CLEAN COAL TECHNOLOGIES FOR

SUSTAINABLE POWER DEVELOPMENT

Dr. V. K. SETHI
Prof. & Head
RGPV
Bhopal
WORLD SUMMIT ON SUSTAINABLE DEVELOPMENT

PRIORITIES ON ENERGY GENERATION SECTOR:

 Increased use of Advanced Fossil Fuel Technology.

 Promote CCT in countries where coal is main stay

fuel for Power Generation.

 Reduce Atmospheric Pollution from Energy

Generating Systems.

 Enhance productivity through Advanced Fossil Fuel

Technology.
 POWER SCENARIO IN INDIA

Installed capacity in utilities (March 31, 2002)

 
 Thermal 73,274 mw
 Hydro 25,574 mw
 Nuclear 2,860 mw
 Wind 1,427 mw
 Total 1,03,135 mw

 Total energy generation - 383 billion kwh

 Per Capita Energy Consumption -400 kwh
 DEMAND PROJECTION

YEAR 2012 CAPACITY ADDITION BY SECTORS

 Central 46,500 MW
 State & IPP 41,800 MW
 NCES 10,700 MW
 Nuclear 6,400 MW
 Total 105,400 MW

YEAR 2020 MIX OF GENERATION

 Thermal 326,000MW
 Renewable & Hydro 104,000 MW
 Nuclear 20,000 MW
 Total 450,000 MW
 CLEAN COAL TECHNOLOGIES

 Mining Management & Practices

(Reduction of Extraneous
material)

 Coal Preparation Process after mining to improve

inherent & Extraneous material
(washing & beneficiation)

 Conversion Technologies Supercritical, PFBC and IGCC

 Post combustion cleaning Particulate and gaseous

pollutants removal
(Environmental requirement)
 VISION 2020
PROGRAM

In-combustion Clean-up
Gasification using +
Fluidized bed
fluidized bed, moving bed
combustion (CFBC,
or Entrained bed Gasifiers
PFBC, AFBC)

Post combustion Clean-up-

Pre combustion Clean- Desulfurization
up beneficiation/washing (FGC systems) Supercritical

CLEAN COAL
TECHNOLOGIES

Technologies for utilization of Coal for Power Generation with minimal

pollutants discharged to the atmosphere (Reduced CO2, Sox, Nox,
SPM) at high conversion efficiency……….World Coal Institute.
 CLEAN COAL
TECHNOLOGIES
Clean Coal Technologies
(CCTs) are defined as
‘technologies designed to
enhance:

Efficiency of conversion

Environmental
acceptability of coal
 COAL FOR POWER
GENERATION
China and India are projected to
account for30% of the world’s
increase in energy consumption
between 2000-2020 and 92% of
increase in coal use.

The key environmental challenges

facing the coal industry are related to
:

Coal Mining
Particulate emission

Disturbance land me
INDIA AMONGST TOP
SIX EMITTERS OF CO2
Country Total emission
Percentage of
(Million Tonnes of CO2) world
emission

USA 5470 24%

China 3121
14%
Russian Federation 1456 6%
Japan 1173 5%
Germany 884 4%
India 881 4%
 Note : Green House
inventory for India for
Energy Sector (Million
Tonnes
Energy Sector
of CO
CO2 2 ) CO2
equivalent

(CO2+CH4+NOx)

Total Emission 508 565

(58% of total) (64% of
total)

Source : IAE : 1999

PER CAPITA EMISSIONS OF CO2

Top 6 Polluters
World Developed countries Developing Countries
Parties
(Tonnes of CO2 per (Tonnes of CO2 per
capita) capita)

Qatar 44.08 USA 20.50 Qatar 44.08

Bahrain 35.23 Luxemboury 20.42 Bahrain 35.23
UAE 30.11 Australia 16.52 U.A.E. 30.11
Kuwait 25.01 Canada 15.76 Kuwait 25.01
Singapore 23.47 Finland 12.47 Singapore 23.47
U.S.A 20.50 Estonia 12.47 Saudi Arabia 13.27
Note : Per capita CO2 equivalent emissions for India in 1990 are estimated to be
1.194 tonnes or 325 kg of Carbon per capita. This contribution 58% of National
Emissions and 4% of global emission.
Source : IEA 1999 & UNDP 1998.
 COST OF VARIOUS CO2
MITIGATION OPTIONS FOR
INDIAN POWER SECTOR
Potential Green house COST (Rs/Tonnes CO2)
.

