BHEL'S Role in CCT

Bharat Heavy Electricals Limited, Tiruchirappalli
Power-Gen India, 2011 BHEL’s Role in Clean Coal Technology

Clean Coal Technology

Trends in Power Plant Engineering
Efficiency Improvement
 Sub Critical Cycle
 Super Critical Cycle
 Ultra Supercritical Cycle
Emission Control
 Particulate
 Sox (FGD)
 Nox
Alternate Fuels/ In situ control
 CFBC/ BFBC
Technology Development
 IGCC
 Oxy Combustion
 CO2 Separation
Collaboration, In-house R&D, Joint Development adopted, as appropriate

Trends in Power Plant Technology

Conventional Thermal Power generation has been
undergoing rapid advancement towards
 Improving the Efficiency of Power Generation
 Minimising atmospheric pollutants
 CO2 reduction, Capture and Storage

Fuels for Steam Power Plants
Coal & Lignite:
Abundant availability
Lower cost
Will continue as the main fuels in many countries including India

Trend in unit sizes & Cycle parameters

SHO/RHO
SHO Pressure Year of
Unit Size Temperature
(kg/cm2(a) Introduction
(Deg.C)
60 / 70 MW 96 540 1965
110 / 120 MW 139 540/540 1966
200 / 210 MW 137 / 156 540/540 1972
250 MW 156 540/540 1991
179 540/540 1979
500 MW
179 540/568 1985
540/540
600 MW 179 2008
540/568
660 MW 256 568/596 2008
700 MW 256 568/596 2010
800 MW 256 568/596 2008

Technology Development Over the Years

1960s Boiler design as per Czechoslovakian technology, 30 MW, 60 MW
1970s Technology from Combustion Engineering, USA; Unit capacities 110 MW,
210 MW – Low Pressure Steam cycle
1980s
Pressure ratings increased to achieve higher plant efficiency; Unit capacity
increased to 500 MW; Controlled circulation introduced for very high
pressures
Firing system design for Low NOx emission
Deteriorating coal properties led to increased tube erosion and
performance deviations; units redesigned for inferior coals. Tower type
boilers introduced for highly erosive coals


1990s
250 MW units developed
130 MW unit firing Steel plant by- product gas (Corex gas)
Boiler efficiency improvement by designing for low exit gas
temperatures

2000s
Technology tie up for Super critical steam generators with ALSTOM,

France
Introduction of IT based ‘Performance Analysis Diagnostic and

Optimisation” (PADO) for monitoring Power Plant performance and
optimisation
Designs for firing Washed Coals /Imported coals developed.

Technology Options
Pulverised Coal Combustion (PCC)

Fluidised Bed Combustion (FBC)
Circulating Fluidised Bed Combustion (CFBC)
Combined Cycle Gas Turbine/co-generation Plants
Integrated Gasification Combined Cycle (IGCC)

Pulverised Coal Combustion (PCC)

PCC is the most commonly used method in coal-fired power plants
and is based on many decades of experience.
The technology is well developed and understood and there are

thousands of units around the world.
Boiler design - two broadly different arrangements are used for PCC
boilers - conventional two-pass or single-pass tower type.

BHEL Utility Units - A Summary
Unit Rating, MW Contracted Commissioned
No. MW No. MW
30 4 120 4 120
60 16 960 16 960
67.5 9 607.5 8 540
70 14 980 9 630
80 14 1120 3 240
100 6 600 6 600
110 39 4290 39 4290
62 % Total
120 31 3720 27 3240 Installed
125 7 875 0 0
130 2 260 2 260
Capacity of
150 17 2550 0 0 India is
200 24 4800 20 4000
210 116 24360 112 23520
Contributed by
250 58 14500 29 7250 BHEL Utility
270 32 8640 0 0
500 83 41500 45 22500
Sets
525 6 3150 2 1050
600 20 12000 0 0
660 8 5280 0 0
700 1 700 0 0
800 4 3200 0 0
TOTAL 511 134213 322 69200
BHEL Industrial Units - A Summary

