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A Brief Introduction to Indian Power Scenario / NTPC Super Critical Technology in NTPC
024 33. 15000 MW Thermal:Fuel Mix (MW) Coal Gas Diesel Thermal 69.0% Private Sector 12% Central Sector 32% State Sector 56% (70.810 3.191 127.0% (15.1% 1.408 13.4% 100.673 MW) 3 Source: Ministry of Power. GOI .431 MW) (41.900 6.5% 16.925* 66 % 26 % 3% 5% 100.024 82.821 MW) About 88% of Capacity is owned by Central/State Governments *Excluding Captive generation capacity of appx.202 84.Currently India has Power Generating Capacity of about 127.925 MW Generating Capacity (MW) Thermal Hydro Nuclear Renewable TOTAL 84.582 1.
and distribution business and for setting up of small hydro plants Setting up coal based power plant in Srilanka 4 . trading. and exploring oil / gas blocks in consortium with partners Subsidiary & JV companies for taking up power generation. developing coal mines for captive use.144 MW 18 coal based and 8 gas based power plants Setting up hydro power plants.A Brief Introduction to NTPC The largest power generation company in India under Central Government Current installed capacity – 29.
) ALLOCATED • ONE OIL/GAS BLOCK ALLOCATED.A Brief Introduction to NTPC • HYDEL POWER ~9.000 MW BY 2017 • NUCLEAR POWER 2000 MW BY 2017 • RENEWABLES~1000 MW BY 2017 LATERAL INTEGRATION • GLOBALISATION SETTING UP OF POWER PLANTS ABROAD INTERNATIONAL CONSULTANCY FORWARD INTEGRATION • POWER TRADING • POWER DISTRIBUTION RELATED DIVERSIFICATION • SIX COAL MINE BLOCKS (~47 MTPA CAP. • SECTORAL SUPPORT •PIE •APDRP •RURAL ELECTRIFICATION •TRAINING UNDER DRUM • R&M OF POWER STATIONS • JV FOR CAPTIVE POWER 5 .
Clean Coal Technologies in NTPC Efficiency Improvement New Technologies Green Power Environment Management Renewable 6 .
SOx and SPM control 7 .Clean Coal Technologies in NTPC Mature Clean Coal Technologies Supercritical/Ultra Supercritical Circulating Fluidized Bed Combustion Clean Coal Technologies under Development Integrated Gasification Combined Cycle Environmental Impact Mitigation Technologies NOx.
Over Fire Air Environmental mitigation Technologies (ESP. Ash Utilization etc) 8 . DeSOx.Clean Coal Technologies in NTPC Sl No 1 2 3 4 5 Technology Efficiency Improvement √ Environmental benefit √ √ √ √ √ √ Super critical /USC Technology FBC Technologies IGCC Low NOx burners. DeNOx.
2%) 5370C / 5370C Base Efficiency=37.6 % (Gross.5%) 5370C/5370C (eff = 38.1%) Efficiency % 5650C/5650C (eff = 38.8%) 5370C/5650C (eff = 38.Super Critical Technology will improve efficiency 6000C/6000C (eff = 39.4%) 5650C/5930C (eff = 39. GCV) 170 246 MS Pressure Kg/cm2 316 Efficiency figures corresponds to boiler efficiency of 85% on GCV basis 9 .9 %) 6000C/6000C (eff = 39.
64% More tolerant to coal quality changes 1.69% to 1.24% 10 .SUPERCRITICAL ADVANTAGES Enhancements Plant efficiency Fuel tolerance Reductions Coal Consumption Ash production CO2 SO2 Nox Improvements Startup time Sliding Pressure Operation Load following capability 0.79% to 4.
CO2 78300 tons . SO2 and NOx between 1.79% to 4.SO2 365 tons .5% PLF per year is .Nox 71 tons 11 .ENVIRONMENTAL ASPECTS Reduction in CO2.24% Reduction for 500 MW at 68.
