DADRI

Bio-mass Co-firing
experience
& combustion practices
in NTPC

VIVEK SINGHAL
NCPS Dadri, NTPC Limited
PRESENTATION HIGHLIGHTS

1 BACKGROUND

2 FIRST PHASE OF TRIAL OPERATION

3 NTPC DADRI EXPERIENCE

4 REQUIREMENTS BEFORE COMMERCIAL

5 ENVIRONMENTAL BENEFITS OF BIOMASS FIRING

6 WAY FORWARD

2
 BACKGROUND

 SMOG was worst experienced in NCR during November’

2016.
 The SMOG scenario repeats every year during early
SMO
G winters with more intensity.
 During this period Air Quality Index (AQI) of NCR crossed
2000 scale (whereas >400 considered as “severe”).
Satellite imagery showing smog in NCR
 Studies revealed that one of the reasons of SMOG in NCR
regions
is due to agro residue / stubble burning in near by states.
 The Rice stubble & other residual’s left outs in the fields
are because of Mechanical harvesting.
 Farmers used to burn the rice straw /stubbles in the fields
itself for preparing next crop.
Agro residue burning  In 2017,NTPC Dadri was identified as pilot project
for implementation of the co-firing of3 pellets with
coal.

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Pre-work of
Implementation
• As Biomass co-firing along with coal will
be done for the first time in India, members
from CC-OS, CC-Engineering, NETRA-
NTPC’s research wing and site have done
brain storming and come out with the
following :

• Specification of Pellets

• Operational procedures including

precautionary safety measures

• As a first step it was decided to co-fire 100

MT of pellets in one of the 210 MW unit
initially through one mill (gradually
increasing from 5%, 7.5% and finally 10% of
pellets) and then through all running mills
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Technical Specification Of Biomass Pellets
S.N. PROPERTIES TECHNICAL SPECIFICATION

1 Material Crop residue, wood chip, forest residue

2 Shape Cylindrical

3 Diameter 8-8.5 mm

4 Length In range of 4-32 mm

6 GCV Not less than 3800 Kcal/ Kg (Penalty if GCV<2800 & incentive for higher GCV)

7 Moisture Less than 8.5 %

8 Ash Less than 5%

3 mm plus size < 5%

Particle size distribution 2-3 mm size ~ 10-12 %
9
in pellets 1-2 mm size ~10-15 %
Below 1 mm size ~75-78%

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Platform for biomass sample collection Infrared moisture analyzer
(Rejection if moisture>14%)

6
 Combustion Preparation of Samples:
• 100 % coal sample provided by Site
Characteristics Of • 100% biomass sample provided by PE-
Coal-biomass Blend MECH
In Lab • Blend of 95% coal and 5% biomass
• Blend of 90% coal and 10 % biomass

Lab Analysis:

SN Sample ID Condition Proximate Analysis GCV

Moisture Ash VM FC Kcal/kg
% % % %
1 100% coal (Only Air Dried 6.36 41.05 22.19 30.40 3620
Coal)
2 95% coal+5% Air Dried 6.24 39.70 24.46 29.60 3654
Biomass (Cofired)
3 90% coal+10 % Air Dried 6.09 37.61 26.85 29.45 3684
Biomass (Cofired)
4 100 % Biomass Air Dried 5.76 10.21 67.29 16.74 3850
7
(Only Biomass)
 • The analysis indicates that the VM in 5%/10% biomass blended coal is
2-4 % higher than in Coal sample.
• Sulphur content is less.

SN Sample ID Condition Ultimate Analysis

M% Ash C% H% N% S% O%
% Diff
1 100% coal Air Dried 6.36 41.05 39.64 3.18 0.86 0.54 8.37
2 95% coal+5% Air Dried 6.24 39.70 40.45 3.26 0.83 0.45 9.07
Biomass
3 90% coal+10 % Air Dried 6.09 37.61 40.89 3.38 0.75 0.62 10.66
Biomass
4 100 % Biomass Air Dried 5.76 10.21 42.75 5.42 0.12 0.11 35.63

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Combustion Analysis

The biomass sample starts evolving Volatile Matter from 200 deg C and
completes VM burning at 360 deg C.