Unit Contracted Commissioned
VU 40 46 44
VU 40 S 15 15
VU 60 35 19
MU 3 3
VP 23 16
V2R 17 16
HRSG 161 121
AFBC 69 59
CFBC 25 9
Others 28 28
Total 423 330

Efficiency Improvement

Improvement in cycle efficiency with higher

steam parameters
Parameters at Turbine Inlet Increase in efficiency

(kg/cm2 / o C/ o C) (% points)
170 / 537 / 537 Base (500MW)
170 /537 / 565 0.75
247 / 565 / 565 1.31%
247 / 565 / 593 1.64%
247 / 600 / 600 1.96%

Boiler Parameters
(Sub-critical)
250 MW 500 MW 500 MW 600 MW 600 MW
Steam flow at SHO t/h 810 1625 1590 1950 2000
Steam pressure at SHO Kg/cm2 (g) 155 178 178 178 178
Steam temperature at 0C 540 540 540 540 540
SHO
Reheat steam flow t/h 696.2 1389.76 1358 1665.7 1613.8
Steam temperature at 0C 540 540 568 540 568
RHO
Feed water temperature 0C 247.2 254.6 254.5 254.6 280.3

NTPC / SIMHADRI STPP STAGE II -2 x 500 MW
Customer NTPC Limited
Project Simhadri STPP Stage II – 2 x 500 MW
Contract No. 0645 & 0646
Zero Date 26.03.07
Parameters at SHO / RHO
Steam Flow 1590/1353 t/h.
Pressure 178/42.7 kg/cm2 (g)
Temperature 540 / 568 oC
Fuel Coal
Major Auxiliaries
Mill 10 Nos. Bowl Mill, XRP 1003
PAH - 2 Nos. 27 .5 VI 2000, SAH-2
Airheater
Nos 30 VI 2000
FD Fan 2 Nos. AP 1 26/16, Axial Reaction
PA Fan 2 Nos. AP 2 20/12, Axial Reaction
ID Fan 2 Nos. NDZV 47 Sidor, Radial ( VFD )
Dust Collector 4 Nos. FAA – 10 x 45H- 2 x 90135 - 2

TNEB / NORTH CHENNAI TPP 1 x 600 MW

Customer TNEB
Project NORTH CHENNAI TPS –1 x 600 MW
Contract No. 1600
Zero Date 19.01.08
Parameters at SHO / RHO
Steam Flow 2000 / 1612.4 t/h.
Pressure 178/42.8 kg/cm2 (g)
Temperature 540 / 568 oC
Fuel Coal
Major Auxiliaries
Mill 9 Nos. Bowl Mill, XRP 1043
Airheater 32.5 VIMT 2000, TRI-SECTOR
FD Fan 2 Nos. FAF 24.5/11.8-1, Axial Reaction
PA Fan 2 Nos. PAF 20/10.6-2, Axial Reaction
ID Fan 2 Nos. NDZV 47 Sidor,Radial [VFD]
Dust Collector 4 Nos. FAA-10x37.5M-2x112150-2

Contracts under execution Offering 540/568 Deg. C Subcritical boilers

NCTPP Dadri 1 x 490 MW
NTPC Simhadri - St II- Unit -3 & 4 - 2 x 500 MW
APCPL Aravali - unit 1, 2 & 3 - 3 x 500 MW
NTECL Vallur TPP - unit1 & 2 - 2 x 500 MW
Mauda TPP- Unit 1 & 2 - 2 x 500 MW
NTPL Tuticorin TPP-Unit 1 & 2 - 2 x 500 MW
NTPC RIHAND-UNIT 5 - 2 x 500 MW
NTPC VINDHYACHAL-UNIT 11 & 12 - 2 x 500 MW
NTECL Vallur TPP 1 x 500 MW
WBPDCL Sagardighi Ph. II 2 x 500 MW

Contracts under execution Offering 540/568 Deg. C Subcritical boilers
TNEB - North Chennai 2x600 MW

