SURFACE WATER VELOCITY DRIVEN HYDROKINETIC TURBINE VIKALP … · 2019. 8. 24. · VIKLAP-I as...

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SURFACE WATER VELOCITY DRIVEN HYDROKINETIC TURBINE

VIKALP-I FLOATING POWER PLANT

BY

C-21, Kiran Garden, Matiyala, New Delhi-110059

www.maclec.com, [email protected]

August 2019

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Innovation in Detail

1. Introduction to the Product:

VIKALP-I is first of its kind indigenous hydro turbine module which harness kinetic hydro power from

surface velocity of running waters. There is significant potential of hydro power in flowing

streams/canals and rivers in India. Conventional-hydro turbines are not suitable to tap this flowing water potential to generate electricity. The proposed hydrokinetic turbine can harness energy from flowing

water with adequate depth, width and adequate water velocity required (>0.5 m/s) available at these sites.

The installation of the system requires minimum civil structure for anchoring only and doesn't need big civil structure or diversion of water body from its natural source.

2. Company profile:

MACLEC is First Startup, working to explore and exploit hydrokinetic potential of available rivers and

canals in India through Indigenous Technology. Apart from Hydrokinetic Turbine, MACLEC introduces MACLEC ADVANCE SWACCH BHARAT TRASH (MAST) a unique waste collection, spot

segregation, compaction cum smart call back system and MACLEC VAYU (MV-I) a unique technology

driven solution which purify ambient air and generate electricity from road traffic itself, are in their various stage of development. Our 5 year old startup is DIPP registered, having in house capacity to

manufacture and install 1MW/6months and presently working with UJVN Limited, IIT Roorkee, NEERI

Delhi, DTRL DRDO, etc.

3. Product Details

The NOVELTY of proposed system is of tapping the surface velocity of the flowing stream and turbine

is not submerged in water completely which has been attempted first time. Therefore, it can also be

installed on shallow streams. The turbine, generator and other equipment are fitted on a floater and anchored at the banks of the stream through steel ropes. The floater can be adjusted according the water

level in the stream without changing its installation. This attempt is the first of its kind in India.

Regarding cost of the turbine it has been aimed that the equipment cost may be at par the cost of

conventional micro turbines cost after development.

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a) Scope of Product

All Major Minor Irrigation Canal Network, All Flowing Rivers, All Hilly Streams, all downstream

canals of Existing Hydro Dams, Power Canals and Tail Race Canals/Discharge Canals of Hydro power

Plants, even all sewage canals having regular flow of sewage (Example - Nazafgarh Drain, Delhi) are potential sites to install proposed Hydrokinetic Turbine technology because of its robustness, simple and

smart IoT Driven Technology.

Right now our target market is Irrigation Departments and PSUs of India working in Electricity Generation and Distribution sector because all these targeted PSUs have access to Canals/Rivers and

capability to get into PPA Agreement easily. They also have legal liability of indigenous technology

absorption to diversify and spread their business.

We are also simultaneously targeting individual authorities such as forest department, hotel chains,

resorts, village panchayats and individual farmers/industrialists having establishment near running water bodies.

As far as size of Indian Market alone is concerned, then we have personally identified 70 sites with

24757.3 Megawatt Scope in Grid based mega Hydrokinetic Turbine Power Plant Establishment. Moreover proposed technology have huge potential worldwide as well specially in USA, Canada,

Australia, UK, South East Asia, Africa and Latin America.

In case of off-grid potential, there can be millions of sites where our system can be installed off-grid

basis to fulfill round the clock electricity need of the establishment as standalone power plant.

b) Technical Specifications:

It is Cross flow turbine technology having Power Coefficient (Cp) in the range of 0.40 to 0.48 and Tip

Speed Ratio (TSR) in the range of 0.22.

Fig: Graphical Representation of TSR and Cp Values calculated by HRED, IIT Roorkee

Specific Turbine Blade Profile as well as blade angle allows turbine to harness maximum hydrokinetic

energy available in running water without blocking or creating any major head up in the streamline flow

of running water body.

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The turbine blades of VIKALP-I interacts with the water flow in radial flux manner that is why it require

only half submergence of rotor in order to get maximum power output.

Radial installation of VIKALP-I Turbine makes it debris free/ silt free/floating garbage free and allows it to harness electricity even from heavily silted /floating debris containing water bodies without getting

damaged.

Fig: Radial Flux installation of VIKALP-I and Simulation in ANSYS showing interaction of water stream with turbine blade profile

The radial orientation of turbine does not block the flow of water body and provide low RPM but higher

torque which make it fish friendly/aquatic life friendly and able to run even in shallow waters.

