K Ravikumar1

ENERGY CONCLAVE 2006
TECHNOLOGY FRONTIERS AND

MODERNISATION
ENERGY R&D
BHEL ROLE & CONTRIBUTION
PRESENTATION
BY
RAVI KUMAR
DIRECTOR (POWER)
BHEL, NEW DELHI
1
Bharat Heavy Electricals Limited
R&D – WORLD STATUS
Expenditure on R&D per capita

(IN US $)
INDIA - 5.5
CHINA - 11.7
S. KOREA - 241
AUSTRALIA - 285
UK - 460
USA - 705
JAPAN - 978
2
R&D – BHEL
TARGETS
2006-07 2005-06
EXPENDITURE ON R&D RS. 150 CR. RS. 125 CR.
NO. OF PATENTS TO BE 55 NOS. 45 NOS.

FILED
COMMERCIALISATION OF RS. 700 CR. RS. 650 CR.

IN HOUSE DEVELOPED
PROJECTS
3
BHEL-R&D EXPENDITURE AS % OF T.O.
History of R & D Expenditure as % of T.O.
1.6
1.4
1.2
R & D Expenditure
0.8
0.6
0.4
0.2
0
1992- 1993- 1994- 1995- 1996- 1997- 1998- 1999- 2000- 2001- 2002- 2003- 2004- 2005-
93 94 95 96 97 98 99 00 01 02 03 04 05 06
Year
4
TECHNOLOGY TRENDS
POWER SECTOR
 Lower Cost of Generation
 Environment Friendly
 Higher Efficiency
 Higher Reliability
 Compatible to Local Conditions
5
CENTRE OF EXCELLENCE SETUP BY BHEL
 Center Of Excellence For Simulators
 Center Of Excellence For Computational

Fluid Dynamics
 Center Of Excellence For Permanent

Magnet Machines
6
STATE OF ART TECHNOLOGIES / PRODUCTS INTRODUCED
BY BHEL
 Low Nox Oil/ Gas Burners
 Large Capacity Atmospheric FBC
 High Efficiency Pelton Turbine
 Controlled Shunt Reactor (CSR)
 Flexible AC Transmission System (FACTS)
 Space Grade Solar PV Panels
 Phase Shift Transformer
 145 KV Gas Insulated Switchgear
 India’s Largest Vertical AC Motor (6 MW, 6.6 KV)
 Micro Controller Based Flame Scanner
 Performance Analysis, Diagnostics and Optimization
(PADO) Package
 91 Ton/hr BHEL 280 Bowl Mill 7
TECHNOLOGIES SUBSTANTIALLY DEVELOPED
 Supercritical Thermal Power Plants
 Circulating Fluidised Bed Combustion
 Coal Based Combined Cycle Plants
 IGCC
 PFBC
 Nuclear Power Generation with Fast Breeder

Technologies
 Fuel Cells
 Solar Photo Voltaic

8
SUPERCRITICAL THERMAL POWER PLANTS
 The supercritical cycle offers a ‘burn less

fuel for the same output’ approach
 Involves economical use of energy

resources resulting in higher efficiency and
low emissions
 BHEL is equipped to supply Supercritical

Power Plants upto 1000 MW
9
Cycle Efficiency benefits of supercritical units are derived
from higher pressures and temperatures of steam
10
Super Critical R&D Projects
Areas identified R&D Actions Taken

Heat Transfer Correlations Joint Project with
IIT-Chennai
DNB, Tube Dry-out
Flow Instability
Spiral to Vertical Transition Piece Joint Project with AU FRG
Load Transfer Attachment
Dynamics, Temperature Control BHEL Corp R&D
Ripple Effect BHEL In-House

Chemical Lab
FW Oxygenated Treatment
Low NOx Burner BHEL In-House
11
CFBC TECHNOLOGY
 Burns low grade fuels like lignite

 No pulverising
 Low NOx & Low SOx emissions
 Higher efficiency
 BHEL commissioned 2x390 TPH
boilers for Surat Lignite Power
Project
 Number of 125 MW CFBC based
power plants are under execution
 Order received for 2x250 MW NLC,
the largest CFBC technology based
power plant in the country
12
ENVIRNOMENTAL ASPECTS – ROAD MAP
Area of focus - NOx control in pulverized coal fired boilers
NOx emission scenario of Indian plants while firing different fuels:

