4 th annual “coal markets in india-2014” the imperial new delhi 22.08.2014

4th Annual “Coal Markets in India-

2014”The Imperial

New Delhi

22.08.2014

Improving Coal Efficiency -Role of Coal Additives

--------ooo--------

Abhitech Energycon LimitedA/1020, Oberoi Garden Estate, Chandivali Farm Road,

Chandivali, Mumbai – 400072

Tel (91-22) 2847 9999 Fax (91022) 2847 9988

E-Mail : abhitech@abhitechenergycon.com

Visit us at : www.abhitechenergycon.com

Coal Efficiency

• Coal Efficiency represents the amount of Energy that can be extracted from a single unit of Coal.

• So, we are essentially talking about Plant Efficiency, or more specifically Combustion Efficiency; which can be measured to see what amount of Energy is being extracted from a single unit of Coal in a particular system.

Combustion Efficiency

• Combustion Efficiency is a measure of how efficiently a device/system consumes fuel. Ideally, it should be 100%, meaning that the fuel is completely consumed.

• In practice, this level of efficiency is impossible to achieve, but it's possible to come close.

• The lower the combustion efficiency, the less efficient the device is, making it expensive to run, wasteful of fuel, and harmful for the environment.

Factors affecting Combustion Efficiency and Overall Plant

Performance • Poor Combustion • Excess Air control• Deviation of fuel quality from designed values• Heat Transfer Fouling• Pre-water treatment• Condenser Performance• APH Performance• Poor Operation and Maintenance of Boilers

Methods used to overcome these problems

• Scheduled Maintenance and AOH of Boilers.

• Modification and Renovation in the Boilers

• Energy Audit to keep an account of various losses in Boilers.

• Different types of analysis like CFD Analysis to improve flue Gas Path.

Disadvantages of employing these methods

• High Capital Expenditure

• Shutdown required

• Complexity of these methods

• Highly skilled Professionals required

• For analysis purpose, expensive equipment required.

Alternative ???

Then, Is there any solution which is -

Simple in Application,

Involves no Downtime, and

Requires no Capital Expense ?

Combustion Catalysts

Coal Additives

Effective Additive – Reduction in Losses, Impact on GUHR & Boiler

Efficiency• 1% Red’n in UFA – 20 Kcal/kwh on GUHR & 0.8% in Boiler Eff.

• 1% Red’n in UBA – 2.5 Kcal/kwh on GUHR & 0.2% in Boiler Eff.

• 1% Red’n in Excess Air – 7.4 Kcal/kwh on GUHR & 0.6% in Boiler Eff.

• 1% Red’n in FGT – 1.2 Kcal/kwh on GUHR & 0.067% in Boiler Eff.

• 1TPH Red’n in S/H Attemp. – 0.03 kcal/Kwh on GUHR

• 1TPH Red’n in R/H Attemp. – 0.25 kcal/Kwh on GUHR

• 1 mm of soot deposit Red’n – 0.83 % savings in Coal

(Ref :- BEE , NTPC, IGEN, BS 2885)

• Thus, due to improvement in all above parameters, with the use of an effective Additive, 2 to 4 % savings in coal can be achieved.

Bureau of Energy Efficiency – BoilersTypes, Combustion in Boilers, Performance evaluation, Analysis of Losses, Feed Water

Treatment, Blow down, Energy conservation opportunities

Bureau of Energy Efficiency - Boilers

NTPC-USAIDHeat Rate Improvement Guidelines for Indian

Power Plants

Saving Potential• All India Yearly Coal Consumption for Power

Generation (Utilities) : 454 MMT• Coal that can be saved @ 2 % using Additive :

9.09 MMT• Total Generation possible from the amount of Coal

saved @ 0.75 kg/kWh : 12.1 MMWHr• Average Power Consumption per Annum for a Single

Household in India : 3.11 MWHr• No. of Households that can be enlightened for whole

year in India with the amount of Coal Saved: 38.97 Lacs

Current Status

• The Coal Additive Market is in its infancy, although the outlook is bright.

• There aren’t many Companies in the market producing Coal Additives as yet.

• Abhitech is doing the Leadership work – • Creating Awareness• Developing a Model for Evaluation• Establishing Additives as an Alternative• Creating an Industry• Serving the National Cause of Fuel Conservation

Abhitech - Mission Efficiency

Abhitech’s aim is to not only save the Coal and other Carbon based Fuels by increasing the Boiler Efficiency using specially formulated Additives, but also lend a helping hand in making the environment pollution free and making this Planet a better place to live in.

