Sustainable Power Plant TechnologiesSustainable Power Plant Technologies

R. K. Jain Director (Technical)

NTPC Limited

towards mega-growth and cleaner environment

International SymposiumNew Energy Markets 2006

Gelsenkirchen

2

OutlineOutline

• Indian Power Scenario

• Fuel Options

• Technology Options

• Large Capacity Addition

• Renewable Energy

• Renovation & Modernization

• Equipment Suppliers / Manufacturers Issues

• Challenges & Cooperation Areas

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Giant strides made in Indian electricity sector in Giant strides made in Indian electricity sector in past few decadespast few decades

v Installed capacity has increased to 1,27,423 MW as on September 2006

v Despite this phenomenal increase, power supply continues to remain short of requirement (8.0% energy shortage, 12.2% peak power shortage) with per capita consumption of just 606 kwh/year

v India’s Projected Growth is > 8% of GDP – Projected power requirement by year 2012:

v Per capita consumption 1000 units per annum

v Installed capacity over 2,00,000 MW

v Projected power requirement by year 2032:

v Per capita consumption about 3000 units per annum

v Installed capacity about 6,00,000 to 7,00,000 MW

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Future Power demand will grow at even more faster Future Power demand will grow at even more faster pace to meet the demand of growing economy …pace to meet the demand of growing economy …

This necessitates :This necessitates :vv Looking into Fuel options with respect to it’s Looking into Fuel options with respect to it’s

characteristic and availability in Indian conditionscharacteristic and availability in Indian conditionsvvTechnology options with respect to fuel, improved Technology options with respect to fuel, improved

efficiency and environmental performanceefficiency and environmental performancevvSustainable Large Capacity Addition Program at Sustainable Large Capacity Addition Program at

affordable priceaffordable pricevvEmphasis on Renewable energyEmphasis on Renewable energyvvUpgrading fleet of Old Power Stations which are Upgrading fleet of Old Power Stations which are

inefficient and have poor availabilityinefficient and have poor availabilityvvManufacturers / Suppliers development and Manufacturers / Suppliers development and

availability availability

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Fuel Options Fuel Options -- Coal Coal

• Proven coal reserve of about 96 billion tons

• Being the cheapest and indigenously available fuel, it will remain the mainstay fuel for power generation in India for many more years

• Ever-evolving environment policy will dictate more and more cleaner use of coal : Clean Coal Technologies

• Ultra-supercritical and IGCC technologies, which are still under development stage, will be the future technologies for coal based power generation

• Ultimate aim is to achieve near “zero emission technologies”. One such initiative is “FutureGen” to build world’s first coal based, zero emission plant.

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Indian Coal Scenario: DemandIndian Coal Scenario: Demand--Supply positionSupply position……

361.16382.13

421.5

576.38

380.9404.19

473.18

676

0

100

200

300

400

500

600

700

800

03-04 Actual 04-05 Actual 06-07 Projected 11-12 Projected

Indigenous Supply Demand (All India)

(Figures in MTs)• Indian coal Reserves Inventory: 253

BT (only 96 BT proven). 81% production from Open cast mines.

• 75% Coal is consumed by Power Sector as domestic coal is the cheapest option

• Projected shortage of about 99 MT in 2011-12

• However, GOI’s “Vision Coal 2025”envisages meeting the demand of steam coal by 2012 by introduction of advanced technologies for improved productivity. It also provides opportunity for Captive use

Source: Ministry of Coal, GOISource: Ministry of Coal, GOI

Meeting the coal shortfall:

Short Term - Through imports

Long Term - Involvement of more players, absorption of latest mining technology and acquiring overseas coal mines

