Dr. V. K. SETHI

Prof. & Head

RGPV

Bhopal

CLEAN COAL TECHNOLOGIES FOR CLEAN COAL TECHNOLOGIES FOR SUSTAINABLE POWER DEVELOPMENTSUSTAINABLE POWER DEVELOPMENT

PRIORITIES ON ENERGY GENERATION SECTOR:PRIORITIES ON ENERGY GENERATION SECTOR: Increased use of Advanced Fossil Fuel Technology.Increased use of Advanced Fossil Fuel Technology.

Promote CCT in countries where coal is main stay Promote CCT in countries where coal is main stay fuel for Power Generation.fuel for Power Generation.

Reduce Atmospheric Pollution from Energy Reduce Atmospheric Pollution from Energy Generating Systems.Generating Systems.

Enhance productivity through Advanced Fossil Fuel Enhance productivity through Advanced Fossil Fuel Technology.Technology.

WORLD SUMMIT ON SUSTAINABLE DEVELOPMENT

POWER SCENARIO IN INDIAPOWER SCENARIO IN INDIA

Installed capacity in utilities (March 31, 2002)Installed capacity in utilities (March 31, 2002)

   ThermalThermal 73,274 mw73,274 mw HydroHydro 25,574 mw25,574 mw NuclearNuclear 2,860 mw 2,860 mw WindWind 1,427 mw 1,427 mw TotalTotal 1,03,135 mw 1,03,135 mw

Total energy generation - 383 billion kwhTotal energy generation - 383 billion kwh Per Capita Energy Consumption -400 kwhPer Capita Energy Consumption -400 kwh

DEMAND PROJECTIONDEMAND PROJECTION

YEAR 2012 CAPACITY ADDITION BY SECTORSYEAR 2012 CAPACITY ADDITION BY SECTORS CentralCentral 46,500 MW46,500 MW State & IPPState & IPP 41,800 MW41,800 MW NCESNCES 10,700 MW10,700 MW NuclearNuclear 6,400 MW6,400 MW TotalTotal 105,400 MW105,400 MW

YEAR 2020 MIX OF GENERATIONYEAR 2020 MIX OF GENERATION ThermalThermal 326,000MW326,000MW Renewable & Hydro Renewable & Hydro 104,000 MW104,000 MW NuclearNuclear 20,000 MW20,000 MW TotalTotal 450,000 MW450,000 MW

CLEAN COAL TECHNOLOGIESCLEAN COAL TECHNOLOGIES

MiningMining Management & Practices Management & Practices (Reduction of Extraneous (Reduction of Extraneous material)material)

Coal PreparationCoal Preparation Process after mining to improve Process after mining to improve inherent & Extraneous material inherent & Extraneous material (washing & beneficiation)(washing & beneficiation)

Conversion TechnologiesConversion Technologies Supercritical, PFBC and IGCCSupercritical, PFBC and IGCC

Post combustion cleaningPost combustion cleaning Particulate and gaseous Particulate and gaseous pollutants removal pollutants removal (Environmental requirement)(Environmental requirement)

VISION 2020

PROGRAM

Post combustion Clean-up-Desulfurization

(FGC systems) Supercritical

In-combustion Clean-up Fluidized bed

combustion (CFBC, PFBC, AFBC)

Gasification using + fluidized bed, moving bed or Entrained bed Gasifiers

Pre combustion Clean-up beneficiation/washing

Technologies for utilization of Coal for Power Generation with minimal pollutants discharged to the atmosphere (Reduced CO2, Sox, Nox, SPM) at high conversion efficiency……….World Coal Institute.

CLEAN COAL TECHNOLOGIES

CLEAN COAL CLEAN COAL TECHNOLOGIESTECHNOLOGIES

Clean Coal Technologies Clean Coal Technologies (CCTs) are defined as (CCTs) are defined as ‘technologies designed to ‘technologies designed to enhance: enhance:

Efficiency of conversionEfficiency of conversion

Environmental Environmental acceptability of coal acceptability of coal extraction, preparation and extraction, preparation and use. use.

COAL FOR POWER COAL FOR POWER GENERATIONGENERATION

China and India are projected to China and India are projected to account for30% of the world’s account for30% of the world’s increase in energy consumption increase in energy consumption between 2000-2020 and 92% of between 2000-2020 and 92% of increase in coal use.increase in coal use.