Floating installation allows turbine module to adjust its submergence level according to the water level

and lower down the risk of any damage to the turbine module during flash flood, sudden velocity/flow change/water level rise.

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Fig: Installation Plan.

c) Indian/International Standards Applicable

The fabrication Material of turbine module is RoHS compliance and follow all necessary standards

applicable for conventional hydro turbines prescribed by Hydro and Renewable Energy Department IITR and MNRE, etc.

d) Design Details

Standard Turbine Module consisting of Four Components:

(i) Turbine Rotor: Consisting of Specially designed Turbine blades attached to a rotor in a manner so that in case of any

damage, only specific blade can be repaired/replaced.

Fig: Turbine Module

(ii) Turbine Floater: Consisting of two floating pontoon like tanks having smooth ball mouth at both entry and exit sites of

water flow. Floater provides stable floating platform to Turbine Rotor, Turbine Gearbox Generator Drive

Train and Power Evacuation unit. Floater also have buoyancy adjustment system and provision to install solar PV Modules to give extra backup.

(iii) Turbine Gearbox Generator Drive Train:

One of the most important component which consists of specially designed couplers and mechanical energy transmission mechanism which allows smooth transmission of mechanical energy from turbine

rotor to generator through specially designed Gearbox.

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Fig: Turbine Gearbox Generator Drive Train:

(iv) Power Evacuation System:

Consisting of first of its kind Voltage and Frequency stabilization system as well as power monitoring

unit which stabilize the generated power and feed into Grid/Off-Grid use.

e) Test Reports (If Any)

Technical Evaluation, Computational Fluid Dynamics (CFD) Analysis, Field Trial, Scale Up Turbine Performance testing done by Hydro and Renewable Energy Department, Indian Institute of Technology

Roorkee.

Third Party review of Testing done by HRED IIT Roorkee have been concluded recently in July 2019 by

Central Board of Irrigation and Power (CBIP).

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f) Limitations:

S/No. Parameters Details

1. Minimum Stream Velocity Required 0.5 Meter/Second

2. Maximum Threshold Velocity 6 Meter/Second

3. Minimum Water Depth Required 0.4 Meter

4. Maximum Threshold water depth Infinite ( )

5. Minimum Required Width of Water body 1 Meter

6. Maximum Width of Water Body Infinite ( )

7. Required Water Quality All kind of flowing water (No issues with Silt

or any kind of floating debris )

No issues with pH, Salinity, Turbidity, Hardness, Alkalinity, TDS, etc.

4. Applications in Indian Context / works done in India (100)

Proposed technology enables the villagers, farmers, urban population, industries and all other electricity

consuming human establishments which are situated nearby canals/rivers/hilly streams, to generate 24*7 eco-friendly electricity without any carbon footprint.

Fig: Use of Diesel Pumps to lift water from Canals is still continue which can be replaced easily through

VIKLAP-I as Distributed Generation Cum Water lifting Plant

Our Technology can replace all of these diesel/electric pumps installed at running water source and reduce cost of farming drastically.

Our Turbine modules can also be installed at downstream of all Lift Canals to recover at least 50% of

energy used to lift the water through VIKALP-I Turbines. Army/Police Establishments, Railway Stations/Railway Gates, etc. established nearby running water bodies can also be potential beneficiaries.

We have done more than 68 field trials of our turbines throughout India and Nepal. Currently installing

100 kW in Uttarakhand with 1 MW order from Punjab is in hand.

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Fig: Glimpses of recently installed Pilot project in Roorkee

5. Cost Economics

( Material Cost & Installation or Execution Cost)

Cost of Grid Connected Per Megawatt VIKALP-I Turbine Plant

S/No Activity Work plan Cost (in

Lakhs)

Time

frame

(in

Working

Days)

Remarks

1. DPR Preparation Site Visit,

Site Potential

Estimation,

Execution Planning

20

0-60

Done by

MACLEC

under guidance

of HRED, IITR

2. Fabrication of

VIKALP-I Modules

0.90 lakh / kW 900.0 60-180 Done by

MACLEC

3. Assembling of

Modules at Site and

Installation

0.20 Lakh/kW 200.0 100-200 Done by

MACLEC

4. Electro Mechanical

Work & Grid

Connectivity

As per Standard 185.0 150-230 Done by

MACLEC

under guidance

of HRED, IITR

5. Performance Run

and Final

Commissioning

As per required 20.0 230-260 Done by

MACLEC

under guidance

of HRED, IITR

6. Contingencies &

Unforeseen

As per Standard 50.00 260

Working

Days

Grand Total 1375 (Inr Crores)

