BHEL

1Bharat Heavy Electricals Limited

ENERGY CONCLAVE 2006

TECHNOLOGY FRONTIERS AND MODERNISATION

ENERGY R&DBHEL ROLE & CONTRIBUTION

PRESENTATIONBY

RAVI KUMARDIRECTOR (POWER)

BHEL, NEW DELHI


R&D – WORLD STATUS

Expenditure on R&D per capita(IN US $)

INDIA - 5.5 CHINA - 11.7 S. KOREA - 241 AUSTRALIA - 285 UK - 460 USA - 705 JAPAN - 978


R&D – BHEL

TARGETS

2006-07 2005-06

EXPENDITURE ON R&D RS. 150 CR. RS. 125 CR.

NO. OF PATENTS TO BE FILED

55 NOS. 45 NOS.

COMMERCIALISATION OF IN HOUSE DEVELOPED PROJECTS

RS. 700 CR. RS. 650 CR.


BHEL-R&D EXPENDITURE AS % OF T.O.

History of R & D Expenditure as % of T.O.

0

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

1992-93

1993-94

1994-95

1995-96

1996-97

1997-98

1998-99

1999-00

2000-01

2001-02

2002-03

2003-04

2004-05

2005-06

Year

R &

D E

xpen

dit

ure


Lower Cost of Generation

Environment Friendly

Higher Efficiency

Higher Reliability

Compatible to Local Conditions

TECHNOLOGY TRENDS

POWER SECTOR


Center Of Excellence For Simulators

Center Of Excellence For Computational

Fluid Dynamics

Center Of Excellence For Permanent

Magnet Machines

CENTRE OF EXCELLENCE SETUP BY BHEL


Low Nox Oil/ Gas Burners

Large Capacity Atmospheric FBC

High Efficiency Pelton Turbine

Controlled Shunt Reactor (CSR)

Flexible AC Transmission System (FACTS)

Space Grade Solar PV Panels

Phase Shift Transformer

145 KV Gas Insulated Switchgear

India’s Largest Vertical AC Motor (6 MW, 6.6 KV)

Micro Controller Based Flame Scanner

Performance Analysis, Diagnostics and Optimization (PADO) Package

91 Ton/hr BHEL 280 Bowl Mill

STATE OF ART TECHNOLOGIES / PRODUCTS INTRODUCED BY BHEL


TECHNOLOGIES SUBSTANTIALLY DEVELOPED

Supercritical Thermal Power Plants

Circulating Fluidised Bed Combustion

Coal Based Combined Cycle Plants

IGCC

PFBC

Nuclear Power Generation with Fast Breeder

Technologies

Fuel Cells

Solar Photo Voltaic


The supercritical cycle offers a ‘burn less fuel for the same output’ approach

Involves economical use of energy resources resulting in higher efficiency and low emissions

BHEL is equipped to supply Supercritical Power Plants upto 1000 MW

SUPERCRITICAL THERMAL POWER PLANTS


Cycle Efficiency benefits of supercritical units are derived from higher pressures and temperatures of steam


Super Critical R&D Projects

Areas identified R&D Actions Taken

Heat Transfer Correlations Joint Project with

IIT-ChennaiDNB, Tube Dry-out

Flow Instability

Spiral to Vertical Transition Piece Joint Project with AU FRG

Load Transfer Attachment

Dynamics, Temperature Control BHEL Corp R&D

Ripple Effect BHEL In-House Chemical Lab

FW Oxygenated Treatment

Low NOx Burner BHEL In-House


CFBC TECHNOLOGY

Burns low grade fuels like lignite No pulverising Low NOx & Low SOx emissions Higher efficiency BHEL commissioned 2x390 TPH

boilers for Surat Lignite Power Project

Number of 125 MW CFBC based power plants are under execution

Order received for 2x250 MW NLC, the largest CFBC technology based power plant in the country


ENVIRNOMENTAL ASPECTS – ROAD MAP

Development of low NOx wall fired coal burner - 2006Establishment of SCR demo plant - 2007Commercialisation of wall burner - 2008Commercialisation of SCR system - 2010

Area of focus - NOx control in pulverized coal fired boilers

Unit capacity, MW fuel NOx emission, ppm at 3.0 % O2

500 gas 73

500 oil 129 to165

500 coal 271 to 434

250 coal 266 to 322

210 coal 247 to 478

210 lignite 242 to 280

120 coal 389

NOx emission scenario of Indian plants while firing different fuels:


6.2 MW IGCC Pilot Plant at its Trichy Complex.

Technical feasibility of upgrading the 6.2 MW Combined Cycle Demonstration Project of BHEL to ~100 MW had been established

Preliminary assessment made for 400 MW IGCC Plant

Plan to set up 125 MW IGCC Demonstration plant

IGCC POWER GENERATION - DEVELOPMENT IN BHEL


PFBG SCALE - UP

IGCC POWER GENERATION - DEVELOPMENT IN BHEL


A glimpse of Fuel Cell Developments at BHEL(Inter-disciplinary approach followed for Fuel Cells Development)