APGENCO - Kakatiya 1x600 MW
JITPL - Jindal India 2x600 MW

Restoring the design level performance thru’ R&M

Improvement in PLF
Addressing current coal quality
Implementing current design like
 Membrane wall furnace
 Upgradation of Pressure Part materials
Regenerative Air pre heater
 High efficiency fans
 More reliable and Higher Efficiency ESPs

Using Advanced Steam Cycles to

Improve the Environmental & Economic
Performance of India’s Power
Generation

Once Through Supercritical Technology for

Higher Unit Ratings 660 MW to 1000 MW
BHEL under license from Alstom offers Once through supercritical
technology to Indian power utilities with the following benefits
 Increased efficiency
 Lower Fuel consumption
 Lower emission levels of CO2 NOX SOX
 Lower operating costs
 Greater operational flexibility
These benefits are possible because of the higher steam pressures
and temperatures which are the hallmark of the technology

Offering 660/800 Once thro’ supercritical boilers in collaboration with Alstom

Contracts under execution
NTPC / BARH 2 x 660MW
PPGCL / BARA 3 x 660 MW
KPCL / Bellary 1 x 700 MW
14 Boilers
APPDCL / Krishnapatnam 2 x 800 MW
Contracted
RPCL / Yermaras 2 x 800 MW
LPGCL/Lalithpur- BHL 3 x 660 MW
RPCL / Edlapur 1 x 800 MW
BHEL has geared up to

meet the planned capacity
addition in the country

NTPC / BARH 2 x 660MW

APPDCL / Krishnapatnam 2 x 800 MW

PPGCL / BARA 3 x 660 MW

RPCL / Yermaras 2 x 800 MW

Furnace Wall Designs
Spiral Wall Configuration Vertical Wall Configuration

Spiral Wall
Windbox
Comanche #3 Supercritical Boiler with Vertical wall

Unit Mwe: 750
Max. Continuous Rating: 5,560,000 lb/hr (2522 t/hr)
SH Outlet Press: 3800 psig (262 bar)
SH Outlet Temp: 1054°F (568°C)
RH Outlet Temp: 1105°F (596 °C)
Fuel: Sub-bituminous (PRB)

Vertical Wall Sliding
FRONT WALL
Pressure Supercritical Design
SIDE WALL
RIFLED TUBING
RIFLED TUBING SCREEN TUBES
SMOOTH TUBING
HANGER TUBES
SMOOTH TUBING
ARCH
RIFLED TUBING
1 1/4” (31.8 mm)O.D. Tubing
1 1/8” (28.5 mm)O.D. Tubing

SIDE WALL
RIFLED TUBING
REAR WALL
RIFLED TUBING
FRONT WALL
RIFLED TUBING
SMOOTH TUBING
FROM THIS ELEVATION
ALL WALLS

Spiral vs. Vertical Wall Comparison
• Spiral Furnace System • Vertical Furnace Wall System
Applicable for all size units Limited to larger capacity units
• Benefits from averaging of (>700 MW depending on fuel)
lateral heat absorption variation • Less complicated windbox
(each tube forms a part of each openings
furnace wall) • Traditional furnace water wall
• Simplified inlet header support system
arrangement • Elimination of intermediate
• Large number of operating units furnace wall transition header
• Use of smooth bore tubing • Less welding in the lower furnace
throughout entire furnace wall wall system
system • Easier to identify and repair
• One material utilized tubes leaks
throughout entire waterwall • Lower water wall system
system pressure drop thereby reducing
• No individual tube orifices – required feed pump power
Less maintenance & pluggage
potential

Advanced Ultra Super Critical Plants
Gearing-up to introduce Advanced Ultra

supercritical boilers (AUSC)
AUSC Boilers (300 ata, 700 C / 700 C) will

be developed based on OTSC technology
Test Facility (400 bar, 700 Deg. C) installed

and tests are on to collect critical design
data
BHEL is one among the Five MNC’s to have

this facility
Member of the National Technology

Mission program to install AUSC plant by
2017

Emission Control

Current Pollution Control Systems- Typical

SCR for > 85 % NOx
reduction
Low NOx Burner
for 50 % reduction
FGD for > 90 % Dust collection to

reduction of SO2 meet standard
Particulate Emission Trend
450
Emission mg/Nm3
275
150
100
50
20
Year