The key environmental challenges The key environmental challenges facing the coal industry are related to facing the coal industry are related to ::

Coal MiningCoal MiningParticulate emissionParticulate emissionDisturbance land meDisturbance land meAcid rainAcid rainOzone and Waste disposalOzone and Waste disposal

INDIA AMONGST TOP INDIA AMONGST TOP SIX EMITTERS OF CO2SIX EMITTERS OF CO2

Country Country Total emission Total emission Percentage ofPercentage of

(Million Tonnes of CO2) (Million Tonnes of CO2) world world emissionemission

USAUSA 54705470 24%24%

China China 3121312114%14%

Russian FederationRussian Federation14561456 6%6%

Japan Japan 11731173 5%5%

GermanyGermany 884884 4%4%

India India 881881 4%4%

Note : Green House Note : Green House inventory for India for inventory for India for Energy Sector (Million Energy Sector (Million

Tonnes of COTonnes of CO22) ) Energy Sector Energy Sector CO2CO2 CO2 CO2 equivalentequivalent

(CO2+CH4+NOx)(CO2+CH4+NOx)

Total EmissionTotal Emission 508 508 565 565

(58% of total)(58% of total) (64% of (64% of total)total)

Source : IAE : 1999Source : IAE : 1999

PER CAPITA EMISSIONS OF COPER CAPITA EMISSIONS OF CO22

Top 6 PollutersTop 6 Polluters

World Developed countriesParties(Tonnes of CO2 percapita)

Developing Countries

(Tonnes of CO2 percapita)

Qatar 44.08Bahrain 35.23UAE 30.11Kuwait 25.01Singapore 23.47U.S.A 20.50

USA 20.50Luxemboury 20.42Australia 16.52Canada 15.76Finland 12.47Estonia 12.47

Qatar 44.08Bahrain 35.23U.A.E. 30.11Kuwait 25.01Singapore 23.47Saudi Arabia 13.27

Note : Per capita CO2 equivalent emissions for India in 1990 are estimated to be1.194 tonnes or 325 kg of Carbon per capita. This contribution 58% of NationalEmissions and 4% of global emission.

Source : IEA 1999 & UNDP 1998.

COSTCOST OF VARIOUSOF VARIOUS CO2 CO2 MITIGATION OPTIONS FOR MITIGATION OPTIONS FOR INDIAN POWER SECTORINDIAN POWER SECTOR

PotentialTechnologies

1. Co-generation2. Combined Cycle3. PFBC4. IGCC5. Supercritical6. Coal Washing

Green housegas emissionreduction (kg/kWh)

1.500.960.180.230.180.125

COST (Rs/Tonnes CO2).

48026002400016000160008500Source: ADP 1998

Zero Emission Zero Emission Technology (ZET)Technology (ZET)

This technology combines and forms a This technology combines and forms a part of :part of :

Clean Coal TechnologiesClean Coal Technologies Solid to liquid fuel technologySolid to liquid fuel technology GHG mitigation technologyGHG mitigation technology Clean Development Mechanism for power Clean Development Mechanism for power

sectorsector Non-CFC Refrigerant and Non-CFC Aerosol Non-CFC Refrigerant and Non-CFC Aerosol

Propellant TechnologyPropellant Technology Clean Aviation Fuel or ATF for aircraftClean Aviation Fuel or ATF for aircraft Substitute LPG for domestic use.Substitute LPG for domestic use.

Measures to achieve Measures to achieve Sustainable Sustainable

DevelopmentDevelopment Promoting CCTs, including Promoting CCTs, including carbon sequestration is essential carbon sequestration is essential to a balanced cost effective climate to a balanced cost effective climate change response change response

Developing countries where coal Developing countries where coal combustion efficiencies are low combustion efficiencies are low CCT promotion a need of the day.CCT promotion a need of the day.

