Asia Pacific Partnership on Clean

Development & Climate

Brown Coal ( Lignite ) Best Practices

Work Shop

India - Country Perspective

23-27 th June2008
 THE INDIAN DELEGATION

 NTPC Delegates :

 I.K.Rajdeva, Additional General Manager, NTPC Ltd.

 A.Nagasundaram, Dy. Gen. Manager, NTPC Ltd.

 Saju K Sebastian, Dy. Gen. Manager, NTPC Ltd.

 P.S.Chatterjee, Chief Design Engineer, NTPC Ltd.

 CESC Delegates :

 Souvik Dutta, Station Manager, Southern generating Station, CESC Ltd .

 Kushal Bhowmick,  Senior Manager ( Environment),  CESC Ltd.

Robust Economic Growth – THE DRIVER

 THE GDP GREW AT 9.6% DURING FISCAL 2007,

AVERAGE RATE OF GROWTH OVER LAST 4 YEARS IS
8.6%.
 GDP GROWTH DURING 2008-09 IS EXPECTED TO BE
around 9%.
 GDP GROWTH TARGET OF 9% SET BY GOVT. DURING
XI PLAN (2007-2012).
 ELECTRICITY IS AN IMPORTANT INPUT TO THE MARCH
OF PROGRESS OF ANY COUNTRY TODAY.
 IT IS THEREFORE NATURAL THAT THE GROWTH IN
ELECTRICITY GENERATION & AVAILABILITY, BE
COMMENSURATE WITH GROWTH IN GDP.
Existing Generating Capacity- March 2008

Fuel wise break-up Sector wise break-up (MW)

(MW)

Thermal 92,426 63.8%

Private
Hydro 36,033 24.9% Sector
14%
Nuclear 4,120 2.8%
State
Renewable 12,194 8.5% Central Sector
Sector 52%
TOTAL 144,773 100.0% 34%

(Excluding captive capacity of 14636 MW connected to

grid)
(All figures provisional from CEA)

Total generation in 2007-08 – 704.45 BU

 PLF (%)

48
53
58
63
68
73
78
1985-86

1986-87

1987-88

1988-89

1989-90

1990-91

1991-92

1992-93

1993-94

1994-95

1995-96

1996-97

YEARS
1997-98
- COAL FIRED THERMAL POWER STATIONS

1998-99

1999-2000

2000-01

2000-02
ALL INDIA PLANT LOAD FACTOR (%)

2002-03

2003-04

2004-05

2005-06

2006-07

2007-08
Energy Shortage
9.8%
750 737
9.6%
REQUIREMENT AVAILABILITY
691
700
8.3%

650 631
7.3% 665
7.1% 591
600 8.8% 624
7.5% 559
7.8% 546
550 579
523
507 548
500 519
498
483
450 467
2001 2002 2003 2004 2005 2006 2007 2008

DURING 2007-08, PEAKING SHORTAGES WERE 16.6%

Per capita Consumption remains low

In
665 2006
India NATIONAL ELECTRICITY POLICY
618
TARGETS PER CAPITA
Egypt
1,465 AVAILABILITY OF 1000 KWH BY
China 2012
1,684
Brazil
2,340
Russia
6,425
Germany
7,442
Japan
8,459
USA
14,240
World Average Figures in kwh
2,701
Source: UNDP Human Development Report 2007-08 – Data for 2004
Projected Capacity Requirements

778 GW

425 GW

220 GW
132 GW

2007 2012 2022 2032 Energy Policy

Source: Integrated
GOI

Large Capacity addition required to meet the

demand
CAPACITY ADDITION EXPECTED DURING 11th PLAN
(2007-12) (Conventional) – 78,520 MW

HYDRO,
NUCLEAR,
15,627MW,
3,380MW, 4%
21%

THERMAL,
59,5130MW,
75%
Thermal – 59,513MW
( Coal – 51,890 MW, Gas- 5343 MW, Lignite- 2280 MW)

Additional capacity expected : New Renewables – 14,000 MW

: Captive – 12,000 MW
11TH PLAN PROGRAMME (2007-2012)
(Thermal+Hydro+Nuclear)

 Proposed : 78,577 MW
 Expected : 78,520MW
 9,263 MW capacity already commissioned
 60,214 MW (77%) under construction
 10,950 MW - Letter of awards yet to be placed
 Fuel Availability for 96% of coal based stations – tied up
 88% hydro capacity under construction /commissioned
 All gas based projects under execution or gas tied up from
local sources
 Additional 13,000 MW gas based projects identified –
subject to gas availability
 11TH PLAN PROGRAMME
NON-CONVENTIONAL ENERGY PLANTS

 Installed Capacity (as on 31.03.2008)- 11125 MW

 11th Plan target- 14,000 MW consisting of
• Wind Power - 10,500 MW
• Biomass Power
Baggasse
Co-generation - 2,100 MW
• Small Hydro
(up to 25 MW) - 1,400 MW
CAPACITY ADDITION DURING XIITH PLAN
(2012 - 2017)

