Asia Pacific Partnership on Clean Development & Climate

Brown Coal ( Lignite ) Best Practices Brown Coal ( Lignite ) Best Practices Work ShopWork Shop

India - Country Perspective23-27 th June2008

THE INDIAN DELEGATIONTHE INDIAN DELEGATION

NTPC DelegatesNTPC Delegates : :

I.K.RajdevaI.K.Rajdeva, , Additional General Manager, NTPC LtdAdditional General Manager, NTPC Ltd..

A.NagasundaramA.Nagasundaram, , Dy. Gen. Manager, NTPC Ltd.Dy. Gen. Manager, NTPC Ltd.

Saju K SebastianSaju K Sebastian, Dy. Gen. Manager, NTPC Ltd., Dy. Gen. Manager, NTPC Ltd.

P.S.ChatterjeeP.S.Chatterjee, Chief Design Engineer, NTPC Ltd., Chief Design Engineer, NTPC Ltd.

CESC DelegatesCESC Delegates : :

Souvik DuttaSouvik Dutta, , Station Manager, Southern generating Station, CESC Ltd .Station Manager, Southern generating Station, CESC Ltd .

Kushal BhowmickKushal Bhowmick,  ,  Senior Manager ( Environment),  CESC Ltd.Senior Manager ( Environment),  CESC Ltd.

Robust Economic Growth – THE Robust Economic Growth – THE DRIVERDRIVER

THE GDP GREW AT 9.6% DURING FISCAL 2007, THE GDP GREW AT 9.6% DURING FISCAL 2007, AVERAGE RATE OF GROWTH OVER LAST 4 YEARS IS AVERAGE RATE OF GROWTH OVER LAST 4 YEARS IS 8.6%.8.6%.

GDP GROWTH DURING 2008-09 IS EXPECTED TO BE GDP GROWTH DURING 2008-09 IS EXPECTED TO BE around 9%.around 9%.

GGDP GROWTH TARGET OF 9% SET BY GOVT. DURING DP GROWTH TARGET OF 9% SET BY GOVT. DURING XI PLAN (2007-2012).XI PLAN (2007-2012).

ELECTRICITY IS AN IMPORTANT INPUT TO THE MARCH ELECTRICITY IS AN IMPORTANT INPUT TO THE MARCH OF PROGRESS OF ANY COUNTRY TODAY.OF PROGRESS OF ANY COUNTRY TODAY.

IT IS THEREFORE NATURAL THAT THE GROWTH IN IT IS THEREFORE NATURAL THAT THE GROWTH IN ELECTRICITY GENERATION & AVAILABILITY, BE ELECTRICITY GENERATION & AVAILABILITY, BE COMMENSURATE WITH GROWTH IN GDP.COMMENSURATE WITH GROWTH IN GDP.

Existing Generating Capacity- March Existing Generating Capacity- March 20082008

Fuel wise break-up (MW)

(Excluding captive capacity of 14636 MW connected to grid)

ThermalThermal 92,42692,426 63.8%63.8%

HydroHydro 36,033 36,033 24.9%24.9%

NuclearNuclear 4,1204,120 2.8%2.8%

RenewableRenewable 12,19412,194 8.5%8.5%

TOTALTOTAL 144,773144,773 100.0%100.0%

Sector wise break-up (MW)

State Sector

52%

Private Sector

14%

Central Sector

34%

Total generation in 2007-08 – 704.45

BU

(All figures provisional from CEA)

ALL INDIA PLANT LOAD FACTOR (%) ALL INDIA PLANT LOAD FACTOR (%) - COAL FIRED THERMAL POWER STATIONS- COAL FIRED THERMAL POWER STATIONS

48

53

58

63

68

73

78

1985

-86

1986

-87

1987

-88

1988

-89

1989

-90

1990

-91

1991

-92

1992

-93

1993

-94

1994

-95

1995

-96

1996

-97

1997

-98

1998

-99

1999

-200

0

2000

-01

2000

-02

2002

-03

2003

-04

2004

-05

2005

-06

2006

-07

2007

-08

YEARS

PL

F (

%)

