Clean Coal Initiatives of Bhel: Conference On Clean Coal and Carbon Capture and Storage Technologies

Bharat Heavy Electricals Limited
Conference on Clean Coal and Carbon Capture and

Storage Technologies
Clean Coal Initiatives

of
BHEL
(Bharat Heavy Electricals Limited)
Mr. M. Muthukrishnan
General Manager,
R&D and Coal research,
BHEL,Trichy
Conference on CCT and CCS 2-3rd December,2013
Overview of BHEL corporation

BHEL – Activity Locations in India
Conference on CCT&CCS
Dec 13
BHEL’s GLOBAL FOOTPRINT

BHEL’s Boiler Range
Pulverised Fuel Boilers Fluidised Bed Combustion

Boilers
Sub critical Bubbling Fluidized Bed

• 60 MW
• 20 MW
• 110 MW
• 45 MW
• 200 MW
• 60 MW
• 210 MW
• 80 MW
• 250 MW
• 120 MW
• 500 MW
• 600 MW
Circulating Fluidized Bed

Super Critical • 60 MW
• 660 MW • 75 MW
• 700 MW • 125 MW
• 800 MW • 135 MW
• 1000 MW • 250 MW

BHEL Corporate – Turn over


BHEL Initiatives towards CCT and CCS

Our Goals on CCT and CCS

Research facilities in BHEL Trichy Complex

ScTF Coal Gasification CFBC
SFBTF Coal Characterization Collaborative Research

Coal Research Centre

CRC Equipments
Total = 22 Equipment
Project Outlay Rs 1743 Lakhs
FUEL THERMAL MINERAL PARTICLE

ENVIRONMENTAL LAB
CHARACTERISATION CHARACTERISATION CHARACTERISATION CHARACTERISATION
Proximate Thermo Gravimetric High Temperature X- Particle Size X-Ray Fluorescence

Analyser Analyser Ray Diffraction Analyser Spectrometer
Spectrometer
Inductively Coupled
Surface Area And Plasma Mass
Ultimate Analyser Differential Scanning Computer Controlled
Scanning Electron Pore Analyser Spectrometer
Calorimeter Microscope
Microwave Digestor
Bomb Calorimeter Drop Tube Low Temperature Zeta Meter
Furnace System Asher
Mercury Analyser
Sulphur
Determinator Gas Pyconometer
Portable Flue Gas
Analyser
PM 10 & PM 2.5
FTIR Spectrometer
Particle Analyser
Gas Chromatography

Drop Tube Furnace Test Facility

Key research areas on CCT and CCS
• Increasing efficiency of PF Boilers

-Development of AUSC boiler
• Development of CFBC and IGCC of higher capacity
• Biomass Co-firing and Oxy fuel combustion technology
• Technology development for Carbon dioxide capture from
flue gas
• Reduction measures for non GHG like NOx through
-Over Fire Air compartment
-Bypass Over Fire Air Firing
-SCR development



Reduction of CO2 emission with increase of

steam parameters
Plant type Steam Steam CO2 Coal saving for
Efficiency
with power Pressure Temperature Emissions one 800 MW unit
(%)
rating (kg/cm2) (C) (g/kW-hr) ( t/year ) **
Sub Critical 170 540 38-39 900 Base
Super Critical* 247 565 40 830 1,01,000
Ultra Super
250 600 42 784 2,88,000
Critical
Advanced Ultra
300 700 45 740 5,38,000
Super Critical
* The improvements are with respect to the best units under construction in India
** For the coal HHV of 3500 Kcal/kg
• Extension of coal reserves by 11%
• Competitive in electricity cost on deployment
Indian Govt. National Mission for Technology - AUSC
Driven by the government’s National Mission for Technology, the

Advanced Ultra Super Critical (AUSC) project ( 300Bar, 710/720°C) is
under Development by a joint venture of BHEL, NTPC and the Indira
Gandhi Centre for Atomic Research (IGCAR).

World Class
• To conduct experiments
at Supercritical (SC)/ Ultra
Supercritical (USC)
Objective conditions of steam
• Know why generation for
establishing SC & USC
boiler technology
Investment • Rs. 12 cr.
• Pressure - 400 bar

Capabilities • Temperature - 700 Deg.C
• Heat flux - 1000 kW/m2
• Commissioned in Dec. 2008

Status
• Experiments under progress

NTPC/ BARH II STPP – 2 x 660 MW

Customer National Thermal Power Corporation
Project BARH II – 2 x 660 MW
Contract No. U6/1700 & U6/1701
Zero Date 31.03.2008
Parameters at SHO / RHO
Steam Flow 2120/1708.2 t/h.
Pressure 255/54.65 kg/cm2 (g)
Temperature 568 / 596 oC
Fuel Coal
Major Auxiliaries
Mill 9 Nos. Bowl Mill, HP 1103