Technologies gas emission

reduction (kg/kWh)

1. Co-generation 1.50 480

2. Combined Cycle 0.96 2600
3. PFBC 0.18 24000
4. IGCC 0.23 16000
5. Supercritical 0.18 16000
6. Coal Washing 0.125 8500
Source: ADP 1998
 Zero Emission
Technology (ZET)
This technology combines and forms a
part of :
 Clean Coal Technologies
 Solid to liquid fuel technology
 GHG mitigation technology
 Clean Development Mechanism for power
sector
 Non-CFC Refrigerant and Non-CFC Aerosol
Propellant Technology
 Clean Aviation Fuel or ATF for aircraft
 Substitute LPG for domestic use.
 Measures to achieve
Sustainable
Development
Promoting CCTs, including
carbon sequestration is essential
to a balanced cost effective climate
change response

Developingcountries where coal

combustion efficiencies are low
CCT promotion a need of the day.
 Super Critical PC Power Plant (15 oC Amb.)
60
Super Critical PC Power Plant (Indian Condition)
IGCC (15 oC Amb)
Net Thermal Efficiency (%)
55
IGCC (Indian Condition)
Sub Critical PC Power Plant (Indian Condition)
50 1500 oC
1300o C
623 oC
45 600o C
566 oC

40 Ceramic gas
1184o C turbine
650o C
35
540oC
30
1990 1995 2000 2005 2010
Year of commercial use

EFFICIENCY IMPROVEMENT FORECAST

CONVENTIONAL Vs IGCC ( Courtesy BHEL)
 POLLUTANT GENERATION FROM PC PLANTS
128
150
85
100
No Change Scenario
MMT

20
50 13.3
0
Specific Coal Consumption
1997 2002 1997 2002
ASH =0.75 KG/KWH
15
10 Coal
10
MMT

6.6 Ash : 43%

4.3
5 2.8
Sulphur : 0.6%
0
1997 2002 1997 2002

SO2

600 570 Ideal Scenario

500 Specific Coal Consumption
400
380 384
=0.35 KG/KWH
MMT

300 256

200 Coal
100 Ash : 15%
0
1997 2002 1997 2002 Sulphur : 3%
CO2
 RELATIVE EMMISSION

120
110
PERCENTAGE OF PC PLANTS

100
90 PC
80
PC+FGD
70
60 PFBC
50
40 IGCC
30
20
10
0
SOx NOx Particulates
 SUPER CRITICAL UNITS
 Standardized Unit Size 660 MW, 246 ata, 537 oC
 Station Size 2x660 MW (Minimum)

 Common Off site facility

 FW Temperature 270 oC – 275 oC with 6 Heaters.

Total Capacity Planned 14,560 MW *

Number of Units 22 Units

* Includes 6x720 MW and 2x500 MW Imported sets.

Main advantages of
Super-Critical Steam Cycle
 Reduced fuel cost due to improved thermal
efficiency
 Reduction of CO2 emissions by 15% per unit of
Power generated compared to sub-critical
 Very good part load efficiencies
 Plant costs are comparable with sub-critical units
Current State-of-Art
Super-critical Steam Power Generation Plants
Pressure - 300 bar
Temperature - 600oC
Efficiency - 45% (LHV Basis)

Nickel based alloys allows up 650oC

By the year 2005 - 620 oC
By the year 2020 - 650-700 oC
Cycle Efficiency - 50-55%
 R&D IN
SUPERCRITICAL
TECHNOLOGY
Main Thrust Areas :
 Materials & Metallurgy for components
of boiler & turbine subjected to high
temperature and high pressure.
 Supercritical cycle optimization
-incremental heat rate improvement
 Retrofit of supercritical boiler to
subcritical PC boiler
 Fluidized bed supercritical steam cycles

 Once through HRSGs with supercritical

parameters
 SUPER CRITICAL SCENARIO

EXPECTED BENEFITS:

 Coal Saving 1,565,200 Tonnes

 Co2 Emission Reduction 1,909,544 ”

 SO2 Emission Reduction 11,648 ”

 Ash Reduction 661,752 ”

 COAL BASED COMBINED CYCLE PLANT
Routes

Combustion Gasification

Hot Flue gas under pressure Pressurized gasification

drives the G.T. process produces fuel for
G.T.

Pressurized Options Available

Fluidized – BED  Moving – BED
Combustor (PFBC)  Fluidized – BED
 Entrained – BED
 COAL BASED
COMBINED CYCLE POWER GENERATION

 Offers Plant efficiency over 44% with advanced GT

 Has Lower emission of gaseous and solid pollutants

 Accept Inferior and varying quality of coals

 Lower water requirement

 Capability of phased construction and retrofitting

IGCC TECHNOLOGY ...
 Gasification of coal is the cleanest way of
utilization of coal, while combined cycle power
generation gives the highest efficiency.