EFFICIENCY IMPROVEMENT FORECASTCONVENTIONAL Vs IGCC ( Courtesy BHEL)

60

55

50

45

40

35

301990 1995 2000 2005 2010

Year of commercial use

Net

The

rma

l Effi

cie

ncy

(%)

Ceramic gasturbine

566 Co 600 Co623 Co

1300 Co 1500 Co

540 Co

650 Co1184 Co

IGCC (15 C Amb)

IGCC (Indian Condition)

Super Critical PC Power Plant (15 C Amb.)o

Super Critical PC Power Plant (Indian Condition)o

Sub Critical PC Power Plant (Indian Condition)

570

256

384380

0

100

200

300

400

500

600

CO2

MM

T

2.84.3

10

6.6

0

5

10

15

SO2

MM

T

85

128

13.3 20

0

50

100

150

ASH

MM

T No Change Scenario

Specific Coal Consumption

=0.75 KG/KWH

Coal

Ash : 43%

Sulphur : 0.6%

Ideal Scenario

Specific Coal Consumption

=0.35 KG/KWH

Coal

Ash : 15%

Sulphur : 3%

POLLUTANT GENERATION FROM PC PLANTS

1997

1997

1997

1997

1997

1997

2002

2002

2002

2002

2002

2002

SOx NOx Particulates0

102030405060708090

100110120

PE

RC

EN

TAG

E O

F P

C P

LAN

TS

PC

IGCC

PFBC

PC+FGD

RELATIVE EMMISSION

SUPER CRITICAL UNITSSUPER CRITICAL UNITS

Standardized Unit Size 660 MW, 246 ata, 537 Standardized Unit Size 660 MW, 246 ata, 537 ooCC Station Size 2x660 MW (Minimum)Station Size 2x660 MW (Minimum) Common Off site facilityCommon Off site facility FW Temperature 270 FW Temperature 270 ooC – 275 C – 275 ooC with 6 Heaters.C with 6 Heaters.

Total Capacity Planned Total Capacity Planned 14,560 MW 14,560 MW **

Number of UnitsNumber of Units 22 Units22 Units

** Includes 6x720 MW and 2x500 MW Imported sets.Includes 6x720 MW and 2x500 MW Imported sets.

Main advantages ofMain advantages ofSuper-Critical Steam CycleSuper-Critical Steam Cycle

Reduced fuel cost due to improved thermal Reduced fuel cost due to improved thermal

efficiencyefficiency

Reduction of COReduction of CO22 emissions by 15% per unit of emissions by 15% per unit of

Power generated compared to sub-criticalPower generated compared to sub-critical

Very good part load efficienciesVery good part load efficiencies

Plant costs are comparable with sub-critical unitsPlant costs are comparable with sub-critical units

Current State-of-ArtCurrent State-of-Art

Super-critical Steam Power Generation PlantsSuper-critical Steam Power Generation Plants

PressurePressure -- 300 bar300 bar

TemperatureTemperature -- 600600ooCC

EfficiencyEfficiency -- 45% (LHV Basis)45% (LHV Basis)

Nickel based alloys allows up 650Nickel based alloys allows up 650ooCC

By the year 2005By the year 2005 -- 620620 o oCC

By the year 2020By the year 2020 -- 650-700650-700 o oCC

Cycle EfficiencyCycle Efficiency -- 50-55%50-55%

R&D IN R&D IN SUPERCRITICAL SUPERCRITICAL TECHNOLOGY TECHNOLOGY

Main Thrust Areas :Main Thrust Areas : Materials & Metallurgy for components Materials & Metallurgy for components of boiler & of boiler & turbine subjected to high turbine subjected to high temperature and high temperature and high pressure.pressure. Supercritical cycle optimization -Supercritical cycle optimization -incremental heat rate incremental heat rate improvementimprovement Retrofit of supercritical boiler to Retrofit of supercritical boiler to subcritical PC boilersubcritical PC boiler Fluidized bed supercritical steam cyclesFluidized bed supercritical steam cycles Once through HRSGs with supercritical Once through HRSGs with supercritical parametersparameters Multi-reheat supercritical boilers with Multi-reheat supercritical boilers with double/triple double/triple reheater.reheater.

EXPECTED BENEFITS: EXPECTED BENEFITS:

Coal SavingCoal Saving 1,565,2001,565,200 TonnesTonnes

Co2 Emission ReductionCo2 Emission Reduction 1,909,5441,909,544 ” ”

SO2 Emission ReductionSO2 Emission Reduction 11,648 11,648 ” ”

Ash ReductionAsh Reduction 661,752 661,752 ” ”

SUPER CRITICAL SCENARIOSUPER CRITICAL SCENARIO

COAL BASED COMBINED CYCLE PLANTCOAL BASED COMBINED CYCLE PLANT

RoutesRoutes

CombustionCombustion GasificationGasification

Hot Flue gas under pressure Hot Flue gas under pressure drives the G.T.drives the G.T.