PAH - 2 Nos. 28.5 VI 58 (70)MR,2NOS
Airheater 31.5 VI 70 (82)MR ALSTOM Supply
2 Nos. FAF 25/11.2 – 1, Axial
FD Fan
Reaction-TLT
2 Nos. PAF 19/10.6 – 2, Axial
PA Fan
Reaction-TLT
2 Nos. SAF 42.5/26.6-1, Axial
ID Fan
Reaction-TLT
Dust Collector Not in SG Package

APPDCL / Sri Damodaram Sanjeevaiah

TPS 2 x 800 MW
Customer APPDCL
Project Sri Damodaram Sanjeevaiah T P S –2 x
800 MW
Contract No. 1800, 1801
Zero Date 25.07.2008
Parameters at SHO / RHO
Steam Flow 2600 / 2052 t/h.
Pressure 255/57.9 kg/cm2 (g)
Temperature 568 / 596 oC

Blended Coal ( 70 % Indian Washed Coal, 30
Fuel
% Imported Coal)
Major Auxiliaries
Mill 6 Nos. Bowl Mill, HP 1203
Airheater 2 Nos. TRI-SECTOR, 34.5 VI 94,
FD Fan 2 Nos. SAF 27.3/12.2-1, Axial Reaction
PA Fan 2 Nos. PAF 20/12.5-2, Axial Reaction
ID Fan 2 Nos. SAF – 40/ 21-1, Axial Reaction
Dust Collector 4 Nos. FAA-8x45M-2x112150-2

Integrated Gasification Combined Cycle

Heat Flow Diagram
Misc Loss-
3% 17%
18% Steam
35% 33%
Stack Loss Condenser

Loss - 8% 10
% Loss
GT Exh
74%
47% HRS
G
100%
Loss-2%
Efficiency – 42%
Coal 25
%
Loss-2%

Coal Gasification – CCDP 6.2 MWe

Milestones in BHEL’s IGCC Development

Scale up:
Geometrical - 1:1.14 450- 650 MW
Capacity - 1: 1.21
Pressure - 1:0.9 IGCC
Scale up:
Geometrical - 1: 2.91 182 MW
Future
Capacity - 1: 11.1 IGCC Commercial Scale
Pressure - 1:3 IGCC Plant
Scale up:
Geometrical - 1: 3.3 APGENCO
125 MW
Capacity - 1: 9.33 Vijaywada
Pressure - 1:1.2
IGCC
Scale up:
Geometrical - 1: 2.25 6.2 MW Concept
Capacity - 1: 15 CCDP Design
Pressure - 1:5
18 Tiruch
Dia 0.2 m TPD y
Press 2.0 ata (PEDU)
1.2
TPD Corp. R&D,
(APFBG)
Hyderabad
Corp R&D
Hyderabad

Role of CFBC in CCT
• High fuel flexibility
• Can burn coal of high moisture content (Lignite)
• Low SOx emission due to absorption of SOx in lime bed
• Because of lower bed temperature, it generates less amount of NOx.
• Efficiency is comparable with PCC of same capacity.

CFB Boiler Development

2010
2009
2x135MW order received from
2x30 MW PT MSW, Indonesia KNS,NewCaledonia
2008
1x120 t/h First Export order
2007 received from PT BR, Indonesia
2 x 125 MW repeat order
2006 received from SLPP
1 x 135 t/h repeat Order 3 x 275 t/h Petcoke fired units 2 x 125 MW NLC – Barsingsar
2005 received from GACL 2 x 250 MW order received
from BORL
125 MW repeat order received from Neyveli Lignite
2004 from RVUNL, Giral
2 x 135 t/hr M/s Gujarat Corporation
Ambuja cement 75 MW order
2003
received from GEB, Kutch 125 MW, RVUNL, Giral
Collaboration with LLB ends
2002
Y
2001
e 2000
a 1999
First Utility reheat boiler
r 1998 (2x125 MW) installed at
First CFB boiler (175 t/hr ) SLPP, Mangrol
1997 installed at BILT , Bhigwan
1996
1995
1994
1993 Collaboration with
1992
1991
Test Facility installed
1990
0 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 850 900
Boiler Capacity in t/hr

CFB Product Range

Combustor Wing Wall Non Integral FBHE Integral FBHE Pant Leg
< 30 MW 60-100 MW 60-135 MW 125 MW 250 MW
Conference on CCT and CCS 27