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Indian CoalIndian Coal

n Indian coal is characterized with extremely abrasive high ash (30-45%) and low CV (2800-3800 kcal/kg), but with low sulphur(0.2 – 0.5%)

n Ash fusion temperature range - 1100-1400 deg C

n Major problems with this type of coal is low furnace absorption, high spray, high tube metal temperature, slagging/clinkering tendency , erosion leading to tube failure

n Furnace sizing to be coal specific due to slagging

n Low flue gas velocity (max 10 m/s)

n Adequate additional tube erosion allowance

n Super heater tube material selection for higher duty

n Generous sizing of bottom ash handling system

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Coastal Thermal Power StationsCoastal Thermal Power Stations

n High capacity sea transportation from Eastern Coal Mines for Coastal Stations

n Coastal Stations based on imported / blended coal

n Imported coal can reduce the gap between the coal demand and domestic production

Scarcity of sites

Limited availability of water

Rail Transportation Bottleneck

COASTAL THERMAL

POWER STATIONS

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Fuel Options Fuel Options -- Gas & Oil Gas & Oil

• Limited reserves available for oil and gas

• Oil reserves of around 786 Million Tons

• Gas reserves of around 1101 Billion Cubic Meters

• Use of gas can be increased in India’s energy mix with new finds of gas reserves and LNG imports

• Gas based combined cycle power generation is relatively environment friendly

• High efficiency, advanced class gas turbines for gas based powergeneration

• However long term availability of Gas at affordable price is thekey

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Fuel Options Fuel Options -- HydroHydro

• Renewable and emission free source of power generation

• Out of available potential of 148,701 MW, only 33,003 MW (22.2%) tapped so far with 15,655 MW (10.5%) under various stages of construction (As on 31.08.2006)

• GoI’s 50,000 MW initiative

•Pre FR for 163 schemes completed

•DPR for 73 Schemes (34,020 MW) taken up

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Fuel Options Fuel Options -- Nuclear Nuclear

• Nuclear energy has the potential to meet future needs of electricity demand in the country.

• Current nuclear generation capacity is only 3900 MW with 16 reactors in operation and 7 reactors under construction. By the end of 12th

plan, 10,000 MW of nuclear capacity is to be added.

• In order to achieve the target of generating 20,000 MW of nuclear electricity by the year 2020, nearly 46 reactor units should be operational. Long term target is of 40,000 MW of nuclear electricity by 2030.

• Uranium reserves in India is 67,000 T and Thorium reserves is 2,90,000 T. Thorium deposits can sustain about 300,000 MW of power generation capacity for about 300 years.

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Nuclear Power Nuclear Power -- Three Stage ProgramThree Stage Program

n The first stage of indigenous Uranium based , PHWR based power generation capacity needs to be completed

n The second stage of fast breeder reactor technology based generation will be dependent on Plutonium extracted from spent fuel of the first stage

n In the third stage, country’s vast thorium resources will be utilized for power generation

12 GW

30 Yr

300 GW

30 Yr

500 GW

500 Yr

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TechnologyTechnology

• Adopting higher unit size supercritical steam (SC) and ultra-supercritical (USC) conditions to improve Rankine Cycle efficiency

• Improving Joule Brayton Cycle efficiency by adopting higher firing temperature in gas turbines

• Fluidized Bed Combustion technology (FBC) for burning low grade high ash coals & lignite

• Integrated Gasification Combined Cycle (IGCC) for improved efficiency and environmental performance

• Renewable Resources specially Wind Power

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Induction of Large Unit Sizes essential for rapid Induction of Large Unit Sizes essential for rapid capacity addition envisaged during capacity addition envisaged during XXthth and and XIXIthth Plan..Plan..

nHigher unit size offers following advantages

Ø Faster capacity addition in terms of MW / year

Ø Reduction in Capital Cost due to Economy of Scale

Ø Lower Cost of Generation

Ø Reduced Land Requirement

Ø Reduced Manpower Requirement

Ø Better suited to supercritical steam parameters with Increased efficiency

Ø Lower Green House Gas Emissions

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n Technology is quite mature as most of the units are operating for last 10 to 30 years

n Main steam pressure of these units is in the range of 240-250 Kg/cm2

n Units built in 1970s have MS/RH temperature of 540/540

n Units built in late 1990s have MS/RH temperature of 566/593 or 593/593

n Ultra super critical units are in Japan, Germany, Denmark & USA

n Work on ultra supercritical parameters for pressure over 300 Kg/cm2 and temperature over 700 Deg C is in progress under THERMIE program in Europe and Project Set 66 C in USA

