4 th annual “coal markets in india-2014” the imperial new delhi 22.08.2014
TRANSCRIPT
4th Annual “Coal Markets in India-
2014”The Imperial
New Delhi
22.08.2014
Improving Coal Efficiency -Role of Coal Additives
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Abhitech Energycon LimitedA/1020, Oberoi Garden Estate, Chandivali Farm Road,
Chandivali, Mumbai – 400072
Tel (91-22) 2847 9999 Fax (91022) 2847 9988
E-Mail : [email protected]
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 – [email protected]
Head Office : A/1020, Oberoi Gardens,
Chandivali Farms Road, Chandivali, Mumbai - 400 072.
Tel - +91-22-2847 9999 ; Fax - +91-22-2847 9988
Mail – [email protected]
Website - www.abhitechenergycon.com