Introduction

Payra 1320 MW Thermal Power Plant, governed

Bangladesh China Power Company Limited (BCPCL)
stands as one of the largest thermal power plants in
the country.

It plays a pivotal role in ensuring a stable and reliable

electricity supply to industries, households, and
commercial entities across Bangladesh.
• The plant is located along the banks of the Payra river, Kalapara, Patuakhali,
Bangladesh.

• The plant is strategically located in Payra due to its close proximity to coal ports,
facilitating efficient fuel sourcing. Additionally, its placement along the Payra
river provides convenient access to water resources crucial for cooling operations.

• This location enables optimal distribution of electricity across Bangladesh and

fosters regional infrastructure development, contributing to economic growth in
the area.
Background
❑Bangladesh is becoming dependent on coal-based power, as various challenges still
remain for development of renewable energy.
❑According to UK-based company report, Bangladesh is set to increase its coal-based
power generation capacity to ensure supply security at a time when many other countries
are focusing on development of renewables and cutting dependency on thermal power to
achieve climate goals.
❑On 19 March, 2014, North-West Power Generation Company Limited (NWPGCL)
signed a Memorandum of Understanding (MOU) and on 9 June, 2014, NWPGCL singed
the Joint Venture Agreement (JVA) with China National Machinery Import & Export
Corporation (CMC), China.
❑Then, on 1 October, 2014, Bangladesh-China Power Company (Pvt.) Limited (BCPCL)
was formed.
Background (cont’d)
❑On 29 March 2016, Bangladesh-China Power Company (Pvt.) Limited and
Consortium of NEPC (Northeast Electric Power Engineering Company) & CECC
(China National Energy Engineering and Construction Company Ltd) signed the
EPC (Engineering, Procurement and Construction) contract.
❑To implement Payra 1320 MW Thermal Power Plant Project in the fasted possible
time, the EPC work started on 30 March, 2016 and the project was completed in due
time.
❑With the completion of Payra 1320 MW Thermal Power Plant Project, Bangladesh
has been credited with the 13th Ultra Supercritical Technology using member-
country of the world.
❑BCPCL has received the EIA (Environmental Impact Assessment) approval from the
Department of Environment (DoE) for implementing Payra 1320 MW Thermal
Power Plant.
Component
1. Coal Handling

Components: Function:
✓Conveyor belts ✓Unloads,
✓coal crushers ✓stores,
✓storage silos ✓crushes, and

✓feeding systems. ✓transports coal to the boiler.

Component (Cont’d)

Fig. Jetty Fig. Coal Transfer Fig. Conveyer Belt

Component (Cont’d)

(a) (b)

Fig. Coal Domes

Component (Cont’d)
2. Boiler

Components: Function:
✓ Furnace
✓Burns coal to produce hot steam.
✓ superheater,
✓ economizer,
✓ air preheater.
Component (Cont’d)

(a) (b)

Fig. Boiler
Component (Cont’d)

(a) (b) (c)

Fig. Boiler Coal Pulverizer & Feeder

Component (Cont’d)
3.0 Steam Turbine
Steam Turbine at Payra 1320 MW Power Plant has the following specifications:
• Type: Ultra-supercritical temperature and pressure
• Operating pressure: 270 bar
• Operating temperature: 600°C
• Configuration: Single shaft with 4 cylinders and 4 exhausts
• Rated power: 660 MW
• Rated voltage: 22 KV
• Manufacturer: Shanghai Turbine Plant
Component (Cont’d)
Component Function:

✓Condenser ✓ Converts the thermal energy

✓Low Pressure Heaters (LPH) of steam into mechanical
✓Main Turbine energy.
✓High Pressure Heaters (HPH)
✓Intermediate Pressure Heaters (IPH)
✓External Steam Cooler
✓Deaerator
✓Generator
Component (Cont’d)

Fig. Turbine Fig. Condenser

Component (Cont’d)

Fig. Low Pressure Heater Fig. High Pressure Heater

Component (Cont’d)

Fig. External Steam Cooler Fig. Deaerator

Component (Cont’d)

✓ Converts mechanical energy

from the turbine into electrical
energy.

Fig. Generator
Component (Cont’d)
4.0 Control

✓Main Control Room (MCR)

✓Chemical Operation Control Room (COCR)
✓Coal Operation Control Room (COC)
✓FGD & ESP Control Room
Component (Cont’d)

(a) (b)
Fig. Main Control Room
Component (Cont’d)

Fig. Coal Control Room

❑ OPERATION
➢Coal unloading at coal jetty from ship.

Fig. 1: Coal Jetty

❑ OPERATION
➢Coal conveying to coal bunker via coal dome.
➢There are 4 coal domes, each of them 1,80,000 tons of storage.
capacity.

Fig 2: Conveyer Belt Fig 3: Coal Domes

❑ OPERATION
➢Coal feeding to coal pulverizer.

Fig 4: Coal Pulverizer

❑ OPERATION
➢Pulverized coal carrying to burner for combustion.
➢All operation is maintained by control room.