The Coal sample starts evolving the VM at around 300 deg C, completes VM
burning at 380 deg C

The samples of 100 % biomass, 10%/5% biomass in coal burns comparatively

faster than coal sample

The ash evolved in the two sample of 10%/5% biomass in coal is observed to
be loose deposits indicating minimal chances of sticky ash deposits.

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NTPC Dadri Experience

 Biomass test firing was First started in September 2017 in 3 phases

 As a first step,5% pellets and 95% coal through one mill was fired in Unit
#4(210MW).

 In the second step 10% pellets and 90% coal through one mill was fired.

 After observing the performance of firing, 10% pellets and 90% coal through four mill
was fired and Unit full load operation done.

 Based on the experience, system was designed for handling, storage and 24x7 co-
firing considering the safety of man and machine in all units of Dadri.

 4th December,2018 was Historic day for Dadri when commercial co-firing of
Biomass started at NTPC Dadri station.

 16 Jan 2020 was another milestone as biomass firing was started in first 500 MW
unit at NTPC Dadri station

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 Coal Blending

 For first two trucks of biomass pellet,

Coal and biomass pellets blending (5%
biomass pellets by weight) done in
coal yard and thereafter, mixture fed
through emergency hopper with the
help of dozer.

 For rest of consignment of biomass

pellets, feeding done through
emergency feeder in controlled manner
by adjusting rack and pinion gate and
covering grill proportionally,
thereafter, it’s blending (5% of
biomass pellets by weight) with coal at
TP.

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Unloading System For Co-firing-present

Provision of separate Biomass fuel handling system for continuous and uninterrupted
blending with coal

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Unloading System For Co-firing- future

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Biomass Feeding for Blending

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Reclaim Hoppers

Hopper

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Biomass Blending

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 Blending of biomass

TRACK HOPPER/
WAGON
TIPPLERS COAL BIOMASS
BLENDED
COAL
TRANSFE COAL
R POINT BUNKERS
FEEDING OF
RECLAIMIMG BIOMASS
OF COAL USING
USING S/R COAL EMERGENCY BIOMASS
HOPPERS BLENDED
COAL/ BIOMASS

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 SYSTEM ANALYSIS & MODIFICATION
SYSTEM ANALYSIS & MODIFICATION
 Milling system Motorised Inerting Valve

Coal Pipe Temperature points

 Control - Inlet temperature
 Installation - Add. Inlet temp. T/C
 Mill outlet temperature-> 60-65 C
 PA header pressure-> slightly higher than normal(800
MMWC)
 Fire protection : HAG closing - Inlet temp high(>195C)

 Mill Inerting system

 Installation - Motorized Inerting valve in each mill.
 Provision - Individual PF pipe temp sensor.
 Installation - Orifice in mill inerting lines.

ON/OFF
Biomass
Bio-Mass
Co-firing
Negligible impact
on Boiler 18
Efficiency

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Mill Parameters And Operation

• Mill outlet temperature-> 60-65 C

• Mill inlet temperature -> not more than 180 C

• PA header pressure-> slightly higher than

normal(800 MMWC)

• Pre start and post shutdown purging of mill is

mandatory.

• Continuous monitoring of mill parameters

most importantly mill inlet air temperature ,
mill outlet temperature, mill current and mill
DP

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Mill Parameters And Operation

• Mill reject system to be kept under observation

continuously

• Operator should be deployed at local for monitoring in

wake of fire hazard.

• In case of fire, mill should be tripped and steam

inerting should be done immediately by opening steam
inerting motorised valve, keeping watch on furnace
pressure. Fire tender may also be used if required.

• FG temperature in SH zone and APH FG outlet temp

to be monitored continuously.

• Clinkering and slagging tendency to be observed from

local as well as from rise in SH zone FG temperature.
Soot blowing and LRSB to be done accordingly.