Unit capacity, MW fuel NOx emission, ppm at 3.0 % O2
500 gas 73
500 oil 129 to165
500 coal 271 to 434
250 coal 266 to 322
210 coal 247 to 478
210 lignite 242 to 280
120 coal 389
Development of low NOx wall fired coal burner - 2006

Establishment of SCR demo plant - 2007
Commercialisation of wall burner - 2008
Commercialisation of SCR system - 2010
13
IGCC POWER GENERATION - DEVELOPMENT IN BHEL
 6.2 MW IGCC Pilot Plant at its Trichy Complex.
 Technical feasibility of upgrading the 6.2 MW Combined

Cycle Demonstration Project of BHEL to ~100 MW had
been established
 Preliminary assessment made for 400 MW IGCC Plant
 Plan to set up 125 MW IGCC Demonstration plant
14
IGCC POWER GENERATION - DEVELOPMENT IN BHEL
PFBG SCALE - UP
15
A glimpse of Fuel Cell Developments at BHEL
(Inter-disciplinary approach followed for Fuel Cells Development)
Anodes, Cathodes,
Skid Design Membrane Electrode
(Renewable Assemblies etc
Energy Systems (Fuel Cells Lab) Bipolar &
Lab) Cooling plates
(Fuel Cells Lab)
Inverter System
(Power Fuel Cell Stack Hardware
Electronics Lab)
Development & Assembly
(Design Analysis &
Value Engg)
Data Acquisition,
display & Controls
(Control Reactants &
Instrumentation Lab) Stack Heating
& Cooling Coolant Supply
(Turbo Machinery
(Heat Transfer
Lab)
Lab)
16
Indigenous Fuel Cell R&D - Achievements
Phosphoric Acid Fuel Cells (PAFC)

BHEL R&D: 1 kW (1991), 5 kW (1995) & 50 kW (2000, 2 stacks of 25 kW
each) - with data acquisition and display system & inverter have been
demonstrated.
Performance of a state-of-the-art 200 kW FCPP (PC 25 C, procured
from M/s IFC / ONSI / Toshiba) also evaluated, using LPG as fuel.
Polymer Electrolyte Membrane Fuel Cells (PEMFC)

Single cells & small stacks for evaluating electro-catalysts. Also tested
Direct Methanol FCs – Basic Tech acquired from IISc, B’lore
High Temperature Fuel Cells (SOFC)

BHEL R&D & CTI, Bangalore: Materials, processes & components
developed. Assembled & tested single cells of planar SOFC.
17
BHEL IN PHOTOVOLTAICS
 Over two decades experience in Photovoltaics
 Manufacturing capacity of 3MW
 Single crystalline (mono) cells upto 2.3W (15%

efficiency)
 PV modules range is from 10W to 160W
 PV systems integration capabilities- have supplied PV

power plants ranging from 1 KWp to 150 KWp
 PV modules internationally certified to IEC 61215

standards
 Cumulative shipments from BHEL over 20 MWp

18
Future outlook for PV in BHEL
 Automatic manufacturing capacity over 30 MW planned

 Plan for improving solar cell efficiencies to over 18% by
2010
 Capability to process both mono & multi crystalline
wafers
 Opportunities for backward integration into silicon wafer
manufacturing
 Large scale deployment of PV power plants
 Explore alternate technologies like Thin film cells,
multijunction cells etc
19
BHEL - R&D
DEVELOPMENT OF 765 KV TRANSMISSION SYSTEM

2006-07 TARGETS
 DESIGN & MANUFACTURE OF 765 KV, 500 MVA

TRANSFORMER
 DESIGN & MATERIAL PROCUREMENT FOR

MANUFACTURE OF 765 KV 80MVAr SHUNT
REACTOR
 DEVELOPMENT OF COMPOSITE INSULATORS

FOR TRACTION & TRANSMISSION WITH NANO
ADDITIVES
20
POWER PLANT PERFORMANCE IMPROVEMENTS
AUXILIARY POWER CONSUMPTION REDUCTION
 Power plant consumes nearly 7 to 9% of energy

generated
 Auxiliary power can be brought down by proper

selection of technology, equipments and cycle
parameters
 Power consumption of BHEL manufactured equipment

has been recently reduced from 7% (of total power
consumption) to 6.65% for 250 MW & from 4% ( with
turbine driven boiler feed pump) to 3.8%
21
POWER PLANT RENOVATION &
MODERNISATION
LEADING PLAYER IN R&M AND UPRATING
 R&M and LE of Large No. of Units in India and Abroad
 Uprating of 110 MW Czech Units to 120 MW