Combustion Catalyst

THERMACT

Technology Collaboration with IIT-Bombay.

Abhitech Energycon Ltd.Abhitech Energycon Ltd.

Established across various Sectors

• Large Capacity Power Plants from 60 MW to 800 MW

• Sugar Industry ( Co-generation )

• Steel Plants (Coke making & Blast Furnace)

• Captive Power Plants (AFBC Boiler)

• Biomass fired IPPs.

Abhitech Energycon Ltd.Abhitech Energycon Ltd.

THE LARGEST MANUFACTURER OF COMBUSTION CATALYSTS IN INDIA

INDIAN TECHNOLOGY

GLOBAL PRESENCE

ONE OF THE FEW COMPANIES WORLD WIDE, WITH PRODUCTS FOR SOLID & LIQUID FUELS

TECHNICAL MANPOWER : 266 ENGINEERS

Abhitech - Background

Abhitech Energycon Ltd.Abhitech Energycon Ltd.

Global Presence

Baddi (HP)Baddi (HP)

Chennai

Braz

il

Germ

any

Bhubaneshwar

Raipur

Cze

ch R

epublic

Vijayawada

Bangaluru

Delhi

Kolkatta

Slovenia

Nep

al

SudanSrilanka

HeadofficeHeadoffice

Belgaum

Zonal officesZonal offices

Head officeHead office

Manufacturing unitManufacturing unit

Export Export

Abhitech Energycon Ltd.Abhitech Energycon Ltd.

Manufacturing Unit at Baddi, Himachal Pradesh

THERMACT

Abhitech Energycon Ltd., INDIA

A Multifunctional Catalyst for COAL

IIT, Bombay

Abhitech Energycon Ltd.

Manufacturer ABHITECH ENERGYCON LTD

Name THERMACT

Packing 20 Kg Silsack Bag

Appearance Black Colour (Powder Form)

Odour Odourless

Dosage 1:15,000 on Kg/Kg basis (1 Kg of THERMACT for 15 Tons of Coal)

Product Specifications

Abhitech Energycon Ltd.Abhitech Energycon Ltd.

Special Features of THERMACT

THERMACT is a multifunctional combustion improver manufactured by Abhitech Energycon Ltd, with collaboration of IIT, Mumbai.

No capital expenses (NO CAPEX)

“NO SHUTDOWN” required for installation of Dosing equipment.

Tested and approved by – Indian Institute of Technology, Bombay CMRI (Central Mining Research Institute) CMERI (Central Mechanical Engineering Research

Institute) Jadavpur University, Ostrava University SGS, USA - Toxicity Characteristic Leaching Procedure

(TCLP) testAbhitech Energycon Ltd.Abhitech Energycon Ltd.

No shutdown required for

installation of Dosing equipment

1 kg of THERMACT is added with 15 Tons

of Coal

Two Vibro or Screw Feeders opposite

corners

F

SCHEMETIC OF THERMACT DOSING

Regulator

AC Supply

Apparatus Power Consumption

AC Supply

Vibro-feeder + Thyristor Control Panel

1.8 kWh/day 240 V. single phase, 50 Hz

DOSING MECHANISM

1 kg of THERMACTis added to

15 Tons of Coal.

DOSING MECHANISM

Abhitech Energycon Ltd.

Working Principle

Abhitech Energycon Ltd.

THERMACT

Catalyst 1

Catalyst 2

C + H2 CH 4

C + H2 O CO + H 2

THERMACTCatalysts

CH4 heat given Reduction in coal consumption / GUHR

CarbonParticle

H2O

Fixed Moisture

Abhitech Energycon Ltd.

CO +1/2 O2 CO2

Activation Energy

THERMACT reduces the activation energy required for various reactions aiding combustion.

The rate of reactions are increased.

with

THERMACT

Abhitech Energycon Ltd.Abhitech Energycon Ltd.

Benefits

Reduction in Unburnts in Ash Reduction in Excess Air Reduction in O2%Reduction in Flue Gas TemperatureReduction in Slag and ClinkerReduction in R/H and S/H AttemperationReduction in GUHRReduction in Coal consumptionReduction in Soot blowing frequency Improved Generation Reduction in Secondary Fuel Consumption

Abhitech Energycon Ltd.Abhitech Energycon Ltd.

