Low Cost Energy Efficiency Measures...
Transcript of Low Cost Energy Efficiency Measures...
NTPC Energy Technology Research Alliance
Implementation of PAT Scheme in Thermal Power Stations - Issue & Challenges
Low Cost Energy Efficiency Measures – NTPC’s Experience
At
India Habitat Centre
Presented For
30th Jan’2015
Aux Power Reduction Projects……… 8 Slides
Energy Efficiency Enhancement Projects……… 4 Slides
Renewables based Projects……… 10 Slides
Presentation Outline
Low Cost Energy Efficiency Measures – NTPC’s Experience
Back Ground:A typical 210 MW unit consumes coal equivalent of 550 MW and reject 350 MW – 125 MW in Chimney & 225 MW in Cooling TowerThere is large potential to capture & utilize this low grade energy
Project: Low Grade Flue Gas based Air Conditioning
Status: Implemented at NTPC Ramagundam Coal Station – Oct’13
Unit Size MWe
Heat Recovery (140-110C)
(MWth)
Eqv. Air Conditionin
g (TR)110 4.8 960210 7.9 1600500 17.6 3520
Cooling Water
Chilled Water
Flue Gas
Hot Water
4
Stack
BoilerESPID Fan
Slip Stream`
Fan (VFD)
Flue Gas Heat
ExchangerHeat
Recovery (500 kW th )
Pumps
DM Water Make up
Vapor Absorption Machine(VAM)
100 TR
Hot water
150 oC110 oC
12 oC90 oC
80 oC
7 oC
ESP &
ASPH CR
Steam heat ex standby
Cooling Tower
40 T/hr
32 oC
pump
Pumps
38 oC
Low Cost Energy Efficiency Measures – NTPC’s Experience
Process Flow Diagram:
5
Benefits:APC Saving: ~ 0.4 MU/YrCO2 avoided: ~ 312 Tons/YrGreen House Gas (CFC & HCFC) free A/C system Huge scale-up potential
Methodology:Waste heat is used to generate hot water which drives a Li-Br based Vapor Absorption machine (VAM)Chilled water generated from VAM is distributed to different locations (ESP Control rooms) for Air conditioning.
Low Cost Energy Efficiency Measures – NTPC’s Experience
Low Cost Energy Efficiency Measures – NTPC’s Experience
Project: Low Grade Flue Gas based Desalination
Status: In Tendering, at NTPC Simhadri, completion by Mar’16
Methodology:Waste heat is used to generate hot water (~90C)Hot water is flashed to produce Low Pressure Steam (~0.32 ata)LP Steam is used to drive a Multi Effect Distillation System and produce sweet water from sea water
Low Cost Energy Efficiency Measures – NTPC’s Experience
Salient Details:Plant Capacity: 120 TPDGain Output Ratio (GOR) ≥ 6
Benefits:Energy Saving: ~ 16 GJ/YrNo need of Sweet water - DM Water directly from Sea WaterOperating temperature below solubility temperature - No chemicals
Benefits:Korba (U #5,6)
4-5 deg C increase in PAPH air outlet tempTanda (U #1,2,3,4)
50 kW/Fan ID Fan power saving in Tanda50 mmWC pressure drop reductionNo duct repair work done in next overhaul
Vindhychal (U #2,5)13 mmWC Pressure drop reduction35 kW/Fan ID Fan power savingNo duct repair work done in next overhaulDecreased ESP pass flow variation 23% to 5%
CFD Results for Tanda 110 MW unitVSTPP U#5 FG flow at different ESP passes
291269
286 296287
371358
306
250270290310330350370390
ESP_OUT-A ESP_OUT-B ESP_OUT-C ESP_OUT-DESP Pass
Flow
in T
/hr Before
After
Non uniform flow in ESP passes
Status: Implemented at Korba, Tanda & Vindhyachal
Low Cost Energy Efficiency Measures – NTPC’s Experience
Project: CFD modeling for Duct for reduction of Aux Power & Erosion
Low Cost Energy Efficiency Measures – NTPC’s Experience
Description:Motor up-gradation (18 No's) for VFD operation with in-house developed refurbishing technique.VFD panel with bypass contactor arrangement. Closed Loop CT Fan’s speed control – based on Condenser heat load & Ambient condition.Remote Operating Work Station (OWS) at CCR with Fibre Optic communication.