This is estimated cost based upon market survey, actual cost can be calculated only after

DPR Preparation)

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Proposed Outcome Per MW

S/No. Feature Outcome Remarks

1. Power generation 80.4 Lakh Units/Year

Ideal Outcome

Savings equivalent to Rs. 7.23 Cr

/year (@ INR 9/Unit Cost)

2. Coal Saving 582 Ton Coal/year Reduction of 31536 Ton CO2

3. Saving of Land 5 Acres In comparison of Land used by 1

MW Solar PP Installation

4. Employment

Generation

20 families/Megawatt Permanent Employment to 300 families and indirect Employment

to 3000 Families

5. Immediate

Beneficiaries

200 Farmers having

farmlands near the site

Villages, MSMEs, Schools and all

institutions situated nearby

6. Life of Plant > 35 Years Equivalent to any conventional

Hydro PP

7. Environmental

Impact

No Any Impact to

Environment, Ecology, Fishes, No

Relocation/Rehabilitation

of Local Community,

No Water Logging, No Permanent

Structure, No Permanent Head-up

8. Payback Time Less Than 5 Years Lowest then all existing hydro and

renewable energy generation

technologies.

c) Maintenance and Repairs Cost

Heads Cost (Annually in Lakhs) Details

Staff 18.00 Yearly Salaries and Staff Welfare cost

Regular

Maintenance

6.00 Oiling, Greasing and minor

repair and maintenance

(Monthly)

Scheduled

Maintenance

4.0 Repair and Replacement of

Major Parts (Ones in a year)

Total 28.00 Lakhs/year

d) Life Expectancy

The turbine power plant can continue in service till 35 Years provided with regular Operation and Maintenance.

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e) Cost comparison with Similar Other Products

Name of Hydrokinetic Company Origin Technical Features Details

DLZ Corp Hydrovolts JV

INDIA - US

JV

Turbine type- Ful

Submerged Type,

VELOCITY - > 2.5 M/SEC.

LCOE - >12/kW

Cost - >4 lakh/kW

Foreign Origin of

technology,

Unavailability of Spare Parts,

unable to perform in

low velocity and depth

PAT ICL JV

US

FULLY

SUBMERGED

VELOCITY - > 2.5 M/SEC.

LCOE - >11/kW

Cost - >4 lakh/kW

Foreign Origin of

technology

Can’t perform in low velocity and

depth

SMART HYDRO POWER GMBH

IMP Power India JV

GERMANY

FULLY

SUBMERGED

VELOCITY - >1.5 M/SEC.

LCOE - >9/kW

Cost - >4.2 lakh/kW

First 20 kW Turbine

Installed in Nayveli

Lignite Corp. Tamilnadu in 2018

Elemental Energy Technologies (EET)

+ Kirloskar JV

AUSTRALIA

Turbine Range

available from 2 kW

to 1000 kW with Velocity 3 to 4.5

m/sec.

