India

Presentation Outline

• Overview of Indian Power

Sector
• About BHEL Corporate

• BHEL-Trichy Unit

• BHEL’s CCT & CCS Programme

 SOURCES OF POWER GENERATION IN INDIA
Capacity
Source
(MW)* Source Capacity (MW)*
Thermal 140206
Coal 120103
Nuclear 4780
Gas 18903
Hydro 39291
Diesel 1200
Other renewable 24998
Total 140206
Total 209276
* As on 31-10-2012
Other
renewab Gas Diesel
les 14% 1%
12%
Hydro
19%
Thermal
67% Coal
Nuclear 85%
2%

India’s total coal reserves up to 276 Gt www.powermin.nic.in

India’s Energy Growth Scenario
Presentation Outline

• Overview of Indian Power

Sector
• About BHEL

• BHEL-Trichy Unit

• BHEL’s CCT & CCS Programme

Bharat Heavy Electricals Limited
India’s largest engineering enterprise established more
than 40 years ago

Manufacturing enterprise catering to the core sectors of

the Indian Economy, viz
Power, Transmission, Industry, Transportation, Renewable
Energy, Oil & Gas and Defense.

A Major Integrated Power Plant Equipment Manufacturer

in the World

180 products under 30 major product groups

Footprints in 71 countries

Installed over 1,15,000 MW (Thermal)

Manufacturing capacity of 20000 MW per year

 Operating Business Areas
Power Industry

Thermal Captive Power Plants

Boilers, STG, Auxiliari Boilers, STGs, Auxiliaries,
C&I Systems, DG
es, ESP, EPC

Power Transmission
Hydro Switchgear, Transformers
Turbines, Insulators, Substations
Generators SCADA, HVDC Systems
International
Controls Transportation
Operations
Gas AC/DC Locos
Open Cycle, Diesel electrics Locos
EMUs, Traction Electrics
Combined Cycle
Other Products
Nuclear On-Shore Oil Rigs
STG Compressors, NCES
SG Desalination Plants
Valves, Motors

Serving core & Infrastructure sectors of the Economy

 BHEL Corporate – Turn Over

49301
60000 43337 (7585 million
34154 (6667* million Euros)
50000
28033 (5692 million Euros)
Rupees, Crore

40000 21608 (4833 million Euros)

30000
(3324 million Euros)
Euros )
20000

10000

2007-08 2008-09 2009-10 2010-11 2011-12

* 1 Euro = Rs 65.00
16 Manufacturing divisions, 4 Power Sector regional centres, over 100
project sites, 8 Service centres and 18 Regional offices
BHEL’S Contribution to Indian Power Sector

INSTALLED CAPACITY - Utility

OTHER
S
25%
BHEL
75%
A COMPLETE POWER STATION MANUFACTURER
 180 products under 30 major product groups
POWER GENERATION SYSTEMS
- Turnkey power stations
- Combined-cycle power plants
- Cogeneration systems
- Modernisation of power stations
- Erection commissioning, O&M services.
- Spares management
- Consultancy services
TRANSPORTATION SYSTEMS
- Traction systems
- Urban transportation systems
- Erection commissioning, O&M services
- Consultancy services
TRANSMISSION SYSTEMS
- Sub-stations switchyards
- HVDC transmission systems
- Shunt and series compensation systems
- Power system studies
- Erection commissioning, O&M services
- Consultancy services
INDUSTRIAL SYSTEMS
- Industrial drives and control systems
- Erection commissioning, O&M services
- Spares management
- Consultancy services
Presentation Outline

• Overview of Indian Power

Sector
• About BHEL

• BHEL-Trichy Unit

• BHEL’s CCT & CCS Programmes

Major Products Manufactured At BHEL Trichy

Pulverised Fluidised Nuclear Heat

Fuel Boilers Bed Steam Recovery
Combustion Generators Steam
Boilers Generators
 BHEL’s Boiler Ranges

Pulverised Fuel Boilers Fluidised Bed Combustion

Boilers

Sub critical Bubbling Fluidised Bed

• 60 MW • 20 MW
• 110 MW • 45 MW
• 200 MW • 60 MW
• 210 MW • 80 MW
• 250 MW • 120 MW
• 500 MW
• 600 MW

Circulating Fluidised Bed

Super Critical • 60 MW
• 660 MW • 75 MW
• 700 MW • 125 MW
• 800 MW • 135 MW
• 1000 MW • 250 MW
 Growth in unit size of PF Boilers

Capacity in MW

Sub critical
800
Supercritical

660

500

250
210

120
60
30

1962 1965 1966 1972 1991 1997 2008 2008

Year Of Introduction
CFBC – Growth in Unit Size Over The Years

Capacity, MW

250

125

50

Sinar Mas,1995 SLPP,1995 NLC ,2005

Presentation Outline

• Overview of Indian Power

Sector
• About BHEL

• BHEL-Trichy Unit

• BHEL’s CCT & CCS Programme

 BHEL Initiatives Towards CCT

• Increasing efficiency of PF Boilers

– Supercritical
– AUSC
• Reduction measures for non GHG like NOx through
– BOFA
– SCR
• Reduction of SO2 emissions by
– FGD
• IGCC technology development
• Oxy fuel combustion
• Biomass Co-firing technology
 Utility Boiler Technology Growth
30 SUB CRITICAL SUPER CRITICAL ULTRA SC
NATURAL CIRCULATION CONTROLLED CIRCULATION ONCE THROUGH
800 MW & above
25 300 ata,700°C/700°C
HEAT RATE IMPROVEMENT %