PLAN TOTAL THERMAL HYDRO NUCLEAR

CAPACITY
ADDITION
PLANNED
(MW) (MW) (MW)
(MW)
XIITH 82200 40200 30000 12000
Energy Efficiency

NATIONAL
GOVERNMENT’S THERMAL
STRAGTEGY POWER
/ INITIATIVE
CORPORATION
FOR EFFICIENCY IMPROVEMENTLTD.
- A PROFILE

Setting the Scene today for a future-

oriented Sustainable Energy production
INDIA’s ENERGY PROGRAMS AND POLICIES

 Improving energy efficiency

 Promoting Hydro and renewable energy
 Power sector Reforms
 Promotion of Clean coal technology
 Energy infrastructure Development
 Coal Washing
 Environmental Quality Management
DRIVERS FOR HIGHER PLANT
EFFICIENCY
 Demand of power is set to grow with growing economy
 Large capacity needs to be added to meet the projected growth
in demand
 With Electricity Act 2003 coming into vogue, the power market is
set to attract a lot of investors and competition
 With tariff based bidding becoming a norm, utilities have to bring
down their cost of generation to remain competitive
 Increased emphasis on Environmental considerations for clean
technology
 CDM opportunities arising out of global warming concerns
 Fuel, Land & Water availability becoming more and more difficult
 Efficiency enhancement feasible in future plants as well as
existing plants
Major Initiatives ……

 Improvement in efficiency and performance of existing generating

units through :
 Renovation and Modernisation schemes with emphasis on Energy Efficiency
 Partnership in excellence.
 Establishment of Energy Efficiency cells at thermal power stations ( 37 cells in
operation)
 Energy Conservation through legislation
 Thermal Power Stations notified as Designated consumers
 Promotion of Renewable Energy Sources
 15,627 MW Capacity of Hydro Power planned in XIth Plan
 30,000 MW Capacity of Hydro Power planned in XIIth Plan
 Retiring 5000 MW old capacity with low efficiency in 11th Plan
Major Initiatives …..

Energy Conservation Act 2003 (EC Act)

 Designated Consumers Notified
 Thermal Power Station
 Appoint Energy Manager
 Get Energy Audits conducted by Accredited Energy Auditors
 Implement techno-economic viable recommendations given by
Accredited Energy Auditor
 Comply with norms of specific energy consumption fixed
 Submit report on steps taken
Major Initiatives……

 Adoption of Clean Coal Technologies

– Supercritical / Ultra supercritical Technology
– Circulating fluidized bed combustion (CFBC)
– Integrated Gasification Combined Cycle (IGCC)
Suitable for Indian Coal
 Presently Working to develop a Demonstration
Project for IGCC along with suitable Partner,
development of core technologies for gasifier & Gas
cleaning systems suitable for High Ash Indian Coal.
Major Initiatives …..

 Ultra Mega Power Projects(4000MW capacity)

based on Supercritical Technology at various
pithead and coastal locations. Envisaging
Mandatory Higher size thermal units (660/800
MW) with Supercritical Parameters.

 It is estimated to commission
 10 Nos. units of 660MW (XIth Plan)
 2 Nos. units of 800MW (XIth Plan)
 12 Nos. units of 660MW (XIIth Plan)
 31 Nos. units of 800MW (XIIth Plan)
Major Initiatives …..

• Supercritical Units of 660 MW Rating under construction

• Supercritical Units of 800 MW Rating with higher steam
temperature conditions under consideration

Parameter 660MW 800MW

Main Steam 247 247

Pressure Kg/cm2
Main Steam 535/565 565
Temperature oC
Reheat 565/593 593
Temperature oC
 The Efficiency Roadmap

43%

42%
Gross Efficiency, GCV Basis

320/600/620
(800-1000 MW)
41% 280/600/620
(800-1000 MW)
247/565/593

40% (660/800 MW)

247/537/565
(660 MW)
39%
170/537/537
(500 MW)
38%

‘00 ‘02 Xth ‘07 XIth ‘12 XIIth ‘17 XIIIth ‘22
Plan Plan Plan Plan
Lower Plant Efficiency in India

The reported efficiency of Indian power

plants is generally lower as compared to
efficiency of plants abroad, primarily due to :

• Poorer condenser vacuum due to hot climatic

conditions
• Higher unburnt carbon losses in boiler due to low
grade high ash Indian coal
• Efficiency is reported on HHV basis of coal (same
as the practice followed in USA) as against LHV
used elsewhere.

Typical variation due to above = 3.0 to 4.0 % points (Approx.)

Heatrate Improvement over the Years

Heatrate Improvement Over The Years

P = 247 ata
14
MST = 565
P = 247 ata
RHT = 593
12 MST = 537
P = 170 ata RHT = 565
10 P ==170
P 170ata MST = 537
ata = 537
MST RHT = 565
8 P = 170 ata
MST==537
RHT 537
MST = 537
6 P ==150
P 150ataata RHT = 537
MST
MST ==537537
4 RHT==537
RHT 537
P ==130
130ata
ata
2 MST ==537
MST 537
RHT ==537
RHT 537
0
200 LMZ (1978) 200 KWU (1979) 500 KWU (1982) 500 KWU Mod 500 High RH 660 SC (2004) 660/800 SC
(1998) (2006) (2008)
 Major Initiatives Contd …..