Project: Up-gradation of motors winding & VFD retrofitting in Cooling Tower Fan
Status: Implemented at NTPC Dadri Gas Station – Dec’13
Benefits :APC saving: ~ 1.14 MU/YrCO2 avoided: ~ 436 Tons/YrIntelligent Control of CT fans.Smooth fan start - Low stress of gear box, bearings.Enables overload operation of motor.
Motor Insulation SchemeMotor Insulation Scheme
Key features:Enhanced thermal & di-electric capability.RTDs embedded in stator slots for temp feed back.All CT-1 motors (18 Nos) refurbished at Dadri electrical workshop.
Low Cost Energy Efficiency Measures – NTPC’s Experience
Aux Power Reduction Projects……… 8 Slides
Energy Efficiency Enhancement Projects……… 4 Slides
Renewables based Projects……… 10 Slides
Presentation Outline
Low Cost Energy Efficiency Measures – NTPC’s Experience
Project: NTPC e-Power Plant Solution (NePPS)
Status: Implemented at NTPC Talcher Kaniha & Simhadri
Salient DetailsAimed towards (i) Process Optimization and Performance improvement & (ii) Early Warning and DiagnosticArtificial Intelligence based system - ANN, Genetic Algorithm (GA), Pattern Recognition, Fuzzy rule base Fleet wide performance monitoring with access from plant, region and CorporateDeveloped in ‘Service Oriented Architecture’ (SOA)
Performance
Improvement
DVR
GA Optimizer
Real time Data setFor self learning
NN Inputs(Controllable & Uncontrollable)
Inputs to be optimized
Obj Fun(Blr Effi)
Inputs
Constraints
Real time Operator Advisory
+ DCSSet Point
PID control loop
Set point correction
Energy Intensification and Diagnostic Model (EIDM): Artificial Intelligence (AI) based modeling and optimization software for real time operator advisory. Have features of Retraining
Low Cost Energy Efficiency Measures – NTPC’s Experience
EIDM
ChemAnalyser
P3E
Low Cost Energy Efficiency Measures – NTPC’s Experience
WB Pr: 87 # 78 mmwcBurner Tilt: 60 # 64
WB Pr: 85 # 91.1 mmwcWB Pr: 75 # 99 mmwcBurner Tilt : 72.7 # 69
O2% : 3.2 # 2.9
Burner Tilt : 70 # 62.5O2% : 2.84 # 2.69
Energy Intensification and Diagnostic Model (EIDM) Testing and Results
Low Cost Energy Efficiency Measures – NTPC’s Experience
Aux Power Reduction Projects……… 8 Slides
Energy Efficiency Enhancement Projects……… 4 Slides
Renewables based Projects……… 10 Slides
Presentation Outline
Steam Separator
Pump
Steam to VAM
Solar Paraboloid Dish
Solar BlockFresnel Paraboloid
Solar DishSteam Separator
Air Conditioning Block
Li-Br Double effect VAMChilled Water Tank
Condensate from VAM
Project: Solar Thermal HVAC System
Status: Implemented at NETRA – June’12
8 Bar, 1730 C
1 Bar, 650 C
9 Bar, 650 C
8 Bar, 1730 C
Low Cost Energy Efficiency Measures – NTPC’s Experience
18
Mode of Operation:Mode-1, Working dayMode-2, Weekend & HolidayMode-3, Lean Solar period
Low Cost Energy Efficiency Measures – NTPC’s Experience
Benefits:APC Saving: ~ 0.1 MUs/YrCO2 avoided: ~ 90 Tons/YrLow Carbon, Green House Gas (CFC & HCFC) free A/C system Capable of operating in both Cooling as well as Heating Mode
Low Cost Energy Efficiency Measures – NTPC’s Experience
Project: Solar Thermal Hybrid Plant
Status: NIT by Feb’15
Salient Merit (vis-à-vis Stand Alone Solar Thermal Plant)Higher Thermal Efficiency: 24.39% against 16-18% of stand aloneLow Capital Cost: No separate turbine block, No additional DM PlantLow Operational Cost: No TG auxiliaries -Lo APC & DM makeupNo daily start-stop: Independent of solar radiation.Higher CUF: No daily TG rolling, Lower start-up time.No Thermal Energy Storage: Not required for hybrid operationReduction in CO2 Emission: 4060 Tons /year (approx)
