1. Effect of Blending on Operational Performance and Generation Costs of an Indian Power Plant
Dr Anthony Williams
A&B Mylec
Dr Oliver Scholes
Vale International SA
1st IEA CCC Coal Quality Workshop
9-10 November 2016
New Delhi India

2. Background – Moatize Mine
Vale’s Moatize mine produces a hard coking coal product and a thermal coal product.
Mine is ramping up to an output of 22mt of coal per year.
Coal Quality
Calorific Value – 6050 kcal/kg GAR
Moisture - 5% AR
Ash – 24% AR
Volatile Matter – 20 % AD
HGI – 72
IDT AFT – 1480 oC (red)

3. India – Coal Fired Power Plants
Very high coal production & coal fired power capacity
Numerous coal mines with large rail network
Railways

4. Mundra Power Plant - Coal Supply Options
5x800MW
Supercritical
Design on Indo/SA blend
Indo coal contract
1 coal in blend is fixed

5. Coal Quality
Increasing Energy

6. Blend Modelling – MarketMastor™
Domestic freight+Port+Taxes
Shipping+Port
Scenarios
Power Plant Model
Market Model
Power Plants
Specs
Evaluate Output
Coals
Coal Quality
Mines
Blending
Trade

7. Plant Limitations – Studied coals
Moatize
Raw Coals

8. Binary and Ternary Blends

9. Ternary Blends

10. All Blends Accepted Blends Low No. of blends High No. of blends
Ternary Blends
All Blends Accepted Blends Low No. of blends High No. of blends

11. Pulveriser Performance
Top 50 Blends Accepted Blends All Blends

12. Top 50 Blends Accepted Blends All Blends
Mill Erosion
Top 50 Blends Accepted Blends All Blends

13. Top 50 Blends Accepted Blends All Blends
Boiler Efficiency
Top 50 Blends Accepted Blends All Blends

14. Combustion performance
Top 50 Blends Accepted Blends All Blends

15. Top 50 Blends Accepted Blends All Blends
Carbon-in-ash
Top 50 Blends Accepted Blends All Blends

16. Top 50 Blends Accepted Blends All Blends
Dust Emissions
Top 50 Blends Accepted Blends All Blends

17. Top 50 Blends Accepted Blends All Blends
SO2 Emissions
Top 50 Blends Accepted Blends All Blends

18. Top 50 Blends Accepted Blends All Blends
Auxiliary Power
Top 50 Blends Accepted Blends All Blends

19. Operating and Maintenance Costs
Top 50 Blends Accepted Blends All Blends

20. Top 50 Blends Accepted Blends All Blends
Total Generation Cost
Top 50 Blends Accepted Blends All Blends

21. Electrical Output (GWh/a)
Top 50 Blends Accepted Blends All Blends

22. Best Blends Generation Costs (US$/MWhr) BEST BEST BLENDS BLENDS
Sent out Energy (GWhr/a)

23. POWER PLANT PERSPECTIVE
Power plant confirmed a close match between the actual power plant performance and the desktop analysis.
Agreed with the technical recommendation of using Moatize coal in 20% blend where possible.
Ash deposition potential of currently used coal reduces by 20% when using Moatize coal.
Blend usage has resulted in higher boiler efficiency, improved mill performance, reduction in mill power, and reduction in power for draft system (reduction in auxiliary power use).
Mundra power plant are continuing to use Moatize coal

24. CONCLUSIONS
A different point of view is required when evaluating coals for blending
Negative attributes can be smoothed over by blending
Large number of possible blends can be evaluated
Blending can improve plant performance and reduce fuel costs
Beneficial in applying plant limitations to blend coal quality specs, not on raw coals
Moatize coal was determined to blend very favourably with the existing coal used at Mundra Power Plant
Moatize coal blended better than other coals
Limit to how much can be added but evaluations and plant trials showed coal can be considered as an excellent blending coal
Power plant trials determined Moatize coal improved plant performance and decreased costs

25. ACKNOWLEDGEMENTS
Thanks to A&B Mylec for providing permission to prepare and present at the IEA CCC workshop
Thanks to Vale for sponsoring the trip costs for the workshop