CLIENT NAME LOCATION CAPACITYTata Power ,Mundra Mundra, Gujrat 3 X 800 MW

Sanjay Gandhi TPS Birsinghpur 2 X 210 MW

Santaldih Thermal Power Plant West Bengal 1 x 250 MW

Bandel Thermal Power Station West Bengal 1 x 210 MW; 4 x 62.5 MW

Sagardighi Thermal Power Project

West Bengal 2 x 300 MW

Bakreswar Thermal Power Station

West Bengal 5 x 210 MW

Tenughat Thermal Power Station

Lalpania 1 x 210 MW

Kolaghat Thermal Power Station

West Bengal 6 x 210 MW

The Durgapur Projects Ltd. Durgapur 1 x 110 MW

Satpura TPS, Sarni Sarni 1 x 210 MW

CSEB – Korba TPS Korba 2 x 120 MW; 4 x 50 MW

Amarkantak Thermal Power Station

Chachai2 x 120 MW

Customers using THERMACT in PF Fired Boilers

Abhitech Energycon Ltd.Abhitech Energycon Ltd.

Performance at Various Thermal Power Plants

Abhitech Energycon Ltd.

Savin

gs A

ch

ieved

(i

n %

)

(1 x

62.

5 M

W)

110

x 1

MW

)

(2 x

210

MW

)

(1 x

210

MW

4 x

62.5

MW

)

(5 x

210

MW

)

(6 x

210

MW

)

(1 x

250

MW

)

(2 x

300

MW

)

More than 250 MW

210 MW

Less than110 MW

Clients Name

Abhitech Energycon Ltd.

Case Study – I

SANJAY GANDHI TPS,BIRSINGHPUR

(MPPGCL)(Savings shown by Indirect Method)

   4 x 210 MW,1 x 500 MW

Comparison: Pre-Trial & Post-TrialParameters Unit Pre-Trial Post-Trial Difference Difference %

Average Load MW 146.1 162.61 16.48 11.28%

GCV of Coal Kcal/kg 3756 3725

Unburnt in Bottom Ash % 8.89 3.69 5.20 58.51%

Unburnt in Fly Ash % 4.73 2.43 2.30 48.59 %

O2 @ APH I/L % 6.96 5.73 1.23 16.19%

CO @ APH I/L PPM 943.18 617.26 255.32 27.07%

Boiler Efficiency % 81.08 84.12 3.04 3.75%

Boiler Efficiency after GCV Correction

% 81.08 84.19 3.11 3.84%

Turbine Heat Rate Kcal/Kwh 2369.2 2322.58 46.66

GUHR Kcal/kwh 2922 2758.7 163.37 5.59 %

GUHR after THR Correction

Kcal/Kwh 2922 2805 116.71 3.99 %

Pre-Trial Post-Trial

Effect of THERMACT on Bottom Ash

Pre-Trial Post-Trial

Effect of THERMACT on Fly Ash

Pre-Trial Post-Trial

Effect of THERMACT on Clinker

Pre-Trial Post-Trial

Effect of THERMACT on FLAME

Case Study – II

TENUGHAT THERMAL POWER STATION.

(TVNL)(Savings shown by both Direct and

Indirect method)

  3 x 210 MW

Case Study – III

COASTAL GUJARAT POWER LTD.(A TATA Group of Company)

(Savings shown in terms of reduction in slag and clinker and reduction in Heat Rate)

  An Ultra Mega Power Plant

 4 x 800 MW

THERMACT - DOSING MECHANISM

CLINKER PHOTOS DURING THERMACT USAGE

Abhitech Energycon Ltd.

Before THERMACT With THERMACT

Near Sootblower 175

CLINKER PHOTOS DURING THERMACT USAGE

Near Sootblower 176

Before THERMACT With THERMACT

Case Study – IV

CENTURY PULP AND PAPER, LALKUAN 

100 TPH, AFBC PLANT

(Savings shown in terms of reduction in LOI)

Case Study – V

STATKRAFT , GERMANY(A Biomass Based Unit)

Case Study: STATKRAFT Germany

Reduction in Fly and Bottom Ash

A few customers using THERMACT on regular basis in AFBC Boilers.

S.No. Customer Equipment Details1 KSK Energy Ltd. 90 TPH X 2 – AFBC

2 Birla Cement 70 TPH X 2 - AFBC

3 J. K Cement 89 TPH - AFBC

4 Vasavadatta Cement Ltd 80 TPH - AFBC

5 Madras Cement Ltd 70 TPH - AFBC

6 Century Pulp & Paper Ltd 100 TPH X 2 - AFBC

7 Jubilant Life Sciences Ltd. 90 TPH X 2 – AFBC

8 Delta Paper 50 TPH - AFBC

9 Siddharth Paper 35 TPH - AFBC

10 Merino Industries 25 TPH - AFBC

11 KRBL 25 TPH - AFBC

12 India Glycols Limited 80 TPH X 2

Customers in Sugar Sector using THERMACT-B on regular basis.

