Power Plant

Energy Conservation in Power Plant Sector
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Power plant
Per Capita Consumption 350 kWh (277 kg of oil equivalent)
Energy Intensity 6 – 8% of power generation
Energy saving potential Rs.3000 Million (US $ 60 Million)
Investment potential on
energy saving projects Rs. 5000 Million (US $ 1000 Million)
Investors Manual for Energy Efficiency

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POWER PLANT SECTOR
INTRODUCTION
1.0 Energy Scenario

The power sector has always been high on India’s priority as it is a growing sector, offering
tremendous potential for improvements and new investments.
As per the recent projections by CEA, The total generating capacity which is today at about
1,07,000 MW is expected to reach 2,15,000 MW by 2012. The share of various sources in
meeting this requirement is shown in Table-1.
Table 1: Power Sector Growth Projection in MW
Coal Gas Nuclear Hydro Others Total
Installed Capacity
as on Feb 2003 63800 11560 2720 26760 2800 107644
Additional Capacity
to be increased
(2003-2012) 50690 19860 8380 27050 2170 108150
Total Capacity
by 2012 114490 31420 11100 53810 4970 215800
Source: CEA
Economic growth in India crucially depends on the long-term availability of energy in increasing
quantities from sources that are dependable, safe and environmentally friendly.
India, like many other developing countries, is a net importer of energy, 20 per cent of primary
energy needs being met through imports mainly in the form of crude oil and natural gas.
Confederation of Indian Industry - Energy Management Cell

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Currently, thermal power plants accounts for major share of about 70%. Coal is the mainstay
fuel in India for power generation. With total coal reserve around 220 billion tones, of which
84.4 billion tonnes are proven, coal will continue to be an assured energy source for the next
century and beyond.
Though coal based plants account for major share in power generation, recently there is an
increasing trend in going for gas-based power plants also, particularly in the private sector.
1.1 Power Generation Capacity

The power generating capacity in India has increased over 80-fold, from 1,362 MW in 1947 to
1,07,644 MW in 2003.
The share of various sources of power generated is pictorially shown in figure 1.
(Source: Ministry of Power)
The industrial sector is the highest consumer of electricity (34 percent) followed by agriculture
(30 percent) and domestic (18 percent) sector.
1.2 Per-Capita Energy Consumption

Per capita energy consumption in India is about 277 Kg of oil equivalent, which is 3.5 per cent
of that in the USA, 6.8 per cent of Japan, 37 percent of Asia and 18.7 per cent of the world
average. Per-capita consumption of electricity for various countries is shown in figure 2.
Figure 2: Per-capita consumption in Kwh
(Source: Ministry of Power)

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But, energy intensity, which is energy consumption per unit of GDP, is one of the highest in
comparison to other developed and developing countries. For example, it is 3.7 times that of
Japan, 1.55 times of the USA and 1.5 times of the World average. This signifies that there
is tremendous scope for energy conservation in the country.
1.3 Thermal Power Plants in India

In India, size of thermal power plants started with ratings of 60/70 MW during 1965, which
touched 500MW rating in 1979. At present National Thermal Power Corporation (NTPC) is
planning to install units in the range of 660MW rating, operating with supercritical parameters
at Sipet in Chattishgarh State by the year 2005.
There are about 85 major thermal power plants installed in India. The eastern belt being coal
abundant, major plants are located in that region.
Figure 3: Thermal Power Plants
(Info: http://www.osc.edu/research/pcrm/emissions/thermalemissions)
Apart from private and public utilities and IPP’s, most of the industries have there own captive
generation.

