Mr Sahanu - Reliance Energy[1]

8/11/2019 Mr Sahanu - Reliance Energy[1]

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Use of Coal Blending process– A

Case study of Dahanu TPS

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Flow of Presentation

q About DTPS

q Power sector scenario

q DTPS Performance.

q Problem associated with F-Grade coal

q Blending as solution

q Evaluation of performance

q Conclusion.

3 confidential

DTPS Geographical Location

q Well connected by Western

Railway & National Highway No. 8.

q On the bank of Arabian Sea

q Surrounded by two natural creeks.

q Nearby Surya River dam (32 kms). Dahanu

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LAND

q Total land F 821.58 hectares

q Land For Plant F 351.58 hectares

q Land for Ash disposal F 370.00 hectares

q Land for Colony F 100.00 hectares

Background



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RESOURCE REQUIREMENT

q Total Coal F 2.1 Million tons

q Wash coal F 1.7 Million tons

q Imported coal F 0.4 Million tons

q Sea Water (M3/Hr.) F 84,000

q Sweet Water (M3/Hr.) F 300

Background

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Salient Features Of Dahanu TPS

q First 250 MW sets in the Country

q Indigenous technology of BHEL

q Coastal power plant far away from

Coal Mines

q Sea Water Open Cycle cooling

system

q Tallest Chimney in the Country

q High efficiency Electrostatic

Precipitator for Ash collection

q Advanced process control

equipments

q SCADA based Islanding system for

reliable supply

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DTPS Vision

To be amongst the world class power plants, delivering reliable

generation of electricity at competitive costs, with international

standards of environmental emission.

To set new benchmarks in standards of performance through the

pursuit of operational and financial excellence.

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Plant Performance



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National PLF (Average Thermal units) : 73.6%

Plant Performance

100.34 101.35 101.79 101.53

98.7

2003-2004 2004-2005 2005-2006 2006-2007 2007-2008

Plant Load Factor (%)

Average PLF for last 5 years = 100.74 % (Above 100%)

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Plant Performance

96.8494.71

96.79 96.796.88

2003-04 2004-2005 2005-2006 2006-2007 2007-2008

Availability (%)

National Availability (Average Thermal units) : 81.78%

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Plant Performance

103.61 104.22105.17 104.99104.61

2003-04 2004-2005 2005-2006 2006-2007 2007-2008

Loading Factor (%)

Average Loading for last 5 years = 104.52% (Above 100%)

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22882305

2320

2373

2272

22682261

2286 2278 2279

FY 2003-04 FY 2004-05 FY 2005-06 FY 2006-07 FY 2007-08

HEAT RATE WITH A GEING EFFECT

ACTUAL HEAT RATE

Plant Performance



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National Sp. Oil Consumption : 1.37ml/KWH

0.11

0.18

0.11 0.130.13

2003-04 2004-2005 2005-2006 2006-2007 2007-2008

Specific Oil Consumption(ml/Kwh)

Plant Performance

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0.39 0.38

0.24 0.22

0.37

2003-04 2004-2005 2005-2006 2006-2007 2007-2008

DM Makeup (%)

Design Norm : 3%

Plant Performance

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0.11223937.23101.6296.5298.02DadariNTPC

0.68NA8.82101.7995.7797.49Sabarmati AE CO

0.28NA7.33100.3897.3097.67Jindal SWJINDAL

0.1324718.03103.1297.39101.43Budge BudgeCESC

0.1322797.67104.9996.70101.53DahanuREL

Sp.Oil

(ml/KWH)

Ht rate

(Kcal/KWH)

Aux.

Power %

Loading

(%)

Availability

(%)

PLF

(%)

StationCompany

Name

Benchmarking 2007- 08

0.1423936.66100.5492.2592.75VindhyachalNTPC

0.1923555.5699.6392.4492.10SimhadriNTPC

1.74NA8.9699.3994.6995.59Unchahaar NTPC

0.12624668.13102.8197.0499.77Budge BudgeCESC

0.1122787.64105.1796.79101.79DahanuREL

Sp.Oil(ml/KWH)

Ht rate(Kcal/KW

H)

Aux.Power

%

Loading(%)

Availability(%)

PLF(%)

StationCompanyName

Benchmarking 2006- 07

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20

40

60

80

100

120

140

160

180

2002-03 2003-04 2004-05 2005-06 2006-07 2007-08

T P M E

m i s s i o n i n M g / N M 3

TPM Limit given by MPCB (150mg/Nm3)

TPM Emission from DTPS

Environment Performance…TPM Emission



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Power Sector Scenario

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Total Installed Capacity- 1,43,061 MW (as on March 31, 2008 )

Fuel wise distribution in MW Sector wise Distribution in MW

q More than 70% electricity generation by Thermal Power P lants

q Plant load factor is 78% & Availability is @84% (National Average)

q @8 % non-availability on account of forced outage

q More than 50% outage on account of boiler auxiliaries which are related to coal

quality-DTPS faced similar problems during initial o peration

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Problems With ‘F ’ Grade Coal-During initial Operation

q Poor coal quality – 3300 Calorific Value and 45% ash

q 75% Of Generation Cost Is Fuel Cost.

q High freight cost – Leading to high l anded cost of coal

q Very high erosion rate & F orced Outage

q Availability lo ss due to poor coal quality.

q Higher O&M Cost.