Energy Shortage Energy Shortage

507523

546559

591

631

691

737

467483

498519

548

579

624

665

450

500

550

600

650

700

750

2001 2002 2003 2004 2005 2006 2007 2008

REQUIREMENT AVAILABILITY

7.8%7.5%

8.8% 7.1%

7.3%

8.3%

9.6%

DURING 2007-08, PEAKING SHORTAGES WERE 16.6%

9.8%

Per capita Consumption remains Per capita Consumption remains lowlow

2,701

14,240

8,459

7,442

6,425

2,340

1,684

1,465

618665

World Average

USA

Japan

Germany

Russia

Brazil

China

Egypt

India

In 2006

Figures in kwh

Source: UNDP Human Development Report 2007-08 – Data for 2004

NATIONAL ELECTRICITY

POLICY TARGETS PER CAPITA

AVAILABILITY OF 1000 KWH

BY 2012

Projected Capacity Projected Capacity RequirementsRequirements

2007 2012 2022 2032Source: Integrated Energy Policy GOI

132 GW220 GW

425 GW

778 GW

Large Capacity addition required to meet the demand

CAPACITY ADDITION EXPECTED DURING 11th PLAN CAPACITY ADDITION EXPECTED DURING 11th PLAN (2007-12) (Conventional) – 78,520 MW(2007-12) (Conventional) – 78,520 MW

Thermal – 59,513MW( Coal – 51,890 MW, Gas- 5343 MW, Lignite- 2280 MW)

Additional capacity expected : New Renewables – 14,000 MW

: Captive – 12,000 MW

NUCLEAR, 3,380MW, 4%

THERMAL, 59,5130MW,

75%

HYDRO, 15,627MW,

21%

11TH PLAN PROGRAMME (2007-2012)11TH PLAN PROGRAMME (2007-2012)

(Thermal+Hydro+Nuclear) (Thermal+Hydro+Nuclear)

Proposed : 78,577 MWProposed : 78,577 MW

Expected : 78,520MWExpected : 78,520MW 9,263 MW capacity already commissioned9,263 MW capacity already commissioned

60,214 MW (77%) under construction 60,214 MW (77%) under construction

10,950 MW - Letter of awards yet to be placed10,950 MW - Letter of awards yet to be placed

Fuel Availability for 96% of coal based stations – tied Fuel Availability for 96% of coal based stations – tied

up up

88% hydro capacity under construction 88% hydro capacity under construction

/commissioned/commissioned

All gas based projects under execution or gas tied up All gas based projects under execution or gas tied up

from local sourcesfrom local sources

Additional 13,000 MW gas based projects identified Additional 13,000 MW gas based projects identified

– subject to gas availability– subject to gas availability

Installed Capacity (as on 31.03.2008)- 11125 MW

11th Plan target- 14,000 MW consisting of

• Wind Power - 10,500 MW

• Biomass PowerBaggasse Co-generation - 2,100 MW

• Small Hydro (up to 25 MW) - 1,400 MW

11TH PLAN PROGRAMME11TH PLAN PROGRAMMENON-CONVENTIONAL ENERGY PLANTSNON-CONVENTIONAL ENERGY PLANTS

CAPACITY ADDITION DURING XIITH CAPACITY ADDITION DURING XIITH PLAN PLAN (2012 - 2017)(2012 - 2017)

PLANPLAN TOTAL TOTAL CAPACITY CAPACITY ADDITION ADDITION PLANNEDPLANNED

(MW)(MW)

THERMALTHERMAL

(MW)(MW)

HYDROHYDRO

(MW)(MW)

NUCLEARNUCLEAR

(MW)(MW)

XIIXIITHTH 8220082200 4020040200 3000030000 1200012000

NATIONAL THERMAL POWER CORPORATION

LTD.- A PROFILE

Energy Efficiency Energy Efficiency

GOVERNMENT’S STRAGTEGY / GOVERNMENT’S STRAGTEGY / INITIATIVE FOR EFFICIENCY INITIATIVE FOR EFFICIENCY IMPROVEMENTIMPROVEMENT