- Replaced Internals of HP, MP & LP Turbines with Reaction Type
Blading
- Boiler Upgrades to Ensure Rated
- FlowModernize C&I and Balance of Plant
 Improvised Blade Profiles for 210 MW LMW Sets

- Reaction Type Blades for HP Turbine yield an additional 2.5 MW
- New Monoblock LP Rotor with Reaction Blading Leading to
additional 3.7 MW
22
PERFORMANCE OF BHEL THERMAL SETS
Performance Trend
(Thermal sets in India)
90
85
80
75
PLF-BHEL
%
70 OA-BHEL
PLF-ALL INDIA
65
60
55
50
90- 91- 92- 93- 94- 95- 96- 97- 98- 99- 00- 01- 02- 03- 04- 05-
91 92 93 94 95 96 97 98 99 00 01 02 03 04 05 06
PLF-BHEL 55.8 56.6 59 62.8 61.2 63.1 64.6 65.6 65.7 68.3 70.5 71.3 74.1 74.3 75.7 74.9
OA-BHEL 71.7 72.7 74.6 77 77.5 79.9 80.7 79.8 78.9 80.4 81.8 81.7 83.9 83.9 84.3 83.4
PLF-ALL INDIA 53.8 55.3 57.1 61 60 63 64.2 64.7 64.2 66.7 68.5 69.9 72.2 72.7 74.8 73.6
year 23
THANK YOU
http://www.bhel.com
24

K Ravikumar1

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ENERGY CONCLAVE 2006

TECHNOLOGY FRONTIERS AND

Expenditure on R&D per capita

EXPENDITURE ON R&D RS. 150 CR. RS. 125 CR.

NO. OF PATENTS TO BE 55 NOS. 45 NOS.

COMMERCIALISATION OF RS. 700 CR. RS. 650 CR.

History of R & D Expenditure as % of T.O.

 Lower Cost of Generation

 Compatible to Local Conditions

 Center Of Excellence For Simulators

 Center Of Excellence For Computational

 Center Of Excellence For Permanent

 Supercritical Thermal Power Plants

 Circulating Fluidised Bed Combustion

 Coal Based Combined Cycle Plants

 Nuclear Power Generation with Fast Breeder

 Solar Photo Voltaic

 The supercritical cycle offers a ‘burn less

 Involves economical use of energy

 BHEL is equipped to supply Supercritical

Areas identified R&D Actions Taken

Ripple Effect BHEL In-House

 Burns low grade fuels like lignite

NOx emission scenario of Indian plants while firing different fuels:

Development of low NOx wall fired coal burner - 2006

 6.2 MW IGCC Pilot Plant at its Trichy Complex.

 Technical feasibility of upgrading the 6.2 MW Combined

 Preliminary assessment made for 400 MW IGCC Plant

 Plan to set up 125 MW IGCC Demonstration plant

Phosphoric Acid Fuel Cells (PAFC)

Polymer Electrolyte Membrane Fuel Cells (PEMFC)

High Temperature Fuel Cells (SOFC)

 Manufacturing capacity of 3MW

 Single crystalline (mono) cells upto 2.3W (15%

 PV modules range is from 10W to 160W

 PV systems integration capabilities- have supplied PV

 PV modules internationally certified to IEC 61215

 Cumulative shipments from BHEL over 20 MWp

 Automatic manufacturing capacity over 30 MW planned

DEVELOPMENT OF 765 KV TRANSMISSION SYSTEM

 DESIGN & MANUFACTURE OF 765 KV, 500 MVA

 DESIGN & MATERIAL PROCUREMENT FOR

 DEVELOPMENT OF COMPOSITE INSULATORS

 Power plant consumes nearly 7 to 9% of energy

 Auxiliary power can be brought down by proper

 Power consumption of BHEL manufactured equipment

LEADING PLAYER IN R&M AND UPRATING

 R&M and LE of Large No. of Units in India and Abroad

 Uprating of 110 MW Czech Units to 120 MW

 Improvised Blade Profiles for 210 MW LMW Sets

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