ENVIRONMENTAL AUDIT OF

COAL FIRED THERMAL POWER PLANT

– A CASE STUDY

B R.
B. R Naidu
Zonal Officer (West)
CPCB, Vadodara
 Presentation Contents

Environmental Audit of Thermal Power Plant (TPP)

– A Different Approach
Features of Coal Based Thermal Power Plant
IImportant Sections
S i off E
Environmental
i lAAudit
di FFormat ffor
Thermal Power Plant
• General
• Product Details
• Water
• Air
• Hazardous (Solid) Waste
• Resource
R R
Recovery
Summary of Env. Audit of TPP
 Environmental Audit of Coal based TPP
A “Different Approach” than for other chemical
manufacturing industries
1 Product is Electricity,
1. Electricity which can not be stored.
stored
2. Basic raw materials are Solid fuel, water and water
treatment chemicals
3. By product is ash and heat

4. Highly water intensive industry

5. Material mass balance for Water, Coal and Heat can

b prepared
be d
6. High Potential of Air Pollution while that is low for
water as water is primarily used for cooling
purposes.
 Presentation Contents

Environmental Audit of Thermal Power Plant (TPP)

– A Different Approach
Features of Coal Based Thermal Power Plant
IImportant Sections
S i off E
Environmental
i lAAudit
di FFormat ffor
Thermal Power Plant
• General
• Product Details
• Water
• Air
• Hazardous (Solid) Waste
• Resource
R R
Recovery
Summary of Env. Audit of TPP
Features of Coal Based Thermal Power Plant
Product : Electricity
Product Unit MW
Basic Raw Materials Solid fuel (Lignite/coal), Water
Process Burning of coal converting ‘C’
to CO2
By Product Heat and Ash
Material
M t i l Mass
M C l,H
Coal Heatt and
dWWater
t B Balance
l
Balance
yp of Industry
Type y Water Intensive
Primary use: for cooling
purpose
P ll ti Potential
Pollution P t ti l Ai : Very
Air V High
Hi h ; Water
W t : low
l
 Presentation Contents

Environmental Audit of Thermal Power Plant (TPP)

– A Different Approach
Features of Coal Based Thermal Power Plant
IImportant Sections
S i off E
Environmental
i lAAudit
di FFormat ffor
Thermal Power Plant
• General
• Product Details
• Water
• Air
• Hazardous (Solid) Waste
• Resource
R R
Recovery
Summary of Env. Audit of TPP
 Section - A]] General

• Electric Consumption per unit of the product i.e. Electricity

• “Auxiliary Electric Consumption” – Usually 10%

Study
y Plant – 0.093
9 kwh/kwh
/ generated
g
- i.e. 9.3%
 Presentation Contents

Environmental Audit of Thermal Power Plant (TPP)

– A Different Approach
Features of Coal Based Thermal Power Plant
IImportant Sections
S i off E
Environmental
i lAAudit
di FFormat ffor
Thermal Power Plant
• General
• Product Details
• Water
• Air
• Hazardous (Solid) Waste
• Resource
R R
Recovery
Summary of Env. Audit of TPP
 Section - B] Product Details

• Electricity has to flow or to be utilized

• Plant Load Factor (PLF) = Actual power generated

Installed capacity

• PLF varies from station to station and time to time

depending upon the operating conditions

‘A
‘Annual
l daily
d il average off PLF’ for
f plant
l t under
d study
t d is
i 0.823
0 823
 Section - B] Product Details…
Details

• Identification and Consumption of Raw Materials

per unit of production

Basic Raw Materials

Fuels Water

Coal Liquid
q Fuels
•Indigenous
I di •HSD
•Imported •Residual Fuel Oil
 Section - B]] Product Details…

• Liquid fuel quantity is negligible required only for

start-up operation

• A
Average coall consumption
ti per unit
it off power
generated is important.
 Coal Consumption Per Unit of Power Generated (Kg/unit)
Sr. No. Month Unit - I Unit - II
1 January 0.685 0.501
2 February 0.691 0.498
3 March 0.706 0.510
4 April 0.699 0.516
5 May 0.646 0.453
6 June 0 707
0.707 0 514
0.514
7 July 0.711 0.513
8 August 0.706 0.525
9 September
b 0.683 0.489
10 October 0.660 0.490
11 November 0.624 0.469
12 December 0.637 0.299
Yearly Average 0.679 0.498

For Plant under study – at one of the station coal

Consumption was 50% more than the other stations.
 Section - B] Product Details…

• Coall consumption and

d totall energy consumed
d

should be compared to establish a useful

relationship to identify deviation, if any.