Setting the Scene today for a future-Setting the Scene today for a future-

oriented Sustainable Energy oriented Sustainable Energy

productionproduction

INDIA’s ENERGY PROGRAMS AND POLICIESINDIA’s ENERGY PROGRAMS AND POLICIES

Improving energy efficiency

Promoting Hydro and renewable energy

Power sector Reforms

Promotion of Clean coal technology

Energy infrastructure Development

Coal Washing

Environmental Quality Management

DRIVERS FOR HIGHER PLANT DRIVERS FOR HIGHER PLANT EFFICIENCYEFFICIENCY

Demand of power is set to grow with growing economy Large capacity needs to be added to meet the projected

growth in demand With Electricity Act 2003 coming into vogue, the power

market is set to attract a lot of investors and competition With tariff based bidding becoming a norm, utilities have to

bring down their cost of generation to remain competitive Increased emphasis on Environmental considerations for

clean technology CDM opportunities arising out of global warming concerns Fuel, Land & Water availability becoming more and more

difficult Efficiency enhancement feasible in future plants as well as

existing plants

Major Initiatives ……Major Initiatives ……

Improvement in efficiency and performance of existing Improvement in efficiency and performance of existing generating units through : generating units through : Renovation and Modernisation schemes with emphasis on Energy Renovation and Modernisation schemes with emphasis on Energy

EfficiencyEfficiency

Partnership in excellence.Partnership in excellence.

Establishment of Energy Efficiency cells at thermal power stations ( 37 Establishment of Energy Efficiency cells at thermal power stations ( 37 cells in operation)cells in operation)

Energy Conservation through legislationEnergy Conservation through legislation Thermal Power Stations notified as Designated consumersThermal Power Stations notified as Designated consumers

Promotion of Renewable Energy SourcesPromotion of Renewable Energy Sources 15,627 MW Capacity of Hydro Power planned in XIth Plan15,627 MW Capacity of Hydro Power planned in XIth Plan 30,000 MW Capacity of Hydro Power planned in XIIth Plan30,000 MW Capacity of Hydro Power planned in XIIth Plan Retiring 5000 MW old capacity with low efficiency in 11Retiring 5000 MW old capacity with low efficiency in 11thth Plan Plan

Energy Conservation Act 2003 (EC Act)Energy Conservation Act 2003 (EC Act)

Designated Consumers NotifiedDesignated Consumers Notified Thermal Power StationThermal Power Station

Appoint Energy ManagerAppoint Energy Manager Get Energy Audits conducted by Accredited Energy AuditorsGet Energy Audits conducted by Accredited Energy Auditors Implement techno-economic viable recommendations given by Implement techno-economic viable recommendations given by

Accredited Energy AuditorAccredited Energy Auditor Comply with norms of specific energy consumption fixedComply with norms of specific energy consumption fixed Submit report on steps takenSubmit report on steps taken

Major Initiatives …..Major Initiatives …..

Adoption of Clean Coal TechnologiesAdoption of Clean Coal Technologies

– Supercritical / Ultra supercritical TechnologySupercritical / Ultra supercritical Technology

– Circulating fluidized bed combustion (CFBC)Circulating fluidized bed combustion (CFBC)

– Integrated Gasification Combined Cycle Integrated Gasification Combined Cycle (IGCC) Suitable for Indian Coal(IGCC) Suitable for Indian Coal

Presently Working to develop a Demonstration Presently Working to develop a Demonstration Project for IGCC along with suitable Partner, Project for IGCC along with suitable Partner, development of core technologies for gasifier & development of core technologies for gasifier & Gas cleaning systems suitable for High Ash Gas cleaning systems suitable for High Ash Indian Coal.Indian Coal.

Major Initiatives……Major Initiatives……

Ultra Mega Power Projects(4000MW capacity) Ultra Mega Power Projects(4000MW capacity) based on Supercritical Technology at various based on Supercritical Technology at various pithead and coastal locations.pithead and coastal locations. Envisaging Envisaging Mandatory Higher size thermal units (660/800 Mandatory Higher size thermal units (660/800 MWMW) with Supercritical Parameters) with Supercritical Parameters..

