ppt paper 3 plasma energy technology

“The earth, the air, the land and the water are not an inheritance from

our fore fathers

but on loan from our children. So we have to

handover to them at least as it was handed

over to us.”

- Mahatma Gandhi

Biggest challenge in the 21st century

Rising Oil price

Depleting Oil reserve Increasing Pollution

India depends on Gulf countries for 70% of its oil needs

India ranks among the top 10 largest oil-consuming countries (consumption is 2.2 million barrels per day)

Stringent environmental norms.

Weakening of INR vis-a-vis foreign currencies

Tariff-based bidding in Indian Power Sector.

Present scenario

Welcome to Presentation

A PRESENTATION ON

PLASMA ENERGY TECHNOLOGY

( Eliminating use of oil in coal based power plant through PET)

Presented by

A S GUPTA Supdt(O)

D.S.RAO Dy Supdt (O)

CONTENTS

Disadvantages of using oil

Available Technologies

Plasma Energy Technology

Economic feasibility

Advantages

Conclusion

Disadvantages of using oil

High cost involved (Oil, steam) & Additional capital cost.

Maintenance considerations.

Prone to fire accidents.

Specific problems related with oil (APH fires, ESP, etc)

Pollution issues.

AVAILABLE TECHNOLOGIES FOR OIL FREE BOILER

START UP OR STARTUP WITH LESS OIL

LIGHTUP WITH NATURAL GAS

CORONA DISCHARGE IGNITION

TINY OIL IGNITION TECHNOLOGY


WHAT IS PLASMA???

A state of matter similar to gas in which a certain portion of the particles

are ionized.

After sufficient heating a gas dissociates

its molecular bonds, rendering it into

constituent atoms. It may lead to ionization

BASIC PRINCIPLE OF THE PLASMA-ENERGY TECHNOLOGY(PET)

Sketch of Plasma-Fuel System (PFS).

PET uses high-temperature plasma for the thermal-

chemical preparation of the coal-air mixture for

combustion = partial coal gasification

Pulverized coal + syn gas Plasma torch

Pulverized coal

Furnace

Reactor

The list of the chemical reactions used in the model consists of 116 reactions

The starting chemical stage of coal conversion is the evolution of volatile matter (CO, CO2,CH4, H2, H2O, C6H6, C5H5N, C4H5N, CH3SH, C4H4S).

Two more stages: Char carbon and nitrogen gasification (seven reactions with H2O, CO2, CO, O2, NO, H2S)

The 1st reaction step is the conversion of HCN to NH3 by an attack of an oxidizing agent. The NH3 forms and destructs NO within a pair of competitive parallel reactions.

BASIC PRINCIPLE: ZELDOVICH MECHANISM

plasma flame: measured isotherms

100 kW

Temperature profile

• Temperature of a plasma flame

reaches 4000-6000 K.

• PET provides thermo-chemical

treatment of rich coal/air mixture (0.4-

0.6 kg of coal per one kg of air). It

corresponds to 30 - 40% of air

theoretically needed for complete coal

combustion.

Concentrations of gaseous and solid

components in dependence on

temperature in reactor

BASIC PRINCIPLE OF PET

COMPONENTS OF PLASMA IGNITION SYSTEM

Plasma torch operated with DC power

Rectifier unit to supply the required DC power

Coal burner which can withstand high temperatures

Cooling water for cooling of plasma torch

Instrument air for purging and ionisation.

DC PLASMA TORCH

Cathodes and anodes are made with special anti oxidative alloy

Dimensions: Length: 0.5 m Diameter: 0.25 m weight:30 kg


Plasma torch operated with DC power

Rectifier unit to supply the required DC power

Coal burner which can withstand high temperatures

Cooling water for cooling of plasma torch

Instrument air for purging and ionisation.

Direct flow Reactor

Tangential flow Reactor

Air-coal mixture

Plasma torch

PLASMA REACTORS – THE CORE ELEMENT OF PET

MOUNTING OF PLASMA TORCH

Plasma

reactor

Plasma

reactor

For a 550 MW Boiler, 4 nos of torches are required.

DC PLASMA TORCH

Power consumption ranges between 50 kW and 350 kW Hybrid torches of 1.4 MW are also available.

Actual power supplied depends on: Quality & Volatility of the coal.

LABORATORY PERFORMANCE TEST

Implementation of Plasma Energy Technology

Courtesy: Yantai Longyuan

As per the CERC guidelines capital cost of FOPH for a

2X500 MW plant = Rs 50 Cr. (0.05Cr/MW*)

As per vendor information, capital cost for providing PICS

for 2x500MW plant = Rs 13.8 Cr.

Savings in capital cost ~ Rs 36 Cr.

Courtesy : CERC benchmarks . Vendor Information.

Capital cost for a 2x500 MW plant

Cost-Benefit Analysis for New Units & for Commissioning

(For 2X500 MW Plant)

Savings in capital cost of Rs. 36 Cr.

Oil Consumption during commissioning ~ 4,000 KL LDO

16,000 KL HFO

Cost of Oil ~ Rs. 87.2 Cr.

Equivalent Coal (CV of Oil / CV of Coal) ~ 65866 T

Cost of coal = Rs. (65866 X 2340) ~ Rs.15.41 Cr

Cost of Pulverization = Rs 2.4*(20*65866) = Rs.31.6 Lacs

Cost-Benefit Analysis for New Units & for Commissioning

(For 2X500 MW Plant) Contd..

