FEASIBILITY STUDY OF LIGNITE DRYING (REPORT )
GUJARAT STATE ELECTRICITY CORPORATION LIMITED
GUJARAT ENERGY RESEARCH &
FEASIBILITY STUDY OF LIGNITE DRYING (REPORT )
GUJARAT STATE ELECTRICITY CORPORATION LIMITED
GUJARAT ENERGY RESEARCH &
1ST
Floor, Pandit Deendayal Petroleum University Campus,
FEASIBILITY STUDY OF LIGNITE DRYING (REPORT )
GUJARAT STATE ELECTRICITY CORPORATION LIMITED
GUJARAT ENERGY RESEARCH &
Floor, Pandit Deendayal Petroleum University Campus,
Raisan, Gandhinagar
FEASIBILITY STUDY OF LIGNITE DRYING (REPORT )
SUBMITTED TO
GUJARAT STATE ELECTRICITY CORPORATION LIMITED
SUBMITTED
GUJARAT ENERGY RESEARCH &
Floor, Pandit Deendayal Petroleum University Campus,
Raisan, Gandhinagar
www.germi.org
FEASIBILITY STUDY OF LIGNITE DRYING (REPORT )
SUBMITTED TO
GUJARAT STATE ELECTRICITY CORPORATION LIMITED
SUBMITTED
GUJARAT ENERGY RESEARCH &
Floor, Pandit Deendayal Petroleum University Campus,
Raisan, Gandhinagar
www.germi.org
FEASIBILITY STUDY OF LIGNITE DRYING (REPORT )
SUBMITTED TO
GUJARAT STATE ELECTRICITY CORPORATION LIMITED
SUBMITTED BY
MANAGEMENT INSTITUTE (GERMI)
Floor, Pandit Deendayal Petroleum University Campus,
Raisan, Gandhinagar – 382 007
www.germi.org
FEASIBILITY STUDY OF LIGNITE DRYING (REPORT )
GUJARAT STATE ELECTRICITY CORPORATION LIMITED
MANAGEMENT INSTITUTE (GERMI)
Floor, Pandit Deendayal Petroleum University Campus,
382 007
FEASIBILITY STUDY OF LIGNITE DRYING (REPORT )
GUJARAT STATE ELECTRICITY CORPORATION LIMITED
MANAGEMENT INSTITUTE (GERMI)
Floor, Pandit Deendayal Petroleum University Campus,
Pag
GUJARAT STATE ELECTRICITY CORPORATION LIMITED
MANAGEMENT INSTITUTE (GERMI)
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MANAGEMENT INSTITUTE (GERMI)
97
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Contact Detail
Project Leader (GERMI)
Dr. Sagarkumar M. Agravat (Scientist – E1)
Scientist In-Charge Solar R&D Projects
Cell Phone : +91 90999 50356
Email : [email protected]
Institute’s Address
Gujarat Energy Research & Management Institute (GERMI)
1st Floor, Energy Building, Pandit Deendayal Petroleum University (PDPU) Campus
Raisan, Gandhinagar – 382 007
Gujarat, IN
Phone : +91 79 2327 – 5372
Fax : +91 79 2327 – 5380
Web : www.germi.org
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About the Report
This report is divided into seven chapters with a total no. 97 pages.
Chapter – 1 provides overview of the study site i.e. KLTPS power plant, its basic
operation and different cycles.
Chapter – 2 provides introduction and overview of effect of fuel moisture on
performance / emission.
Chapter – 3 highlights different types of lignite drying technologies, its
function, pros and cons of each one of them.
Chapter – 4 provides experimental details for proximate and ultimate analysis
of lignite samples.
Chapter – 5 provides detailed account of experiments conducted on lignite for
determination of its constituents, moisture content, ash content, fixed carbon,
results and conclusion etc.
Chapter – 6 provides details of energy requirement for drying sample of lignite
and time consumed for direct, indirect and forced convection solar dryer.
Chapter – 7 provides overview of techno-commercial analysis of drying of lignite
through solar energy, flue gas exhaust. It also highlights possibility of tapping
flue gas to convert into useful energy and therby making plant energy efficient.
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EXECUTIVE SUMMARY
Today, considering all types of fossil fuels, coal is the energy rich material
which generates 42% of the world’s electricity. In India, the reserves of lignite
are about 40.91 billion tonnes found in Tamil Nadu, Pondicherry, Kerala,
Gujarat, Rajasthan and Jammu & Kashmir. About 80% reserves are located in
Nevyeli (Tamil Nadu) with about 32.89 billion tonnes. GSECL operates lignite
based thermal power station in Kutch location of Gujarat with source of coal
from adjacent lignite mines of GMDC. The reserves of lignite from GMDC are
almost exhausted and in order to keep the plant running, new source of lignite
need to be identified. Being low grade coal with lots of moisture, transportation
cost of lignite may raise electricity cost.