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1.3.1 Captive Power Plants

Industrial Sector is the largest consumer of energy. Besides consuming power from Utilities,
a number of industries which are primary producers of infrastructure material such as Aluminium,
Cement, Fertilizers, Iron & Steel, Paper and Sugar etc. have their own captive power plants.
The installation of captive generation plants has been either to supplement the electricity
purchased from the Utilities or for emergency use in case of power outages or for producing
energy from by-product of the industrial process (e.g., Sugar Plants).
Table 3 shows sector wise captive power plant installed in the country.
Table 3: The break up of Captive Power Plants
Installed Percentage of
Sl.No. Name of Industry Capacity TotalInstalled
(MW) Capacity
1 Chemicals, Mineral Oil &
Petroleum 1993 13.86
2 Textile 1884 14.54
3 Aluminium 1742 12.32
4 Iron & Steel 1686 15.78
5 Cement 1466 10.16
6 Fertilizers 1155 9.02
7 Sugar 7862.66
8 Paper 5994.06
9 Heavy & Light Engineering 4532.50
10 Non-Ferrous Metal 4243.94
11 Automobiles 2311.13
12 Food 115 0.53
13 Mining & Quarrying 38 0.68
14 Other Industries 1360 8.82
Total 13932 100.00
Source: CEA
India has a total capacity of 2500 MW thermal based Independent power plants (IPP’s)

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CHAPTER II
PROCESS, TECHNOLOGY AND TRENDS
2.1 Technology Trends

Thermal power generation started with ratings of 60/70 MW rating units in the year 1965,
simultaneously raised to 110/120 MW units by the year 1966. The next size of 200/210 MW
plants, which are widely installed all over India from the year 1972 onwards grew into 500 MW
units by the year 1979.
As the unit ratings grew, the boiler parameters supplying steam to such turbines have also
increased. Following table 4 shows the trends in super heater outlet pressures and temperatures
for various unit sizes.
Table 4: Turbine Sizes and Pressure Parameters
Unit Size Steam Flow Super Heater Super heater

(T/H) Outlet Pressure / Re Heater Outlet
(KG/CM2) Temperature (oC)
30 MW 150 63 490
60/70 MW 260 96 540
110/120 MW 375 139 540
200/210 MW 690 137/156 540
250 MW 805 156 540
500 MW 1670 179 540
Source: BHEL
The over all efficiencies of power plants with sub critical parameters fall in the range of 35-
39 percent which can be improved to 45 percent using supercritical parameters with conventional
steam turbines. Using combined cycle mode, the maximum efficiency that can be attained is
about 50 percent.
Table 5 shows the heat rate for various capacities of turbines achieved in power plants.

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Table 5: Turbine Sizes and Heat Rate
Unit capacity Turbine inlet Turbine Heat Rate

parameter (Kcal/Kwh)
60/100 MW 90 ata 535oC 2315
110/120 MW 130 ata 535oC 2180
200/210 MW 130 ata 535oC 2025
210/250 MW 150 ata 535oC 1975
500 MW 170 ata 535oC 1950

Source : BHEL
Power plants are adopting several latest technologies to improve the efficiency and operating
practices. Some of the power plants are installed with multi fuel capabilities by design for the
following benefits.
• Flexibility to use depending on availability and price
• To address environmental issues like Nox and Sox reduction
2.2 Clean Coal Technologies

Environmental performance of thermal power plants is accorded tremendous importance to
meet global emission standards and need for balancing development and social obligations.
Clean coal technologies for power generation that posses the potential to contain pollutants
either at the combustion or pre-combustion stage will be the technologies that would eventually
replace the conventional PC firing.
India’s experience in clean coal technology started with the development of AFBC (Atmospheric
Fluidized Bed Combustion) for high ash coals. CFBC (Circulating Fluidized Bed Combustion)
was later introduced to cater to higher capacity power plants and to realize higher efficiency.

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It has been a challenge for the Indian power plants to adopt several measures to bring down
the ash disposal and to meet the stringent environmental regulations, some of which are
shown below
• Importing high grade coal
• Lower emission technologies
• Improving efficiency of equipment
Power plants are also exploring various possibilities to utilize the fly ash as by-product for
some processes like
• Utilising in cement preparation as substitute for clinker
• Manufacturing of Flyash bricks
2.2.1 AFBC Boilers

Atmospheric fluidized bed Combustion (AFBC), promises to provide a viable alternative to
conventional coal fired boilers for utility and industrial application.
The advantages of AFBC boilers are
• Suitable to burn variety of fuels
• Combustion efficiency is higher
• It can completely burn fine particle (Fuel size range:6-12 mm)
• Losses due to unburnt are avoided
• Simple auxiliaries i.e., Lower operating cost
2.2.2 CFBC Boilers