Pressurized gasification Pressurized gasification process produces fuel for process produces fuel for G.T.G.T.

PressurizedPressurized

Fluidized – BEDFluidized – BED

Combustor (PFBC)Combustor (PFBC)

Options AvailableOptions Available Moving – BEDMoving – BED Fluidized – BEDFluidized – BED Entrained – BEDEntrained – BED

COAL BASEDCOAL BASEDCOMBINED CYCLE POWER GENERATIONCOMBINED CYCLE POWER GENERATION

Offers Plant efficiency over 44% with advanced GTOffers Plant efficiency over 44% with advanced GT

Has Lower emission of gaseous and solid pollutantsHas Lower emission of gaseous and solid pollutants

Accept Inferior and varying quality of coalsAccept Inferior and varying quality of coals

Lower water requirementLower water requirement

Capability of phased construction and retrofittingCapability of phased construction and retrofitting

IGCC TECHNOLOGY ...IGCC TECHNOLOGY ...

Gasification of coal is the cleanest way of Gasification of coal is the cleanest way of utilization of coal, while combined cycle power utilization of coal, while combined cycle power generation gives the highest efficiency.generation gives the highest efficiency.

Integration of these two technologies in IGCC Integration of these two technologies in IGCC power generation offers the benefits of very low power generation offers the benefits of very low emissions and efficiencies of the order of 44-emissions and efficiencies of the order of 44-48%.48%.

The comparative indices show that in case of The comparative indices show that in case of IGCC, emission of particulate, NOx and SOx are: IGCC, emission of particulate, NOx and SOx are:

7.1%, 20% and 16%, respectively, of 7.1%, 20% and 16%, respectively, of the the corresponding emissions from corresponding emissions from PC plant. PC plant.

IGCC ...IGCC ... Environmental performance of IGCC plants Environmental performance of IGCC plants

far exceeds that of conventional and even far exceeds that of conventional and even supercritical plants.supercritical plants.

Three major areas of technology that will Three major areas of technology that will contribute to improvements in IGCC are :contribute to improvements in IGCC are :

hot gas de-sulfurisationhot gas de-sulfurisation hot gas particulate removal hot gas particulate removal advanced turbine systemsadvanced turbine systems

DEVELOPMENTAL GOALS FOR IGCCDEVELOPMENTAL GOALS FOR IGCC

To utilize India’s low grade coal for power generation To utilize India’s low grade coal for power generation with improved plant efficiency.with improved plant efficiency.

To introduce coal gas in Natural Gas based Combined To introduce coal gas in Natural Gas based Combined Cycle Plants in a phased manner.Cycle Plants in a phased manner.

To increase power generation capacity at the level of To increase power generation capacity at the level of present emission.present emission.

To develop state of Art Technology for Indigenous and To develop state of Art Technology for Indigenous and Export Markets.Export Markets.

Gasifier

Raw Gas Cooler

CombustionChamber

Comp. Turb.

Alternator

Air

COAL

Ash

Exhaust Gases

Condenser

WHB

Alternator

ST

Air

Fuel

Steam

Gas Clean Up

Booster

Steam

IGCC

IGCC DEVELOPMENT PROGRAM IN INDIAIGCC DEVELOPMENT PROGRAM IN INDIA

MAJOR MILE STONES:MAJOR MILE STONES:

Choice of gasification for high ash coals by BHELChoice of gasification for high ash coals by BHEL

6.2 MW IGCC demonstration plant established by BHEL both with 6.2 MW IGCC demonstration plant established by BHEL both with

Moving Bed and Fluidized Bed.Moving Bed and Fluidized Bed.

Coal Characterization by BHEL & IICT for gasification application.Coal Characterization by BHEL & IICT for gasification application.

Intensive data generated by IICT on oxygen-steam gasification in their Intensive data generated by IICT on oxygen-steam gasification in their

Moving Bed gasifier.Moving Bed gasifier.

