1 ENERGY EFFICIENCY IMPROVEMENT IN THE POWER SECTOR Presentationby BHEL - Corporate Engineering & Product Development 5 June 2008

2 Improvements in existing technologies such as sub-critical power plants and hydro power plants. Introduction of supercritical and ultra supercritical power plants. Introduction of advanced technologies such as Integrated Gasification Combined Cycle plants or IGCC. ENERGY EFFICIENCY IMPROVEMENT IN THE POWER SECTOR

3 Initiative - New materials and availability of advanced engineering techniques such as FEM, CFD, Simulation, etc., running on faster and cheaper computers. Development of more efficient aerodynamic blade profiles and re- designing the inlet and outlet sections using modern CFD techniques. Improved cycle introduced - increasing steam parameters like main steam pressure, main steam temperature and hot reheat temperature or improving the internal efficiency by reducing losses in the steam turbines ENERGY EFFICIENCY IMPROVEMENT IN THE POWER SECTOR Improvements in existing technologies Steam Power Cycle 1 kcal/ kWh reduction in TG cycle heat rate, coal consumption reduces by 300 and 700 tonnes per year for 210 and 500 MW sets.

4 Losses restricted by employing more effective inter-stage sealing and shaft sealing by keeping radial clearances to the minimum. New Rating Developed - A new cost effective and thermodynamically efficient plant with a unit rating of 600 MW. ENERGY EFFICIENCY IMPROVEMENT IN THE POWER SECTOR Improvements in existing technologies Steam Power Cycle

5 Use of aerofoil bladed PA fans, with inlet guide vane control in place of damper control - reduced fan losses. Replacement of worm gear by planetary gear in pulverisers has improved their energy efficiency. Efficiency of boiler feed pumps - Enhanced by one percent through thermo hydraulic re-design Use of variable speed drives with ID fans and BFPs - reduced energy losses at part loads. ENERGY EFFICIENCY IMPROVEMENT IN THE POWER SECTOR Improvements in existing technologies Auxillary power consumption

6 PADO (Performance Analysis, Diagnosis and Optimisation) can provide online guidance to operators to run the plant with minimum losses and downtime Smart wall blowing system - Optimises the steam blowing cycle for soot blowers, thus improving the heat absorption in boiler surfaces and reducing the consumption of auxiliary steam. ENERGY EFFICIENCY IMPROVEMENT IN THE POWER SECTOR Improvements in existing technologies Control and Instrumentation

7 Washing of coal, or beneficiation, to maintain ash content to % The benefits are:  Coal quality becomes consistent wrt ash %age  Economical design of Boiler, less space, fewer pulverisers, reduced size of Auxiliaries – Lower capital cost  Low operational costs  Better efficiency  Lower particulate emissions ENERGY EFFICIENCY IMPROVEMENT IN THE POWER SECTOR Improvements in existing technologies Coal Washeries Establishment of coal washeries needs to given a high priority.

8 The station heat rate is 3% lower than with the conventional sub-critical cycle. Power plant cycles operating above the critical pressure bar. Supercritical cycle’s advantage - ‘burn less fuel for the same output’ and low emissions. Steam parameters like 250 bar pressure, 568 C main steam temperature and 600 C hot reheat temperature are commonly used World-wide R & D efforts are focused on development of power plants with ultra-supercritical steam parameters of 350 bar, 700 C main steam and reheat steam temperatures and net efficiency of 50% by the year ENERGY EFFICIENCY IMPROVEMENT IN THE POWER SECTOR Introduction of supercritical power plants BHEL is associated with 660 MW Barh Super critical Project

9 GAS CLEAN-UP GAS TURBINE H R S G STEAM TURBINE GT POWER STACK ST POWER 2 BLOCKS IN COAL GASIFICATION PLANT CLEAN FUEL GAS 3 BLOCKS IN COMBINED CYCLE POWER PLANT STEAM GAS EXHAUST WHAT IS IGCC NG OIL COAL GASIFICATION

10 IGCC Advantage Conventional Coal plant* IGCC Plant NOx 350 ppm<25 ppm SOx600 ppm245 ppm SPM50 mg/Nm32 mg/Nm3 CO 2 EmissionHigh10% Less Fuel consumptionHigh7% less Water consumptionHigh40% Less * Typical 500MW thermal plant Low Emission, High Efficiency Power Generation Technology

11 Reduce adverse impact of fossil fuel combustion on environment  Acid rain  Suspended Particulate Matter in atmosphere  Green House Effect WHY IGCC ? Uses Low Grade fuels Environment Friendly Power Generation

12  BHEL has worked for more than 2 decades on development of IGCC  1st ever plant of 6.2 MW set up in 1988 at Trichy  Feasibility of scale up of the 6.2 MW to ~100 MW is established by BHEL  High powered R&D committee set up under chairmanship of scientific advisor has recommended for scaling up to 100 MW site rating plant  BHEL has signed an MOU with APGENCO on 10th May08 for IGCC Plant at Vijaywada  BHEL has contracted more than 60 FBC and 17 CFBC boilers Largest in operation : 125 MW : Under construction : 250MW  Next Step - Basic Engineering for 400 MW IGCC completed BHEL’s Gasification & IGCC Development Program 1 st Largest size 125MW IGCC Plant order expected from APGENCO in 2-3 months.

13 ENERGY EFFICIENCY IMPROVEMENT IN THE POWER SECTOR Introduction of advanced technologies Transmission and distribution of Power AC Transmission – 400 kV, 765 kV DC Transmission – 500, kV AC Transmission – Transformer, Disc Insulators, Switchgears, CT, CVT HVDC

14