Circulating Fluidized Bed Combustion (CFBC) boiler is normally designed for high reliability
and availability with low maintenance.
Some of the advantages of CFBC boilers are
• Thermal efficiency is higher than AFBC
• Technology is suitable to burn a wide range of fuels (high ash coal, high sulphur coal,
lignite, pet, coke, anthracite clum, wood paste, etc.)
• CFBC boiler availability is more than 95%.
• Lesser Sox, Nox emissions
• Auxiliary power consumption of these boilers is relatively lower (do not require high pressure
blowers)

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2.2.3 Super Critical Boilers

Super critical boilers operate at main steam pressures exceeding 225 ata i.e., critical pressure
at which there is spontaneous changeover from liquid phase to vapour phase.
Supercritical units normally operate around pressure of 240-250 ata. The main steam temperature
& reheat temperature for these units are normally in the range of 535-565oC. Boilers with
steam pressures and temperatures beyond 250 ata/565oC are termed as ultra supercritical
boilers.
Some of the excellent features of supercritical boilers are
• Enhanced boiler efficiency
• Operational flexibility to respond quickly to load changes
• Reduced emissions
2.4 Renovation & Modernization
Old power plants are modernized to keep up the operation of the equipment and its efficiencies.
The advantages of Renovation & modernization are
• Enhancement of operational efficiency
• Improvement in Plant Load Factor (PLF)
• Meeting stringent environmental pollution control standards
• Extend plant life
• Capacity augmentation
Some of the renovation and retrofitting techniques that are followed by the power plants are
1. Steam turbine retrofitting (blades replacement and improvement of the labyrinths’ operation
and turbine control system, etc)
2. Improvement of the fuel preparation and firing system
3. Implementation of techniques for further reduction of the Nox emissions and for the flue gas
de-sulphurization

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4. Improvement of particles collecting systems
5. Optimization of the existing fuel drying system or implementation of new effective drying
techniques
6. Replacement, rearrangement or size change of heat exchange surfaces
7. Supplementary heat exchange surfaces for further heat recovery from flue gas
8. Improvement of the air preheating system
CHAPTER III
ENERGY SAVING PROJECTS
3.1 Energy Saving & Investment Potential in Power plants

The consumption of electricity by power plant auxiliaries depends on factors such as unit size,
level of technology, plant load factor, fuel quality etc.
The auxiliary consumption in general varies between 3 to 6% for larger plants and close to 10
% for smaller captive power plants.
CII studies indicate that the energy saving potential in small size power plants (CPP’s & IPP’s)
varies between 6% - 10% of auxiliary consumption. It is estimated that the saving potential is
150 MW of power amounting to Rs.300 crores annually.
CII study also indicates that the investment potential for energy efficiency in small size
power plants is Rs.500 crores. This does not include saving potential in utility plants.
3.2 List of Projects

All energy saving projects are classified in to three categories namely Short term, Medium term
and Long term based on the investment and returns available in each project.
These projects apply to IPP’s & CPP’s and can be easily implemented. Some of these
projects are equally applicable in utility power plants.
3.2.1 Short Term Projects
A) Boilers
1. Install online O2 analyser and improve combustion efficiency of the boilers
2. Arrest air infiltration in boiler flue gas path, particularly economiser and air preheater section
3. Install water heating system for preheating gas through waste heat recovery from Boiler
exhaust
4. Install waste heat recovery system for boiler blow down
5. Install LP steam air heater for FD fan air inlet to boiler
6. Optimise the operating breakdown voltage of ESP’s

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B) Steam & Condensate Systems