Task force CEA, CSIR, NTPC & BHEL constituted to assess Task force CEA, CSIR, NTPC & BHEL constituted to assess

technological maturity & Financial requirement for a green field IGCC technological maturity & Financial requirement for a green field IGCC

plant of 100 MW capacity at Dadri (NTPC).plant of 100 MW capacity at Dadri (NTPC).

BHEL, CSIR & NTPC prepared proposal for setting up of this 100 MW BHEL, CSIR & NTPC prepared proposal for setting up of this 100 MW

IGCC demonstration plant.IGCC demonstration plant.

Circulating Fluidized Bed Combustion Circulating Fluidized Bed Combustion (CFBC) technology has selectively (CFBC) technology has selectively been applied in India for firing high been applied in India for firing high sulphur refinery residues, lignite, etc.sulphur refinery residues, lignite, etc.

CFBC Technology is superior to PC CFBC Technology is superior to PC Power Plant Technology:Power Plant Technology:

Lower NOx formation and the ability Lower NOx formation and the ability to capture SOto capture SO22 with limestone with limestone injection the furnace.injection the furnace.

Circulating fluidized Bed Combustion

Good combustion efficiencies Good combustion efficiencies comparable to PC Power Plants.comparable to PC Power Plants.

The heat transfer coefficient of the CFB The heat transfer coefficient of the CFB furnace is nearly double that of PC which furnace is nearly double that of PC which makes the furnace compact.makes the furnace compact.

Fuel Flexibility:Fuel Flexibility: The CFB can handle a The CFB can handle a wide range of fuels such as inferior coal, wide range of fuels such as inferior coal, washery rejects, lignite, anthracite, washery rejects, lignite, anthracite, petroleum coke and agricultural waste petroleum coke and agricultural waste with lower heating.with lower heating.

Circulating fluidized Bed Combustion

Steam to Super Heater

Cyclone

FurnaceCoal FeedHopper

Ash Cooler

Back-Pass

ESP

ExternalHeat-Exchanger

HP Air

Circulating Fluidised Bed Boiler

CFBC Vs Other Clean CFBC Vs Other Clean Coal TechnologiesCoal Technologies

At present pulverized fuel firing with FGD are At present pulverized fuel firing with FGD are less costly than prevailing IGCC technology. less costly than prevailing IGCC technology. However, firing in CFB Boiler is still more However, firing in CFB Boiler is still more economical when using high sulfur lignite economical when using high sulfur lignite and low-grade coals and rejects.and low-grade coals and rejects.

0.8-0.980.8-0.981.491.491.01.0Relative O&M Relative O&M Cost/kWCost/kW

1.15-1.15-1.421.421.03-1.191.03-1.191.01.0Relative Capital Relative Capital

Cost/kWCost/kW

41-4241-4236.736.734.834.8Cycle Eff. %Cycle Eff. %

IGCCIGCCPF+FGD/PF+FGD/SCRSCRCFBCCFBCITEMITEM

Renovation & Modernization (R&M) and Renovation & Modernization (R&M) and Life Extension (LE) of old power plants is Life Extension (LE) of old power plants is a cost-effective option as compared to a cost-effective option as compared to adding up green field plant capacities.adding up green field plant capacities.

Growing environmental regulations would Growing environmental regulations would force many utilities within the country to force many utilities within the country to go for revamping these polluting old go for revamping these polluting old power plants using environmentally power plants using environmentally benign CFBC technology.benign CFBC technology.

Sustainable Power Development calls for adoption of Clean Coal Technologies like Supercritical cycles, IGCC and FBC technologies

Supercritical Power technologies may selectively be used for Pit Head power generation using washed coal

SUMMERY

IGCC can revolutionize the power IGCC can revolutionize the power generation scenario in India, once the generation scenario in India, once the commercial viability of technology with commercial viability of technology with high ash coals is established at the high ash coals is established at the proposed 100 MW plant. proposed 100 MW plant.

The success of the project will largely The success of the project will largely depend on maturity of Fluidized bed depend on maturity of Fluidized bed gasification technology for high ash gasification technology for high ash Indian Coals.Indian Coals.

CFBC technologies are particularly useful CFBC technologies are particularly useful for Boiler Emission reduction through for Boiler Emission reduction through revamping of old polluting plants.revamping of old polluting plants.

SUMMERY