Technology of 800 to 1000 MW Size Units installed Technology of 800 to 1000 MW Size Units installed worldwideworldwide

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Cost ComparisonCost Comparison

3 X 660

3 X 800

2 X 1000 247/537/565

247/565/565

247/565/593

247/593/593

1.048

0.999

0.962

1.038

0.990

0.953

1.029

0.980

0.944

1.019

0.971

0.935

0.860

0.880

0.900

0.920

0.940

0.960

0.980

1.000

1.020

1.040

1.060

Rel

ativ

e C

ost

Unit Size

Steam Parameters

Cost / KW Vs Unit Size & Steam Parameters

247/537/565247/565/565247/565/593247/593/593

Unit Cost / KW of 500 MW size units with 170/537/537 steam parameters = 1.0 (Base)

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Thermal Efficiency Improvement by Steam Thermal Efficiency Improvement by Steam Parameter EnhancementParameter Enhancement

MS Pressure Kg/cm2

6000C / 6200C (41.20%*)

5380C / 5380C (39.29%*)

5380C / 5660C (39.56%*)

5660C / 5660C (39.91%*)

6000C / 6000C (40.56%*)

Eff

icie

ncy

5380C / 5380C (38.60%*)

170 246 316

5660C / 5930C (40.24%*)

* Gross Efficiency on HHV Basis

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SubcriticalSubcritical Vs SupercriticalVs Supercritical(A Comparison)(A Comparison)

2.1%BaseCO2 Emissions

4.3%BaseCoal Consumption

2.1%BasePlant Efficiency

2.1%BaseSO2 Emissions

1.5%BaseCost of Boiler & Turbine Generator Block

246/538/566169/538/538Steam Parameters

(ata / Deg.C/ Deg.C)

660 MW Unit Size

(Supercritical)

500 MW Unit Size

(Subcritical)

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Supercritical Technology Supercritical Technology -- StatusStatus

• More than 500 Units of various sizes operating worldwide

• Material technology matured up to 600 Deg.Ctemperature

• Availability of the order of 88 – 90% which is comparable with that of subcritical units

• European union working on program “AD 700” which aims at temperature up to 700-720 Deg.C

• First supercritical unit in India targeted to be commissioned in 2007 by NTPC

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n A large group of major suppliers to the power industry and a number of leading utilities in Europe, proposed a demonstration project"Advanced ("700°C") PF Power Plant" to the THERMIE programme in January 1997.

n Schedule for AD700 - Design & Construction of Demonstration plant by 2011 & Demonstration by 2012-14.

n The power plant will be coal-fired, achieving an efficiency of up to 55 % with approximately 400 MW and the steam parameters 700 °C/720 °C/350 bar. Compared with a coal-fired power plant with an efficiency of 35 %, this will yield a reduction of greenhouse gases of roughly 30 %.

n The aim of the project is to break the “Steel Barrier" and introduce new nickel-based super-alloys for the hottest areas of the steam cycle - named the 2010 cycle - where boiler outlet temperatures should be raised to 700°C.

n High chromium steels are not suitable any more for such steam conditions. As a consequence nickel based alloys or cobalt basedalloys are necessary which are capable to achieve the required creep and yield strengths in such temperature regions.