LCOE >8/Unit

Any Successful test

in India is not

published so far

Instream Energy Systems

CANADA

Submerged Vertical

access hydrokinetic

turbines (VAHTs) , ~ 2 m/Sec to 4.2 m/s

HIGHER O&M

COST,

HIGHER INSTALLATION

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INR 5.7 Lakh/kW

with INR

70,000/year O&M

COST, HIGHER

SPARE PART

COST

Hydroquest SAS

France

Crossflow

technology with

dual vertical axes, Minimum current

flow speed of 3.1

m/s, INR 4.2 Lakh/kW

with INR

80,000/year O&M

LESS USER

FRIENDLY

HIGHER O&M COST,

HIGHER

INSTALLATION COST, HIGHER

SPARE PART

COST

TOCARDO

Netherlands

Submerged Axial

Flux technology

Similar to Wind Turbines,

Minimum current

flow speed of 2.5 m/s,

INR ~5 Lakh/kW

with INR 550,000/year O&M

LESS USER

FRIENDLY

HIGHER O&M COST,

HIGHER

INSTALLATION COST, HIGHER

SPARE PART

COST

MAKO Turbines

Australia

Submerged Axial Flux technology

Similar to Wind

Turbines,

Minimum current

flow speed of 3.5

m/s, INR ~7.14 Lakh/kW

with INR

90,000/year O&M, LCOE Range – INR

12-22/Unit

Presently Running

Plants

Tasmania, Canada,

UK Coast lines, HIGHER O&M

COST,

HIGHER

INSTALLATION COST,

Hydro Green Energy,

Birmingham

Zero Head and Low

Head Submerged Axial Flux

technology Similar

to Wind Turbines,

Presently Running

Plants

USA, UK

HIGHER O&M

COST,

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Minimum current

flow speed of 2.1

m/s, INR ~6.78 Lakh/kW

with INR

82,000/year O&M,

LCOE Range – INR 12-22/Unit

HIGHER

INSTALLATION

COST,

Xinda Green Energy,

China

Submerged Axial

Flux technology with bell mouth

Minimum current

flow speed of 2.6 m/s

INR ~3.78 Lakh/kW

with INR


8-20/Unit

Presently Running

Plants

Unorganized Off

grid

LESS USER FRIENDLY

HIGHER O&M

COST,

HIGHER INSTALLATION

COST, HIGHER

SPARE PART COST

SCHOTTEL

Germany

Submerged Axial

Flux technology

Horizontal axis Dual rotor free

flow turbine

Minimum current flow speed of 2.5

m/s

INR ~7.78 Lakh/kW with INR

85,000/year O&M,

LCOE Range – INR

12-22/Unit

Presently Running

Plants

Unorganized Off

grid HIGHER O&M

COST, HIGHER

INSTALLATION

COST, HIGHER SPARE PART

COST

NEW ENERGY CORP.,

CANADA

Submerged Vertical

Axis Cross Flow

Turbine Operating

Conditions

Minimum current flow speed of 2.5

m/s

INR ~8.0 Lakh/kW

with INR

Presently Running

Plants

Unorganized Off

grid HIGHER O&M

COST, HIGHER

INSTALLATION

COST, HIGHER

SPARE PART

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55,000/year O&M,

LCOE Range – INR

12-22/Unit

COST

VERDANT

USA

Submerged

horizontal-axis

turbines Similar to

Wind Turbine Technology

Operating

Conditions Minimum current

flow speed of 2.2

m/s

Cost INR ~7.5Lakh/kW

with INR


12-22/Unit

Presently Running

Plants

USA, UK

HIGHER O&M COST,

HIGHER

INSTALLATION COST,

GUINARD

FRANCE

compact

MegawattBlue turbine (3.5kW to

20kW) coupled with

batteries and other renewable energy

sources (PV, Wind,

etc)

Minimum current

flow speed of 2.1

m/s

INR ~6.78 Lakh/kW with INR

82,000/year O&M,

LCOE Range – INR 12-22/Unit

0.15 – 0.33

Euro/Unit Generation Cost

Presently Running

Plants

Unknown

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f) Cost comparison with Similar Conventional Techniques

S.N

o

Power

generation

system

Capital Cost

INR/kw

Operation

and

Maintenan

ce cost

INR/Kw/

Year

Life

(years)

Plant

Load

factor

Carbon

Emission

g/kWh

Levelised cost

of energy

INR/Kwh

1 Con. Hydro 70,000-

1,20,000

1800 40-50 0.60 10 5.74

2 Wind Energy 68,000-78,000 1540 25 0.15 9 1.83-4.8

3 Solar PV 60,000 600 25 0.19 38 2.44

4 Nuclear

Power

85,000 1700 60 0.80 6 6.53

5 Coal 50,000-70,000 2870 40 0.60 957 4..4

6 Natural Gas 45,000-60,000 1200 22 0.60 422 4.6

7 Biomass 55,000-65,000 1300 15-20 0.70-0.75 - 2.72

8 Tidal energy Under

Development

-

-

9. VIKALP-I 80,000-

1,30,000

2200 35-60 0.95 4 1.21

6. Company’s Recommendation/ Prospective Use of Product

In last 8 years of continuous field trails and technical analysis by IIT Roorkee, the company found the

proposed technology useful to harness green energy from all flowing water bodies including but not

limited to irrigation canals, river streams, backwaters, power canals of hydro dams, etc.

The technology is customizable, scalable, replicable, easily transportable, repairable without any

specialized tools or skills and environmentally sustainable because of its specialized design and working parameters.

Above features enables the proposed technology, capable to bring revolution in renewable hydro power

sector by reducing installation time, cost, LCOE, Payback time and environmental risks associated with conventional hydro plants.

8. Contact Details TECHNICAL & MARKETING SECTION

Mr. Narayan Bhardwaj,

Innovative CMD,

+91-8285948337

Er. BalRam Bhardwaj,

Innovative MD,

+91880217309

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Results of Performance Testing and CFD done in

collaboration with HRED, IIT Roorkee

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Third Party Review by CBIP

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1100.. AAWWAARRDDSS && RREECCOOGGNNIITTIIOONNSS

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C-21, Kiran Garden, Matiyala Main Road, Nawada, New Delhi-110059

www.maclec.com, [email protected], +91-8285948337

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