 Member of Carbon Sequestration Leadership Forum

(CSLF)
 Participating in FutureGen Project of USA
 275 MW coal fired Zero Emission power plant
 India contributing US$10 Million
 Participating in Asia Pacific Partnership (APP) for Clean
Development and Climate
 The Indian Project Proposals in the TF Action plan
 Inputs like case studies & contact details of experts in areas of
India’s interest.
 Work on Efficiency improvement of two thermal power
plants namely Ropar and Kolaghat thermal Power station
already started with support of USAID.
Major Initiatives …..

 Mapping of Thermal Power Stations under

Indo-German Programme
 33 thermal units mapped ( 31 thermal stations)
 85 Thermal Power Stations targeted

 Energy Conservation Awards

 National Award for improving performance
of Thermal Power Stations
 Awards for reducing T & D losses.
Efficiency Improvement through
Renovation and Modernization

A COST EFFECTIVE APPROACH ……

CONTINUE GETTING THE BEST OUT OF EXISTING FLEET
NEED FOR R&M – EXISTING UNITS

 Improvement in performance parameters – PLF,

Availability, heat rate/efficiency, auxiliary power
consumption, partial loading & forced outage.
 Restore derated capacity
 Extension of economic life.
 Obsolescence & non availability of spares (eg C&I)
 Environmental issues/other statutory requirements.
 Safety requirements.
 POTENTIAL FOR EFFICIENCY
INTEGRATED R&M
 A large number of 200/250 MW & some 500 MW Units are in operation
for more than 15/20 years and have considerable potential for life
extension & efficiency improvement

Total No. of Nos. of Units as potential

Units Candidate
Age >15 years >20 years

200/210 MW Units 53 -- 53
(LMZ design)
200/210 MW units 88 37 12
(KWU design)
500 MW units 35 12 2
FUTURE APPROACH TOWARDS R&M

 Shift in focus from ‘Generation Maximization to ‘Plant

Performance Optimization’ – Older units have many more
opportunities to reduce heat rate than newer units.
 Retirement of very old small size low efficiency units and
replacement with higher efficiency units.
 Use of high end technology solutions for efficiency
enhancement to manage rising costs & reduce carbon, foot
prints, e.g.,
 Steam flow path modification
 Steam turbine and boiler upgrades
 Improved plant control
FUTURE APPROACH TOWARDS R&M …

 Additionality in efficiency improvement

 Efficiency improvement as a result of normal R&M,
aims at to minimising losses ( to approach design
values)
 Efficiency improvement through technology
intervention/enhanced R&M, targeting efficiency
enhancement even beyond design value.
Parameters For Performance
Monitoring

 Unit Heat Rate

 Unit Auxiliary Power consumption
 Unit Specific secondary fuel oil
consumption
 Unit Specific coal consumption
 Plant Load Factor (PLF)
 Planned Maintenance, Forced outage and
Operating availability
Projects for the Task Force

Sl. No. Project Title Proposing Country

1 Best Practices for Power Generation Activity Plan USA, JAPAN, KOREA
2 Best Practices for Transmission and Distribution Activity Plan USA
3 Best Practices for Demand Side Management Activity Plan USA
4 Energy Regulatory & Market Development Forum AUSTRALIA
5 Trade Exhibitions/Conferences and Trade Missions USA
6 Hydroelectric Generation Best Practices USA
7 Combustion Optimization in Coal Based Power Plants INDIA
8 Implementation of Artificial Intelligent Soot Blowing System for Improving the Steam INDIA
Generator Efficiency by Increasing the Effectiveness of Soot Blowers.
9 SOx Reduction Technologies in Flue Gas INDIA
10 Risk Evaluation and Prioritization (REAP) for Maintenance and Renovation & INDIA
Modernization (R&M) of Power Plants
11 Life Extension & Remaining Life Assessment Of Power Plants INDIA
12 Site visit of energy conservation and environment protection technology—Application CHINA
of Plasma Ignition Technology in Power generation
13 Generator Transformer Programs (Inspection Procedures, Diagnostic Tools and INDIA
Maintenance)
Fly Ash Utilization Record – NTPC
AS A SAMPLE CASE ONLY

Highest ever utilisation of Fly Ash a testimony to ecology

preservation

25
22.3
Ash Utilisation in Million tonnes

19.6
20

15
12.7

10
7.5
5.7
5 3.7
3.0
0.3
0
1991-92 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07
Afforestation Efforts – A Priority for
sustenance of HUMANITY!!
Forest Banks concept
NTPC has created a Green wealth of 18.2
Million Trees by Summer 2007
Plantation of 1.25 Million trees around
Ramagundam Project has resulted in
Summer Peak temperature
reduction by 3 deg C
Ash Mound Reclamation and Dry ash
disposal system