Energy Consumed (Kcal supplied by coal/KWH)

Sr. No. Month Unit - I Unit - II

1 January 3800 3200
2 February 3830 2586
3 March 3900 2360
4 April 3880 3440
5 May 3590 2230
6 June 3800 2900
7 July
l 3940 2723
8 August 3887 2680
9 September 3795 2577
10 October 3631 2612
11 November 3436 2549
12 December 3186 1643
Yearly Average 3723 2625
 Section - B]] Product Details…

• Determine turbine efficiency at different stations

• Overall plant efficiency can also be calculated and

compared against design value

Overall Energy Consumption – 2911.3 Kcal/Unit

Designed Energy Consumption – 2450 Kcal/Unit
Overall Plant efficiency – 29.5%
Designed efficiency – 35.1%
 CoalSection
(1401 T/day)
- B] Product
On a Given
Details…
Day

Moisture Carbon Sox Volatiles Non

Content Content 1 401
1.401 567 4
567.4 Combustible
267.6 484.2 80.4

Converted
d Unburnt Ash Reject
to CO2 Carbon in the 59.4 21.0
478.8 gases
5.4
Fly Ash Bottom Ash
47.5 11.9

Collected & Lost with Utilized

Disposed off to flue gases directly
ash p
ponds 2.22 20.0
25.28
Coal Balance Diagram
 Heat Contained in Feed
Heat Units SuppliedSection - B] Product Details…
Water (Recovered Heat)
by Coal 2.73 x 109
7.12 x 10 9

Economizer LPH inlet to Air Preheater

0.66 x 109 HPH outlet 0.58 x 109
1.49 x 109

Total Recovered Heat Input

2.73 x 109

Total Heat Input 9.85 x 109

Heat contained Losses Heat Lost with

in the steam 1.53 x 109 Flue gases
7 6 x 109
7.6 0 72 x 109
0.72
Power generated
Heat Lost at Other Losses
2.3 x 109
Cooling Tower 0.12 x 109
5.18 x 109
Heat Balance Diagram (Unit : Kcal)
 Salient Points of Heat Balance Diagram

• Source of Heat Input – Coal and Recovered Heat

• The unit is recovering 2.73 x 109 kcal/day i.e. 24.71%

of the total heat input

• Heat recovery is done by economizer, low pressure

heater and high pressure heater

• % conversion to useful energy i.e electricity –

23.35% of total heat input

• Energy lost to the environment – 76.65%

• Numerically the energy converted to electricity is

equal to the recovered heat
 Presentation Contents

Environmental Audit of Thermal Power Plant (TPP)

– A Different Approach
Features of Coal Based Thermal Power Plant
IImportant Sections
S i off E
Environmental
i lAAudit
di FFormat ffor
Thermal Power Plant
• General
• Product Details
• Water
• Air
• Hazardous (Solid) Waste
• Resource
R R
Recovery
Summary of Env. Audit of TPP
 Section - C]] Water

General Water Requirements

Water Requirements

Cooling Tower
Water Boiler Feed Water Domestic & Other Uses
Desired Quality - D i d Quality
Desired Q lit - - Domestic
D ti S
Supply
l to
t Colony
C l
Soft Water Demineralized Water - Spraying on Coal at Coal
-Softening Plant - DM Plant yard
- Gardening
 Total Water Withdrawal
Section - B]] Product Details…
47,158 m3/day

Cooling System Process (Boiler) Domestic and Other Uses

28 399
28,399 2 116
2,116 16 643
16,643

Make up Regenerant Make up Regenerant

26,959 1,440 1,576 540

Blow Evaporation & Blow Coal Yard & Domestic

Losses U in
Use i Colony
Down Drift Losses Down inclusive of
1,496 Gardening 3,802
8,423 18,536 80 Floor Wash
12,745 96
To Catch Pit
To Neutralization Pit, 540 To Drains
Final Holding Pit,
Pit 8,423
8 423
Water Sump 8,963

Receiving Water Body Ash Ponds 5,574

5 574 Ash Slurry Sump 10,579
10 579 Seepage Evaporation,
Evaporation 5,009
5 009

Water Balance Diagram

 Analysis of Water Balance Diagram

Total Water Quantity = 47,158 m3/day

• No. of water withdrawing stations / borewells – 20

•Referring
R f i llog sheets
h t maintained
i t i d tto record
d pump HP,
HP
Pump Discharge, No. of pump running hrs, etc.

•Total quantity pumped, = [ No. of pumps x yield of

m3/day pump, m3/hr x no. of
operational
p hrs,, hrs/day
/ y]

For Plant under study – water used per unit of

Power Generated = 55.36
36 L
 Analysis
y of Water Balance Diagram…
g

Pump Discharge – very imp.

