NETRA A Maharatna Company
NETRA Presentation
On Carbon mitigation
technologies20th Dec. 2011
Prakash D Hirani
NTPC Energy Technology Research Alliance Developing Economic and Green Energy Technologies
NETRA A Maharatna Company
Presentation Outline
• NTPC overview (5 slides)
• About NETRA (12 slides)
•Carbon sequestration (26 slides)
NETRA A Maharatna Company
NTPC Overview
NETRA A Maharatna Company 35 Years since Inception and ‘Energizing India
PAN India Presence
NETRA A Maharatna Company Performance Highlights - Operational
Consistently Delivering
NETRA A Maharatna Company Capacity Addition by 2017
Long Term Corporate Plan prepared for next 21 years upto GW by 2032 to position NTPC as the World’s largest and best power producer and leader in Green Power
NETRA A Maharatna Company Global Stature
Number 1 independent power producer in Asia in 2010 (by Platts, a division of McGraw-Hill companies)
# 1 in the world in capacity utilization# 3 in Asia in electricity output and # 10 in the world# 3 in the world in plant availability
10th largest generator in the world
NETRA A Maharatna Company Environmental Initiatives
More than 30 Million tons of CO2 has been avoided in NTPC
NETRA A Maharatna Company
About NETRA
NETRA A Maharatna Company
Climate Change
New & Renewable
Energy
Efficiency and Availability
Improvement& Cost reduction
Focus Areas of NETRA
Support to Stations
NETRA A Maharatna Company
Principle:Ramagundam fly ash contains 4.5% CaO (i.e. 1 T/Hr. per 200 MW unit) which requires 0.78 T CO2 for carbonation
Lab. Studies conducted and established carbonation by mixing CO2 in ash Slurry with Ramagundam fly ash.
Objectives:1. CO2 Utilization2. Reduction in scaling in ash pipelines3. Reduction in acid consumption4. Reduction in acidic gases from flue gas5. Reduction in maintenance cost6. Carbonated ash for construction purposes or Agriculture use
Further Activities (Ramagundam)• Design of a pilot plant for 1 T/hour of Ash Slurry
• Fabrication & Installation at site
• Trials at Ramagundam
• Feasibility Report
Chimney
Flue gas Scrubber
ESP
Flue gas
Treated Ash Slurry to Ash Pond/disposal
ID Fan
Blower
Tests with Dadri Flue gas Carbonated fly ash after 2 days in air
Feasibility of CO2 capture technology by aqueous carbonation of ash at Ramagundam
Schematic of trials
NETRA A Maharatna Company
Installation of integrated biodiesel pilot unit from Installation of integrated biodiesel pilot unit from Pomognia fruit at DadriPomognia fruit at Dadri
Benefit: Benefit: Unique technology, self powered useful in Unique technology, self powered useful in remote areasremote areas
Technique:Technique:•Previous Previous set up produces only raw oil from fruit using set up produces only raw oil from fruit using expeller. Cake and shells were used as manure (Utilization expeller. Cake and shells were used as manure (Utilization 15% energy)15% energy)•Now, Shell and cakes are gasified and power is also Now, Shell and cakes are gasified and power is also generated to make the system self driven (Utilization 83% generated to make the system self driven (Utilization 83% energy)energy)
Status: Pilot setup is demonstrated at Pilot setup is demonstrated at Dadri and surplus Dadri and surplus power is also generated for lighting. Patent filedpower is also generated for lighting. Patent filed
From 65 Kg Pomognia Fruit
Biodiesel: 8kg
Electricity production: 24Kwh