It is estimated to commissionIt is estimated to commission 10 Nos. units of 660MW (XIth Plan)10 Nos. units of 660MW (XIth Plan) 2 Nos. units of 800MW (XIth Plan)2 Nos. units of 800MW (XIth Plan) 12 Nos. units of 660MW (XIIth Plan)12 Nos. units of 660MW (XIIth Plan) 31 Nos. units of 800MW (XIIth Plan)31 Nos. units of 800MW (XIIth Plan)

Major Initiatives …..Major Initiatives …..

• Supercritical Units of 660 MW Rating under constructionSupercritical Units of 660 MW Rating under construction

• Supercritical Units of 800 MW Rating with higher steam Supercritical Units of 800 MW Rating with higher steam temperature conditions under considerationtemperature conditions under consideration

ParameterParameter 660MW660MW 800MW800MW

Main Steam Main Steam Pressure Kg/cm2Pressure Kg/cm2

247247 247247

Main Steam Main Steam Temperature Temperature ooCC

535/565535/565 565565

Reheat Reheat Temperature Temperature ooCC

565/593565/593 593593

Major Initiatives …..Major Initiatives …..

The Efficiency RoadmapThe Efficiency Roadmap

247/537/565

(660 MW)

170/537/537

(500 MW)

‘02 ‘07 ‘22‘17‘12Xth Plan

XIth Plan

XIIth Plan

XIIIth Plan

‘00

247/565/593

(660/800 MW)

280/600/620

(800-1000 MW)

320/600/620

(800-1000 MW)

Gro

ss E

ffic

ien

cy, G

CV

Bas

is

38%

39%

43%

42%

41%

40%

Lower Plant Efficiency in IndiaLower Plant Efficiency in India

The reported efficiency of Indian power The reported efficiency of Indian power plants is generally lower as compared to plants is generally lower as compared to efficiency of plants abroad, primarily due efficiency of plants abroad, primarily due to : to :

• Poorer condenser vacuum due to hot climatic conditions

• Higher unburnt carbon losses in boiler due to low grade high ash Indian coal

• Efficiency is reported on HHV basis of coal (same as the practice followed in USA) as against LHV used elsewhere.

Typical variation due to above = 3.0 to 4.0 % points (Approx.)

Heatrate Improvement Over The Years

0

2

4

6

8

10

12

14

200 LMZ (1978) 200 KWU (1979) 500 KWU (1982) 500 KWU Mod(1998)

500 High RH(2006)

660 SC (2004) 660/800 SC(2008)

P = 170 ataMST = 537

P = 130 ataMST = 537RHT = 537

P = 150 ataMST = 537RHT = 537

P = 170 ataMST = 537RHT = 537

P = 170 ataMST = 537RHT = 565

P = 247 ataMST = 537RHT = 565

P = 247 ataMST = 565RHT = 593

P = 170 ataMST = 537RHT = 537

P = 130 ataMST = 537RHT = 537

P = 150 ataMST = 537RHT = 537

Heatrate Improvement over the Heatrate Improvement over the YearsYears

Member of Carbon Sequestration Leadership Forum Member of Carbon Sequestration Leadership Forum (CSLF)(CSLF)

Participating in FutureGen Project of USAParticipating in FutureGen Project of USA

275 MW coal fired Zero Emission power plant275 MW coal fired Zero Emission power plant

India contributing US$10 MillionIndia contributing US$10 Million

Participating in Asia Pacific Partnership (APP) for Clean Participating in Asia Pacific Partnership (APP) for Clean Development and ClimateDevelopment and Climate

The Indian Project Proposals in the TF Action plan The Indian Project Proposals in the TF Action plan

Inputs like case studies & contact details of experts in areas of Inputs like case studies & contact details of experts in areas of India’s interest.India’s interest.