A] Three approaches of Field Measurement :

(1) Use of ultrasonic flow meters

((2)) Requires
q actual measurement of ‘H’ over the ‘V’
Notches
Q = (8/15) Cd tan(θ/2)(2g)1/2H5/2
(3) Actual Measurement of Discharge from Pump
Discharge Line. = Measured Volume/Time
 Analysis
y of Water Balance Diagram…
g

B] Field Measurement and Theoretical Calculation :

(4) Power Consumption by Pump

Kw = 1.73 Vi Cosø
= 1.73 Vi PLF---------------Eq.1

Where, Vi = Consumed current in Ampere measured

by Ampere meter
PLF = Plant Load Factor
 Analysis
y of Water Balance Diagram…
g

(4) Power Consumption by Pump […..Continue]

Substitute the value of Kw (HP) in Eq.2 to calculate Q

B.H.P = W x Q X H -----------------------Eq. 2
75 η
i.e., Q = B.H.P x 75
WxH
Where, B.H.P = Break Horse Power
W = Density of water, 1000 Kg/m3;
H = Total Head (suction + discharge)
discharge), m
η = Pump Efficiency
 Analysis of Water Balance Diagram…

Cooling Water 28,399 m3/day

Make Up Water, 26,959 Softening plant

regeneration
Water, 1440

Bleed – off, 8423 Evaporation and Drift • Quantity

losses, 18,536 depends upon
•Water for final
di
disposal
l •1.2
1 2 % off totall water iin the design and
circulation for natural operation of the
•Depends on COC plant
draft CT
•COC – 3 ((usually)
y)
•1.5%
1 5% off ttotal
t l water
t iin
•COC up to 6 can be circulation for induced
achieved by addition of draft fan
chemicals to lower
down the quantity of
w/w to be disposed off
 Analysis of Water Balance Diagram…

Boiler Feed Water, 2116 m3/day

Make-up Water , 1576 Regeneration water

from DM Plant, 540
• Depends on design
Blow Down, 80 Other Losses, 1496 and operating
parameters of DM
•3 – 5% of make-up
make up •To get the quantity plant
water deduct blow down
from total Boiler make-
up water quantity
 Analysis of Water Balance Diagram…

Domestic and Other Uses = 16, 643 m3/day

To get the quantity for Domestic and other uses :

Domestic + other uses = Total Quantity – (CT + Boiler

Make up)

= 47,158 – (28,399 + 2,116)

= 16,643 m3/day
 Presentation Contents

Environmental Audit of Thermal Power Plant (TPP)

– A Different Approach
Features of Coal Based Thermal Power Plant
IImportant Sections
S i off E
Environmental
i lAAudit
di FFormat ffor
Thermal Power Plant
• General
• Product Details
• Water
• Air
• Hazardous (Solid) Waste
• Resource
R R
Recovery
Summary of Env. Audit of TPP
 Section - D]:
] Air

• Source - Flue gas stacks

• Monitoring Parameters: PM, SO2, NOx

• PM control is imp.
imp for coal/lignite based thermal
power plant

• The unit under study has installed ESP for each

power generating station
 Determination of ESP Efficiency and Operating
conditions

• Sampling at Inlet and Outlet of ESP

 Results of Flue Gas Analysis
Sr. Parameter Unit - I Unit - II
No. Inlet Outlet Inlet Outlet
[A] PARTICULATE MATTER
1 Stack Flue gas temp. (Deg. 144 131.00 144.00 124.00
C)
2 Volume of gas sampled at 0.174 0.591 0.162 0.582
NTP (cu.m)
( )
3 Wt of SPM collected (mg) 3675.57 274.22 2516.20 178.68
[B] GAS CONCENTRATION
DATA
4 Particulate Matter (PM) 21124 464 15532 307
mg/Nm3
5 Sulphur
p Dioxide (SO
( 2) 134 75 102 49
mg/Nm 3

6 Nitrogen Dioxide (NO2) 3 3 2.5 2.0

mg/Nm3
 PM REMOVAL EFFICIENCY OF ESP
Sr. No. Parameter Unit - I Unit - II

I II III I II III

1 Avg. Inlet 21124 13465 23225 15532.1 18986 13500

Conn
2 Avg. 464 87.55 464.5 102.4 111 135
Outlet
Conn

3 Removal 97.80 99.34 98.00 99.34 99.41 99.0

Efficiency
4 g
Designed 99.77 99.77 99.77 99.37 99.37 99.37
Removal
Efficiency
5 % (-) 1.97 (-) 0.43 (-) 1.77 (-) 0.03 (-) 0.04 (-) 0.37
Deviation

I – 1st Monitoring, II – 2nd Monitoring, III – 3rd Monitoring

 Section - D]:
] Air

• For study plant ESP efficiency – 99% plus - near the

design value

• One Exceptional power station with efficiency –

97% (200% Deviation from GPCB Norms)