Integrated biodiesel pilot plant at DadriIntegrated biodiesel pilot plant at Dadri
ObjectiveObjective: : Demonstrating utilization of 83% of energy from Pomognia fruit in form Demonstrating utilization of 83% of energy from Pomognia fruit in form of Biodiesel and power instead of existing 15% (total) of Biodiesel and power instead of existing 15% (total)
From 1 Hectare plantation
Biodiesel: 1 Ton
Electricity gen: 4800 Kwh
Saving Power: 3800Kwh
Payback: 5 Years
NETRA A Maharatna Company
Status : Technical specification for Ramagundam STPS completed, NIT by Apr2011
Chimney
12 oC
7 oC
Comparison with vapor compression
FGHR VAM Demo
Vapour compression system
Capital cost (Mn 34.2 8.5
Auxiliary power (kWe)
86 137
NPV of Operating cost for 25 year Mn
13.8 22.1
C Credit @ 10 USD / ton of CO2 in Lacs
70 ---
Objective- Waste heat from flue gas for 100TR Air Conditioning at RamagundamBenefit- • Utilizes Waste heat instead of electrical power/ steam to generate Air
Conditioning• Green house gas free Air conditioning.• Auxiliary Power Saving of 0.4 MU per year (266 ton of CO2) • Initial cost of demonstration pilot plant is high, but expected to come down after
large scale deployment
ID Fan
HeatRecovery (500 kW th )
Vapor Absorption Machine(100 T R)
155 oC
130oC
90 oC
80 oC
Hot Flue Gas Hot Flue Gas
HeatRecovery (500 kW th )
Fan
Waste Heat Recovery System: FGHR-AC Pilot PlantWaste Heat Recovery System: FGHR-AC Pilot Plant
NETRA A Maharatna Company
Objective
Status:
S.No Activities Status / Schedule
1 Development of 5kW test loop and Experimentation
Completed in Dec 2010
2 Analysis of results and report 15.03.11
• Based on analysis of 5kW results Technical specifications for 100 kW Pilot plant shall be prepared for deployment in one of NTPC station.
Use of ammonia-water mixture as working fluid instead of water & taking advantage of variable temperature boiling and condensation
Technique
More efficient utilization of low grade/waste heat from flue gases, LP steam, solar energy for increasing cycle efficiency and power generation
BenefitsEfficiency improvement by around 1 % compare to Rankine cycle in low temperature range source (150oC ; Sink-32oC)
Am
mon
ia V
apor
Sep
arat
or
Ammonia VaporSuperheating
RecuperationHeat Exchanger
Am
mon
ia A
bsor
ber
Turb
ine
Qsup`
W
RE
PC
PC=Partial Condenser, RE = Re-BoilerMulti -composition Aqua Ammonia Liquor Absorption
Engine
Qout
Qin
Am
mon
ia V
apor
Sep
arat
or
Ammonia VaporSuperheating
RecuperationHeat Exchanger
Am
mon
ia A
bsor
ber
Turb
ine
Turb
ine
Qsup`
W
RE
PC
PC=Partial Condenser, RE = Re-BoilerMulti -composition Aqua Ammonia Liquor Absorption
Engine
Qout
Qin
Aqua Ammonia Power CycleAqua Ammonia Power Cycle
NETRA A Maharatna Company Solar Platform
S.No Project Deliverable
18-sensor Solar Radiation Station
Ground Level Solar Radiation Data: Global, Diffuse, DNI, UV, IR, Albedo, Sun Shine Duration
2
Setting up of Solar based HVAC system
1. GHG free, low CO2 Solar HVAC
2. Thermal storage for lean/non-solar period operation
3. Can be replicated in power plants
3
Setting up of 1 MW Solar R&D Project at NETRA
1. Proofing of solar thermal technology for low cost solar power – CLFR
2. R&D test bed for component & prototype testing
3. Insight & feedback for O&M issues of solar thermal power plant
4 Setting up of Solar PV Multi-technology test bed and measurement lab
1. Solar PV R&D test bed of five different
technology for performance assessment.
