser pressure: 9,958
1C APH exit gas temp: 5,886
1C Main steam temp: 3,140
The demand for CenPEEP services increasingconsistently.
CenPEEP expanded its activities by establishing tworegional CenPEEP Centers; set of instruments /
equipments provided by USAID
8/7/2019 Coal efficiency
29/32
Coverage
1. NTPC: A Snapshot
2. NTPC USAID Partnership
3. Indian Power Scenario
4. CenPEEP Strategies
5. CenPEEP Experience
6. Future Options & Initiatives
8/7/2019 Coal efficiency
30/32
GHG Emission Reduction: Other Options
Setting up advanced technology plants like IGCC,Fuel Cells; their feasibility is being explored
Use of non conventional energy resources;
Reduction of T&D Losses
Energy End Use Efficiency
End use energy efficiency improvement leads to lessenergy consumption, less power requirement for
same usage and hence less GHG emission.
Potential areas includes:1. Efficient motor & pumps for agricultural application
2. Energy efficient equipments / system in industries
3. Efficient lighting, domestic electrical appliances, air
conditioning, building design etc.
I i i l i i i i
8/7/2019 Coal efficiency
31/32
500 MW plants & 660 MW supercritical plants for futurecapacity addition
Establishment of CenPEEP to reduce GHG, SPM and
other pollutant emissions
Accelerated Power Development & Reform Program toprovide support to state utility to reduce T&D losses.
Promulgating Energy Conservation Act and establishingBureau of Energy Efficiency to improve end use energyefficiency
Employing highly efficient pollution control devices Large scale Afforestation
Use of washed coal in plants 1000 Km away from mine
end, in sensitive areas & suburbs
Institutional initiatives
8/7/2019 Coal efficiency
32/32
Thank You