Technology:Solar: Single / Two Axis Tracking, Concentrated Solar Thermal Power Generation & Evacuation: Thru existing Turbo-Generator & Switch Yard
Integration Configuration
FW 200 Bar / 200 C / 600 TPH
NTPC’s Existing System
Proposed System
Control Valve: Used to regulate the flow of feed water in solar heat exchanger according to varying Solar Radiation with a view to maintain required temperature at HPH-6 outlet
From HPH-5 To Economizer
Solar Field
Steam 40 Bar / 350 C
FW 170 Bar / 247 C / 600 TPH
Steam Separator
Solar Heat Exchanger
Pump
Saturated Steam
Control Valve
Drain To HPH - 5
From HP Turbine
200 C / 200 TPH
Wet Steam
64.2 Bar, 280 C
Process Patent Filed
HPH-6
FW 200 Bar / 200 C / 400 TPH
Condensate, 250 C
280 C
65 Bar, 280 C 70 Bar
247
C /
200
TPH
Low Cost Energy Efficiency Measures – NTPC’s Experience
Project: Solar Thermal Cooking System
Status: Under Execution at NTPC Dadri, completion by July’15
Salient DetailsAll mode of cooking possible i.e Boiling (100C), Frying (220C) and Baking (270C)All weather solution – thru integrated LPG fired Thermic Fluid HeaterQuick Start Up – Sp. heat of Thermic Fluid is 0.58 vis-a-avis 1 of waterThermal Energy StorageNo steam – no scale – no chemicalDelinked Solar & Cooking Block
Solar Block
(2 No of Two Axis Tracking, Paraboloid
Solar Dish)
Cooking Block
(2 No each of Boiling Vessel. Frying Pan &
Tawa)
Balance of Plant
(LPG Fired TF Heater, Expansion Tank, Pumps,
PLC etc)
Block Diagram
P&ID:
Low Cost Energy Efficiency Measures – NTPC’s Experience
0
50,000
100,000
150,000
200,000
250,000
JanFe
bM
ar Apr
May Jun JulAu
gSe
pt OctNo
v De
c
Energy (kcal/day)
Solar Energy
Cooking Energy Required / Day: 2.15 Lac Kcal
1.75 Lac Kcal/Day Solar Cooking System for Main Plant Canteen
(at the 500 W/sq.mtr DNI)
69 75
93
83 91
77
0 0
73
89
67
81
24 9
0
7
2
13
96 93
17
4
23
12
0
20
40
60
80
100
LPG Cylinde
rs / M
onth
Consp 24 9 0 7 2 13 96 93 17 4 23 12
Saving 69 75 93 83 91 77 0 0 73 89 67 81
Jan Feb Mar Apr May Jun Jul Aug Sept Oct Nov Dec
LPG cylinder consp:Present: 1095/YrWith STCS: 400/YrCO2 avoidance: 40 T/Yr
Low Cost Energy Efficiency Measures – NTPC’s Experience
Benefits:
Key FeaturesWeb based Remote MonitoringSeasonal tiltString MonitoringPipework for panel cleaning
Salient DetailsInstalled Capacity:110 kWpCollector Area:1,560 Sq.m
BenefitsEstimated Generation: 0.17 MUs / YrCO2 avoidance: 163 Tons / Yr
Project: Remotely monitored 110 kWp Solar PV Rooftop as R&D test bed
Status: Implemented at EOC Annexe Noida – Oct’14
Low Cost Energy Efficiency Measures – NTPC’s Experience
Project: Integration of rooftop PV with existing 24 V DC battery charger
Status: Under installation at NTPC Unchahar
Low Cost Energy Efficiency Measures – NTPC’s Experience
Configuration: Solar PV DC system installed on TG roof & integrated to existing DC battery charger system feeding DDCMIS load.
PV Panels
Charge Controller
LOAD (DDCIM
S)
Present Charger
3 Phase, 415V AC 24V
DC BUS
Interconnection Point
At TG Roof
Battery
Benefit:APC Saving: ~ 30,000 Units/YrCO2 avoidance: ~ 24 Tons/Yr
Salient DetailsSolar Block : 16 kWpSize of Charger : 400 AExisting charger efficiency : 70%
Thank Thank YouYou