Development Initiatives in Europe (AD700 )Development Initiatives in Europe (AD700 )

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Super Alloysstarting 2010700

650

600

550

(EC)

250 300 350 400 (bar)

Main steam pressure

Main steam temperature

P92starting2001

P91since late 80's

X20sinceearly60's

The Steel Barrier

The Steel BarrierThe Steel Barrier

Further enhancement in steam parameters is restricted Further enhancement in steam parameters is restricted by the steel barrierby the steel barrier

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Challenges in setting up large unit sizesChallenges in setting up large unit sizes

n Low calorific value of Indian coal

n Higher ash content in coal

n Abrasive ash quality

n Availability of Indian manufacturers/vendors/sub-vendors for large capacity auxiliaries

n Design Changes

n Amendments required in Indian codes and regulations to keep pace with changes in supercritical technology

n Transport Limitations

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Challenge in setting up UltraChallenge in setting up Ultra--supercriticalsupercritical

Ultra-supercritical technology with pressure 320 bar and above, steam temperatures in excess of 650OC involves lot of R&D work on the metallurgy front and associated welding and manufacturing technology

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Recent Advancements in Gas Turbine TechnologyRecent Advancements in Gas Turbine Technology

Turbine Inlet Temperature• The turbine inlet temperatures have been increased from 1100 deg.C in

recent past to 1450 deg. C with more sophisticated gas path cooling which is the main reason for the increase in combined cycle efficiency by almost 10-12 % points, from 46% to 58%

Compressor• Pressure ratios increased from 11 to almost 30• Aerodynamic blade design introduced

Blading• Serpentine and turbulated cooling passage in blades• Film cooling design of blades

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Gas Turbine Inlet Temp. TrendsGas Turbine Inlet Temp. Trends

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IGCC TechnologyIGCC Technology

• Indian Coal necessitates another promising clean coal technology based on gasification of coal

• Advantages are its ability to use low grade high ash Indian Coal, lower SOx and NOx emissions

• Overall efficiency in the range of 38% for Indian Pilot Plant with potential to improve (40-42%) further with improvements in gas turbine technology. The auxiliary power consumption of IGCC plant is of the order of 12-14%

• The technology is costlier than conventional PC technology

• Carbon conversion is 85-90% and is expected to be better in commercial gasifier

• The HHV of syngas from air blown fluidized bed gasifier is expected to be in the range of 1050 to 1250 kcal/Nm3

• Technology for low grade coal is under development

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Integrated Gasification Combined Cycle (IGCC)Integrated Gasification Combined Cycle (IGCC)

Ash

Gasifier

steam

steam

HEAT RECOVERY BOILER

HRSG

Stack

syngas GAS CLEANING SYSTEM

GT

GT Exhaust Gas

syngas syngas

syngas

ST

Condenser

Saturated steam

Air

COAL

Water

Air

Comp

Air

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NTPC Efforts in IGCCNTPC Efforts in IGCC

100 MW IGCC DEMO PLANT AT NTPC-DADRI

FEASIBILITY STUDY BY NEXANT

INDIGENOUS IGCC TECHNOLOGY DEVELOPEMENT

AND SETTING OF 100 MW IGCC DEMO PLANT AT NTPC-AURAIYA

JOINT EFFORT BY NTPC-BHEL AND R&D COMMITTEE

Phase-A

Comparison of IGCC with other technology

Phase-B

IGCC technology selection for Indian coal

Phase-C

Draft Feasibility study for 100 MWe IGCC Demonstration Plant at Dadri – Final report by end Nov. 2006

• Site Identified

• EIA and Topographical studies completed

• Final DPR under preparation

Issues

• Scale up for 100 MW IGCC Gasifier• Development of cold gas clean up system

• Establishing the reliability of Critical components

• Improving IGCC efficiency

• Low CV and Unburnt Carbon

Indigenous EffortsInternational Cooperation

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Advanced/New Technology Initiatives Advanced/New Technology Initiatives -- IGCCIGCC

nIGCC offers opportunity to utilize coal in high efficiency combined cycle

nDue to higher efficiency, suitability for carbon capture and ease of capturing other pollutant IGCC is promising technology.

