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This is a presentation from Aban Power Company Limited, one of the finalists at the 5th CII-GBC National Award for Excellence in Water Management in 2008 The awards are in 2 categories, Within the Fence for work done on minimizing the organisations water footprint, and Beyond the Fence for work done in the community around the industry. This presentation was in the "Within the Fence" category. We thank CII and the respective companies for giving us permission to upload these presentations on the India Water Portal website for dissemination to a wider audience.
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Aban CII_wate r Award 0812/9/2008
1
A Presentation on
EXCELLENCE IN
WATER MANAGEMENT2008
By
ABAN POWER COMPANY LIMITED
Aban CII_wate r Award 0812/9/2008
2
COMPANY PROFILE
– Independent Power Project (IPP) with Natural gas based Combined cycle power plant of Capacity 119.8 MWH
– Established thro InternationalCompetitive Bidding (ICB) route
– Power supply to the TNEB Grid on Long-term basis
Part of LANCO group
Aban CII_wate r Award 0812/9/2008
3
CDM APPROVEDSmoke free chi mne y
ØABAN is the First project in the world for a gas
based combined cycle power plant to obtain
CDM tag under AM 0029 methodology.
Ø Registered as CDM Project with UNFCCC on
29th May 2007 VER 2005 – 68946CER 2006 – 213891CER 2007 – 215925
Aban CII_wate r Award 0812/9/2008
4
ISO 14001 & OHSAS 18001 CERTIFIED
Aban CII_wate r Award 08
AIR
C T G
ST
HOT WELL
D .M PLANT
GUA RD PO ND
R.O PLANT
AIR CO OLED C OND ENSO R
G
N ATUR AL GAS
BY PASS S TACK
HRSG
MAIN STAC K
BL
O
W
DO
WN
SO LAR EVAPO RATO N PO NDS
PERMEATE - FO R RECY CLE
REJECTS TO SO LAR PO NDS
MAKE UP TO HRSG
C OND ENSATE BAC K TO H RSG
STEA M TO TU RBINE
FLUE G AS TO ATMOSPH EREGAS TU RBINE
G ENER ATOR
FLUE GAS TO HRS G
FEED WATER TO
HRS G
WATER FR OM TWAD BO RAD
GT WAS H / C T BLO W DO WN
12/9/2008
5
PROCESS FLOW
Aban CII_wate r Award 0812/9/2008
6
WATER CONSERVATION PROJECTS – DESIGN STAGE
Air Cooled CondenserDry Low NOX
Sav ings in m3/yr
2006-07 : 2061368
2007-08 : 2142673
Sav ings in m3/yr
2006-07 : 148750
2007-08 : 148750
18,000 m3/yr
RWHP
Aban CII_wate r Award 08
Profit and saving on natural resources.
Highly efficient (more than 47 %)
Efficiency is less
State of the art technology
No need of steam or water
425 MT/d of steam is needed for reducing NOx level to 45 ppm (max)
Less pollution – better environment
About 374 kg/day of NO x is only emitted
About 1402 kg/day of NO x emitted in the flue gas
New standard / bench mark
Maximum of 20 ppm of NO x in the emission.
Minimum 45 ppm of NO x level in the emission even after Water or steam injection
Saving on natural resources
No steam or No DM water
Super heated Steam is consumed for reducing the NO x level
RemarksABANTYPICAL PO W ER PLANT
DRY LOW NOx BURNERS
Aban CII_wate r Award 08
No generation of effluent
Effluent generation in the steam or DM water production
Cost of the project Rs.16 crores approx
Cost of the project –Additional to existing HRSG piping
DM water consumption is NIL litres / MWH
DM water consumption is 335 ltrs / MWH
No impact on environmentReduction in water consumptionEn vironmental investment can be paid back Zero discharge of effluents was possible
NIL treatment cost so savings is 4.52 crores per annum approx
Cost of steam injection would result in 4.52 crores per annum approx
RemarksABANTYPICAL POWER PLANT
DRY LOW NOx BURNERS
Aban CII_wate r Award 0812/9/2008
9
Rs. 448Lakhs
148750 m32007-2008
Rs. 448Lakhs
148750 m32006 – 2007
Rs. 307.2Lakhs
102000 m32005 – 2006(eigh t mon ths of operation)
DLN BURNERS FOR GAS TURBINE –Selected a GT with DLN burners (GE 6FA Gas Turbine) in place of conventional turbine without DLN Result: Savings includes the cost of production for steam using DM water, fuel, chemical dosing and handling of effluent generation & reduce d e mission, water conservat ion