One of the possible solutions is to make plant energy efficient by drying of
lignite through high temperature exhaust gas / flue gas. GERMI has conducted
laboratory experiments to confirm possibility of drying lignite at higher
temperatures than ambient and also reviewed available technologies across
globe. All these technologies being new and due to lack of sizeable market are
costly at present. It was found that such an initiative is attractive due to
following factors.
1. Higher fuel costs
2. Higher moisture content of lignite
3. Carbon credits
GoI has started taking measures for clean coal technologies. Appropriate
mendate through legislation can also help.
We have recommended following two methods for drying of lignite (Refer
Chapter – 7)
1. Drying of lignite through WTA technology
2. Drying of lignite through use of solar thermal energy
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Alternately, high temperature flue gas can be converted into electricity
generation through Kalina Cycle which is well mature technology used in
geothermal thermal energy exploration and industrial exhaust heat recover.
We believe that cleaning of flue gas through Pneumatic Saturation
Condensation Process for cleaning of flue gas for desalination of water is also a
very good solution for desalination of salty water which may be useful in the
plant operation and also for supply to neighbouring village as part of CSR
activities.
Such projects may have pay-back period of around 20 years without any
financial incentives and carbon revenue, however, with financial support from
UNIDO / UNDP, the returns can be very attractive.
We propose to conduct preparation of Detailed Project Report as next stage.
We take this opportunity to congratulate GSECL management for initiating the
study and providing financial support to GERMI for the study.
Dr. Sagarkumar M. Agravat
20.03.2016
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Contents
About the Report .......................................................................................................................................... 3
(Author)EXECUTIVE SUMMARY .................................................................................................................... 4
EXECUTIVE SUMMARY .................................................................................................................................. 4
CHAPTER-1: OVERVIEW ABOUT KUTCH LIGNITE THERMAL POWER STATION ............................................. 8
Introduction .................................................................................................................................................. 8
The flowchart of the plant is as follows: ..................................................................................................... 10
Water Cycle ................................................................................................................................................. 14
Gas cycle ..................................................................................................................................................... 16
CHAPTER 2: INTRODUCTION ....................................................................................................................... 17
Effect of Fuel moisture on Performance ..................................................................................................... 21
Effect of Fuel moisture on Emission ........................................................................................................... 23
CHAPTER 3: DRYING TECHNOLOGY ............................................................................................................ 25
RWE- WTA Technology ............................................................................................................................... 25
Vantefall PFBD ........................................................................................................................................ 28
Dryfining ...................................................................................................................................................... 29
Rotary Drying .............................................................................................................................................. 30
. Rotary drying .................................................................................................................................... 30
Rotary tubes ........................................................................................................................................ 31
Microwave Technology ............................................................................................................................... 31
Microwave drying ............................................................................................................................... 31
Screw Conveyor Dryer ................................................................................................................................ 32
Hydrothermal dewatering .......................................................................................................................... 33
Integrated Drying ........................................................................................................................................ 33
Solvent Extraction Method ......................................................................................................................... 34
References .................................................................................................................................................. 35
Chapter 4 ..................................................................................................................................................... 37
4.1 Determination of proximate and ultimate analysis of lignite ............................................................... 37
4.1.1 Procedure for proximate analysis ...................................................................................................... 37
4.1.1.1 Moisture content ............................................................................................................................ 37
Observation Table ................................................................................................................................. 39
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Sample 1- ................................................................................................................................................. 39
Calculation .............................................................................................................................................. 39
Scale Requirements .............................................................................................................................. 39
4.1.1.2 Volatile Matter ................................................................................................................................ 42
4.1.1.3 Ash content ..................................................................................................................................... 45
4.1.1.4 Fixed Carbon ................................................................................................................................... 48
4.1.2 Procedure for ultimate analysis ......................................................................................................... 49
4.1.3 Results and Conclusion ...................................................................................................................... 54
CHAPTER-5 .................................................................................................................................................. 56
Experimental study of lignite drying through solar energy ........................................................................ 56
Materials and method ................................................................................................................................ 56
Results and Discussion....................................................................................................................... 67
Analysis ....................................................................................................................................................... 74
CHAPTER – 6: ENERGY ANALYSIS ................................................................................................................ 79