2. Related Test and measurement equipment
5
In-house development of two axis solar tracker for heliostat application
Can be used for:
1. Mounting measuring instruments
2. Photovoltaic module to harness more energy.
3. Heliostat for natural lighting/solar tower
NETRA A Maharatna Company
Solar tracker, tracks the movement of sun Used for focusing
• Various measuring instruments to the sun.• Photovoltaic module to the sun for harnessing
more energy.• heliostat for natural lighting/solar tower
Features:•Microprocessor controlled•Track the sun with 0.072 Deg of accuracy.•Power Consumption – 28 Watt
Cost - Rs. 30,000/- approximately (Market cost Rs. 5 lacs)
In-house development of two axis solar tracker for heliostat application
Power supply unit
Stepper motor
Microcontroller Unit
Motor Driving Circuit
Real time clock
NETRA A Maharatna Company
Why MSW to Energy ?MSW
Contains 70 % organic content, suitable material to be used as a fuel resource (presently considered as a waste, creates pollution)
Advantages of using MSW
Represents a renewable energy source Considered as carbon neutral fuel (CO2 neutral fuels)
Pollutant emissions are lower than coal Can be exploited for their energy instead of destined to landfill
Energy content of typical treated Indian MSW = 3766 Kcal/kg
NETRA A Maharatna Company Waste to Energy
Technology :
Using high pressure steam to convert municipal solid waste (MSW) into solid fuel, and it may be used as a co-firing fuel in boiler / stand alone system.
Comparison with other technologies
1. Use of Saturated steam for treatment (All in one process)
(other technology uses – 1. Dry – 2. Shred – 3. Compress with binders to
produce pellets – Energy intensive process)
2. Requires low energy consumption (only steam is required)
3. Produce grounded fuel with uniform properties
4. Moisture removal is easy (Inherent moisture is removed)
(Others – Only surface moisture is removed)
5. Increase the shelf life of the fuel (fuel becomes non hygroscopic)
(others – Moisture will be reabsorbed by the fuel)
6. Removes bad / stinky odor (Sterilize the waste)
NETRA A Maharatna Company Treatment Performance
Experiment Result of treated MSW
* Calorific value comparable to the Indian coal
Proposed Usage of MSW
Paper Waste
Kitchen Waste
**
Solid FuelSteam
Treatment MSW
Co-firing with coal
Stand alone system
NETRA A Maharatna Company
Plant schematic
Boiler
NETRA A Maharatna Company
Proposed steam treatment
Improves drying performance Suitable for mixed MSW It can produce uniformly grounded fuel Fuel with uniform properties Higher density Removes stinky odor Removal of inherent moistureRequires 39 % less energy compared to traditional methods
NETRA A Maharatna Company
Carbon Sequestration
Carbon Capture Technologies
NETRA A Maharatna Company
CO2 Management
CO2 CaptureUtilization
FuelChemicals
Single source CO2 Emission
Geological storageOceanic storage
Physical & chemical methods
Physical & chemical methods
Biological methods
Biological methods
AbsorptionAdsorptionMembraneCryogenic distillation
BacteriaAlgaeOther related items
Storage
NETRA A Maharatna Company
• There are three option to control the CO2 emission without severely or negatively changing the standards of living:
- Increase in energy efficiency
- Switching over to less carbon intensive source of energy
- Carbon sequestration
The Energy-Carbon ConflictThe Energy-Carbon Conflict
Major steps for carbon sequestration:
• CCapture -CO2 separation from flue gases
• TTransport -Probably in liquid form at high pressure
• FFix -Back to mother Earth- storage in geological formation
The Separated gas may also be used for:
- Use for enhanced coal bed methane [ECBM] recovery
- Use for enhanced oil recovery [EOR]
- Making value added products
NETRA A Maharatna Company
Carbon Emission Reduction Technologies
Efficiency Enhancement
CO2 Capture
• Combustion efficiency improvement in conventional power plant • Low grade heat utilization
• IGCC