Aux Consumption for plasma guns = 1097 * 2 * 0.2 MWh

Power consumption for plasma guns = Rs. 10.53 Lacs

Total power consumption for coal firing =

Cost of Coal + Cost of Pulverization + Cost of energy by Plasma

= Rs (15.41 + 0.31 + 0.10) = Rs. 15.83 Cr.

Savings = Cost incurred with oil - Cost with coal

= Rs. (87.2 – 15.83) Cr. = Rs. 71.36 Cr.

Total savings on fuel cost during commissioning = Rs. 71.36

Cr.

Consumption: LDO - 409 kl; HFO – 759 kl

Cost of oil: Rs. ( 58000*409 + 40000*759) = Rs. 5.41 cr.

Equivalent coal = 1390 + 2480 T = 3870 Tons

Cost of coal = Rs.(3870*2340) = Rs. 90,55,800.

Cost of pulverization= 2.40*(20*3870) = Rs. 1,85,760.

Assumptions: LDO Calorific value: 10200 kCal/kl

HFO Calorific value: 9800 kCal/kl

Coal calorific value: 3000 kCal/kg

Cost-Benefit Analysis: Oil Savings (Last 3 years Average)

Energy requirement of plasma guns = 64.5hrs * 2 Nos* 0.2 MWh

= 25.8 MWh

Cost of energy consumed by Plasma Guns = Rs (25800*2.40)

= Rs 61,920.

Total cost incurred in coal light-up =

Cost of Coal + Cost of Pulverisation + Cost of Addl. APC

= Rs. (90,55,800 + 1,85,760 + 61,920)

= Rs. 93.03 lacs

Proposed annual savings = Rs(5.41 – 0.93) Cr. = Rs. 4.5 Cr.

Cost-Benefit Analysis: Oil Savings (Last 3 years Average) Contd..

Daily Aux Steam consumption for HFO tracing ~ 150 T

Cost of DM water per ton = Cost of water +

Cost of chemicals + Overhead

= Rs. (8+7+15)

= Rs. 30.

Annual cost of DM water for HFO tracing Steam

= Rs(30*150*365)

= Rs 16,42,500.

Cost-Benefit Analysis: Steam On an annual basis

Annual cost of DM water for HFO tracing = Rs 16,42,500

Improvement in Heat Rate:

For 1% reduction in DM Make Up, HR savings = 20.72kCal/kWh

Present DM Consumption = 0.497% of MCR

Eliminating 150 T Aux Steam Consumption = 0.310% of MCR

So, proposed HR savings = 0.187*20.72 = 3.874 kCal/kWh.

For 1kCal/kWh reduction in HR, savings ~ Rs 5000/day

So, proposed savings = Rs (3.874*5000) per day

(due to reduction in HR) = Rs 19,370 per day

= Rs 70,70,050 per year.

Annual savings = Rs.(16,42,500 + 70,70,050) = Rs 87.12 lacs

Cost-Benefit Analysis: Steam On an annual basis Contd..

With Plasma guns, un-burnt carbon can be reduced from 1.4% to

1.0%

So, un-burnt coal reduced from 3.5% to 2.5%

Reduction in NOx by 15%.

Savings in FOPH and boiler front maintenance costs.

Cost-Benefit Analysis: Other benefits

ADVANTAGES

PET eliminates the need for the use of any supplemental

fuel.

PET enables unit to operate at ~10% load with stable flame

with a variety of coal qualities.

PET improves boiler efficiency and decreases harmful NOx

emissions

ESP can be put into service during startup and hence

damage to ID fan Blades and Black Smoke can be avoided.

After retrofitting we will get CDM benefits due to reduction in

GHG emissions.

Roadmap

Power requirement in coming decades

India’s India’s

ROAD MAP

Implement PET in any of existing units in different

regions, to study its performance and reliability for Indian

conditions.

Further implement this technology in all upcoming plants.

Will help India to maintain Energy security.

CONCLUSION

Plasma Energy Technology is a “READY TO GO”

alternative solution for cleaner energy from coal.

Return on investments does not exceed 18 to 30

months.

Potential solution to the stringent environmental

norms.

CONCLUSION

THANK YOU

REFERENCES • Simulation of Coal Plasma Ignition and Combustion in a Furnace

Chamber by A.Askarova, E.Karpenko, V.Messerle, A.Ustimenko.

• 5th International Workshop and Exhibition on Plasma Assisted Combustion (IWEPAC), 15-18 September 2009, Hilton Alexandria Mark Center, Alexandria, Virginia, USA

• Mr. Srinivasan S, Mr. Jogesh Singh - M/S Jasubhai Industries

• M/S Gondian Power Corporation, China

• CERC website.

• www.energy-tech.com

http://www.energy-tech.com/



Assumptions and clarifications

• All calculations are for Simhadri St-I (2*500 MW) units.

• 4 nos of 200 kW plasma guns for each 500 MW unit.

• CV of LDO = 10200 kCal/kl, cost = Rs 58,000/kl

• CV of HFO = 9800 kCal/kl, cost = Rs. 40,000/kl

• CV of coal = 3000 kCal/kg, cost = Rs. 2,340/T

• Power required for pulverisation of coal = 20 kWh/ ton

The Yantai Lonyuan Power Technology Co. CHINA.

In India, M/s Jasubhai Industries are the sole vendor of Plasma Ignition Combustion System (PICS)

PLASMATRONICS™

New York, USA www.plasmatronicsllc.com

Beijing Compass Technologies Co Ltd.

Email: [email protected]

Beijing, P.R China

Welford Technology Holdings Limited

Hong Kong. http://www.welford.com.cn

Vendors:

mailto:[email protected]