2-3rd December,2013
BHEL CFB – Fuel Summary

Project Fuel %S
BILT ,Sinarmas IC 0.35
SLPP, Mangrol L 2.00

GLPP, Giral L 6.00
GACL, Kodinar IC 0.43
KLTP Ext, Kutch L 4.90
BTPP, Barsingsar L 1.70
SLPP Extn, Mangrol L 2.00
BORL, Bina IC P 5.63
PT IBR, Indonesia IC 0.96
KNS, Koniambo AC 0.80
PT MSW, Indonesia IC 0.28
BECL Bhavnagar L 4.00
Conferenceon
Conference onCCT
CCT and
and CCS
CCS 2-3rdrdDecember,2013
2-3 December,2013
CFB Boilers – Capacity & Range
Range
Upto 850 t/h (250 MWe ), 545ºC & 172 kg/cm2(g)
Fuels Range
Lignite, Petcoke, Coal, Middlings, Washery Rejects
HHV >1800 kcal/kg
Ash < 70%wt
Total Moisture < 55%wt
Sulphur < 6%wt

CFBC capacity status-worldwide

Lignite Potential In India
Lignite Reserves – 39 bill. Tons

(Proven in Mill tons)
Tamil Nadu 31327 (2831)
Rajasthan 4485 ( 561)
Gujarat 2663 ( 785)
Puduchery 417 ( 0)
J&K 28 ( 0)
Kerala 10 ( 0)
West Bengal 1 ( 0)
Total 38931 (4177)
Potential 70 Nos: 250 MW

(Approx. 50 mill tons one 250 MW plant)

BHEL 125 MWe CFBC Boilers – SLPP Units
1&2 Units Commissioned in 1999

3&4 Units Commissioned in 2010
One of the best performing lignite power plants
RVUNL (Giral) – 2 x 125 MWe CFB Boiler
Location : Giral, Barmer Dt , Rajasthan

Fuel : Lignite ( 40 % M & 6 %S) Highest in world
Design fuel, kcal/kg : HHV – 3000
Start-up : 2007
Availability : 60-90%
NLC BARSINGSAR CFB 2 x 125 MWe
Location : Barsingsar, Bikaner Dt , Rajasthan

Fuel : Lignite ( 40 % M & 0.8 %S) Unique Palana Lignite
HHV : 1900 - 3300kcal/kg
Start-up : 2010
Availability : 80-90%
250MW – What’s New

• Combustor – Single to Pant Leg
• Cyclones – Two to Four
• Pressure rating – 170 ata vs 130 ata
• FBHE – Integral to Separate
• Airheater – Tubular to Quadsector RAPH

HIGHER CAPACITY CFBC BOILERS ESTABLISHED
Successfully established CFB technology for difficult Lignite Variety available in

Rajasthan
- High Sulphur Content
- with shrinking ash characterisitics
Plants firing lignite from Gujarat & Rajasthan are operating successfull today
The Largest CFB boiler of 250 MW has demonstrated full load capacity firing
Lignite from Neyveli, Tamil Nadu
BHEL has extensive R&D facilities to characterize various fuels and

successfully fired washery rejects of 70% ash content, various coals etc.
BHEL has solution for firing various fuels of coal & lignite in CFB boilers

BHEL-TRECSTEP
EU Project on Demonstration and deployment of
CCT and CCS project
BHEL has initiated the following projects
Pilot scale testing of Oxy fuel combustion
Cofiring of Biomass

Biomass is a Carbon Neutral Fuel

Demonstration of Wood Pellets (20% by wt) Co-

firing with Coal in SFBTF to European Union Team
Dr. Rodrigo Ubierna (ROM) Visit
on 12th June 2013 to BHEL
Mr. ARNO SCHAEFER (Head of

Operation, EU Delegation to India) &
Ms. SMITHA SINGH (Project
Manager) VISIT to BHEL on
14.06.2013

Biomass Co-firing with Coal – Project

Firing with coal and 20% of
Completed Wood pellets
Firing with
100% coal
Flame
Photograph from
rear side of the
combustion
chamber
• Studies with wood pellets has been showed good results and temperature profiles, heat
flux values near wall are closely matching with 100% coal test results.
• Better flame stability observed as biomass co-firing proportion increases
• With limited proportion of firing biomass with coal up to 20% by mass
• No slagging, fouling or heavy deposition observed
• Flowability issues observed when biomass proportion is more than 20% by wt

Oxy- combustion Technology in PC Boilers

400 KW Pilot scale – Oxy fuel Combustion Test

Facility

CO2 capture and regeneration by Ammonia

absorption process
• CO2 separation from flue gas and fuel gas by wet scrubbing
with ammonia solvents.
• Ammonia method offers lower solvent cost, lower energy for
regeneration, applicable for retrofits and new plants.
• BHEL has developed the ammonia process for CO2 capture in
bench scale.