Particulate Emission
TNEB / North Chennai, 600 MW <50 mg/Nm3
MAHAGENCO / Bhusawal, 500 MW <50 mg/Nm3
KWPCL / Avantha, 600 MW <50 mg/Nm3
KNPCL / Vizag, 520 MW <50 mg/Nm3
Visa Power, 600 MW <50 mg/Nm3
JITPL / Derang, 600 MW <50 mg/Nm3
Aravali # 1,2 & 3, 500 MW <21 mg/Nm3
NTECL / Vallur # 1, 500 MW <19 mg/Nm3
Rihand # 5 & 6, 500 MW <18 mg/Nm3
Bongaigaon, 250 MW <18 mg/Nm3
Vindhyachal # 11 & 12, 500 MW <17 mg/Nm3

BHEL supplied Bag Filter Systems

SL. EMISSION,
CUSTOMER APPLICATION
NO mg/Nm3
01 BHEL / HARDWAR Electric Arc Furnaces – Fume extraction
India system (Water cooled hoods, Gas cooler, 100
FF, ducts, Fan, chimney)
02 MAHAGENCO, India KORADI TPS, Unit – 5,
200 MW – Coal fired boiler (Retrofit FF in
ESP casing, Water spray system, Implosion 40
protection system, ID fan, duct, Gates,
furnace pressure control)
03 ISPAT SIDEX, ROMANIA Cast house de -polluting system, Romania,
ambient and source limits (Hoods, duct, FF, 20
Fan, chimney)
04 Koniambo Nickle Project, CFBC-Coal
New Caledonia 30

Bypass Over Fire Air (BOFA) System
Development of “Bypass Over Fire Air (BOFA) System” to reduce

NOX emission by about 40%.

NOx Reduction
BOFA
duct
In Furnace Low Excess air Air staging

Post Combustion Selective Catalytic Reduction

Overview of Firing Systems
NOx < 0.18 – 0.30 kg/MKcal*

Furnace
Diagonal
Close-Coupled
Overfire Air
Separated CFS Air Nozzle Tips

Overfire Air
HP Pulverizer Flame Attachment

with Dynamic Coal Nozzle Tip
Classifier
*NOx at furnace outlet

Separated Overfire Air
Lower SOFA
in Corners
Tilt
+/-30o
Yaw
+/-20o
Upper SOFA
on Walls

Benefits of Low NOX Design Strategy

Retention of all the inherent benefits of tilting tangential firing
CFS provides waterwall cleanliness/protection from corrosion
SOFA yaw enable greater emissions and unbalance control
LNCFS technology yields the lowest NOX

FGD in India – An overview

National Ambient Air Quality Standard revised in November 2009. Industrial
and Residential area are combined and the ambient air standard norms for SO2
are reduced.
Sulphur in Imported Coal high compared to Indian coal
In all the 660 /800 MW Projects, space provisions are made to install FGD at
later date.
FGD retrofit a distinct possibility in future
FGD Projects
 Saint Gobain glass India Semi Dry – 800 mg/Nm3
 Trombay Unit 8 – 250 MWSea Water – 70 mg/Nm3
 NTP Bongaigaon 3x250 MW Wet Lime – 280 mg/Nm3

NTPC Bongaigaon – 3x250 MW FGD

CFBC/ BFBC Boilers for Alternate Fuels

Alternate Fuels
Alternate fuels
High sulphur coals
Coal Washery Rejects
Waste coal from Steel plants
Lignite
Petcoke
Biomas
Fluidised Bed Combustion (bubbling/circulating) Steam Generators

suitable for the above fuels; The process ensures lower emission with In-
situ control of Sox, NOx
About 65 BFBC , 8 of 125 MW and 4 of 250 MW CFBC