1. Avoid steam leakages
2. Insulate all steam and condensate lines
3. Monitor and replace defective steam traps on a regular basis
4. In case coal has higher percentage of fines, ensure wetting is done.
5. Install flash vessels for heat recovery from hot condensate vapours
6. Replace electric heaters with LP steam heaters for RFO tracing lines
C) Electrical Areas
1. Install delta to star converters for lightly loaded motors
2. Use translucent sheets to make use of day lighting
3. Install timers for automatic switching ON-OFF of lights
4. Install timers for yard and outside lighting
5. Install CFL’s for lighting in non-critical areas, such as, toilets, corridors, canteens etc.
6. Group the lighting circuits for better control
7. Operate at maximum power factor
8. Switching ‘OFF’ transformers based on loading
9. Optimise TG sets operating frequency, depending on user needs
10. Optimise TG sets operating voltage
D) Miscellaneous
1. Replace Aluminium blades with FRP blades in cooling tower fans
2. Install temperature indicator controller (TIC) for optimising cooling tower fan operation,
based on ambient conditions
3. Install dual speed motors/ VSD for cooling tower fans
4. Avoid/ minimise compressed air leakages by vigorous maintenance
5. Segregate the service air &
instrument air and optimise optimise operating pressure
6. Reduce system pressure of the compressed air system close to operating pressure of
the users
7. Install variable frequency drive for hot well makeup water pump
8. Install Variable Frequency Drive (VFD) for cooling tower make up pump with water level
control feed back
9. Install Variable Frequency Drive for DM water transfer pump

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10. Close Suction Dampers at Stand-By Equipment and Reduce RPM of Dust Extraction
Blowers in the Coal Handling Plant
11. Install the next lower size impeller for the chilled water pumps
12. Avoid idle flow of cooling water in stand by DG sets and compressors
13. Install chlorine dosing and HCL dosing for circulating water
3.2.2 Medium Term Projects
A) Boilers
1. Install economiser/air preheater for boilers
2. Install high temperature deaerator (120°C to 140°C) with suitable boiler feed water pump
to enhance cogeneration
3. Install VSD for SA fan, FD fan and ID fan
4. Install VSD for boiler feed water pump
5. Segregate Intermediate Pressure & High Pressure Boiler Feed Water Pump
6. Install Variable Frequency Drive (VFD) for CCW pump and operate in closed loop control,
based on the discharge header pressure.
7. Reduce Heat rate of gas turbines by optimizing NOx water injection and arresting of
leakages through bypass dampers
8. Install Turbine inlet air cooling to increase power output of gas turbines
9. Install Low excess air burners
10. Reduce one stage of feed water pump or install variable frequency drive with feed back
control to exactly match with the system pressure
11. Install lower head fan for power plant boiler ID fan
B) Steam & Condensate Systems

1. Convert medium pressure steam users to LP steam users to increase co-generation
2. Install condensate recovery systems in air heaters
3. Utilise waste condensate for de-superheating the process steam
4. Install Variable Fluid Coupling or variable frequency drive for condensate extraction pump
5. Utilise flash steam from boiler blow down for deaerator heating

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C) Electrical & Miscellaneous Areas

1. Install maximum demand controller to optimise maximum demand
2. Install capacitor banks to improve power factor
3. Replace rewound motors with energy efficient motors
4. Replace conventional ballast with high efficiency electronic ballasts in all discharge lamps
5. Install Sodium vapour lamps instead of MV lamps for Yard, Street and General Lighting
6. Install LED lamps for panel indication instead of filament lamps
7. Install neutral compensator in lighting circuit
8. Optimise voltage in lighting circuit by installing servo voltage stabilisers
9. Minimise overall distribution losses, by proper cable sizing and addition of capacitor banks
10. Replace V-belts with synthetic flat belts/Cog ‘V’ belts
11. Replace heater - purge type air dryer with heat of compression (HOC) dryer for
compressed air requirement above 500 cfm
12. Replace old and inefficient compressors with screw or centrifugal compressors
3.2.3 Long Term Projects

1. Install VFD for Boiler ID/FD fans
2. Install VFD for Boiler feed water pump
3. Install Circulating Fluidised bed boilers for Efficient combustion
4. Install steam driven equipment to prevent HP steam flow through pressure reducing valves
5. Convert chain grate/spreader stoker boilers to AFBC technology
6. Install high efficiency turbines
7. Install vapour absorption system to utilise LP steam for air-conditioning
8. Install Distributed control system (DCS) for Power Plant Operation and monitoring