Pilot scale CO2

capture testing
facility

CO2 absorption trend using Ammonia Solution

16.0
14.0 13.5 13.2 13.6
12.0
10.0
8.0
6.0
4.0
2.0 1.2
0.6 0.3
0.0
3.1% NH3 soln 6.25% NH3 12.5% NH3
soln soln
% CO2 before absorption % CO2 minimum in absorption

Bypass Over Fire Air (BOFA)System

Bypass Over Fire Air (BOFA) system
• Cost effective technology among the technologies

available for NOx reduction in pulverised coal fired
thermal power plants.
• Employs deep air staging technique to abate NOx
emission.
• The BOFA system was retrofitted into a 250 MW boiler
supplied by BHEL (Suratgarh).
• The NOx reduction capability around 50%.

Selective Catalytic Reduction
• BHEL has developed Selective Catalytic Reduction

system for NOx reduction in PC fired boilers by injecting
ammonia in to the flue gas in the presence of a catalyst.
• SCR pilot plant has been established at Fuel Evaluation
Test Facility at BHEL Trichy.
• NOx reduction capability of the SCR system was
demonstrated to be in the order of 90-95%.

Selective Catalytic Reduction(SCR) System

Summary
BHEL has implemented Supercritical parameters for PF boilers and
moving towards USC and AUSC towards Higher Efficiency and Lower
Emissions.
Process development for IGCC of higher capacity is completed and is
ready for commercialization
CFBC of 250MWe capacity established to handle wide variety of fuels
including Lignite
Developed technology for biomass co-firing and oxyfuel combustion
technology
Know how on CO2 capture from flue gas is developed and demonstrated
on pilot scale
Reduction of non GHG emissions like NOx is commercialized based on
need


Clean Coal Initiatives of Bhel: Conference On Clean Coal and Carbon Capture and Storage Technologies

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Clean Coal Initiatives of Bhel: Conference On Clean Coal and Carbon Capture and Storage Technologies

Uploaded by

Copyright:

Available Formats

Bharat Heavy Electricals Limited

Conference on Clean Coal and Carbon Capture and

Clean Coal Initiatives

Overview of BHEL corporation

Conference on CCT and CCS 2-3rd December,2013

BHEL – Activity Locations in India

BHEL’s GLOBAL FOOTPRINT

Conference on CCT and CCS 2-3rd December,2013

BHEL’s Boiler Range

Pulverised Fuel Boilers Fluidised Bed Combustion

Sub critical Bubbling Fluidized Bed

Circulating Fluidized Bed

Conference on CCT and CCS 2-3rd December,2013

BHEL Corporate – Turn over

Conference on CCT and CCS 2-3rd December,2013

Conference on CCT and CCS 2-3rd December,2013

BHEL Initiatives towards CCT and CCS

Conference on CCT and CCS 2-3rd December,2013

Our Goals on CCT and CCS

Conference on CCT and CCS 2-3rd December,2013

Research facilities in BHEL Trichy Complex

SFBTF Coal Characterization Collaborative Research

Conference on CCT and CCS 2-3rd December,2013

Coal Research Centre

Conference on CCT and CCS 2-3rd December,2013

FUEL THERMAL MINERAL PARTICLE

Proximate Thermo Gravimetric High Temperature X- Particle Size X-Ray Fluorescence

Conference on CCT and CCS 2-3rd December,2013

Drop Tube Furnace Test Facility

Conference on CCT and CCS 2-3rd December,2013

Key research areas on CCT and CCS

• Increasing efficiency of PF Boilers

Conference on CCT and CCS 2-3rd December,2013

Conference on CCT and CCS 2-3rd December,2013

Conference on CCT and CCS 2-3rd December,2013

Reduction of CO2 emission with increase of

Sub Critical 170 540 38-39 900 Base

Super Critical* 247 565 40 830 1,01,000

Indian Govt. National Mission for Technology - AUSC

Driven by the government’s National Mission for Technology, the

Conference on CCT and CCS 2-3rd December,2013

Investment • Rs. 12 cr.

• Pressure - 400 bar

• Commissioned in Dec. 2008

Conference on CCT and CCS 2-3rd December,2013

NTPC/ BARH II STPP – 2 x 660 MW

Contract No. U6/1700 & U6/1701

Zero Date 31.03.2008

Parameters at SHO / RHO

Steam Flow 2120/1708.2 t/h.

Pressure 255/54.65 kg/cm2 (g)

Temperature 568 / 596 oC

Mill 9 Nos. Bowl Mill, HP 1103

Dust Collector Not in SG Package

Conference on CCT and CCS 2-3rd December,2013

APPDCL / Sri Damodaram Sanjeevaiah

Zero Date 25.07.2008

Parameters at SHO / RHO

Steam Flow 2600 / 2052 t/h.

Pressure 255/57.9 kg/cm2 (g)

Temperature 568 / 596 oC

Mill 6 Nos. Bowl Mill, HP 1203

Airheater 2 Nos. TRI-SECTOR, 34.5 VI 94,