Position of Coal Position of Coal

in Future Energy in Future Energy

Scenario in Scenario in

IndiaIndiaKalyan Sen

Director

Central Fuel Research Institute, Dhanbad (India)

Status of Power Generation Status of Power Generation in Indiain India

Per capita Primary energy Consumption:

India 243 kgoe/y

developed Countries 1000

Average 7000-8000

(IEA Coal research, Nov.’98)

Against projected GDP Growth

rate of 7% -

Power sector requires expansion @ 9-10%

i.e. Additional capacity of 10 GWe/y for next 10 years (IEA Coal research, Nov.’98)

Capacity of power Capacity of power generationgeneration in India in India

(in MW)(in MW)

Year Thermal Hydro-electric Nuclear Total

1996 60,000 20,976 2,225 83,288

1998 63,038 21,729 1,840 86,607

1999 67,618 22,438 NA 93,249

1999-2012

(projected)

1,43,610 56,418 11,615 2,11,643

(CPU 1999; CEA, July, 1999)

Capacity Utilization of Power Fuels and Capacity Utilization of Power Fuels and

Electricity generatedElectricity generated

(Source: CPU 1999)

Thermal fuel No. of stations Capacity(MW) Generation(GWh)

Coal 73 51134 276605

Lignite 3 2280 13853

Gas 30 7203 35396

Oil/Diesel & others 11 1017 2387

Multi-fuel 2 1404 7292

119 63038 336033

'60-'61 '70-'71 '80-'81 '90-91 '96-'97* @'97-'98* '98-'99*0

10

20

30

40

50

60

70

Cap

acit

y (M

W)

(Th

ousa

nd

s)

0

100

200

300

400

Electricity (G

Wh

) (Th

ousan

ds)

Capacity (MW)

Electricity (GWh)

Growth of Installed capacity and Electricity generated in Thermal Power Plant

* Monitored capacity @ end of 8th plan

Coal consumption, Coal consumption,

productionproduction and and qualityquality

Increased demand and Increased demand and dependence on coaldependence on coallead tolead to

• ecological disbalance on mining site

• transportation overloading

• alarming emission of hazardous matters

Geological reserves of coal in India (Mt)

Sl.No.

Type of coal Proved Indicated Inferred Total

1 Prime coking 4614 699 - 5313

2 Medium coking 11267 1114 1106 23506

3 Semi coking 282 904 222 1408

4 High Sulphur 412 77 398 887

5 Non coking 65820 76696 37971 180479

82386 88427 39697 211594

(GSI Jan 2000)

Annual/ Estimated Coal consumption and Ash generation by Coal-based Thermal Power PlantsYear

1997-98

2001-02

2006-07

2011-12

Installedcapacity (Mt)

51135

75000

111070

162000

ThermalPower (BU)

277

425

615

920

CoalConsum.(Mt)

203

267

450

660

AshGener.(Mt)

80

107

180

265

(Source: CEA, April,1999)

Coal Consumption pattern in different states (as on March,1999)

States

Delhi, Punjab, Hariana, Rajasthan

Bihar, West bengal & Orissa

Gujarat

Maharastra

Madhya Pradesh

Tamilnadu & Karnataka

Andhra Pradesh

Uttar Pradesh

Assam

No. ofPlants

Generation

(MW)

Coalconsumption

(Mt)10

21

5

8

7

5

6

10

1

73

5153

12300

3820

6476

7163

4020

5043

8941

240

53126

20

50

15

26

28

16

20

36

-

211

(Source: CEA, 1999)

Trend of Coal Production in India

0

50

100

150

200

250

300

350

Year

Pro

du

ctio

n (

Mt)

95-9

6

1900

1915

1930

1945

1956

1971

1980

1983

1986

1989

1992

1999

(A.B.Ghosh 1997, MoC 1998-99)

Demand - Supply projection of coal:

Year

2001-02

2006-07

2007-12

Demand (Mt)

400

576

872

Supply (Mt)

360

484

652

Short-fall (Mt)

40

92

220

(Draft Report, Energy policy Committee, planning Commission, march, 1999)

Futuristies in Coal productionFuturisties in Coal production

Identification of a no. of Collieries

Advancement in mining technology

Optimum mixing of underground &

opencast mining

Quality improvement by beneficiation

Coal for Power Plants Coal for Power Plants

Grade-wise reserves of Indian non-coking coal

Grade Reserves, bt Share, % Ash, % CV, kcal/kg

A+B+C 23.8 13 28.7 >4940

D 29.0 16 34.0 4940-4200

E+F+G 125.2 71 55.0 4200-1300

(Source: GSI, 2000)

COAL RESERVES Total: 212 Btnon-coking: 83%coking: 14%others: 3%

Common Coal Quality IndicesCommon Coal Quality Indices

Combustion specific

Heating value

C- burn out

Char behaviour

Traditional inspection properties:

MoistureV.MAsh

Size character.Grindability

IndexElements ( S,

Cl, N)

Rank

PetrographyLinking parameters ------>

Indian Coal as feed to TPS Constraints:

Genetic : high inertinite content, high moisture

Operational : mechanized mining in large OCP

Organizational: multiple sources/ linkages

Indian Coal as feed to TPS (contd…)