25 660 / 800MW
250 ata,
568°C/598°C
500 MW 20.5
210/250 MW 500 MW 170 ata,
20
150 ata, 170 ata, 540°C/568°C
540°C/540°C 540°C/540°C 17.2
110/200 MW
15.7
130 ata, 14.6
15 540°C/540°C
12.5
60/100 MW
96 ata,
10 540°C

0
1960 1970 1980 1990 2000 2010 2020

YEAR
 Advanced USC Boilers

Government of India has taken initiatives to develop

boilers with 800 MW capacity to meet 300 bar
700°C/700°C cycle requirements with consortium
with BARC, NTPC, Midani and BHEL with a target
completion of 2017.
 Bypass Over Fire Air (BOFA) System

• Cost effective technology among the technologies available for NOx

reduction in pulverised coal fired thermal power plants.

• Employs deep air staging technique to abate NOx emission.

• The BOFA system was retrofitted into a 250 MW boiler supplied by

BHEL (Suratgarh).

• The NOx reduction capability around 50%.

 Selective Catalytic Reduction

• BHEL has developed Selective Catalytic Reduction system for NOx

reduction in PC fired boilers by injecting ammonia in to the flue gas
in the presence of a catalyst.

• SCR pilot plant has been established at Fuel Evaluation Test

Facility at BHEL Trichy.

• NOx reduction capability of the SCR system was demonstrated to

be in the order of 90-95%.
 FGD in India –An Overview

• National Ambient Air Quality Standard revised in November 2009.

Industrial and Residential area are combined and the ambient air
standard norms for SO2 are reduced.
• Sulphur in Imported Coal is higher than Indian coal
• FGD retrofit a distinct possibility in future
• FGD Projects
• TrombayUnit 8 –250 MWSea Water –70 mg/Nm3

• NTP Bongaigaon3x250 MWWet Lime –280 mg/Nm3

BHEL’s Supercritical Test Facility

Parameter Value
Pressure 400 bar
Temperature 700° C
Mass flux 3500 kg/m2 s
Heat flux 1000 KW/m2
Tube Geometry Smooth and Rifled
Heating Uniform and One-sided
Horizontal, Vertical and
Tube orientation
inclined

• 400 Tests with 360⁰ heated smooth

vertical tube completed
• Tests under Ultra Supercritical
conditions (303 bar, 607⁰ C) carried out
• Design verification of low load
conditions of supercritical boilers
 Commercialisation Of IGCC – BHEL’S Approach
Scale up:
Geometrical - 1:1
Capacity - 1: 1.1
No. of Gasifiers - 2-3
Scale up: Pressure - 1:1.2
Geometrical - 1:1.14 450-600 MW
Capacity - 1: 1.21
Pressure - 1:0.9
IGCC
Scale up:
Geometrical - 1: 2.91
182 MW Future
Capacity - 1: 11.1 IGCC IGCC
Pressure - 1:3

Scale up: 125 MW APGENCO

Geometrical - 1: 3.3 Vijayawada
Capacity - 1: 9.33 IGCC
Pressure - 1:1.2
NTPC
6.2 MW Auraiya
Scale up:
Geometrical - 1: 2.25 CCDP
Capacity - 1: 15
Tiruchy
Pressure - 1:5
18
TPD
(PEDU)
Dia 0.2 m
Press 2.0 ata Corp. R&D,
1.2 Hyderabad
TPD
(APFBG)
Corp R&D
Hyderabad
BHEL’S PFBG Based IGCC Demo Plant At Tiruchy

Coal throughput 168 T / DAY

Power Output 6.2 MW

Gasification media Air / Steam mix

1000º C
Gasification temp.

Gasification pr. 11.0 Kg/cm2

Gas Calorific Value 1050 Kcal/Nm3

 BHEL-TRECSTEP
EU Project on Demonstration and deployment of CCT and
CCS project

BHEL has initiated the following projects

• Co-firing of biomass with coal (Trials completed for pelletised wood)

• Pilot scale testing of Oxy fuel combustion (Target completion 2013)

MoU Signed between BHEL, Trichy and TREC-STEP, Trichy on 10th Sept, 2011.

33
FLUE GAS RECYCLE VENT TO STACK
HOT FLUE
HEATER GAS
COOLER
AIR or CO2
HEATER
SECONDARY
STREAM
MIXING CHAMBER CEM CYCLONE
ANALYSER
DIRECT OXYGEN
PRIMARY
STREAM
MIXING CHAMBER

FLUE GAS FAN

O2
STORAGE

PC
BIN OXY FUEL
BURNER
COMBUSTOR
PC
FEEDER

HEATER

EDUCTOR

FD FAN 400 KW Pilot scale – Oxy

fuel Combustion Test
Facility
CO2 STORAGE
FGR
 Post-Combustion CO2 Capture

• Pilot Scale development of CO2

absorption from flue gas and
Syngas in Progress
• Liquid NH3 is used for this
purpose
Newly Established Coal Research Centre at BHEL’s Tiruchirapalli Unit
Facilities At Coal Research Centre
Major Facilities at Coal Research Centre

Computer Controlled Scanning Electron Microscope

High Temperature X-Ray Diffraction Spectrometer

X-ray Fluorescence Spectrometer

Inductively Coupled Plasma with Mass Spectrometer

Powder Particle Size Distribution Analyser

Fourier Transform Infrared Spectrometer

Thermogravimetric Analyser
 Acknowledgements

• BHEL Trichy

• TREC-STEP, Tiruchirapalli

• European Union