Saving of waterPeriodMethod
DRY LOW NOx BURNERS
Aban CII_wate r Award 0812/9/2008
10
AIR COOLED CONDENSERS
Rs. 642 Lakhs
2142673 m32007-2008
Rs. 618 Lakhs
2061368 m32006 – 2007
Rs. 406 Lakhs
1353056 m32005 – 2006(eigh t mon ths of operation)
AIR COOLED CONDENSERS –
Installed Air Cooled Condensers in place of conventional cooling towers
Result: Consumption is 102 litres/MWH instead of 2500 lit/MWH
Saving of waterPeriodMethod
Aban CII_wate r Award 0812/9/2008
11
AIR COOLED HEAT EXCHANGERS
Rs. 15.30Lakhs
51000 m32007-2008
Rs. 15.30Lakhs
51000 m32006 – 2007
Rs. 10.80Lakhs
36000 m32005 – 2006(eigh t mon ths of operation )
AIR COOLED HEAT EXCHANGERS–Installed Air Cooled Heat Exchangers (ACHE) for Closed Cooling water system (CCW) in place of conventional cooling towers using water resource.Result: Consumption is almost NIL requirement of water; hence saving of 6.07 m3 /Hr
Saving of waterPeriodMethod
Aban CII_wate r Award 0812/9/2008
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RAIN WATER HARVESTING POND
Rs. 10.8 Lakhs –Proactive practice to enrich water table
36000 m32006-07 &2007-08
Storm water reservoir –18000 KL approximate capacity with 9 percolation pits.Utilizing this water as and when required for maintaining: 14985 trees, 22000 shrubs11000 hedges15000 Sq Mt of Lawn
Saving of waterPeriodMethod
Aban CII_wate r Award 0812/9/2008
13
Reverse Osmosis
Auxiliary Cooling Water
Sav ings in m3/yr
2006-07 : 2448
2007-08 : 3366
WATER CONSERVATION PROJECTS –CONTINUAL IMPROVEMENT
Sav ings in m3/yr
2006-07 : 3240
2007-08 : 3240
Aban CII_wate r Award 0812/9/2008
14
IMPROVEMENT IN R.O RECOVERY
Rs. 1.01 Lakhs
3366 m32007-08
Rs. 0.74 Lakhs
2448 m32006-07R.O PLANT Pre treatment-Feed pH brought down from 7.0-7.5 to 6.0-6.2 by acid treatment thereby keeping LS I close to zero or slightly negativeResult : Permeate increased by 0.9 m3 /hr
Saving of waterPeriodMethod
Aban CII_wate r Award 08
GUARD POND
DMF
C. F
R.O SKID
PERME ATE
REJE CTHP PUMP
N PITDM PLANT
SETT LING TANK
HCLFeCl3POLY
R.O Treatment after modi fications
ACW, BOILE R BLOW DOWN
HRSG SUMP
EFFLUENT fro m DM PLANT
12/9/2008
15
R.O– Improved performance after pretreatment modification
Aban CII_wate r Award 0812/9/2008
16
C.T – COC INCREASE
Rs. 3.45 Lakhs
6480 m32006-07 &2007-08
By Increase in Cycle of Concentration – COC – in Auxiliary Cooling Tower from 5 COC to 8 COC
Result:A) Reduction in consumption
of water by 270 M3/ MonthB) Cost saving in reduction of
chemical treatment Rs. 6044 per month
Saving of waterPeriodMethod
Aban CII_wate r Award 08
Raw Water Consumption
0
2000
4000
6000
8000
10000
12000
Aug-05
Oct-05
Dec-05
Feb-0
6
Apr-06
Jun-0
6
Aug-06
Oct-06
Dec-06
Feb-07
Apr-07
Jun-0
7
Aug-07
Oct-07
Dec-07
Feb-08
Apr-08
Jun-0
8
Aug-08
Oct-08
Months
in K
l
Aban CII_wate r Award 0812/9/200818
SPECIFIC WATER CONSUMPTION
0.0284893525.054 253902007 - 08
0.057858903.454 452702006 - 07
0.08564298.49 452002005 – 06(8 months)
M3/ MWh
Generation (MWh)
Annual Water Consumption
(M3)
Year
Aban CII_wate r Award 0812/9/200819
SPECIFIC WATER CONSUMPTION
Specific Water Consumption
0.000.010.020.030.040.050.060.070.080.09
2005-06 2006-07 2007-08Year
m3/M
WH
Aban CII_wate r Award 08
R e c yc le d /Unit G e n e ra tio n in M 3 /M W H
0 .03 8
0 .0 2 5 0 .0 2 5
0 .0 0 0
0 .0 0 5
0 .0 1 0
0 .0 1 5
0 .0 2 00 .0 2 5
0 .0 3 0
0 .0 3 5
0 .0 4 0
0 .0 4 5
2 005 -0 6 20 06-0 7 20 07-08
Y ea r
Aban CII_wate r Award 08
GOOD GREEN GOVERNANCE AWARD - 2007
Aban CII_wate r Award 08
CII ENERGY EFFICIENT UNIT AWARD - 2008
Aban CII_wate r Award 0812/9/2008
23
IN A NUT SHELLThe project was implemented with:v Zero Discharge facility v R.O plant to recycle the effluents & rejects to solar evaporation pondsv GT with DLN burners does not require steam or water vEnergy and water saving A.C.C & A.C.H.E system in place of conventional cooling towersvISO 14001 & OHSAS 18001 Certifiedv CDM Approved Project
Aban CII_wate r Award 0812/9/2008
24
Thanks