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3.2 Case Studies
Case Study: 1
Convert Spreader Stoker Boilers to Fluidised Bed Boilers
Background
In the older power plants, the boilers are the conventional stoker boilers.
These boilers were characterised by:
• Higher unburnts in ash
• Lower thermal efficiency
The latest trend has been to install the fluidised bed boilers or conversion of the existing chain
/ spreader stocker boilers, which have the following advantages:
• Coal having high ash content/ low calorific value can be used
• Biomass fuels can also be used
• Lesser unburnts in ash
• Higher thermal efficiency
Hence, the older plants are also in a phased manner, converting their old stoker-fired boilers
to fluidised bed boilers. This case study describes one such project implemented.
Previous Status
A power plant had four numbers of spreader stoker boilers, operating to meet steam
requirements of the plant. These spreader stoker boilers, were designed for high calorific value
coal (4780 kCal/kg) with low ash content.
Due to non-availability of this type of coal, these boilers had to be fired with coal of low calorific
value and high ash content. This resulted in the capacity down-gradation and loss in efficiency.
The steam generation was only 14 TPH, as against the design rating of 30 TPH. The boiler
efficiency achieved was only 65%.
Energy saving project

The plant team modified two of the spreader stoker boilers into fluidised bed combustion
boilers.

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Benefits of the Project

In addition to the benefits of fluidised bed combustion mentioned earlier, they also enable the
use of biomass fuels, such as saw dust, generated in the chipper house.
The steam generation capacity increased to 27 TPH and the thermal efficiency improved to
78%, with this modification. The improved thermal efficiency has resulted in an annual coal
saving of 5639 MT. Additionally, the use of saw dust (calorific value of about 3000 kCal/kg) has
resulted in an annual coal savings of 3600 MT.
Finalcial Analysis
The annual benefits achieved were Rs.10.50 million. This required an investment of Rs.27.0
million (for the conversion of two spreader stoker boilers to fluidised bed combustion boilers),
which had a simple payback period of 31 months.
Cost benefit analysis

• Annual Savings – Rs 10.50 millions
• Investment – Rs 27.0 millions
• Simple payback - 31 months
Implementation Strategy
The plant took up implementation of the project after a detailed planning with the EPC contractor.
The modification was taken up during the annual shut down (30 days). The shut down had to
be extended to avoid 30 days to complete the project. The commissioning of the new boiler
took about 4 days and there were no problem during implementation.

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Case Study: 2
Install VFD for Boiler ID fans and PA fans
Background
In a major captive power plant, three irculating fluidised bed combustor (CFBC) were in
operation. Each boiler has two ID fans and three PA fans.
• All these fans had higher capacity & head by design and controlled either by IGV’s or
Dampers to meet the operating requirements.
• The IGV opening of the ID fans varied between 50-60%, resulting in tremendous energy
loss. The measured pressure loss across the damper & IGV was of the order of 40-45%
of the total pressure rise of the fan.
Concept of the Project

• The operation of a fan with damper control or IGV control is an energy inefficient practise,
as a part of the energy supplied to the fan is lost across the damper or IGV.
• Also, the operation of a fan operating with IGV or damper control will result in operation of
the fan in an energy inefficient zone on the fan performance curve. Instead the speed of the
fan can be varied to meet the operating condition of the boiler by installing variable frequency
drives.
• The estimated operating efficiency of the fans was in the range of 60% - 65% as against
design efficiency of 80%. It was confirmed that the fans were operating in an energy
inefficient zone.
Energy Saving Project

Variable frequency drives were installed for 6 nos of ID fans and 9 nos of PA fans to control
the speed of the fan with respect to operation of the boiler.

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Implementation Strategy
The VFD’s were installed during the stoppage of the plant for maintenance. The plant personnel
were well trained in operation and maintenance of VSD’s (prior to the installation of VFD) and
therefore no problems were faced with implementation. The inlet guide vanes were kept fully
opened after the VFD was installed.
Benefits of the Project

• The advantage of installing a variable frequency drive for the boiler ID fans are as follows:
Energy saving
Precise control of parameters
Financial Analysis
The annual energy savings achieved was Rs 6.0 million and the investment was Rs 10.0
million for installing 15 nos of variable frequency drives, which got paid back in 20 Months.