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Boiler performance analysis

 Increase in exit flue gas temperature ~7 deg

 Increase in mill power

 Negligible Decrease in boiler efficiency ~0.33%

 Decrease of unburnt carbon ~ 10% in fly ash

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Biomass
Intimation by
CHP

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Change Over To Biomass Mode And Vice-versa

For operator ease Biomass On/OFF buttons have been provided on individual Mill
screen. Whenever Biomass ON is selected on screen then following changes
happen in the Mill logics-:
 Mill temperature control by CAD (cold air damper) of the mill shifts to Mill inlet
temperature control as per the Inlet temperature set point.
 Mill HAG (hot air Gate) will close on protection if Mill inlet temperature reaches
195 deg. Alarm for Mill inlet temperature is provided at 185 deg.

 HAG (hot air gate) protection at mill outlet temperature 95 deg will also remain
in service irrespective of Biomass ON/OFF mode.

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OWS Mimic of biomass mode

ON/OFF
Biomass
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Changeover to Biomass mode ON/OFF mode in OWS :

 Put the CAD& HAD control to manual mode.

 Ensure the set value for Mill temperature to 170-175 deg.
 Maintain the position of HAD & CAD so as to bring the actual Mill inlet
temperature in the set value range. Wait for temperature stabilization

 Select Biomass ON button.

 Put CAD & HAD in auto.

 Mill CAD control will shift to Mill inlet temperature.

 Bring the set value of Mill temperature near to actual running Mill outlet
temperature by manually adjusting the Mill HAD/CAD.
 Select Biomass OFF mode, CAD control will shift to Mill outlet temperature

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 •Do’s
• Call the CISF fire personnel for immediate assistance.
• Increase the feeder speed to maximum and dump the coal to
mill for few minutes.

Case Of • Stop the feeder after few minutes.

Fire • Close HAG from control room and CAG & Mill seal air
valve from local.

During • If the pulverizer temperature continues to rise, admit inert

steam by opening the motorized steam inerting valve from
control room.

Biomass • If fire occurs in the feeder then, close the feeder, seal air
valve and open the hydrant valve provided near individual

Co- feeder.
•Don’ts

Firing • Do not admit cold primary air in order to cool the mill.
• Do not expose any part of the mill (roller, scrapper chamber
and tramp iron gate for any inspection until the mill temp
comes down to normal value).
•

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Biomass Receipt & Unloading

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Biomass Storage

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Storage for Biomass Pellets @Dadri

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Torrefied Sludge Firing

5% AT DADRI- DATED 19-04-2022

 Torrefied Sludge Firing

• The torrefied sludge pellets received from Delhi Jal Board’s STP through truck and
packed in bags. The approx. weight is 30 MT received at Dadri STPP on 15.04.2022.

• GCV approx. 2300 Kcal/m3 (against the domestic coal of approx. 4000 kcal/m3 )

• Blending @5% done with coal Bunker D – unit#4 .

• No issues observed in operation. No spark or any abnormality observed in mill reject

outlet.
• Rate of co-firing was so low that no further conclusions could be derived.
 Benefits of Agro Residues Biomass Pellets

Description Savings
 Industrial Benefit
Natural Resource 21,000 ton Coal eq* • Conservation of Natural Resources.
Conservation • Green House Gas (GHG) reduction.
Green House Gas 27,598 ton CO2 eq* • Cost savings in ash handling.
emission reduction • Reduction in O&M cost for SO2
Ash evacuation & Rs 0.7 million/annum** emission control devices.
Transportation • Energy recovery from waste.
SO2 Emission Control Rs 18.2 million/annum**
Devices  Social Benefits / Skill Development
Energy Recovery 1,200 kWh/ton of • Employment opportunities in rural
from Waste Biomass pellet areas.
Farmers Benefit Rs 1,500 – 2,000 / acre • Opportunities for New business
for farmers.
* Project period – Five Months (Nov, 2019 – July 2022)
** Calculated on 100% PLF at 10 % blending for 210 MW unit • Development of Entrepreneurial
skills.

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 DADRI

THANK YOU!