• Super critical & Ultra super critical technology
• Advanced class gas turbine
• Hydrogen technology & fuel Cell
Pre-combustion
During Combustion
Post combustion
NETRA A Maharatna Company
Pre-Combustion During -Combustion Post-Combustion
• IGCC - Gas turbine - Hydrogen separation for Fuel Cell
• CFBC
• PFBC
• Oxy- fuel Combustion • Pulverized coal
fired based plant
CO2 Capture Technologies
NETRA A Maharatna Company Pulverized coal
based
Power Plant
Fuel
Air CO2 Separation
Flue gas
Post Combustion approach
Pre-combustion approach
Oxy-fuel Combustion
Fuel
Air Separation
Oxygen
Air
CO2
CO2
IGCC Fuel
Air
Shift reaction & CO2 separation
Gas
GT CO2 Separation Flue gas
H2
CO2
CO2
NETRA A Maharatna Company
CO2 Capture Fundamental Research is required to develop
Cost Effective Technology
Fundamental R&D may not required as Options are known
Major Issues are
• Environmental and Safety• CO2 piping network • Long Term Integrity of CO2 storage • Monitoring and Verification • Legal Frame Work
CO2 Fixation
CO2 Transport
Major steps for carbon sequestration
NETRA A Maharatna Company Technologies for CO2 SeparationTechnologies for CO2 Separation
CO2 Capture Process
Physical Separation
Chemical Separation
Membrane
Separation
Hybrid Separation
Cryogenic Distillation
High Pressure
Separation
NETRA A Maharatna Company
Need for Cost effective Technologies
Indian condition
FGD / SCRSystem
To be installed
CO2 Capture
Western country
FGD / SCRSystem
Already existing
Higher Generation cost
Flue gas
Carbon Capture TechnologiesCarbon Capture Technologies
CO2 Capture Technology
The Separated CO2 may also be used for: - Use for enhanced coal bed methane [ECBM] recovery- Use for enhanced oil recovery [EOR]- Making value added products
NETRA A Maharatna Company Challenges in Carbon CaptureChallenges in Carbon Capture
Combustion in boiler at Atmospheric pressure
Low CO2 concentration in Flue Gas: GT / Gas fired boiler is 4-5%
Low CO2 concentration in Flue Gas: Coal fired boiler: 13-15%
Low Discharge pressure of
Flue Gas: 350-500 mmwc
Combustion in boiler at Atmospheric pressure
Facts
High Energy for
pressurization
Bulky equipment - Higher capital
costs
High partial pressure based CO2 separation
process like Benefild or Catacrab cannot be used
Issues
Low partial pressure of CO2
1. Low partial pressure of CO2
NETRA A Maharatna Company Challenges in Carbon CaptureChallenges in Carbon Capture
2. High temperature of flue gases
Facts
Flue gas temperature
is generally 140-160 °C
Present solvent based
process operates at 40-
50 °C
CO2 laden solvent is
regenerated at 120 °C -
130 °C
Issues
Cooling is
required for
CO2 separation
Flue gas
cooling below
50°C is required
for membrane
or PSA process
Concerns
Cooling is very energy intensive process
Lower temperatures also pose risk of acid corrosion
NETRA A Maharatna Company Challenges in Carbon CaptureChallenges in Carbon Capture
3. SOx Removal
Flue gases from coal fired units contains 700-1200 mg/Nm3 of SOx
In amine process, SO2 reacts with amines to form thermally stable corrosive salt.
SO3 forms sulfuric acid mist in cooler causing corrosion
SOx may adversely reacts with membrane materials or solid adsorbent or may get adsorbed on adsorbent
Facts:
The acceptable limits of SO2 for solvent process is 10 ppmv
A lime stone or wet FGD system followed by caustic soda or soda ash based scrubber is must for SO2 removal
Issues:
Cost of FGD (not mandatory otherwise), results in higher cost of CO2 capture
Concerns:
NETRA A Maharatna Company Challenges in Carbon CaptureChallenges in Carbon Capture
Level in flue gas 500- 800 mg/Nm3
In amine process, solvent degradation due to formation of thermally stable salts
Corrosion due to nitric acid formation
Adverse reaction or adsorbed in solid absorbents
Facts
NOx may degrade membrane materials
NOX is removed by SCR process at 250-300 °C
Plugging of catalyst by fly ash is a problem
Flue gas heating to reaction temperature not possible when SCR is after Economizer.