Steam Generators contracted. Two 135 MW CFBCs under export

BASIC FLOW DIAGRAM OF A CIRCULATING

FLUIDIZED - BED COMBUSTION BOILER (CFBC)

SLPP 4 x 125 MWe CFBC Boiler NLC-Neyveli 2 x 250 MWe CFBC

Boiler

BILT, Bhigwan (1 x 175 t/hr )

SLPP, Mangrol, (4 x 125 MW)
RVUNL, Giral, (2 x 125 MW)
GACL, (3 x 135 t/hr)
BORL, Bina, (3 x 275 t/hr)
NLC, Barsingsar, (2 x 125 MW)
NLC, Neyveli, (2 x 250 MW)
BECL, Bhavnagar, (2 x 250 MW)
PT IBR, Indonesia, (1x120 t/hr )
Koniambo Nickel SAS, New Caledonia, ( 2 x 135 MW)
PT MSW, Indonesia, ( 2 x 30 MW )
27 Boilers Contracted. 19 in operation.

PDMS Model of Koniambo Nickel 2x135 MW CFBC Boiler

JSPL 2 x 165 tph BFBC Boiler

JSPL, ( 3 x 180 t/hr – Largest capacity )

JSPL, ( 4 x 165 t/hr – Rejects fired)
PSEB, ( 1 x 10 MW - Straw fired)
BSSL, (1 x 120 t/hr, 2 x 75 t/hr)
TISCO, (1 x 56 t/hr, 2 x 62 t/hr, 1 x 75 t/hr)
JAL, (1 x 125t/hr, 1x 150 t/hr)
ACC, (4 X 40 t/hr)
TNPL, (2 x 40 t/hr-Bagasse & Pith fired)
PT IBR Indonesia, ( 3 x 17 MW )
PT MP, Indonesia, ( 3 x 18 MW )
66 Boilers Contracted. 60 in operation.

Integrated Gasification Combined

Cycle (IGCC)

6.2 MW IGCC Plant at CCDP

BHEL pilot scale fluidized bed gasification test facility
Coal throughput 18 T / DAY
Gasifier diameter 450 mm
Gasification media AIR / Steam mix
Gasification temp. 1000ºC
Gasification pr. 11 kg / cm2

Gas calorific value 1000-1100 Kcal / Nm3

BHEL’s 6.2 MW demo plant with fluidized bed

technology
CAPACITY OF THE CCDP PLANT 6.2 MWe( 4 MWGT+2.2MW ST)

PRESSURIZED FLUIDIZED BED
150 TPD coal
GASIFICATION
COAL FEED SIZE (0-6mm)
OPERATING PRESSURE 10 Kg/cm2 (g) (980.65 KPa)
GASIFICATION MEDIA Air / Steam Mix
OPERATING TEMPERATURE MAX. 1100º C
GAS CALORIFIC VALUE (HHV) 1000 – 1200 (Kcal / Nm3)

ADVANTAGES OF FLUIDISED BED GASIFIER

Higher unit capacity
Inbed sulfur removal option
No tar or oil formation and easy gas cleaning
No liquid effluent formation
Ability to accept finer coals
Capability to accept all types of coals
Better reliability and control
Operates in non-slagging mode unlike entrained bed gasification
Best suited for high ash Indian coals
Lower capital and operating cost compared to entrained bed gasifier

IGCC Development
PFBG pilot Plant PFBG Retrofit Proposal for 182 MW IGCC
Studies to 6.2 MW Scale up Demonstration
(18TPD PEDU) CCDP Plant - APGENCO
Studies in APFBG
6.2 MW IGCC Research Gasifier
Pilot Plant
(CCDP) with
Moving Bed
Gains
Gasifier
PFBG gasification technology
Gains for Indian coals established.
Design & Operation of Design parameters met/exceeded
Gasifier & Wet gas Clean up
System Integration

As the climate change is pressing for cleaner power generation and as the
reliability of IGCC process is increasing, it is clearly evident that IGCC will
be one of the future technologies for green power generation.
IGCC plant cost is higher at this point of time as compared to PC boilers

without gas cleaning but as the emission standard and carbon capture
increases IGCC plant will have more advantage.
Improvement and development in technologies like gas turbine, hot gas

clean up, gasifier will make IGCC more competitive for power generation.
BHEL gained lot of experience via continuous operation of the gasifier

island for the past one year and is geared fully in commercializing the
technology for higher size plants.


