Asia Pacific Partnership on Clean Development & Climate

Brown Coal ( Lignite ) Best Practices Work Shop

India - Country Perspective

23-27 th June2008

THE INDIAN DELEGATION

NTPC Delegates :
I.K.Rajdeva,

Additional General Manager, NTPC Ltd.

A.Nagasundaram, Dy. Gen. Manager, NTPC Ltd. Saju K Sebastian, Dy. Gen. Manager, NTPC Ltd. P.S.Chatterjee, Chief Design Engineer, NTPC Ltd.

CESC Delegates :
Souvik Dutta, Station Manager, Southern generating Station, CESC Ltd .
Kushal Bhowmick, Senior Manager ( Environment), CESC Ltd.

Robust Economic Growth THE DRIVER

THE GDP GREW AT 9.6% DURING FISCAL 2007, AVERAGE RATE OF GROWTH OVER LAST 4 YEARS IS 8.6%. GDP GROWTH DURING 2008-09 IS EXPECTED TO BE around 9%. GDP GROWTH TARGET OF 9% SET BY GOVT. DURING XI PLAN (2007-2012). ELECTRICITY IS AN IMPORTANT INPUT TO THE MARCH OF PROGRESS OF ANY COUNTRY TODAY. IT IS THEREFORE NATURAL THAT THE GROWTH IN ELECTRICITY GENERATION & AVAILABILITY, BE COMMENSURATE WITH GROWTH IN GDP.

Existing Generating Capacity- March 2008

Fuel wise break-up (MW)
Thermal Hydro Nuclear Renewable 92,426 36,033 4,120 12,194 63.8% 24.9% 2.8% 8.5%

Sector wise break-up (MW)

Private Sector 14% Central Sector 34% State Sector 52%

TOTAL

144,773 100.0%

(All figures provisional from CEA)

(Excluding captive capacity of 14636 MW connected to grid)

Total generation in 2007-08 704.45 BU

PLF (%)
48 1985-86 1986-87 1987-88 1988-89 1989-90 1990-91
53 .9 55 .3 57 .1 61 60 63 64 .4 64 .7 64 .6 67 .3 69 56 .5 55 53 .2 56 .5 52 .4

53

58

63

68

73

78

1991-92 1992-93 1993-94 1994-95 1995-96

ALL INDIA PLANT LOAD FACTOR (%)

- COAL FIRED THERMAL POWER STATIONS

Y EARS
1996-97 1997-98 1998-99 1999-2000 2000-01 2000-02 2002-03 2003-04 2004-05 2005-06 2006-07 2007-08

69 .9 72 .7 74 .3

72 .2

74 .8

77 . 03 78 . 61

Energy Shortage
9.8%
750 REQUIREMENT 700 650 600 550 500 450 467 2001 483 2002 498 2003 2004 2005 2006 2007 2008 546 507 7.8% 523 7.5% 519 591 631 AVAILABILITY 691 737

9.6%

8.3%
665 624

7.3%
579

8.8%

559

7.1%
548

DURING 2007-08, PEAKING SHORTAGES WERE 16.6%

Per capita Consumption remains low

In d ia Eg yp t C h in a B r a z il R u s s ia Ge rm a ny Japan USA W o r ld A v e r a g e

665 618 1 ,4 6 5 1 ,6 8 4 2 ,3 4 0

In 2006

NATIONAL ELECTRICITY POLICY TARGETS PER CAPITA AVAILABILITY OF 1000 KWH BY 2012
6 ,4 2 5 7 ,4 4 2 8 ,4 5 9 1 4 ,2 4 0

2 ,7 0 1

Figures in kwh
Source: UNDP Human Development Report 2007-08 Data for 2004

Projected Capacity Requirements

778 GW

425 GW 132 GW 220 GW

2007

2012

2022

2032
Source: Integrated Energy Policy GOI

Large Capacity addition required to meet the demand

CAPACITY ADDITION EXPECTED DURING 11th PLAN (2007-12) (Conventional) 78,520 MW

NUCLEAR, 3,380MW, 4% HYDRO, 15,627MW, 21%

THERMAL, 59,5130MW, 75%

Thermal 59,513MW ( Coal 51,890 MW, Gas- 5343 MW, Lignite- 2280 MW) Additional capacity expected : New Renewables 14,000 MW : Captive 12,000 MW

11TH PLAN PROGRAMME (2007-2012) (Thermal+Hydro+Nuclear)

Proposed : 78,577 MW Expected : 78,520MW

9,263 MW capacity already commissioned 60,214 MW (77%) under construction 10,950 MW - Letter of awards yet to be placed Fuel Availability for 96% of coal based stations tied up 88% hydro capacity under construction /commissioned All gas based projects under execution or gas tied up from local sources