 Integration of these two technologies in IGCC

power generation offers the benefits of very low
emissions and efficiencies of the order of 44-
48%.

 The comparative indices show that in case of

IGCC, emission of particulate, NOx and SOx are:
7.1%, 20% and 16%, respectively, of the
corresponding emissions from PC plant.
 IGCC ...
 Environmental performance of IGCC plants
far exceeds that of conventional and even
supercritical plants.

 Three major areas of technology that will

contribute to improvements in IGCC are :
 hot gas de-sulfurisation

 hot gas particulate removal

 advanced turbine systems

 DEVELOPMENTAL GOALS FOR IGCC

 To utilize India’s low grade coal for power generation

with improved plant efficiency.

 To introduce coal gas in Natural Gas based Combined

Cycle Plants in a phased manner.

 To increase power generation capacity at the level of

present emission.

 To develop state of Art Technology for Indigenous and

Export Markets.
 IGCC
Gas
Clean Up
Fuel
COAL
Raw Gas
Steam Combustion
Cooler
Chamber

Air
Gasifier
Booster Alternator

Comp. Turb.

Ash Air

Steam Alternator

ST

Exhaust
Gases

Condenser
WHB
 IGCC DEVELOPMENT PROGRAM IN INDIA
MAJOR MILE STONES:
 Choice of gasification for high ash coals by BHEL
 6.2 MW IGCC demonstration plant established by BHEL both with
Moving Bed and Fluidized Bed.
 Coal Characterization by BHEL & IICT for gasification application.
 Intensive data generated by IICT on oxygen-steam gasification in their
Moving Bed gasifier.
 Task force CEA, CSIR, NTPC & BHEL constituted to assess
technological maturity & Financial requirement for a green field IGCC
plant of 100 MW capacity at Dadri (NTPC).
 BHEL, CSIR & NTPC prepared proposal for setting up of this 100 MW
IGCC demonstration plant.
Circulating fluidized Bed Combustion
 Circulating Fluidized Bed Combustion
(CFBC) technology has selectively
been applied in India for firing high
sulphur refinery residues, lignite, etc.

CFBC Technology is superior to PC

Power Plant Technology:

 Lower NOx formation and the ability

to capture SO2 with limestone
injection the furnace.
Circulating fluidized Bed Combustion
 Good combustion efficiencies comparable
to PC Power Plants.

 The heat transfer coefficient of the CFB

furnace is nearly double that of PC which
makes the furnace compact.

 Fuel Flexibility: The CFB can handle a wide

range of fuels such as inferior coal,
washery rejects, lignite, anthracite,
petroleum coke and agricultural waste
with lower heating.
 Circulating Fluidised Bed Boiler
Steam to Super Heater

Cyclone

Back-Pass
Coal Feed
Furnace
Hopper
ESP

External
Heat-Exchanger
Ash Cooler
HP Air
CFBC Vs Other Clean
Coal Technologies
PF+FGD/SC
ITEM CFBC IGCC
R

Cycle Eff. % 34.8 36.7 41-42

Relative Capital 1.15-

1.0 1.03-1.19
Cost/kW 1.42

Relative O&M
1.0 1.49 0.8-0.98
Cost/kW

At present pulverized fuel firing with FGD are

less costly than prevailing IGCC technology.
However, firing in CFB Boiler is still more
economical when using high sulfur lignite
and low-grade coals and rejects.
 Renovation & Modernization (R&M) and
Life Extension (LE) of old power plants is a
cost-effective option as compared to
adding up green field plant capacities.

 Growing environmental regulations would

force many utilities within the country to
go for revamping these polluting old power
plants using environmentally benign CFBC
technology.
 SUMMERY

 Sustainable Power Development calls for

adoption of Clean Coal Technologies like
Supercritical cycles, IGCC and FBC
technologies

 Supercritical Power technologies may

selectively be used for Pit Head power
generation using washed coal
 SUMMERY
 IGCC can revolutionize the power
generation scenario in India, once the
commercial viability of technology with
high ash coals is established at the
proposed 100 MW plant.

 The success of the project will largely

depend on maturity of Fluidized bed
gasification technology for high ash Indian
Coals.

 CFBC technologies are particularly useful

for Boiler Emission reduction through
revamping of old polluting plants.