golden jubilee year 1958 - 2008 optimizing boiler...
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1958 - 2008
GOLDEN JUBILEE YEAR
Dr. Gopal P. SinhaCentral Mech. Engg. Res. Institute
Durgapur, West Bengal
OPTIMIZING BOILER DESIGNS FOR
INDIGENOUS COAL
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97500719005450050700
78037 81492115705
157107
Mar '01 Mar '03 Mar '07 Mar ''12
PeakRequirement(MW)
EnergyRequirement(MU)
INDIAN POWER SECTOR
Capacity to increase to 2,12,000 MW
By 2012, India’s peak demand would be 157,000 MW with energy requirement of 97,500 MU
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Capacity in MW (1,32,329)
PRESENT ELECTRICITY SCENARIOInstalled Electricity Generation Capacity
(1st April 2007)
Note: Coal-based captive generation capacity of 8000 MW is
not included.
Absolute Value
Renewable (6%)Nuclear (3%)
Hydro (26%) Thermal (65%)
Thermal Capacity in MW(86015)
Oil (0.9%) Gas (10.3%)
Coal (53.7%)
PF
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•DEMAND IS GROWING @ 7-8 %
•PER CAPITA CONSUMPTION 15 Kwh/yr 350Kwh/yr
•PROJECTED TO INCREASE TO 750 Kwh/yr BY 2012
•PEAK DEMAND TO REACH 157,000 MW BY 2012
100,000 MW ADDITIONAL CAPACITY REQUIRED
•COAL WILL CONTINUE TO DOMINATE POWER
GENERATION SCENARIO
POWER SECTOR SCENARIO
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FUEL OPTIONS
Various Fuel Options for Power Generation are:
18000 – 20000 KJ/KgBiomass
10000 – 16000 toe*Uranium and Thorium
42000 - 47000 KJ/KgPetroleum
35000 – 40000 KJ/KgNatural Gas
15000 – 27000 KJ/KgLignite
15000 – 27000 KJ/KgCoal
Calorific ValuesVarious Fuels
*1 toe = 42 GJ
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COAL - the main stay of India’s electricity supply
• Present generation capacity: 1,35,000 MW
• Projected ( 2032 ) 8,00,000 MW
• About 50 to 55 % of generation capacity will be coal based.
• Coal consumption is projected to increase 5 fold in 25 years.
• Estimated reserve: 255 billion tonnes
• Out of this 98 billion tonnes is of proven category.
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< 0.5Phosphorus
0.3-8.3Sulphur
3-60Ash
Trace-5MgO
Trace-12CaO
2-20Fe2O3
15-36Al2O3
45-63SiO2
3-43Moisture
1-36V.M
38-60F.C
Wt % RangeIndian Coal
CONSTITUENT
-
0.3-3.8
5-19
Trace - 3
Trace - 12
3 - 27
18 - 29
30 - 61
2-37
3-37
29-81
Wt % RangeImported Coal
INDIAN VIS-À-VIS IMPORTED COAL CHARACTERISTICS
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CONSUMPTION & SUPPLY OF COAL IN 2005-06
• Consumption 448.72 million tonnes (333.15) million tonnes
• Supply– Indigenous production 401.72 million tonnes
(307.16) million tonnes– Imports 41.67 million tonnes
(17.78) million tonnesTotal 443.39 million tonnes
Gap (domestic supply) 47.0 million tonnes (26.0 million tonnes)
Figures in brackets pertain to coal used in power generation
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TO IMPROVE CONVERSION (EFFICIENCY)
• COST OF GENERATION
• GREEN HOUSE GASES EMISSION
• PARTICULATE EMISSION
• CLEAN COAL TECHNOLOGIES
FUTURE THERMAL GENERATION TECHNOLOGIES NEED
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DIFFERENT VARIANTS OF FLUIDIZED BED COMBUSTORS
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265 Mwe CFBC Power Plant
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CFB BOILERSAtmospheric Circulating Fluidized Bed Combustion (CFBC) Boiler
•Solids lifted from bed, rise, return to bed
•Steam generation in convection section
•Benefits: more economical, better space utilization and efficient combustion
(Thermax Babcock & Wilcox Ltd, 2001)
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• Low NOX (combustion temp. 850°C.)