Work on Efficiency improvement of two thermal power Work on Efficiency improvement of two thermal power plants namely Ropar and Kolaghat thermal Power station plants namely Ropar and Kolaghat thermal Power station already started with support of USAID.already started with support of USAID.

Major Initiatives Contd …..Major Initiatives Contd …..

Mapping of Thermal Power Stations under Mapping of Thermal Power Stations under Indo-German ProgrammeIndo-German Programme

33 thermal units mapped ( 31 thermal stations)33 thermal units mapped ( 31 thermal stations)

85 Thermal Power Stations targeted85 Thermal Power Stations targeted

Energy Conservation AwardsEnergy Conservation Awards

National Award for improving performance National Award for improving performance of Thermal Power Stationsof Thermal Power Stations

Awards for reducing T & D losses.Awards for reducing T & D losses.

Major Initiatives …..Major Initiatives …..

Efficiency Improvement through Efficiency Improvement through Renovation and ModernizationRenovation and Modernization

A COST EFFECTIVE APPROACH ……A COST EFFECTIVE APPROACH ……

CONTINUE GETTING THE BEST OUT OF EXISTING CONTINUE GETTING THE BEST OUT OF EXISTING FLEETFLEET

NEED FOR R&M – EXISTING NEED FOR R&M – EXISTING UNITSUNITS

Improvement in performance parameters – PLF, Improvement in performance parameters – PLF, Availability, heat rate/efficiency, auxiliary power Availability, heat rate/efficiency, auxiliary power consumption, partial loading & forced outage.consumption, partial loading & forced outage.

Restore derated capacityRestore derated capacity Extension of economic life.Extension of economic life. Obsolescence & non availability of spares (eg C&I)Obsolescence & non availability of spares (eg C&I) Environmental issues/other statutory requirements.Environmental issues/other statutory requirements. Safety requirements.Safety requirements.

A large number of 200/250 MW & some 500 MW Units are in A large number of 200/250 MW & some 500 MW Units are in operation for more than 15/20 years and have considerable operation for more than 15/20 years and have considerable potential for life extension & efficiency improvementpotential for life extension & efficiency improvement

POTENTIAL FOR EFFICIENCY POTENTIAL FOR EFFICIENCY INTEGRATED R&MINTEGRATED R&M

Total No. of Total No. of UnitsUnits

Nos. of Units as potential Nos. of Units as potential CandidateCandidate

AgeAge >15 years>15 years >20 years>20 years

200/210 MW Units 200/210 MW Units (LMZ design)(LMZ design)

5353 ---- 5353

200/210 MW units 200/210 MW units (KWU design)(KWU design)

8888 3737 1212

500 MW units500 MW units 3535 1212 22

FUTURE APPROACH TOWARDS FUTURE APPROACH TOWARDS R&MR&M

Shift in focus from ‘Generation Maximization to ‘Plant Shift in focus from ‘Generation Maximization to ‘Plant Performance Optimization’ – Older units have many Performance Optimization’ – Older units have many more opportunities to reduce heat rate than newer more opportunities to reduce heat rate than newer units.units.

Retirement of very old small size low efficiency units Retirement of very old small size low efficiency units and replacement with higher efficiency units.and replacement with higher efficiency units.

Use of high end technology solutions for efficiency Use of high end technology solutions for efficiency enhancement to manage rising costs & reduce carbon, enhancement to manage rising costs & reduce carbon, foot prints, e.g.,foot prints, e.g.,Steam flow path modificationSteam flow path modificationSteam turbine and boiler upgradesSteam turbine and boiler upgradesImproved plant controlImproved plant control

FUTURE APPROACH TOWARDS FUTURE APPROACH TOWARDS R&M …R&M …

Additionality in efficiency improvementAdditionality in efficiency improvement Efficiency improvement as a result of normal Efficiency improvement as a result of normal

R&M, aims at to minimising losses ( to R&M, aims at to minimising losses ( to approach design values)approach design values)

Efficiency improvement through technology Efficiency improvement through technology intervention/enhanced R&M, targeting efficiency intervention/enhanced R&M, targeting efficiency enhancement even beyond design value.enhancement even beyond design value.

