Professional Documents
Culture Documents
Thermal
Non Conventional
Gas
Combined Cycle GT + ST
Pulverised Coal
The 8 fold increase in the ash passing thru an Indian coal fired boiler, warrants incorporation of special design features for high availability. Clean Coal Technologies - September 2008
2.0 250 bar / 550 C / 570 C 260 bar / 580 C / 600 C 280 bar / 600 C / 620 C
Turbine Efficiency
Condenser Pressure Process Optimisation (FWT, feed heater arrangement) Steam Parameters Feed Water Temperature Measures on Steam generator
1960
1970 Year
1980
1990
2000
3.44 1.47
600 / 620
0.75
566 / 566 538 / 566
580 / 600
Cycleefficiency efficiencywith with:: Cycle 175bar barand and538/ 538/538 538C C= =38.0 38.0% %(BASE) (BASE) 175 241bar barand and538/ 538/566 566C C= =38.0 38.0x x1.0264 1.0264= =39% 39% 241 Clean Coal Technologies - September 2008
Supercritical Cycles
Steam Power plant efficiency increases with increase in steam pressure and temperature. Power plant Cycles operating above critical pressure (221.2 bar) are classified as Supercritical cycles With higher cycle efficiency, the supercritical cycle offers the advantage of emission. burn less fuel for the same output and lower
Pressure(bar)
250 290 285 270 246 246 246
Temp C
540 / 540 580 / 580 / 580 545 / 560 580 / 600 538 / 566 566 / 593 593 / 593
255 bar 568/596 Deg C commonly used presently Ultra super critical units (parameters up to 375 bar & 700 C) with plant efficiency approaching combined cycle plants (50%+) are in development stage with parallel development in Materials Clean Coal Technologies - September 2008
UNIT
ata
O
500 MW
170 537 1515 40.5 537 1335 45 336 253 1625
800 MW
247 565 2400 54 593 1990 60 343 290 2575
t/h ata
O
t/h ata
O O
C C
t/h
Environmental Benefits
Station Cap (
Supercritical Units
Units
(No.x MW)
MS Pressure
(kg/cm2)
CO2 Emissions
(MMT/Yr)
4000 4000
8x500 5x800
169 246
22.90 21.97
Savings Savingsin incoal coalconsumed consumed::0.63 0.63MMT/Yr MMT/Yr(about (about4% 4%Saving) Saving) Savings 2 emissions Savingsin inCO CO emissions ::0.93 0.93MMT/Yr MMT/Yr
2
Supercritical Boilers
Once thru Boiler technology facilitates adoption of Supercritical parameters Higher pressure & temperature stress the boiler components at a high level New materials in use/trial operation to withstand the demanding service conditions 9 T 91/P91 9 T 92/P92 9 T 23/T24 9 TP347HFG 9 Esshete 1250
Plant Efficiency Improvement - Boiler Side Measures Flue Gas Temperature at Boiler outlet
EFFICIENCY %
GAS TEMP. LEAVING AH Deg.C
89 88 87
86
175 150 125 0 1980s 2000
Plant Efficiency Improvement - Boiler Side Measures Auxiliary Power Consumption Reduction
Use of High efficiency Boiler Auxiliaries Axial Reaction fans Bowl Mills ESP with Intelligent operating systems Use of High Efficiency Drives like VFD Reduction in the duty of the auxiliaries by system design optimisation
Clean Coal Technologies - September 2008
9 Ideally suited for Low Grade fuels, Lignite, Pet coke 9 Does not need coal pulverisation system 9 Keeps SOx & NOx emissions low
6.2 MWe capacity coal based combined cycle demonstration facility at BHEL, Trichy BHEL is now setting up a 125 MW plant jointly with a customer
Coal Gasifier
Air HRSG
Air
FETF, a fire side boiler simulator for study of complex interrelated effect of fuel characteristics. Rated for heat input of 756,000 kcal/h (880 KW).
Clean Coal Technologies - September 2008
SFBTF of 10 Mkcal/h capacity is used for coal burner/nozzle development, evaluation of flame stability, combustion efficiency & turndown.
Clean Coal Technologies - September 2008
Existing Existing Power Power Plants Plants Performance Performance Improvement Improvement
9 Sophisticated Controls & Instrumentation 9 Vibration monitoring systems for high speed equipment 9 Equipment trip provisions
Operator Training Renovation of Boilers Use of well proven equipment Redundancy for Critical equipment
&
design
practices,
Results in lesser number of plant outages, start ups Minimises fuel oil consumption
Clean Coal Technologies - September 2008
Future Outlook
Coal & Lignite will continue to be main fuels for Power Plants for some more decades Economics will decide the optimum power plant cycle parameters to be adopted. Increasing focus on minimising Emissions, improving efficiencies, fuel flexibility, enhanced Availability & Reliability Pulverized coal firing will continue to be the mainstay, till other technologies mature into commercially viable options Boiler technology will continue the advance towards increased efficiencies.
Clean Coal Technologies - September 2008