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ENERGY EFFICIENCY IMPROVEMENTENERGY EFFICIENCY IMPROVEMENTIN THE POWER SECTOR IN THE POWER SECTOR

PresentationPresentationbyby

BHELBHEL -- Corporate Engineering &Corporate Engineering &

Product DevelopmentProduct Development5 June 20085 June 2008



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Improvements in existing technologies such as sub-critical powerplants and hydro power plants.

Introduction of supercritical and ultra supercritical power plants.Introduction of advanced technologies such as IntegratedGasification Combined Cycle plants or IGCC.

ENERGY EFFICIENCY IMPROVEMENT IN THE POWER SECTOR ENERGY EFFICIENCY IMPROVEMENT IN THE POWER SECTOR



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Initiative - New materials and availability of advanced engineeringtechniques such as FEM, CFD, Simulation, etc., running on faster

and cheaper computers .

Development of more efficient aerodynamic blade profiles and re-designing the inlet and outlet sections using modern CFDtechniques.Improved cycle introduced - increasing steam parameters like

main steam pressure, main steam temperature and hot reheattemperature or improving the internal efficiency by reducinglosses in the steam turbines


Improvements in existing technologiesSteam Power Cycle

1 kcal/ kWh reduction in TG cycle heat rate, coalconsumption reduces by 300 and 700 tonnes per year for 210 and 500 MW sets.



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Losses restricted by employing more effective inter-stage sealing

and shaft sealing by keeping radial clearances to the minimum.New Rating Developed - A new cost effective andthermodynamically efficient plant with a unit rating of 600 MW.


Improvements in existing technologiesSteam Power Cycle



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U se of aerofoil bladed PA fans, with inlet guide vane control inplace of damper control - reduced fan losses. Replacement of

worm gear by planetary gear in pulverisers has improved theirenergy efficiency.Efficiency of boiler feed pumps - Enhanced by one percent throughthermo hydraulic re-designU se of variable speed drives with ID fans and BFPs - reduced

energy losses at part loads.


Improvements in existing technologiesAuxillary power consumption



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PADO (Performance Analysis, Diagnosis and Optimisation) canprovide online guidance to operators to run the plant with

minimum losses and downtimeSmart wall blowing system - Optimises the steam blowing cycle forsoot blowers, thus improving the heat absorption in boiler surfacesand reducing the consumption of auxiliary steam.


Improvements in existing technologiesControl and Instrumentation



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Washing of coal, or beneficiation, to maintain ash content to 30-35%

The benefits are:Coal quality becomes consistent wrt ash %ageEconomical design of Boiler, less space, fewer pulverisers,reduced size of Auxiliaries ² Lower capital costLow operational costs

Better efficiencyLower particulate emissions


Improvements in existing technologiesCoal Washeries

E stablishment of coal washeries needs to given a highpriority.



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The station heat rate is 3% lower than with the conventional sub-criticalcycle.Power plant cycles operating above the critical pressure 221.2 bar.Supercritical cycle·s advantage - ¶burn less fuel for the same output· andlow emissions.Steam parameters like 250 bar pressure, 568 C main steam temperatureand 600 C hot reheat temperature are commonly usedWorld-wide R & D efforts are focused on development of power plantswith ultra-supercritical steam parameters of 350 bar, 700 C main steam

and reheat steam temperatures and net efficiency of 50% by the year2015.


Introduction of supercritical power plants

BHEL is associated with 660 MW B arh Super criticalProject



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GAS C LE AN-UP

GAS

TURBI

NE

H R S GST E AM

TURBI

NE

GT POW E R STACK ST POW E R

2 BL OCKS IN COA L GAS IFI CAT ION P L ANT

CLE AN F UEL GAS

3BL

OCKSIN COM

BIN

EDCYC

LEPOW

ER P

LANT

ST E AMGASEXH AUST

WHAT IS IGCC

NGO IL

COA L

GAS IFI CAT ION



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IGCC Advantage

Conventional Coal plant* IGCC PlantNOx 350 ppm <25 ppm

SOx 600 ppm 245 ppm

SPM 50 mg/Nm3 2 mg/Nm3

CO 2 E mission H igh 10% L ess

F uel consumption H igh 7% less

Water consumption H igh 40% L ess* Typical 500MW thermal plant

L ow E mission, H igh E fficiency

Power Generation Technology



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Reduce adverse impact of fossil fuel combustion onenvironment

Acid rainSuspended Particulate Matter in atmosphereGreen House Effect

WH Y IGCC ?

Uses L ow Grade fuels

E nvironment F riendly Power Generation



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BHEL has worked for more than 2 decades on development of IGCC1st ever plant of 6.2 MW set up in 1988 at Trichy

Feasibility of scale up of the 6.2 MW to ~100 MW is established by BHE L

High powered R&D committee set up under chairmanship of scientific advisor

has recommended for scaling up to 100 MW site rating plantBHEL has signed an MO U with APGENCO on 10th May08 for IGCC Plant at

Vijaywada

BHEL has contracted more than 60 FBC and 17 CFBC boilers

Largest in operation : 125 MW :

Under construction : 250MW

Next Step - Basic Engineering for 400 MW IGCC completed

BHEL¶ s Gasification & IGCC D evelopment Program

1 st L argest size 125MW IGCC Plant order expected from

APGE

NCO in 2-3 months.



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Introduction of advanced technologies

Transmission and distribution of Power

AC Transmission ² 400 kV, 765 kVDC Transmission ² 500, 8001200 kV AC Transmission ² Transformer, Disc Insulators,Switchgears, CT, CVTHVDC



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