Additional 13,000 MW gas based projects identified subject to gas availability

11TH PLAN PROGRAMME

NON-CONVENTIONAL ENERGY PLANTS

Installed Capacity (as on 31.03.2008)- 11125 MW 11th Plan target- 14,000 MW consisting of Wind Power 10,500 MW Biomass Power Baggasse Co-generation Small Hydro (up to 25 MW) -

2,100 MW 1,400 MW

CAPACITY ADDITION DURING XIITH PLAN (2012 - 2017)

PLAN

TOTAL THERMA HYDRO CAPACITY L ADDITION PLANNED (MW) (MW) (MW)

NUCLEAR

(MW)

XIITH 82200

40200 30000 12000

Energy Efficiency NATIONAL THERMAL GOVERNMENTS STRAGTEGY / POWER CORPORATION INITIATIVE FOR EFFICIENCY LTD. IMPROVEMENT
- A PROFILE
Setting the Scene today for a futureoriented Sustainable Energy production

INDIAs ENERGY PROGRAMS AND POLICIES Improving energy efficiency Promoting Hydro and renewable energy Power sector Reforms Promotion of Clean coal technology Energy infrastructure Development Coal Washing Environmental Quality Management

DRIVERS FOR HIGHER PLANT EFFICIENCY

Demand of power is set to grow with growing economy Large capacity needs to be added to meet the projected growth in demand With Electricity Act 2003 coming into vogue, the power market is set to attract a lot of investors and competition With tariff based bidding becoming a norm, utilities have to bring down their cost of generation to remain competitive Increased emphasis on Environmental considerations for clean technology CDM opportunities arising out of global warming concerns Fuel, Land & Water availability becoming more and more difficult Efficiency enhancement feasible in future plants as well as existing plants

Major Initiatives

Improvement in efficiency and performance of existing generating units through :

Renovation and Modernisation schemes with emphasis on Energy Efficiency Partnership in excellence. Establishment of Energy Efficiency cells at thermal power stations ( 37 cells in operation)

Energy Conservation through legislation

Thermal Power Stations notified as Designated consumers

Promotion of Renewable Energy Sources 15,627 MW Capacity of Hydro Power planned in XIth Plan 30,000 MW Capacity of Hydro Power planned in XIIth Plan Retiring 5000 MW old capacity with low efficiency in 11th Plan

Major Initiatives ..

Energy Conservation Act 2003 (EC Act)

Designated Consumers Notified

Thermal Power Station

Appoint Energy Manager Get Energy Audits conducted by Accredited Energy Auditors Implement techno-economic viable recommendations given by Accredited Energy Auditor Comply with norms of specific energy consumption fixed Submit report on steps taken

Major Initiatives

Adoption of Clean Coal Technologies

Supercritical / Ultra supercritical Technology Circulating fluidized bed combustion (CFBC) Integrated Gasification Combined Cycle (IGCC) Suitable for Indian Coal

Presently Working to develop a Demonstration Project for IGCC along with suitable Partner, development of core technologies for gasifier & Gas cleaning systems suitable for High Ash Indian Coal.

Major Initiatives ..

Ultra Mega Power Projects(4000MW capacity) based on Supercritical Technology at various pithead and coastal locations. Envisaging Mandatory Higher size thermal units (660/800 MW) with Supercritical Parameters.

It is estimated to commission

10 Nos. units of 660MW (XIth Plan) 2 Nos. units of 800MW (XIth Plan) 12 Nos. units of 660MW (XIIth Plan) 31 Nos. units of 800MW (XIIth Plan)

Major Initiatives ..
Supercritical Units of 660 MW Rating under construction Supercritical Units of 800 MW Rating with higher steam temperature conditions under consideration

Parameter Main Steam Pressure Kg/cm2 Main Steam Temperature oC Reheat Temperature oC

660MW 247 535/565 565/593

800MW 247 565 593

The Efficiency Roadmap

43%

Gross Efficiency, GCV Basis

42% 320/600/620 41% 247/565/593 40% (660/800 MW) 247/537/565 (660 MW) 39% 170/537/537 (500 MW) 38% 280/600/620 (800-1000 MW) (800-1000 MW)

00

02

Xth Plan

07

XIth Plan

12

XIIth Plan

17

XIIIth Plan

22

Lower Plant Efficiency in India

The reported efficiency of Indian power plants is generally lower as compared to efficiency of plants abroad, primarily due to :

Poorer condenser vacuum due to hot climatic conditions Higher unburnt carbon losses in boiler due to low grade high ash Indian coal Efficiency is reported on HHV basis of coal (same as the practice followed in USA) as against LHV used elsewhere.
Typical variation due to above = 3.0 to 4.0 % points (Approx.)