Temperature-538/566 deg C NTPC implemented supercritical technology for two plants i. 12 Implementation of Supercritical Technology NTPC . Japan” to study for adoption of super critical technology in NTPC EPDC evaluated supercritical technology from technical.e Sipat-I (3X660MW) and Barh-I (3X660MW) with above parameter. In 1999 NTPC appointed an International consultant “EPDC. economical and environmental point of view for Indian perspective. Main steam pressure 246 kg/cm2. EPDC recommended supercritical technology for India and suggested following parameter.
Same as sub-critical Project Implementation.Mature and established Availability .By & large same as sub-critical Reduced Environmental Impact Most preferred parameters.246 Kg/cm2-538oC/566oC Materials proven and already in use Indigenous Supplier of Supercritical Technology are under developing stage.Supercritical Technology Analysis Technology .Essentially same as sub-critical O&M . 13 .
Different chemistry control.Reduced diameter. 100% flow CPU. Superior Material. Higher thickness of certain parts Boiler Control. Turbine.SUPERCRITICAL VS SUBCRITICAL MAJOR DESIGN DIFFERENCE Boiler.Increase in thickness of various parts to suit higher parameters Feed Heaters-Increased thickness of tubes. No new superior material is used.Change in philosophy Water Chemistry.No blow down. 14 . water boxes and tube plate BFP-Increased motor rating.Once Through instead of drum type and use of superior material in certain pressure parts Piping. Only the quantity of superior material increases.
critical units Old Unit Size MS Pressure kg/cm2 MS Steam Temp(O C) RH Steam Temp (O C) 500 MW 170 537 537 Recent 500 MW 170 537 565 38.1 % 15 .14 Plant-III 660 MW 247 565 593 39.6% 5.7% 2.26 Plant-I 660 MW 247 537 565 38.6 % 5.Efficiency Improvements Sub .1% BASE 0.7 % 2.6 % 5.96 Gross Efficiency (HHV) % 38.84 CO2 Emission / MW Super .Super Critical Technology .7 % 2.1 % BASE 0.00 Plant 500 MW (170 bar/537 C/537 C) 500 MW (170 bar/537 C/565 C) 660 MW (246 bar/537 C/565 C) 660 MW (246 bar/565 C/593 C) Turbine Heat Rate SO2 Emission / MW BASE 0.critical units Plant-II 660 MW 247 537 565 39.
Chattisgarh – 5x800 MW Cheyyur.NTPC is adopting Super Critical Technology NTPC adopted supercritical technology for unit size over 500 MW in steps as under: PLANTS IN ADVANCE STAGE OF CONSTRUCTION 3 x 660 MW Sipat STPP Stage-I 3 x 660 MW Barh STPP Stage-I UPCOMING PLANTS Barh-II. Tamilnadu – 3x800 MW Marakanam. Jharkhand – 3x660 MW Darlipali. Bihar – 2x660 MW (Order Placed) North Karanpura. Orissa – 4x800 MW Lara.2x660 MW 16 .2x660 MW Meja. Uttar Pradesh . Tamilnadu – 4x800 MW Tanda-II. Uttar Pradesh .
00 2.00 HR Improvement (%) 12.00 8.Heat Rate Improvement Efforts in NTPC 16.00 200 LMZ (1978) 200 KWU 500 KWU 500 KWU 500 High RH (2006) (1979) (1982) Mod (1998) 660 SC (2004) 660/800 SC (2008) P = 130 ata MST = 537 RHT = 537 P = 150 ata MST = 537 RHT = 537) P = 170 ata MST = 537 RHT = 537) P = 170 ata MST = 537 RHT = 537 P = 170 ata MST = 537 RHT = 565 P = 247 ata MST = 537 RHT = 565 P = 247 ata MST = 565 RHT = 593 P = 280 ata MST = 600 RHT = 620) 660/800 USC (2012) 17 .00 10.00 6.00 4.00 14.00 0.