Utilization of high ash Indian coal offers special challenges, Co-operation in the field of following will be useful:

• Coal Gasification

• High ash Indian coal require use of fluidized bed gasifiers which need to be developed . Gasifiers experience worldwide (Entrained bed and Moving bed) may not be very much relevant for Indian coal

• Hot gas cleanup system

• Hot gas clean-up system is vital for higher IGCC efficiencies, which is essential to establish its commercial viability

• Hot gas clean-up system, as suited for high ash Indian coal needs to be developed

• Gas Turbine for low CV Syngas

• Air-blown Fluidized bed gasifiers for Indian coals produce comparatively low CV gas

• Development of appropriate gas turbine to utilize low CV syngas is essential for commercial viability of IGCC which otherwise has to depend on oxygen blown gasifiers/air-enrichment, making it expensive

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Plant Performance & Costs : Comparative AnalysisPlant Performance & Costs : Comparative Analysis

-

42.2

Ultra supercritical

+80 % -+12 %-30%+3 %BaseCapital Cost

3843.8385439.238.2Efficiency, %

IGCC, F Class Turbine

PFBCCFBCCombined Cycle Gas Turbine*,

F Turbine

Super Critical PC

Sub Critical PC

Plant Performance & Costs

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RENEWABLE ENERGY ALTERNATIVES

n Solar Photo Voltaic (SPV)

n Biomass based engines

n Mini and Micro hydro

n Ocean Thermal and Ocean Wave Technologies

n Geothermal Energy

n Wind energy

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WIND ENERGYWIND ENERGY

n Technology mature & proven & already commercialized in India

n Capacity Range 225 kW to 3.5 MW

n OEMs, Manufacturing base & testing facilities available indigenously

n Capital costs : 4 crore / MW, Cost of Generation : Rs. 2.75 / kWh

n Fiscal incentives by state governments

n Indian Electricity act – 2003 clearly states promotion of renewable energy

n CDM benefit

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Wind Power Potential in IndiaWind Power Potential in India

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Renovation & ModerationRenovation & Moderation

c Capacity enhancement

c Sustenance of performance level

c Life extension of old units

c Mitigate obsolescence

c Compliance to applicable pollution norms

c Equipment safety

c Improvement in equipment / system reliability

After 100,000 operating hours machine become due for R&MR&M offers a quick and low cost capacity addition option (1.0-1.25 Cr/MW as compared to 4.0-5.0 Cr/MW for new built)R&M objectives are:

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R&M and ReR&M and Re--poweringpowering

nn R&M will involve up gradation of milling system, APH, ESP, R&M will involve up gradation of milling system, APH, ESP, firing system etc and refurbishment of turbine, condenser, firing system etc and refurbishment of turbine, condenser, pressure parts, fans etc. pressure parts, fans etc.

nn ReRe--poweringpowering may involve following changes in plant design may involve following changes in plant design ::

ØØ Adoption of higher steam parameters Adoption of higher steam parameters

ØØ Introduction of topping cycle, old turbine may be Introduction of topping cycle, old turbine may be retained in bottoming cycle.retained in bottoming cycle.

ØØ Bottoming turbine cycle efficiency improvement by Bottoming turbine cycle efficiency improvement by adoption of high efficiency blade designadoption of high efficiency blade design

Re-powering is challenging from technology as well as engineering point of view and offers huge potential for Indo European

cooperation

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Equipment Suppliers / Manufacturers Equipment Suppliers / Manufacturers -- IssuesIssues

n Few equipment Supplier / Manufacturersn Restricted Competition

n High Price

Measures

n Develop Indigenous Supplier & Manufacturers

n Ensure Technology Transfer

n Allow Joint Venture Route

n Promote Healthy Competition

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Augmentation of Manufacturing & Design capacityAugmentation of Manufacturing & Design capacity

§Present design and manufacturing capability may be constraint for targeted huge capacity addition program

§Manufacturing capacity for higher parameter Steam Generators andlarger size turbo generator

§Enhancing Design and manufacturing capacity for Auxiliaries such as:

Ø High capacity mills

Ø High capacity Fans

Ø High capacity Pumps

Ø Material handling system

Ø Ash handling system etc.