Replication Potential
Similar projects can be taken up for FD & Secondary air fans also. The project has high
replication potential in majority of the captive power plant and IPPs. For ID, FD, secondary air
and primary air fans

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Case Study: 3
Install steam drives to prevent HP steam flow through pressure reducing valves
Background
• In a major captive power plant, the auxiliary steam requirement was at a pressure of 24 kg/
cm2 and 4100C.
• The quantity of process steam requirement was about 11.5 kg/cm2. To meet the process
requirement the steam from extraction was passed through PRDS.
• When steam pressure is reduced by passing through a pressure reducing valve, the enthalpy
of the steam remains constant. But due to pressure loss, the opportunity for converting the
low grade energy (thermal energy) to high grade energy (mechanical energy) is lost.
• The quantity of steam passed through the pressure reducing valve was varied depending
upon the process requirement.
• Instead of dropping the high pressure to low pressure by throttling, the same energy can
be used for power production.
Energy Saving Project

• The potential available was tapped by installing 2 back pressure steam turbines which were
used for driving the drip pumps (2 Nos.). The exhaust steam from the back pressure turbine
was utilised for auxiliary steam requirements.
Implementation Methodology
In a captive power plant the modification of the plant on a continuous basis is essential. A
stoppage for replacing the motor with a turbine for drip pump was not possible. Therefore 2
new drip pumps with back pressure turbines (300 kW) each were installed and the system
was hooked up during a maintenance shut down. Though the investment was high the stoppage
of plant could be avoided.

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Benefits
The implementation of the project resulted in improving the co-generation potential.
Finalcial Analysis
The annual energy savings achieved was Rs 27.5 million and the investment was Rs 12.5
million for installing back pressure turbines, Generator and steam piping, which had a pay
back of 6 Months.


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Case Study: 4
INSTALL VAPOUR ABSORPTION HEAT PUMP IN PLACE OF VAPOUR

COMPRESSION SYSTEM
Background
In a captive power plant (of 21 MW capacity) of a large integrated paper plant, certain areas,
viz., the boiler & TG control room, static excitation room, ESP/Ash handling plant control room
and coal handling plant control room required a temperature of 26 ± 2 °C to be maintained.
The total air-conditioning load was 60 TR. Since, this power plant was in the project stage, the
plant team had the option of choosing between a vapour compression system and a vapour
absorption system, for maintaining these conditions. A techno-economic study favoured the
installation of a vapour absorption system.
Concept of the project

The vapour absorption system scores over vapour compression system when
:
• Back pressure steam from a turbine is available
• Any waste source of heat is available on a continuous basis e.g. DG exhaust
• Cost of a electricity is high
In this case study, the turbine had the capacity to accept additional 300 kg/hr of low cost low
pressure steam. This gives an excellent spin-off benefit by generating additional power in the
turbine.
Energy saving project

The plant team installed a 60 TR vapour absorption system for meeting the air conditioning
requirements of the various control rooms. This project was taken up at the design stage itself.
Comparison of Vapour Absorption Vs Vapour Compression

The comparative analysis of a vapour compression system and a vapour absorption system,
for achieving the same amount of air-conditioning, are as follows:

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Parameter Units Vapour Vapour

compression absorption
system system
Rating TR 60 60
Power consumption kW 60 60
Steam consumption at
4 ksc kg/h - 300
Annual operating cost * Rs.lakhs 16.80 6.60
Annual savings Rs.lakhs - 10.20
Investment required Rs.lakhs 12.00 19.00
* Operating cost based on steam cost @ Rs.250/MT

and electricity cost @ Rs.3.50/kWh
In addition to the above, other benefits achieved were as follows:
• The room conditions were met as desired
• No maintenance shut down required, since there are no moving parts
Benefits & Financial Analysis

The annual energy saving achieved was Rs.1.0 million. This required an investment of
Rs.1.9 million, which had a simple payback period of 23 months.

Replication Potential
The installation of vapour absorption refrigeration system is in its nascent stage in the Indian
industry. The potential for installation of vapour absorption system in combination with a co-
generation system is tremendous in Indian industry and therefore needs to be pursued.