Customer Location1 Modi Sugar Modi Nagar2 SBEC Sugar Baraut3 Yadu sugar Bisauli4 Neoli sugar Kasganj5 Indian Sucrose Punjab6 Bhagwanpura Punjab7 A B Sugar Punjab8 Chadha Sugar Punjab9 Wahid Sugar Phagwara10 Ramala Coop Ramala11 Morna Coop Morna12 Sarsawa Coop Sarsawa13 Semikhera Coop Semikhera 14 Anoopshar Coop Anoopsahar15 Belrayan Coop Belrayan16 Nanauta Coop Nanauta 17 Sampurna Nagar Coop Sampurna Nagar 18 Bisalpur Coop Bisalpur19 Tilhar Coop Tilhar

Effective in all types of Boiler

• Depending on the Boiler type, size, age, operational conditions, fuel used , maintenance practices, renovations done with time, its Efficiency varies.

• In a set of ideal conditions it may also be close to Designed efficiency.

• But still, with Additive use, there is always scope of improvement in its Efficiency and in turn reduction in Coal Consumption.

Business Model

Abhitech Energycon Ltd.Abhitech Energycon Ltd.

Abhitech Energycon Ltd.

Plant visit & Assessment

Submission of Technocommercial Proposal

Installation of Hopper Feeder Assembly

Trial (with THERMACT) 30 days

Submission of Technical Report

Regularisation of Product

TRIAL ORDER

Pre Trial (without THERMACT) 15 days

Abhitech Energycon Ltd.

Trial Methodology

Pre Trial (Without THERMACT) : Initial studies of the boiler and all parameters

will be conducted for 15-20 days

Trial (With THERMACT):THERMACT dosing will be done at appropriate

location. The same study conducted earlier will be repeated & GUHR calculated.

Pre GUHR – Post GUHR% Savings = ------------------------------------------------

X 100 Pre GUHR

Multiple Coal samples will be collected from feeder & composite sample will be prepared for analysis of calorific value Abhitech Energycon Ltd.Abhitech Energycon Ltd.

Contributed by

Inherent moisture latent heat absorption prevention

Formation of useful combustible products

Reduction in unburnts in fly ash

Reduction in unburnts in bottom ash

Reduction in excess air requirement for same power output

Reduction in APH temperature.

Covered byDirect Method

[ using gravimetric feeder ]

Covered byIndirect Method

[ BS2885 ]

Savings : Increase in ŋB (Boiler Effiiciency), Reduction in UHR (Unit Heat Rate)

Abhitech Energycon Ltd., INDIAAbhitech Energycon Ltd.

SAFETYASPECTS

Abhitech Energycon Ltd.Abhitech Energycon Ltd.

INSTITUTES CERTIFICATIONSIndian Institute of Technology, Mumbai

Fully safe for industrial applications, as all the ingredients in preparation of THERMACT are organic in Nature. 

Central Mining Research Institute, Dhanbad

Decomposition of coal was faster with THERMACT with less residual matter. 

Central Mechanical Engineering Research Institute, Durgapur

Effect of prolonged used of THERMACT on Boiler Tubes. 

SGS, USAConducted Toxicity Characteristic Leaching Procedure(TCLP) test. 

American Electric Supply (AES), Hungary  

For positive effects of THERMACT on their 210 MW Unit.

CEZ, Czech Republic For reduction in Heat Rate 

Bandel TPS For reduction in GUHR on their 210 MW x 1, 67.5 MW x 4 units.

Durgapur Projects Ltd For reduction in GUHR on their 77 MW x 1, 130 MW x 1 units.

Santaldih TPS For reduction in GUHR on their 250 MW unitTenughat Thermal Power Station For reduction in GUHR on their 210 MW unitSagardighi Thermal Power Station For reduction in GUHR on their 300 MW unit

Credentials of THERMACT – Govt. & Pvt. Institutes

Abhitech Energycon Ltd.Abhitech Energycon Ltd.

Test Significance:  This is a statutory test required for products being used/ imported into USA which detects the presence of potential hazardous chemicals to human/ environment/ ground water. About 95 different elements are identified as hazardous to humans, environment and ground water. Test Results: The test conducted by SGS Lab on THERMACT confirms that none of the 95 identified hazardous chemicals are present in THERMACT. Test Inference:  The use of THERMACT is safe and does not cause any detrimental effect on humans/ environment. 