Fig 5:Central Control Room Fig 6:Coal Control Room

Fuel Handling
• Payra Thermal Power Plant requires 4.12 million tons of coal annually,
sourced from Indonesia, China, and Australia.
• Coal from Indonesia is loaded onto a 70,000DWT cargo vessel at
Kalimantan Port and then unloaded at the Payra Port.
• The project includes three 8,000DWT coal unloading berths and one
2,000DWT heavy cargo berth.
• Coal is transferred to the 14m-wide 1,750t/h conveyor belt using 16t
gantry-type grab ship unloaders.
Fuel Handling (Cont’d)

Fig: Coal Jetty Fig: Coal Transfer Fig: Coal Sampling

Fuel Handling (Cont’d)

Fig: Coal Domes

Fuel Handling (Cont’d)
• This power plant requires 15,197 metric tons of coal daily at full
capacity.
• Coal transfer from jetty to coal domes involves three transfer towers
(TT).
• Initially, coal moves to TT-1 via a conveyor belt from the jetty.
• From TT-1, coal is sent to the sampling tower for further processing.
• TT-2 and TT-3 receive coal from the sampling tower for weighing.
• TT-2 supplies coal directly to the boiler.
• TT-3 is utilized for storing coal in the coal domes.
Fuel Handling (Cont’d)
Responsibilities of coal domes:
✓Coal storage
✓Dust control
✓Fire prevention
✓Coal feeding
✓Inventory management
Fuel Handling (Cont’d)
Functions of crushing house:
✓Coal size reduction
✓Homogenization
✓Material handling
✓Dust control
✓Safety
Exhaust Control
In payra 1320 thermal power plant, like every other power plants it
produces some exhaust gasses that it releases to the environment. These
exhausts are quite harmful for the environment if released in excess and
should be minimized before releasing to the air. After burning of coal,
40% of total coal consumption is converted into ash which need to be
properly disposed off from the thermal power plant.
Among the exhaust control mechanisms, Flue gas desulphurization,
electrostatic precipitator and ash handling are used in this specific
power plant.
Flue Gas Desulphurization
Flue-gas desulfurization (FGD) is a set of technologies used to remove
sulfur dioxide (SO₂) from exhaust flue gases of fossil-fuel power plants.

Forced Oxidation Wet Limestone Flue Gas Desulfurization System is

followed here. Here Sulfur (in the form of SO₂) reacts with limestone
(CaCO₃) slurry and form Gypsum (CaSO₄, 2H₂O) which will be utilized
for comprehensive use.

Here the SO₂ removal efficiency is not less than 93% with SO₂ outlet
concentration to be 200 mg/Nm³ which is a tolerable concentration of
SO₂ to be released in the atmosphere.
Electro-Static Precipitator (ESP)
To reduce the emission of ash content, Electrostatic Precipitator (ESP)
with an efficiency of 99% is installed with the power plant.

A dry electrostatic precipitator (ESP) electrically charges the ash

particles and imparts a strong electric field in the flue gas to collect and
remove them. An ESP is comprised of a series of parallel, vertical
metallic plates (collecting electrodes) forming lanes through which the
flue gas passes. Centered between the collecting electrodes are
discharge electrodes which provide the particle charging and electric
field. This figure shows a plan view of a typical ESP section which
indicates the process arrangement.
Bottom and Fly Ash Handling
The amount of fly ash is 90% of the total ash. The remaining 10% is the
fly ash. Both the bottom and fly ash are collected for later commercial
use.

Fig: Fly ash silo

Fly ash silo is used for storing fly ash that comes from the ESP. There
are two types of fly ash produced here, one is fine type and another one
is coarse type fly ash which is in less abundance when compared.
Bottom and Fly Ash Handling
Bottom ash silo is under the lower part of the boiler and from here the
bottom ash goes to bottom ash bin. This is where the bottom ash is
stored and later sold to cement industries for commercial use.

Fig : Bottom ash recovery

 Financial Analysis
➢ Initial Financial Agreement was 1.984 Billion USD

➢ Total Project Cost is 2.41 Billion USD

➢ Project Financier - CEXIM Bank

➢ Proportion of Own Capital is 20% remaining 80% is loaned form EXIM Bank at 6.66% annual rate

➢ Repayment periods of long-term loans are 15 years

➢ Unit Investment is 1876.73 USD/kW

➢ Generating Standard Coal Consumption Rate 290.22 kg/kW.h

➢ Coal Price 110 US Dollar/t

➢ Power Consumption 5.8 %

Financial Analysis (Cont’d)
➢ Price of Desulfurizer (CaCO2) 130 Doller/t

➢ Annual Average Salary is 80,000 USD

➢ Estimated Operating Period is 25 years

➢ Estimated Depreciation Period is 8 year

➢ Estimated Accumulated Depreciation Rate is 100%

➢ As of 30 June 2023 Loss on foreign currency fluctuation is 37.27 Billion Taka or 0.33 Billion
USD
 Observation
• Practical Application of Theoretical Knowledge:
The industrial attachment at Payra 1320 MW Thermal Power Plant provided invaluable hands-on experience
complementing theoretical knowledge in power generation principles.

• Multidisciplinary Interplay:
Witnessed the complex interaction of electrical, chemical, control, automation, and safety disciplines crucial for
efficient power production.

• Effective Teamwork:
Impressive collaboration among engineers and technicians, sharing expertise to maintain smooth plant operations,
highlighting the importance of teamwork in critical industries.
Observation
• Commitment to Safety:
Noted the rigorous safety protocols and employee dedication, underscoring the paramount importance of safety in
protecting personnel and ensuring continuous plant operation.

• Contribution to Economic Development:

Acknowledged Payra 1320 MW Thermal Power Plant's vital role in providing electricity to Bangladesh and its
contribution to the country's economic growth.

• Appreciation for Reliable Power Generation:

Developed a profound appreciation for reliable and sustainable power generation, recognizing its importance for
societal development.
The End