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CHAPTER IV
Service Agencies in the sector
4.1 List Of Suppliers
1. Bharat Heavy Electricals Ltd (BHEL)

Building BHEL Building
Street Siri Fort Road
City 110 049 New Delhi
Country India
Telephone (+91) 11 - 649 30 31
Facsimile (+91) 11 - 649 30 21
E-Mail lodpms@bhelindustry.com
Internet www.bhelis.com
Description Power Generation and New & Renewable Energy Technologies
2. Thermax Babcock & Wilcox Ltd (TBW)

Building Sagar Complex
Street Mumbai Pune Road
Place Kasarwadi, Nasik Phata
City 411 034 Pune
Country India
Telephone (+91) 20 - 712 57 45
Facsimile (+91) 20 - 712 55 33
E-Mail tbw-web@tbwindia.com
Internet www.tbwindia.com
Description Heat Recovery Steam Generators, Circulating Fluid Bed Boilers,

Grate & Gas Fired Boilers
3. Thermax Ltd
Building Thermax House
Street 4, Mumbai Pune Road
Place Shivaji nagar
City 411 005 Pune

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Country India
Telephone (+91) 20 - 551 21 22
Facsimile (+91) 20 - 551 22 42
E-Mail abunglow@thermaxindia.com
Internet www.thermaxindia.com
Description Boilers & Heaters, Captive Power, Cooling, Water & Waste
Solutions, Air Pollution Control and Chemicals
4. Larsen & Toubro Ltd – EPC Centre

Building Ashish Complex
Steet NH8, Chhani
City 391 740, Vadodara-Gujarat
Country India
Telephone (+91) 265 – 2775317 /2774941-5
Facsimile (+91) 265 - 27773898/5286
E-Mail yps@enc.ltindia.com,
Internet www.lntenc.com
Description Power Projects Development, Renovation & Modernisation,

Hydro Projects
5. Foster Wheeler India Pvt Ltd

Building Prakash Presidium
Street 110, Mahatma Gandhi Road
Place Nungambakkam
City 600 034 Chennai
Country India
Telephone (+91) 44 - 28227341
Facsimile (+91) 44 - 28227340
E-Mail fwenergy@fwc.com
Internet www.fwc.com
Description PC Fired & FBC Boilers, HRSG, Gasifiers

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6. TurboTech Precision Engineering Pvt Ltd

Street No 28/29, 2nd Main Road
Place Industrial Town, Rajajinagar
City 560 044 Bangalore
Country India
Telephone (+91) 80 - 320 07 89
Facsimile (+91) 80 - 330 72 27
E-Mail turbo1@vsnl.com
Internet www.turbotech-india.com
Description Manufacturers of Small, Efficient Steam and Gas

Turbines
7. Neptunus Power Plant Services Pvt Ltd (NPPS)

Building 511, Arenja Corner
Street Plot 71, Sector 17
Place Vashi
City 400 705 Navi Mumbai
Country India
Telephone (+91) 22 - 789 32 58
Facsimile (+91) 22 - 790 60 81
E-Mail neptunus@vsnl.com
Internet www.neptunus-power.com
Description Captive Power Plants, Power Generation, Co-

Generation etc
8. Aravinthraajan Energy Systems

Building Madhurams Flat
Street 17/1 Senthil Andavar Street
Place Vadapalani
Country India
Telephone (+91) 44 - 484 46 27
Facsimile (+91) 44 - 484 46 27

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E-Mail aessoft@satyam.net.in
Internet www.geocities.com/powerfulsolution/
Description Power Plant System Design and Optimisation

Software
9. Turbo Engineers (TE)

Street 2/C/1, Picnic Garden 3rd Lane
City 700 039 Kolkata
Country India
Telephone (+91) 33 - 343 49 48
Facsimile (+91) 33 - 343 44 11
E-Mail turbo@cal2.vsnl.net.in
Internet www.maxpages.com/turboengineers/
Description Thermal & Hydro Power Generation
10. DUKJIN E & C

Building 277, Nonhyun-Dong
Street Kangnam-GU
City Seoul
Country Korea
Telephone 82-02-3443-0692 to 5
Facsimile 82-02-3443-0696
E-Mail dukjinec@dukjinec.com
Internet www.dukjinec.com
Description Water Treatment & Ultra Filtration system
4.2 List of consultant in the sector
1. TCE Consulting Engineers Limited

Building Sherif Center
Street 73/1 St, Marks Road
Country India
Telephone (+91) 80 – 2274721

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Facsimile (+91) 80 - 2274873
E-Mail kini@bangalore.tce.co.in
Internet www.tce.co.in
Description Consultancy Services in Power Generation, Transmission