Heatrate Improvement over the Years

Heatrate Improvement Over The Years
14 12 10 8 6 4 2 0 200 LMZ (1978) 200 KWU (1979) 500 KWU (1982) 500 KWU Mod (1998) 500 High RH (2006) 660 SC (2004) 660/800 SC (2008)

P =1 0aata P = 130 ta 3 MST=5537 M =3 ST 7 RHT=5 7 RH = 3 T 537

P =1 0a ata = 5 ta 150 MST=5537 M =3 ST 7 RHT=5537 RH = 3 T 7

P=1 0a 7 ta M =5 7 ST 3 RH =5 7 T 3

P =1 0a = 7 ta 170 ata =5 7 M ST 3 MST = 3 RH =5537 T 7

P=1 0a 7 ta M =5 7 ST 3 RH =5 5 T 6

P =2 7 a 4 ta M =5 7 ST 3 RH =5 5 T 6

P=2 7a 4 ta M =5 5 ST 6 RH =5 3 T 9

Major Initiatives Contd ..

Member of Carbon Sequestration Leadership Forum (CSLF) Participating in FutureGen Project of USA
275 MW coal fired Zero Emission power plant India contributing US$10 Million

Participating in Asia Pacific Partnership (APP) for Clean Development and Climate
The Indian Project Proposals in the TF Action plan Inputs like case studies & contact details of experts in areas of Indias interest.

Work on Efficiency improvement of two thermal power plants namely Ropar and Kolaghat thermal Power station already started with support of USAID.

Major Initiatives ..

Mapping of Thermal Power Stations under Indo-German Programme

33 thermal units mapped ( 31 thermal stations) 85 Thermal Power Stations targeted

Energy Conservation Awards National Award for improving performance of Thermal Power Stations Awards for reducing T & D losses.

Efficiency Improvement through Renovation and Modernization

A COST EFFECTIVE APPROACH CONTINUE GETTING THE BEST OUT OF EXISTING FLEET

NEED FOR R&M EXISTING UNITS

Improvement in performance parameters PLF, Availability, heat rate/efficiency, auxiliary power consumption, partial loading & forced outage. Restore derated capacity Extension of economic life. Obsolescence & non availability of spares (eg C&I) Environmental requirements. issues/other statutory

Safety requirements.

POTENTIAL FOR EFFICIENCY INTEGRATED R&M

A large number of 200/250 MW & some 500 MW Units are in operation for more than 15/20 years and have considerable potential for life extension & efficiency improvement Total No. of Units Age 200/210 MW Units (LMZ design) 200/210 MW units (KWU design) 500 MW units 53 88 35 Nos. of Units as potential Candidate >15 years -37 12 >20 years 53 12 2

FUTURE APPROACH TOWARDS R&M

Shift in focus from Generation Maximization to Plant Performance Optimization Older units have many more opportunities to reduce heat rate than newer units. Retirement of very old small size low efficiency units and replacement with higher efficiency units. Use of high end technology solutions for efficiency enhancement to manage rising costs & reduce carbon, foot prints, e.g.,
Steam flow path modification Steam turbine and boiler upgrades Improved plant control

FUTURE APPROACH TOWARDS R&M

Additionality in efficiency improvement Efficiency improvement as a result of normal R&M, aims at to minimising losses ( to approach design values) Efficiency improvement through technology intervention/enhanced R&M, targeting efficiency enhancement even beyond design value.

Parameters For Performance Monitoring

Unit Heat Rate Unit Auxiliary Power consumption Unit Specific secondary fuel oil consumption Unit Specific coal consumption Plant Load Factor (PLF) Planned Maintenance, Forced outage and Operating availability

Projects for the Task Force

Sl. No. Project Title Proposing Country

1 2 3 4 5 6 7 8

Best Practices for Power Generation Activity Plan Best Practices for Transmission and Distribution Activity Plan Best Practices for Demand Side Management Activity Plan Energy Regulatory & Market Development Forum Trade Exhibitions/Conferences and Trade Missions Hydroelectric Generation Best Practices Combustion Optimization in Coal Based Power Plants Implementation of Artificial Intelligent Soot Blowing System for Improving the Steam Generator Efficiency by Increasing the Effectiveness of Soot Blowers. SOx Reduction Technologies in Flue Gas Risk Evaluation and Prioritization (REAP) for Maintenance and Renovation & Modernization (R&M) of Power Plants Life Extension & Remaining Life Assessment Of Power

USA, JAPAN, KOREA USA USA AUSTRALIA USA USA INDIA INDIA

9 10

INDIA INDIA

11

INDIA

Fly Ash Utilization Record NTPC

AS A SAMPLE CASE ONLY
Highest ever utilisation of Fly Ash a testimony to ecology preservation
25 Ash Utilisation in Million tonnes 19.6 22.3

20

15

12.7

10 5.7 5 0.3 0 1991-92 2000-01 2001-02 2002-03 3.0 3.7

7.5

2003-04

2004-05 2005-06

2006-07

Afforestation Efforts A Priority for

sustenance of HUMANITY!!
Forest Banks concept NTPC has created a Green wealth of 18.2 Million Trees by Summer 2007 Plantation of 1.25 Million trees around Ramagundam Project has resulted in

Summer Peak temperature reduction by 3 deg C

Ash Mound Reclamation and Dry ash disposal system