clean coal technology, the indian perspective: challenges and road map presented by himadri banerji...

Clean Coal Technology, The Indian Perspective: Challenges and Road MapPresented by Himadri Banerji at TREC-STEP on 25th Jan 2012

Presented by Himadri Banerji at TREC-STEP Clean Coal Tiruchirapalli on 25th Jan 2012

Some 23% of primary energy needs are met by coal and 39% of electricity is generated from coal.

About 70% of world steel production depends on coal feedstock. Coal is the world's most abundant and widely distributed fossil fuel source.

The International Energy Agency expects a 43% increase in its use from 2000 to 2020.

Burning coal produces about 12 billion tonnes of carbon dioxide each year which is released to the atmosphere, about 70% of this being from power generation.

Other estimates put carbon dioxide emissions from power generation at one third of the world total of over 28 billion tonnes of CO2 emissions.

Coal The most Significant Source of Energy


A continuously developing range of technology solutions which improve the efficiency and environmental impact of using coal as an energy source.

● Beneficiating coal (pre-combustion) – coal de-watering, washing and briquetting.● Efficient alternative uses of coal reserves – UCG, coal seam methane● Efficiency improvements of power plants (post combustion)– Plant upgrades, ● Supercritical and ultra supercritical plants.● Advanced technologies – IGCC, PFBC and IGFC● Super-Advanced Technologies – Carbon sequestration or elimination

What are Clean Coal Solutions?


Why are Clean Coal solutions so important?

Dual Crisis - Energy crisis v Climate change crisis

Energy Crisis – Quick Stats (international Energy Agency, WEO 2006)

•Global energy demand will increase by 70% by 2030.•70% of the increase will come from China and India.•Fossil fuels will account for 83% of global energy production.•Coal will makeup 25% of all fossil fuels used – The largest contributor.•Power generation will account for over 80% of increased Coal usage.

Energy Crisis---Impacts and Concerns

•Fear and uncertainty for growing economies on how to fuel their continued economic success is rising.•Coal is the most abundant source of energy in the world and will be continued to be used as the major feedstock for electricity production for at least the next 30-40 years


UNIVERSAL ENERGY ACCESS BY2030


There are estimates that more than 2 Billion people lack access to clean andmodern energy sources.

In China, 423 Million people rely on conventionalbiomass for cooking applications.

The corresponding number in India and Africa is 855 and 657 Million respectively.

Almost 400 million Indians lack access to electricity. The per capita electricity consumption of India is a measly 600 kWh as against over 12,000 for the US.

Providing clean and cheap energy access is a major challenge, especially in the developing countries.

Availability of, and access to, electricity is a crucial element of modern economies and it helps pave the way for human development.

Accordingly, the power sector has been given a high priority in the national planning processes in India and a concerted focus on enhancing this sector has resulted in significant gains in generation and availability of electricity in the years since independence.

Coal-based power has driven much of the growth in India’s power sector over the past three decades. By 2004-05, coal and lignite accounted for about 57% of installed capacity (68 GW out of 118 GW) and 71% of generated electricity (424 TWh out of 594 TWh) in the country;

Currently, the power sector consumes about 80% of the coal produced in the country. As the demand for electricity is expect to rise dramatically over the next decade, coal will continue to bethe dominant energy source.

India’s Power Sector..Reliance on Coal


The Central Electricity Authority (CEA) has estimated that meeting electricity demand over the next ten years will require more than doubling the existing capacity, from about 132 GW in 2007 to about 280 GW by 2017, of which at least 80 GW of new capacityis expected to be based on coal.

Sub-critical pulverized coal (PC) combustion power plants manufactured by Bharat Heavy Electricals Limited (BHEL) – based on technologies licensed from various international manufacturers – have been the backbone of India’s coal-power sector.

India’s Power Sector Reliance on Sub Critical Technology



India’s Load Curve…Recipe for Disaster Can Smart Metering Help?

Load SheddingUrban Centric SupplyTariff Distortion


History of Efficiencies of Indian Power Plants

Internationally Combustion based on supercritical steam, offering higher efficiencies than sub-critical PC, is a commercial technology.

Ultra-supercritical PC, which offers even higher efficiency, is also being deployed, while oxy-fuel combustion for facilitating capture of carbon-dioxide (CO2) is under development.

Integrated gasification with combined-cycle operation (IGCC), with significant potential for high efficiency and for cost-effective reduction of CO2 and other emissions, is likely to be commercially available in the near future.

The International Scene on Technology:


country Technology Efficiency Projected efficiency with CCS

Australia Black ultra-supercritical WC 43% 33%

Black supercritical WC 41%

Black supercritical AC 39%

own ultra-supercritical WC 35% 27%

own supercritical WC 33%

own supercritical AC 31%

Belgium Black supercritical 45%

China Black supercritical 46%

Czech Republic own PCC 43% 38%

own ICGG 45% 43%

Germany Black PCC 46% 38%

own PCC 45% 37%

Japan, Korea Black PCC 41%

Russia Black ultra-supercritical PCC 47% 37%

Black supercritical PCC 42%

South Africa Black supercritical PCC 39%

USA Black PCC & IGCC 39% 39%

USA (EPRI) Black supercritical PCC 41%

Coal-fired power generation, thermal efficiency

OECD Projected Costs of Generating Electricity 2010, Tables 3.3. PCC= pulverised coal combustion, AC= air-cooled, WC= water-cooled.