q High Ash of generation – disposal problems and costs

q Adverse Impact On Environmental Pe rformance

q Extraneous material – damage to the equipment

q Strain on railway system

q Erratic delivery and uncertainty regarding availability

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Alternatives to Resolve above Problems

q Change of fuel –Modification-No n-availability

q Import coal for total consumption –Design li mitation

q Use beneficiated coal from Indian mines –Feasible -

Establishing washery

q Try blending of various coals available -Feasible



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Advantages of Coal Blending

q Lower ash – less erosion &related breakdowns

q Higher G.C.V. – less coal to handle, grind and fire

q Reduced Auxiliary consumption

q Reduced air and solid effluents

q Location –Most suitable

q Started Blending with F grade & evaluation in 1996-subsequently

washed

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Blended coal

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Blending Process at DTPS

Various ways of Bunkering

q Wagon Tippler And S/R # 1 To Bunker

q Wagon Tippler And S/R # 2 To Bunker

q Wagon Tippler And Vf. To Bunker

q Emergency Stock Pile And S/R # 1 To Bunker

q Emergency Stock Pile And S/R # 2 To Bunker

q S/R # 2 And S/R # 1 to Bunker

q Where :-

S/R : Stacker And Reclaimer

Vf : Vibrating Feeder.



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Blending Ratio- criterion

q GCV of coal

q Cost of imported coal

q Availability of imported coal

q Cost of as fired coal

q Ash percentage in coal

q Efficiency

q cost optimization.

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Proximate Analysis Of Blended Coal

COAL

'F'

Grade

Blended

(F:A)

Washed Blended

W:A

GCV

(Kcl/Kwh)

3500 4250 4100 4250

TM (%) 10.20 11.18 12.60 14.00

VM (%) 22.00 27.00 26.00 28.00

ASH (%) 40 33 30 26

Imported Coal parameters GCV 5300-6400,TM 22 -26,VM 30

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q Operation performance parameters

q Equipment performance

q Cost of Generation

Criteria for Performance Evaluation of Various Coal

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Operation Performance

q Main Steam & Reheat temperature-No appreciable difference

q Unburnt Carbon in bottom ash and fly ash.-Reduced

q Flue Gas outlet temperature.-On lower side

q Mill outlet temperatures.-maintained

q Fouling, Slagging and Flame characteristics.

q Overall Boiler efficiency.-Improved



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Equipment Performance

q Less Erosion

q Less Aux. Power Consumption

q Reduced down time

q Reduced Maintenance cost

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Equipment Performance Details-

Coal mill

q Reduced ball consumption to 80 to 90 mg/Ton coal from 150-170 mg/T

observed normally.

q Increased screw conveyor life to 2½ years from 6 months.

q Increased liners life.

q Reduced initial ball charge reducing Aux.Power consumption.

q Reduced mill down time.

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q Increased coal burner life to 4 years from 1½ years observed.

q Reduced boiler tube leakages due to less erosion.

q Increased APH baskets reversal time to 7 years from 2½ years.

q Virtually no erosion of ducts.

q Virtually no erosion of ID Fan blades.

Equipment Performance Details-Boiler

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Coal Handling Plant

q Crusher operation eliminated.

q No consumption of crusher hammers.

q Reduced Aux. Power Consumption.

Ash Handling Plant

q Only one system operation required for deashing

q Reduced Aux. Power reduction.

Equipment Performance Details



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26

3330

40

0

5

10

15

20

25

30

35

40

45

F Grade Washed Blended (F:A) Blended (W:A)

ASH (%)

Ash Content in various Coal

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15352

8189940510611

7416757476609216

0

5000

10000

15000

20000

" F" GRA DE COAL WASHED BLENDED COAL

(F:A)

BLENDED COAL

(W:A)

POWER FOR AHP(KWH) P O W E R F O R C H P ( K W H )

6878469432

7156873200

66000

68000

70000

72000

74000

" F" GRADE COAL WASHED BLE NDE D COAL

(W:A)

BLENDED COAL

(F:A)

Auxiliary Power ConsumptionCHP / AHP

BOILER

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Total Particulate Matter

124

110

90

80

60

80

100

120

140

F GRADE WASHED BLENDED (F ,A ) BLENDED (W,A)

mg/Nm3

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Indicative Fuel Cost



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U N B U R N T C A R B ON L OS SE S

10

8

30

16

5

10

15

20

25

30

35

F GR AD E W AS HE D B LE ND ED ( F, A) B LE ND ED ( W, A )

K C A L

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DTPS has developed cost optimization model for decision

making regarding blending ratio.

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q Reduction in fuel cost.

q Higher GCV- less coal to handle and grind.

q Lower ash – Less erosion & breakdown.

q Better – equipment performance.

q Stable generation of power at 262 MW against – 250MW.

q Better environmental performance

q Gcv Of Coal Can Be Controlled.

q Low Ash Content.

q Aux. Power Cons. Can Be Reduced.

q Ash Pond Life Can Be Increased.

q Soot Blowing Freq.. Can Be Decreased.

q Saving in DM Water Makeup .

q Maintenance Cost Can Be Decreased.

q Clinkers Formation Can Be Decreased.

Benefits of coal blending process

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Conclusion

q DTPS is first plant using optimized blending of coal governed by efficiency

and cost.

q Top Plant Performance from successive five years is indicative of Blending

effectiveness of DTPS.

q Major benefits due to effective blending are :-

q Saving up in fuel cost by

- Selecting proper coal.

- Selecting optimum blending ratio.

q Provides Customer – low cost power

q Minimum expenditure--Man days

q Stabilised process of blending –Emulated by power plants



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Thank you

Mr Sahanu - Reliance Energy[1]

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