Issues
SNCR at high temperature is an option
Cost of NOx removal results in higher cost of CO2 capture
Development of Nox / corrosion resistant process will be better option
Concern
4. NOx Removal
NETRA A Maharatna Company Challenges in Carbon CaptureChallenges in Carbon Capture
5. Fly Ash in Flue Gas
Facts:About 100 -150 mg/Nm3 of fly ash present in flue gases
Issues:This causes plugging, erosion, solvent degradation etc. in solvent based process
Fly ash may also plug membranes and solid adsorbents
NETRA A Maharatna Company
Flue gas is cooled and scrubbed in a direct contact cooler
CO2 is adsorbed in 15-20 % aqueous solution of MEA at 40-45 ºC in a Absorption Tower
The absorbed CO2 is regenerated by stripping around 120-130 ºC
Steam (3 kg/cm2) required for regeneration is supplied by a reboiler
Regeneration, the most energy intensive process, requires 2 ton of steam per ton of CO2 Corrosion is a major issue
Absorption Process
most widely used Technology
Chemical Absorption ProcessChemical Absorption Process
NETRA A Maharatna Company
Pri. Amine
High Regeneration Energy
LowerRegeneration
Energy
Introduction of
StericHindrance
RegenerationTarget
100 °C
Waste Heat Utilization of flue
Gas for Reboiler
Solvent Development Solvent Development
NETRA A Maharatna Company Chemical Process for CO2 SeparationChemical Process for CO2 Separation
Major Concerns:
• In amine process, 80-90%of total energy required, is consumed in
solvent regeneration
• For a 210 MW coal fired boiler the total energy requirement is about
65 MWe of power.
• This will bring down total efficiency by at least 30%.
• This will approximately double the power generation cost
NETRA A Maharatna Company Efficiency Enhancement: The IGCC TechnologyEfficiency Enhancement: The IGCC Technology
IGCC Fuel
Air Shift reaction & CO2 separation
Gas
GT CO2 Separation Flue gas
H2
CO2
CO2
The IGCC Cycle
Variation of CO2 with Efficieny
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
0.2 0.3 0.4 0.5 0.6Overall Efficiency (LHV)
CO
2 E
mis
sio
ns-
Kg
/KW
h
Coal Gas
PC
Simple Cycle Gas Turbine
CCGT
IGCC
Improvement of overall efficiency would reduce the CO2 emission
level.
CO2 Emission: CO2 Emission: 0.80-0.85 Ton/MW
For 200 MW Size Unit: 160-170 T/Hr
For 500 MW Size Unit: 400-425 T/Hr
NETRA A Maharatna Company
Absorption Process
Gas Absorption Membrane
Gas Separation Membrane
Membrane process
The Cycle
Carbon Capture Technologies: MembraneCarbon Capture Technologies: Membrane
Gas Clean-Up
Polymer Membrane [T< 100C]
Gas Cleanup & Ceramic
Membrane
[H2]
[CO2]
WGSRIGCC[H2, CO]
NETRA A Maharatna Company
Absorbents
Ionic Liquids Non-Corrosive molten organic salts Alkyl ammonium, Phosphonium,
Imidazolium and pyridinium halide salt Aqueous solution of KOH, NaOH,
Na2CO3, NH3 etc.
Membrane process
Carbon Capture Technologies: MembraneCarbon Capture Technologies: Membrane
Needs large efforts on development of Membrane with right permeability
& selectivity.
Flue gas
Membrane
CO2
CO2 absorbing liquid
NETRA A Maharatna Company
N2 [Primary]
CO2[Secondary]
De-
sorp
tio
n C
ycle
Ad
sorp
tio
n C
ycle
Gas
Cle
anu
pF
lue
Gas
CO
2, N
2
Carbon Capture Technologies: AdsorptionCarbon Capture Technologies: Adsorption
The Cycle Works on a Pressure
Temperature / Vacuum swing
process
Research issues • Development of high
performing adsorbents based on zeolite, mesoporous material, hydrotalcte etc.