Parameters For Performance Parameters For Performance MonitoringMonitoring

Unit Heat RateUnit Heat Rate

Unit Auxiliary Power consumptionUnit Auxiliary Power consumption

Unit Specific secondary fuel oil Unit Specific secondary fuel oil consumption consumption

Unit Specific coal consumptionUnit Specific coal consumption

Plant Load Factor (PLF)Plant Load Factor (PLF)

Planned Maintenance, Forced outage and Planned Maintenance, Forced outage and Operating availability Operating availability

Projects for the Task ForceProjects for the Task Force

Sl. No.Sl. No. Project TitleProject Title Proposing CountryProposing Country

11 Best Practices for Power Generation Activity PlanBest Practices for Power Generation Activity Plan USA, JAPAN, KOREAUSA, JAPAN, KOREA

22 Best Practices for Transmission and Distribution Activity PlanBest Practices for Transmission and Distribution Activity Plan USAUSA

33 Best Practices for Demand Side Management Activity PlanBest Practices for Demand Side Management Activity Plan USAUSA

44 Energy Regulatory & Market Development ForumEnergy Regulatory & Market Development Forum AUSTRALIAAUSTRALIA

55 Trade Exhibitions/Conferences and Trade MissionsTrade Exhibitions/Conferences and Trade Missions USAUSA

66 Hydroelectric Generation Best Practices Hydroelectric Generation Best Practices USAUSA

77 Combustion Optimization in Coal Based Power PlantsCombustion Optimization in Coal Based Power Plants INDIAINDIA

88 Implementation of Artificial Intelligent Soot Blowing System for Improving the Implementation of Artificial Intelligent Soot Blowing System for Improving the Steam Generator Efficiency by Increasing the Effectiveness of Soot Blowers.Steam Generator Efficiency by Increasing the Effectiveness of Soot Blowers.

INDIAINDIA

99 SOx Reduction Technologies in Flue GasSOx Reduction Technologies in Flue Gas INDIAINDIA

1010 Risk Evaluation and Prioritization (REAP) for Maintenance and Renovation & Risk Evaluation and Prioritization (REAP) for Maintenance and Renovation & Modernization (R&M) of Power PlantsModernization (R&M) of Power Plants

INDIAINDIA

1111 Life Extension & Remaining Life Assessment Of Power PlantsLife Extension & Remaining Life Assessment Of Power Plants INDIAINDIA

1212 Site visit of energy conservation and environment protection technology—Site visit of energy conservation and environment protection technology—Application of Plasma Ignition Technology in Power generationApplication of Plasma Ignition Technology in Power generation

CHINACHINA

1313 Generator Transformer Programs (Inspection Procedures, Diagnostic Tools and Generator Transformer Programs (Inspection Procedures, Diagnostic Tools and Maintenance)Maintenance)

INDIAINDIA

Highest ever utilisation of Fly Ash a testimony to ecology preservation

0.3

3.03.7

5.77.5

12.7

19.6

22.3

0

5

10

15

20

25

1991-92 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07

As

h U

tili

sa

tio

n i

n M

illi

on

to

nn

es

Fly Ash Utilization Record – NTPCFly Ash Utilization Record – NTPCAS A SAMPLE CASE ONLYAS A SAMPLE CASE ONLY

Afforestation Efforts – Afforestation Efforts – A Priority for A Priority for sustenance of HUMANITY!!sustenance of HUMANITY!!

Forest Banks concept Forest Banks concept

NTPC has created a Green wealth of NTPC has created a Green wealth of

18.2 Million Trees by Summer 200718.2 Million Trees by Summer 2007

Plantation of 1.25 Million trees Plantation of 1.25 Million trees

around Ramagundam Project has around Ramagundam Project has

resulted in resulted in Summer Peak Summer Peak

temperature reduction by 3 deg temperature reduction by 3 deg

CC

Ash Mound Reclamation and Dry ash Ash Mound Reclamation and Dry ash

disposal system disposal system