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Bharat Heavy Electricals Limited, Tiruchirappalli

Power-Gen India, 2011 BHEL’s Role in Clean Coal Technology

Clean Coal Technology

Collaboration, In-house R&D, Joint Development adopted, as appropriate

Trends in Power Plant Technology

Power-Gen India, 2011 BHEL’s Role in Clean Coal Technology

Fuels for Steam Power Plants

Coal & Lignite:

Will continue as the main fuels in many countries including India

Power-Gen India, 2011 BHEL’s Role in Clean Coal Technology

Trend in unit sizes & Cycle parameters

Power-Gen India, 2011 BHEL’s Role in Clean Coal Technology

Technology Development Over the Years

Power-Gen India, 2011 BHEL’s Role in Clean Coal Technology

Technology Development Over the Years

Power-Gen India, 2011 BHEL’s Role in Clean Coal Technology

Technology Development Over the Years

Technology tie up for Super critical steam generators with ALSTOM,

Introduction of IT based ‘Performance Analysis Diagnostic and

Designs for firing Washed Coals /Imported coals developed.

Power-Gen India, 2011 BHEL’s Role in Clean Coal Technology

Pulverised Coal Combustion (PCC)

Power-Gen India, 2011 BHEL’s Role in Clean Coal Technology

Pulverised Coal Combustion (PCC)

The technology is well developed and understood and there are

Power-Gen India, 2011 BHEL’s Role in Clean Coal Technology

BHEL Industrial Units - A Summary

Power-Gen India, 2011 BHEL’s Role in Clean Coal Technology

Power-Gen India, 2011 BHEL’s Role in Clean Coal Technology

Improvement in cycle efficiency with higher

Parameters at Turbine Inlet Increase in efficiency

170 /537 / 565 0.75

247 / 565 / 565 1.31%

247 / 565 / 593 1.64%

247 / 600 / 600 1.96%

Power-Gen India, 2011 BHEL’s Role in Clean Coal Technology

Power-Gen India, 2011 BHEL’s Role in Clean Coal Technology

Power-Gen India, 2011 BHEL’s Role in Clean Coal Technology

TNEB / NORTH CHENNAI TPP 1 x 600 MW

Power-Gen India, 2011 BHEL’s Role in Clean Coal Technology

Contracts under execution Offering 540/568 Deg. C Subcritical boilers

Power-Gen India, 2011 BHEL’s Role in Clean Coal Technology

Contracts under execution Offering 540/568 Deg. C Subcritical boilers

TNEB - North Chennai 2x600 MW

Power-Gen India, 2011 BHEL’s Role in Clean Coal Technology

Restoring the design level performance thru’ R&M

Power-Gen India, 2011 BHEL’s Role in Clean Coal Technology

Using Advanced Steam Cycles to

Power-Gen India, 2011 BHEL’s Role in Clean Coal Technology

Once Through Supercritical Technology for

Power-Gen India, 2011 BHEL’s Role in Clean Coal Technology

Offering 660/800 Once thro’ supercritical boilers in collaboration with Alstom

BHEL has geared up to

Power-Gen India, 2011 BHEL’s Role in Clean Coal Technology

NTPC / BARH 2 x 660MW

Power-Gen India, 2011 BHEL’s Role in Clean Coal Technology

Power-Gen India, 2011 BHEL’s Role in Clean Coal Technology

PPGCL / BARA 3 x 660 MW

Power-Gen India, 2011 BHEL’s Role in Clean Coal Technology