• Cycle of CO2 extractions (PSA, VSA, TSA)
• Process integration • Attrition issue
NETRA A Maharatna Company
Technology Development
for post-combustion capture
of CO2 by AdsorptionCSIR (IIP), DEHRADUN
PROCESS DEV & OPTIMIZATION
CSMCRI, BHAVNAGAR
ADSORBENT DEVELOPMENT
IIT, MUMBAI
SIMULATION MODELING & PROCESS DESIGN
NEERI, NAGPUR
ADSORBENT DEVELOPMENT
Netra Research on CO2 Capture
NETRA A Maharatna Company
Conventional amine based CO2 capture process is cost and energy intensive
PSA process is being developed as an alternative process
In PSA process • CO2 is selectively adsorbed on adsorbent under moderate pressure • Adsorbed CO2 is recovered under vacuum
Research components in process development
• Development of materials for CO2 adsorption
• Development of PSA process using the materials • Modeling and simulation of PSA process • Experimentation in PSA test unit and
process optimization
Pressure Swing Adsorption (PSA) process for CO2 capture from flue gas
PSA test unit
PSA Unit
Synthetic Flue Gas CO2 : 12- 13 %
Moisture : 4- 5 %Oxygen : 3-4 %
Nitrogen : 78-81 %Temperature : 50-55 °C
CO2 purity ~ 85 %recovery ~ 75%
• Three Indian and PCT patent application filed on CO2 selective zeolite based adsorption materials
• The PSA unit has been shifted to NETRA from IIP for further development of the process
• Pilot scale development of the process in collaboration with GNFC and CSMCRI is under active consideration
NETRA A Maharatna Company
Highly selective adsorbent
developed at CSMCRI superior to conventional
adsorbents
0102030405060708090
100
Two bed VSA
Three bed VSA
%CO2 purity
%CO2 Recovery
Over 92% CO2 purities at 80% recoveries achieved at 55 0C from CO2
levels of 11% in flue gas.Simulation model validated
Outcome
NETRA A Maharatna Company
• Over 80% recovery of high purity (>90%) CO2 from flue gas at moderate temperature and low pressure
• Preliminary estimates of Power requirements 0.30 Kw-hr/kg CO2 recovered at 550C , lower than current amine based absorption processes
• Base adsorbent material is commercially available
• Process does not generate any waste stream requiring further treatment
Highlights
NETRA A Maharatna Company Carbon Sequestration
• CO2 Capture and its geological storage is energy & cost intensive (60-80USD/Tonne CO2), uncertain and not yet proven
• India’s focus for CO2 mitigation is directed towards biological fixation/utilization of CO2 in addition to efficiency improvement and use of renewable
CO2 to Bio-oil : Micro Algal Process • Able to produce bio-oil, neutraceuticals, cattle food, etc. • Oil content upto 40% • Potential algal species are Dunaliella, Nannochloris, Spirulina • 30 times more oil production than other energy plantations for
same land • No need for agricultural land – may avoid bio-oil crop conflict
• Typical CO2 consumption : 100 gm/m2/day
• Requirement of land for algal cultivation is an issue
• Commercial process for algae to bio-oil using CO2 from power
plant yet to establish • Extensive global R&D for development of the process
CO2 Fixation Initiative
Micro-algaeAbsorbs CO2
Produces
• Bio-fuel
• Micronutrients
• Animal feed
NETRA A Maharatna Company
• Algae commercially grown for nutritional, feed and specialty products• Lipid / oil content : 2% to 40% • Algae generate 7-30 times more oil than bio-plants like Jathropa, Ratanjot etc• Global R&D for development of the process in open pond and photo-bioreactorsystem
• Typically for a open pond system CO2 consumption rate : 100 gm/ square meter/ day Dry algae production rate : 20 gm / square meter / day Oil production : 30%
IOCL-R&D & NETRA through MoU between IOCL & NTPC
Process Open race way pond
Majorsteps
• Process development in Lab. scale • 1000 m2 open pond pilot study at NTPC’s power station
Present status
• Lab. scale developed has been started • Area of app 1500 Sq M identified at Faridabad Gas Power Plant
Algae
1000 sq. meter algae based pilot plant
Micro-Algal process for mitigation of CO2
• Benefit : The pilot study will help in assesing the feasibility of using flue gas as CO2 source & the possibility of producing bio-diesel