• Reduced Efficiency due to 4 out of 10 operational

ESP fields
 Section - D]:
] Air

• Interesting Observation –50-60% decrease in SO2 in

ESP

• For Nox – Catalytic Burners installed – The values

found within p
prescribed limits
 Presentation Contents

Environmental Audit of Thermal Power Plant (TPP)

– A Different Approach
Features of Coal Based Thermal Power Plant
IImportant Sections
S i off E
Environmental
i lAAudit
di FFormat ffor
Thermal Power Plant
• General
• Product Details
• Water
• Air
• Hazardous (Solid) Waste
• Resource
R R
Recovery
Summary of Env. Audit of TPP
 Section - E]:
] Hazardous Solid Waste

Ash :
(1) Fly Ash and
((2)) Bottom Ash

• Source – Solid Fuel

• Study plant uses blend of indigenous coal with

high ash content and also imported coal with
low ash content
 Section - E]:
] Hazardous Solid Waste
• Two Types of Fly Ash Collection Systems

(1) Dry System – Collected ash sold or utilized

(2) Wet System – Through Fly ash ponds
- Overflow of the pond is
discharged
g to river
18% utilization of fly ash collected within the study plant

Coal Balance diagram can be used to calculate the theoretical

quantities to verify the actual quantities of ash.
 Presentation Contents

Environmental Audit of Thermal Power Plant (TPP)

– A Different Approach
Features of Coal Based Thermal Power Plant
IImportant Sections
S i off E
Environmental
i lAAudit
di FFormat ffor
Thermal Power Plant
• General
• Product Details
• Water
• Air
• Hazardous (Solid) Waste
• Resource
R R
Recovery
Summary of Env. Audit of TPP
 Section - F]:
] Resource Recovery
y

Source of Resource Quantity

y Recovery
y
Recovery System
APC system Fly Ash 18% Dry and Wet
utilization System
of total
quantity
Process
P B
Bottom Ash
A h 15% off totall Manual
M l
(Boiler) quantity Collection
Process Heat 2.73 x 109 Economizer,,
kcal/day Low Pressure
Heater, High
Pressure Heater
 Presentation Contents

Environmental Audit of Thermal Power Plant (TPP)

– A Different Approach
Features of Coal Based Thermal Power Plant
IImportant Sections
S i off E
Environmental
i lAAudit
di FFormat ffor
Thermal Power Plant
• General
• Product Details
• Water
• Air
• Hazardous (Solid) Waste
• Resource
R R
Recovery
Summary of Env. Audit of TPP
 y of Environmental Audit of TPP
9Summary

Sec. Description Particulars Study Plant Reference

No
No. Values Records
maintained
at the Plant
A General Electric Auxiliary Electric Electricity
Consumption Consumption = Bills
per ton of 0.093 kwh / kwh
product
p generated
g
B Product Product and -Annual Daily Log sheets
Details the raw average of PLF = maintained at
materials 0.823 production
p
required per - 29.5% of Energy floor
unit of Efficiency against
production 35.1% of design
g
value
 y of Environmental Audit of TPP
9Summary
Sec. Description Particulars Study Plant Reference
No. Values Records
maintained
at the Plant
C Water y
Quantity, Total Quantity
y= Pumping
p g
Water 47,188 m3/day hrs,
Treatment, Discharge,
W/W Water Balance Log Sheets
generation, Diagram maintained
ETP details, for DM
adequacy of Plant and
ETP
ETP, S ft i
Softening
Compliance Plant
with GPCB
norms
 y of Environmental Audit of TPP
9Summary

Sec. Description Particulars Study Plant Reference

No
No. Values Records
maintained at
the Plant
D Air Stacks, Flue 99% plus ESP Actual
gases, APC efficiency Monitoring of
system, ESP One exception Parameters at
Efficiency
y station with 97% Inlet and
and 50-60% SO2 Outlet of ESP
operating reduction in ESP using Stack
conditions, Monitoring
Nox is under Kit.
control as
catalytic burners
installed
 9Summary of Environmental Audit of TPP

Sec. Description Particulars Study Plant Reference

No. Values Records
maintained
at the
h Plant
Pl
E Hazardous Source, 1.56 MT/MW Log sheets,
Solid Waste Quantity, Ash
Method of collection
collection data, Coal
Storage and Balance
Di
Disposal l Di
Diagram
 y of Environmental Audit of TPP
9Summary

Sec. Description Particulars Study Plant Reference

No
No. Values Records
maintained at
the Plant
F Resource Fly Ash from 18% of total fly Log sheets,
Recovery the APC ash utilized records, Heat
system, Heat from APC Balance
from the system
y Diagram
g
Heat 15% of bottom
Recovery ash recovery
System 2.73 x 109
kcal/day of heat
recovery