Favourable qualities: Genetic

Low Sulphur content ( <0.6%) High ash fusion temperature (>1100oC) Low Iron content Low Chlorine content Low toxic trace elements Reactive inertinites

Average quality of raw coal Average quality of raw coal

fed to the power stationsfed to the power stations

Ash content: 30-55%, ave. 45%

Moisture content : 4-7%, higher in rainy season

Sulphur content : 0.2-0.7%

GCV, Kcal/Kg : 3000-5000, average 3500

Volatile Matter : 20-25%

Year

Co

st

(R

s./t

)

GC

V (

kg

/kc

al)

0

500

1000

1500

2000

1985 1990 1995 2000

2000

2500

3000

3500

4000

4500

price

freight

gcv

Trend of Pit head Price, Freight charges & Quality

(Sachdev-98,CPU-1997 & Boparai-2000)

Quality and Cost of Coal and LogisticsQuality and Cost of Coal and Logistics

Cost of production is cheaper but freight is high For the last 18 years, increase in freight is 13%

against 9% coal price hike/ year For grade “F” transported beyond 750km,

freight increased from 43% to 54% of the delivered cost (1981 to 1999 )

In western and southern states, Indian coals have to compete with imported coals as freight is presently as high as 71%

Non-coking Coal Washing Status in India

Probable Benefaction SchemesProbable Benefaction Schemes

blending low ash imported coal with high ash indigenous coal

mixing finer fraction with Cleans of coarser fraction

mixing cleans of all fractions (whole coal beneficiation )

Present Status of Beneficiation of Non-Coking Coal

Washery yr. of Coalfield Capacity Linkage

comm. (Mt/y)Piparwar,CCL `1997 Singrauli 6.0 Indraprastha

Bina, NCL 1997 N. Karanpura 4.5 Dadri

Dipika, BSES 1998 Korba 2.5 Dahanu

Gidi,CCL 1999 S.Karanpura 2.5 converted

Dugda-I, BCCL 1999 Jharia 1.0 “

Kargali, CCL 1999 E.Bokaro 2.7 “

Parameter : Ash level 34% Ref.: MOEF, Govt.... Of India)

Purpose of Beneficiation Purpose of Beneficiation To reduce mineral matter content To minimize abrasive material To improve combustion qualities

Q ?Does 34% ash (MoEF’s mandate) always assure the desired combustion qualities ?

A: Ash limit depends on specific combustion qualities

From beneficiation point of view, washing a coal at a cut density determined from characteristic ash () of 50-55% minimize the non-combustibles having ash values beyond this limit

Probable alternates for Improvement Probable alternates for Improvement

1 mixing cleans of coarse fraction with untreated smalls

limitation: 20-40% of finer fraction (5-10% of whole coal) included as obvious dirt

2 blending a part of raw coal with its cleans

limitation: Multiple sources - variable feed

3 blending low ash imported coal with high ash indigenous coal

limitation: Blending coals of widely different ranks calls for differential behaviour in boiler

4 mixing cleans of both fractions / whole coal beneficiation

limitation: low density of cut with HM Cyclone

Probable alternates for Improvement Probable alternates for Improvement

beneficiating whole coal, particularly, where crushing to finer size does not help in liberation

washing a coal at a specific gravity determined from = 50-55%.

This will minimize the presence of non-combustibles and reduce the hazardous emissions/kWh electricity generated

CO2 EMISSION IS CONSIDERED

AS THE MAJOR THREAT (THE

GREENHOUSE EFFECT)

‘KYOTO PROTOCOL’ demands the

reduction in CO2- release and

identifies coal fired boilers as the

main industrial source

Coal Combustion Efficiency vs. CO2 emission

Source: Ecoal, vol 27, 1998

20 30 40 50 600

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

1.8

2

CO2 emission

Coal used, t

COCO2 2 emission can be reduced by emission can be reduced by

reducingreducing the the consumptionconsumption of of

coal /kWh of electricity coal /kWh of electricity

generatedgenerated

Economic advantages of Economic advantages of beneficiation:beneficiation:

30% reduction in coal consumption for same

amount of electricity generated

30% offloading in railway traffic

>25% reduction in Fly ash generation

30% reduction in cost of long distant

transportation

Washed coal of consistent quality Washed coal of consistent quality & improved heat value lowers the & improved heat value lowers the sp. coal consumption from >0.6 to sp. coal consumption from >0.6 to 0.52-0.55 kg/kWh0.52-0.55 kg/kWhandandthe same target of electricity the same target of electricity generation can be retainedgeneration can be retained

The combined effect of cost, freight and quality of coal and others dictates the maximum distance beyond which only washed coal transportation becomes techno-economically feasible

LogisticsLogistics

Issues to be addressed

•Strict Quality monitoring

•Revision of pricing & grading system

•Rationalistion of linkages

•Rationalistion of logistics & railway freight

•Removal of barriers for non-coking coal washing

•Advanced technology for power generation

•Proper waste management

Efficiency enhancement in Energy Sector must involve all the activities in ‘Coal - Energy chain’ with special emphasis to Improvement in coal quality by judicious

beneficiation

Conclusion:Conclusion:

Improvement in coal quality by

judicious beneficiation of Indian coal

is, therefore one of the options of

efficiency enhancement processes, if

not the bare necessity under present

context