Anodes, Cathodes,Membrane Electrode

Assemblies etc(Fuel Cells Lab) Bipolar &

Cooling plates(Fuel Cells Lab)

Stack Hardware& Assembly

(Design Analysis &Value Engg)

Reactants & Coolant Supply

(Turbo MachineryLab)

Stack Heating & Cooling

(Heat TransferLab)

Fuel CellDevelopment

Data Acquisition,display & Controls

(Control Instrumentation Lab)

Inverter System(Pow er

Electronics Lab)

Skid Design (Renewable

Energy SystemsLab)


Indigenous Fuel Cell R&D - Achievements

Phosphoric Acid Fuel Cells (PAFC)BHEL R&D: 1 kW (1991), 5 kW (1995) & 50 kW (2000, 2 stacks of 25 kW each) - with data acquisition and display system & inverter have been demonstrated.

Performance of a state-of-the-art 200 kW FCPP (PC 25 C, procured from M/s IFC / ONSI / Toshiba) also evaluated, using LPG as fuel.

Polymer Electrolyte Membrane Fuel Cells (PEMFC)Single cells & small stacks for evaluating electro-catalysts. Also tested Direct Methanol FCs – Basic Tech acquired from IISc, B’lore

High Temperature Fuel Cells (SOFC)BHEL R&D & CTI, Bangalore: Materials, processes & components developed. Assembled & tested single cells of planar SOFC.


BHEL IN PHOTOVOLTAICS

Over two decades experience in Photovoltaics

Manufacturing capacity of 3MW

Single crystalline (mono) cells upto 2.3W (15% efficiency)

PV modules range is from 10W to 160W

PV systems integration capabilities- have supplied PV power plants ranging from 1 KWp to 150 KWp

PV modules internationally certified to IEC 61215 standards

Cumulative shipments from BHEL over 20 MWp


Future outlook for PV in BHEL

Automatic manufacturing capacity over 30 MW planned Plan for improving solar cell efficiencies to over 18% by

2010 Capability to process both mono & multi crystalline wafers Opportunities for backward integration into silicon wafer

manufacturing Large scale deployment of PV power plants Explore alternate technologies like Thin film cells, multijunction cells etc


BHEL - R&D

DEVELOPMENT OF 765 KV TRANSMISSION SYSTEM 2006-07 TARGETS

DESIGN & MANUFACTURE OF 765 KV, 500 MVA TRANSFORMER

DESIGN & MATERIAL PROCUREMENT FOR MANUFACTURE OF 765 KV 80MVAr SHUNT REACTOR

DEVELOPMENT OF COMPOSITE INSULATORS FOR TRACTION & TRANSMISSION WITH NANO ADDITIVES


Power plant consumes nearly 7 to 9% of energy generated

Auxiliary power can be brought down by proper selection of technology, equipments and cycle parameters

Power consumption of BHEL manufactured equipment has been recently reduced from 7% (of total power consumption) to 6.65% for 250 MW & from 4% ( with turbine driven boiler feed pump) to 3.8%

POWER PLANT PERFORMANCE IMPROVEMENTSAUXILIARY POWER CONSUMPTION REDUCTION


LEADING PLAYER IN R&M AND UPRATING

R&M and LE of Large No. of Units in India and Abroad

Uprating of 110 MW Czech Units to 120 MW- Replaced Internals of HP, MP & LP Turbines with Reaction Type Blading- Boiler Upgrades to Ensure Rated - FlowModernize C&I and Balance of Plant

Improvised Blade Profiles for 210 MW LMW Sets- Reaction Type Blades for HP Turbine yield an additional 2.5 MW- New Monoblock LP Rotor with Reaction Blading Leading to additional 3.7 MW

POWER PLANT RENOVATION & MODERNISATION


PERFORMANCE OF BHEL THERMAL SETSPerformance Trend

(Thermal sets in India)

50

55

60

65

70

75

80

85

90

year

%

PLF-BHEL

OA-BHEL

PLF-ALL INDIA

PLF-BHEL 55.8 56.6 59 62.8 61.2 63.1 64.6 65.6 65.7 68.3 70.5 71.3 74.1 74.3 75.7 74.9

OA-BHEL 71.7 72.7 74.6 77 77.5 79.9 80.7 79.8 78.9 80.4 81.8 81.7 83.9 83.9 84.3 83.4

PLF-ALL INDIA 53.8 55.3 57.1 61 60 63 64.2 64.7 64.2 66.7 68.5 69.9 72.2 72.7 74.8 73.6

90-91

91-92

92-93

93-94

94-95

95-96

96-97

97-98

98-99

99-00

00-01

01-02

02-03

03-04

04-05

05-06


THANK YOUTHANK YOU

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