§Diversity of manufacturing source is essential for competitiveness of Indian power sector

§Setting up of manufacturing facility by Companies from EU as wholly owned subsidiary or through joint venture shall fulfill the above requirements

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ChallengesChallenges

n Huge capacity addition at fast pace and at higher efficiency

n Augmentation of manufacturing & design capacity for Indian coal based power plants

n Sustainability of coal based power generation from environmental point of view

n Mining of coal to meet the desired power output

n Enhancing the competence of Indian Power Sector

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CoCo--operation in Efficiency Improvement Avenuesoperation in Efficiency Improvement Avenues

n Adoption of supercritical units

Ø NTPC has adopted supercritical technology (256 bar/ 540 oC MS/568 oC RH) for coal based power plants. Two projects at Sipat and Barh are already under execution. It is now proposed to adopt next higher unit size of 800 MW capacity

Ø European Union has experience with much higher steam parameter

Ø Co-operation in the field of adoption of ultra-supercritical parameters (like 310 bar / 620 oC MS/620 oC RH) for which European Union has experience, would be useful.

n Development and use of advanced material for adoption of 650 to 700 oC steam temperature

Ø European Union is pursuing development of material for ultra supercritical plant with higher than 700 oC steam parameter

Ø Availability of these material at competitive price will lead adoption of high temperature for PC plant and hence reduction in green house gas emission

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nn Interaction and knowledge sharing on identified areas Interaction and knowledge sharing on identified areas

nn Institutional arrangement for networking with experts with similInstitutional arrangement for networking with experts with similar ar interests and Formation of a platform to discuss future cooperatinterests and Formation of a platform to discuss future cooperationion

nn Exposure to the advanced technologies, methodologies practiced Exposure to the advanced technologies, methodologies practiced in Europe by Technology tours, Workshops, Country reports, in Europe by Technology tours, Workshops, Country reports, Training etc.Training etc.

nn Exploring the possibilities of collaboration opportunities in thExploring the possibilities of collaboration opportunities in the area of e area of higher parameter supercritical plant, IGCC and Rehigher parameter supercritical plant, IGCC and Re--poweringpowering

nn Setting up of manufacturing capacity in India by manufacturer oSetting up of manufacturing capacity in India by manufacturer of f Power Plant in EU Power Plant in EU –– Either on their own or through joint ventureEither on their own or through joint venture

nn Cooperation in the area of mining and Cooperation in the area of mining and washerywashery

nn Joint Identification and development of CDM ProjectsJoint Identification and development of CDM Projects

IndoIndo--EU Cooperation : Proposed Action PlanEU Cooperation : Proposed Action Plan

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ConclusionConclusion

nn Coal will play major role in meeting the future power demand in Coal will play major role in meeting the future power demand in the countrythe country

nn Environmental regulations are going to be stricter in coming yeEnvironmental regulations are going to be stricter in coming years ars –– both both from local authorities as well as international treaties. from local authorities as well as international treaties. RenewablesRenewables can play can play major role in coming years.major role in coming years.

nn Deregulation of power market will require induction of Advanced Deregulation of power market will require induction of Advanced Technologies at competitive price in future projectsTechnologies at competitive price in future projects

nn Concerted efforts required from Utilities, Manufacturers & ReseaConcerted efforts required from Utilities, Manufacturers & Research rch Institutes to develop these technologies indigenously to suit thInstitutes to develop these technologies indigenously to suit the local e local needs / through technology transfer needs / through technology transfer

nn There is huge potential in India for R&M activities because of lThere is huge potential in India for R&M activities because of large number arge number of old plants which are inefficient and running below design capof old plants which are inefficient and running below design capacityacity

nn Urgent need to enhance manufacturing capacity / Creation of new Urgent need to enhance manufacturing capacity / Creation of new manufacturing basemanufacturing base

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