SGS TEST REPORT

Abhitech Energycon Ltd.Abhitech Energycon Ltd.

CENTRAL MECHANICAL ENGINEERING RESEARCH INSTITUTE, DURGAPUR (CMERI)

CMERI has investigated the effect of prolonged usage of THERMACT (5 years and above) on boiler tubes at Bandel TPS. Test Results: CMERI has studied the conditions of the boiler tubes at BTPS after THERMACT was used for more than 6 years. They have carried out dimensional measurements of boiler tubes by various methods like Visual Inspection, Chemical Analysis of the 2 Metallographic Examination and Hardness Measurement, Tensile Property Evaluation, Stress Test and Fractographic Examination. Test Conclusion: CMERI has confirmed that even after a prolonged usage of THERMACT for more than 5 years, there is no detrimental effect on the metallurgy of the boiler tubes and various pressure parts. 

Abhitech Energycon Ltd.Abhitech Energycon Ltd.

CONCLUSION:

In view of all the investigations completed as per scope of work (mainly visual examination, dimensional measurement, chemical analysis, metallographic analysis, hardness and tensile test results), no noticeable material degradation of the exposed tubes supplied) under the influence of THERMACT is being observed. Apart from that long term behavioral study from stress rupture tests also do not reveal an significant abnormality. Moreover, attempts were made to confirm the effect of “THERMACT” on the surface and sub-surface characteristics of the tubes using SEM and EDS analysis (as an optional test) also did not depict any harmful effects.

Hence, it seems to be prudent to declare that THERMACT, as a compound to enhance the heat efficiency within the furnace, does not loose any detrimental threat to the life of boiler tubes. However, it is wise to state that this is valid only when all the mandatory inspection schedule of boiler tubing is maintained as per the guidelines.

CENTRAL MECHANICAL ENGINEERING RESEARCH INSTITUTE, DURGAPUR (CMERI)

Abhitech Energycon Ltd.

CENTRAL MINING RESEARCH INSTITUTE, DHANBAD (CMRI)

Test Significance:  This test states the impact of THERMACT on the combustion characteristics of coal. 

Test Results:  Confirm that addition of THERMACT catalyst improves the combustibility of coal.

Abhitech Energycon Ltd.Abhitech Energycon Ltd.

Differential Scanning calorimeter Results

Abhitech Energycon Ltd.

CENTRAL MINING RESEARCH INSTITUTE, DHANBAD (CMRI)

Abhitech Energycon Ltd.

CMRI–Dhanbad has confirmed that due to THERMACT ;

Ignition behavior of Coal is changed

Decomposition of Coal is faster

Catalytic effect on Coal combustion

Residual matter after coal combustion

decreases with

THERMACT.Abhitech Energycon Ltd.

CENTRAL MINING RESEARCH INSTITUTE, DHANBAD (CMRI)

Abhitech Energycon Ltd.

Cost Benefit Analysis For 1 x 660 MW

No Capital Expenditure or Additional manpower cost to be incurred by TPS

Abhitech Energycon Ltd.

Coal Consumption / day : 12,000 Tons

Savings in coal with THERMACT usage (@ 2%) : 240 Tons

Cost of Coal : 4000 Rs./Ton

Gross Monetary Savings / day : Rs. 9,60,000

THERMACT required / day : 800 kgs(1 kg for 15,000 kgs of Coal)

Cost of THERMACT : Rs. 330/kg

Investment in THERMACT / day : Rs. 2,64,000

Net Monetary Savings / day : Rs. 6,96,000

Net Monetary Savings / month : Rs. 208.8 Lacs

Net Monetary Savings / annum (330 days) : Rs. 22.97 Crs

Abhitech Energycon Ltd.

All truth passes through three stages. First, it is ridiculed. Second, it is violently opposed. Third, it is accepted as being self-evident.

Arthur Schopenhauer

Thank you! Abhitech Energycon Ltd.Abhitech Energycon Ltd.

Contact Us

 ABHITECH ENERGYCON LIMITED     

Regional Office : B-1/564, First Floor, Janak Puri,

New Delhi - 110 058;  Telefax - 011 25521884,

Mob No - 8130774999, 9350039580

Mail – abhitech_north@yahoo.in

Head Office : A/1020, Oberoi Gardens,

Chandivali Farms Road, Chandivali, Mumbai - 400 072.

Tel - +91-22-2847 9999 ;  Fax - +91-22-2847 9988

Mail – abhitech@abhitechenergycon.com

Website - www.abhitechenergycon.com