• High heat transfer to boiler tubing, allowing a compact boiler
• High flexibility for using different grades of coal (including with high sulphur ash content)
• Possibility to burn low grade fuels, such as biomass, waste substances and to perform “co-combustion” of different types of fuels;
• Use of crushed fuel with relatively large particles, leading to reduced milling costs.
ADVANTAGE OF FLUIDIZED BED COMBUSTION POWER PLANTS
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BIOMASS: POTENTIAL & USAGE, IN INDIA
35 MW273 MW
16, 000 MW3, 000 MW
Biomass Poweri. Gasifiersii.Co-generation
33.0 Million120 MillionImproved biomass chulhas (cook-stoves)
3.10 Million12 MillionBiogas plants
Usage (till Dec 2000)
Potential (Approx.)
Sources/Technologies
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COMPARISON PF AND CFB BOILERS
Ash upto 70%
Ash upto45%
Fuel flexibility
<6<0.0001Coal size (mm)
80-90smallSOx capture (%)
50-200400-600Nox (ppm)
4039Generation efficiency (%)
95-9995-99Combustion Efficiency(%)
CFBPF
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30
20
10
0800 900 1000 1100 1200
COAL PRICE Vs. IRR
COAL PRICE ( Rs/ ton)
CFB
PC
IRR
(%
)
INTERNAL RATE OF RETURN Vs. FUEL COST
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•Engineering Design
•Cost Effectiveness
•Regulatory Compactness Codes and Standards
•Fuel
•Site Selection Distribution Cost
Future Demand
FACTORS AFFECTING BOILER DESIGN
Competitive Generation (Rs/Gcal)
CapacityReliabilityAvailability
ChemestryCalorific ValueCost / G.cal
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Furnace Chamber Design
•Combustion Requirement
•Fuel Properties
•Heat Transfer Efficiency
•Metal Temperature
•Surface Area Exposed
•Emission Standards
Other Design Considerations
Superheater
Re-Heaters
Hot and Cold Gas Air Heaters
Economizer
Safety
BOILER DESIGN
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SPECIAL FEATURES OF CFB BOILERS
•Fuel Flexibility
•High Combustion
•Efficient Sulphur Removal
•Low NOX Emission
•Smaller Furnace Cross-Section
•Common Material Used
•Cold start (6-7 Hours)
•Hot start (30-45 Miniutes)
•Turn Down (on load demand: 25%)
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CHALLENGE TO OVERCOME
• EROSION & CORROSION
• WATERWALL
• SUPERHEATER
• OMEGA
• AIR NOZZLE
• CYCLONE TARGET
• EXPANSION JOINT
• BULL NOSE (for regulating circulation)
• VORTEX FINDER
• DEPOSIT ON TUBES /REFRACTORY & ECONOMISER
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PROVEN REMEDIAL ACTION
• DESIGN MODIFICATION
• PROPER REFRACTORY(TYPE &
LINING)
• SECRIFICIAL/ HARD COATING
• BAFFLE PLATE & SEALED COVER
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CONCLUSIONS• POWER REQUIREMENT TO DOUBLE IN NEXT 5-10 YEARS.
•COAL WILL CONTINUE TO DOMINATE THE POWER GENERATION SCENARIIO.
• DETERIORATING COAL QUALITY WILL BUILD UP PRESSURE FOR IMPORT, LEADING TO HIGH COST OF POWER.
• ENVIRONMENT NORMS AND CARBON CREDIT WILL MAKE G.H.G.E. A PROHIBITIVE AFFAIR.
SUBSTITUTE/ CONVERT PF WITH CFB TO FLEXIBLE COAL INPUT AND UPTO 20% BIOMASS FEED
•The Solution:
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Candidate materials for turbine in Japan
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Larger CFBC Installations World-wide