Costs and Efficiencies of some referenced plants


The most important challenge is to develop materials towithstand the tough operating conditionsMain requirements:Creep rupture strength >100 MPa at 100,000 hrsResistance to fire side corrosion at elevated temperatures Resistance to steam side oxidation Good thermal conductivityLow coefficient of expansionGood manufacturabilityAmenable to casting, forging, welding, and manufacture of pipesand tubes

Chaleenges to Development of Ultra Super Critical Units


Adv-USC Materials

Nickel based alloys have been developed for 700 °Capplication: IN 617, IN740, Alloy 263 and their variants

Development is also in progress to develop improvedmaterials to meet specific objectives:

12-15%Cr Advanced Martensitic Steels for temperatures up to 650 °C

Z Phase strengthening steels up to 650 °C

Low Nickel alloys for 700 °C to 710 °C


Developing indigenous processes and capacities forcomplex alloys and other materials

Developing technologies and vendors for castings, forgingsfor steam turbines and pipes and tubes for boilers

Developing welding technologies for thick sections and fordissimilar metals in welded rotors

Characterisation and long term testing of indigenouslyproduced materials

Component testing facility for corrosion with Indian coals

Developing capabilities for ab initio design of equipmentlike boilers and steam turbines

Additional Challenges for Adv-USC in India

In the case of electric power, any increase in generation capacity is more than offset by inefficiencies and wastage at every stage — generation, transmission, distribution and delivery.

Without fixing these inefficiencies and wastage, increasing generation capacity and production is like filling a bucket full of holes!

India’s Energy Woes…An Ailing Power Sector


An urgent need to increase energy and electricity availability for human and infrastructure development;

Increasing energy security;

Local environment protection and pollution control; and

Control of greenhouse gas emissions (particularly carbon dioxide).

The key challenges facing India’s power sector :


•Generating utility-scale electricity from coal requires a range of tradeoffs – financial, natural resource, environmental, and social – and there is need to meet the requirements of a diverse set of stakeholders who have strong concerns about decisions made in this sector.

•We need to cut down on transmission and distribution losses and

•Untangle the environmental problems that coal mining has run into.

•Policymakers have to balance the needs of development with environmental considerations.

The key challenges facing India’s power sector


The task of meeting these broad challenges is further complicated by several constraints:

Availability and quality of domestic coal;

Limited financial resources;

Inadequate technical capacity for R&D, manufacturing, and O&M; and

The institutional characteristics of the Indian power sector.

Major Constraints in meeting these key challenges


Commercial supercritical combustion technology is the best option for India in the short-to-medium term.

While gasification and advanced combustion technologies will be potentially important options for the longer-term future, there are significant issues surrounding the current relevance of these emerging technologies for India, including uncertainties in technical and cost trajectory, suitability for Indian conditions, and timing of India’s greenhouse-gas mitigation commitments.

Options in Clean Coal Technology for India:


implement the following roadmap:

(a) improve the efficiency of the power system (generating stock, T&D network, and end-use sectors) to reduce the need for addition in generation capacity and therefore buy time formaking appropriate technology decisions;

(b) implement supercritical-combustion-based generation plants to meet capacity addition needs in the short-to-medium term;

Suggested Roadmap For India:


(c) enforce and tighten local environmental pollution controls through better pollution control technologies and greater and meaningful public participation; and

(d) invest in a focused plan to examine geological carbon storage options, with detailed assessment of CO2 storage locations, capacity and storage mechanisms in order to collect valuable information for India’s carbon mitigation options and inform future technology selection as well as siting decisions for coal-power plants.



(e) Evaluate on an ongoing basis the appropriateness of emergingtechnologies for India through a monitoring and feasibilityassessment program, and

(f) By advancing specific elements of these technologies and ensurethat they can be deployed as and when needed through

(g) Strategic research, development, and demonstration program, in partnership with key actors from the coal and hydrocarbon mining, and the petrochemical industry;

(h) Consolidate the existing coal-based R&D programs inindustry, research institutes, and academia under a common vision

with specific objectives and plans for the future, and help make appropriate international linkages




Funding

Global transition to low carbon technologies is inherently an expensive option.For instance, most renewable sources are expensive as compared withconventional technologies.

Wind is now almost cost competitive, but solar poweris very expensive; almost four times that of coal based power generation.

Developing countries would be unable to undertake such a transition in theabsence of a global funding initiative to incentivize a large – scale deployment ofrenewable power.

The present mechanisms such as CDM and World Bank/GEFfunded projects have only gone so far and are not adequate for large scaleadoption of renewable sources in developing countries.

clean coal technology, the indian perspective: challenges and road map presented by himadri banerji...

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