Impact of Local Conditions on Reported Efficiency 42.2% Un-burnt Carbon Loss 39.8% Vacuum 39.0% 18 .6% LCV /GCV 9% over base 40.
125 Deg C Fuel GCV range 3000 to 4000 Kcal/kg with 10-16% moisture and 32 to 48% ash Start up system Start up system with one no. circulating pump is with alternate drain flow to condenser through flash tank .0 2225 1740 gas temperature at air-heater outlet.Salient Features of the Steam Generator Type Supercritical. suitable for variable pressure or rifled/plain water wall tubing Tower type or two pass type Flow (T/Hr) operation with spiral Rating At SH Outlet At RH Outlet Flue Temperature Deg C 540 568 Pressure Kg/Cm2(a) 256 52. 19 .
TP 347H or approved equivalent. B/C or SA 210C or equivalent Alloy steel to ASME SA-335:P-11/P-12/P-22/P-23. ASME SA-213:T-11/T-12/T-22/T-23 or equivalent.8X105 kcal/hr/m2(Max) 2. SUPER 304H. Austenitic stainless steel. 20 .0 Sec(Min) Boiler Pressure Parts Material Up to 400 Deg C Up to & including 550 deg C Up to & including 605 deg C Above 605 Deg C Carbon steel to ASME A-106 Gr.36x106 kcal/hr/m2 (Max) 600X 105 kcal/hr (Max) 1. Alloy steel to ASME SA-213:T-91/T-92 and ASME SA335:P91 or approved equivalent.Major Furnace Sizing Criteria Net Heat Input/Plan Area Heat liberation rate Burner zone heat release rate Heat input per burner Furnace cooling factor Furnace residence time 4.75X106 Kcal/hr/m2 (Max) 106920 Kcal/hr/m3(max 1.
ata /600 0 C/ 6200 C HP inner casing HP stop and control valves IP inner casing IP stop and control valves 15Cr1Mo1V 15Cr1Mo1V 15Cr1Mo1V 15Cr1Mo1V 25Cr1Mo1V 25Cr1Mo1V 18Cr11MoNiVNb 18Cr11MoNiVNb 15Cr1Mo1V 15Cr1Mo1V G-X12CrMoVNbN9-1 G-X12CrMoVNbN9-1 25Cr1Mo1V 25Cr1Mo1V 18Cr11MoNiVNb 18Cr11MoNiVNb G-X12CrMoVNbN9-1 G-X12CrMoVNbN9-1 G-X12CrMoVNbN9-1 G-X12CrMoVNbN9-1 25Cr1Mo1V 25Cr1Mo1V 18Cr11MoNiVNb 18Cr11MoNiVNb 9-10% Cr Steel 9-10% Cr Steel HP Rotor IP Rotor HPT Blades (Few initial stages) IPT Blades (Few initial stages) 10% Cr Steel 10% Cr Steel 21 .TURBINE COMPONENTS MATERIAL Components 246 ata /537 0 C /5370 C Material 246 ata /537 0 C /5650 C 246 ata /565 0 C / 5650 C -.
NEW MATERIAL In addition to conventional material the following new materials are being adopted on recent-660MW supercritical units and to take care of higher temperature of steam parameters: Super 304H SA-213 T23 SA-335 P23 SA-213 T92 SA-213 P92 SA 302 C 22 .
Typical Tubing for 568 / 595 °C Steam Temperatures OR AUSTENITIC Primary SH Final RH Final SH Primary RH SUPER 304 Economiser 23 .
Detailed feasibility for adoption of IGCC technology for high ash Indian coal (For a demonstration plant of 100 MW capacity) is already completed. Adoption of further higher size Ultra supercritical units with higher steam parameters for efficiency improvement is under study. Increasing Operational Efficiency and introduction of reusable energy sources 24 .Adoption of Clean Coal Technology: Conclusions NTPC has already gone for adoption of higher size ( 660 MW) supercritical units and moving towards higher steam parameter for coming projects.
Thank You 25 .
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