& Distribution
2. Avant-Garde Engineers and Consultants Pvt Ltd (AGEC)

Street 68a, Porur-Kundrathur High Road
Place Porur
Country India
Telephone (+91) 44 - 482 87 17
Facsimile (+91) 44 - 482 85 31
E-Mail avantgarde@vsnl.com
Internet www.avantgarde-india.com
Description Concept to Commissioning of Renewable Energy Projects
3. FICHTNER Consulting Engineers (India) Private Ltd

Street 64, Eldams Road
Country India
Telephone (+91) 44 – 2435 9158
Facsimile (+91) 44 – 2434 4579
E-Mail mail@chn.fichtner.co.in
Internet www.fichtner.co.in
Description Consultancy Services in Gas & Thermal Power Plants
4. Acon Power Consultants

Street 45 Satyanand Vihar
District Rampur
City 482 008 Jabalpur
Country India
Telephone (+91) 761 - 66 72 61

626
Facsimile (+91) 761 - 66 42 07
E-Mail acon@sancharnet.in
Internet www.acon4power.com
Description Engineering Consultancy Services, Specializing in Power

(Thermal/Hydro/Non-Conventional Energy Source)
5. Mitsui Babcock Energy (India) Private Ltd

Building Alsa Tower
Street 186-187 Poonamalle High Road
Place Kilpauk
Country India
Telephone (+91) 44 - 26612901
Facsimile (+91) 44 - 26612907
E-Mail jmcphail@mitsuibabcock.com
Internet www.mitsuibabcock.com
Description Thermal Power Plants
6. L&T - Sargent & Lundy Ltd

Building L&T-Energy Centre
Street Near Chhani Jakat Naka
District Baroda
City 390 002 Vadodara
Country India
Telephone (+91) 265 - 77 23 90
Facsimile (+91) 265 - 79 52 35
E-Mail ltsl@ltecd.ltindia.com
Internet www.lntsnl.com
Description Complete Consultancy Services in the Field of Power

Generation from Concept to Commissioning for Power
Projects

627
7. Mantech Synergies Pvt Ltd

Street 73, Sardar Patel Road
Place Guindy
Country India
Telephone (+91) 44 - 220 02 45
Facsimile (+91) 44 - 220 02 46
E-Mail mantech@vsnl.com
Internet www.mantechsynergies.com
Description Project Development Consultants for Independent Power

Projects from 100 MW to 350 MW
8. Energy Economy & Environmental Consultants

Street #506, 15th Cross
Place Indiranagar 2nd Stage
Country India
Telephone (+91) 80 - 525 61 71
Facsimile (+91) 80 - 525 91 72
E-Mail eeec@vsnl.com
Description Consulting Services for Cogeneration Plants, Distribution Loss

Reduction, Waste Minimisation

Power Plant

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Energy Conservation in Power Plant Sector

Per Capita Consumption 350 kWh (277 kg of oil equivalent)

Energy Intensity 6 – 8% of power generation

Energy saving potential Rs.3000 Million (US $ 60 Million)

Investors Manual for Energy Efficiency

POWER PLANT SECTOR

1.0 Energy Scenario

Table 1: Power Sector Growth Projection in MW

Coal Gas Nuclear Hydro Others Total

Confederation of Indian Industry - Energy Management Cell

1.1 Power Generation Capacity

The share of various sources of power generated is pictorially shown in figure 1.

(Source: Ministry of Power)

1.2 Per-Capita Energy Consumption

Figure 2: Per-capita consumption in Kwh

(Source: Ministry of Power)

1.3 Thermal Power Plants in India

Figure 3: Thermal Power Plants

Confederation of Indian Industry - Energy Management Cell

1.3.1 Captive Power Plants

Table 3: The break up of Captive Power Plants

1 Chemicals, Mineral Oil &

Petroleum 1993 13.86

2 Textile 1884 14.54

3 Aluminium 1742 12.32

4 Iron & Steel 1686 15.78

5 Cement 1466 10.16

6 Fertilizers 1155 9.02

9 Heavy & Light Engineering 4532.50

10 Non-Ferrous Metal 4243.94

12 Food 115 0.53

13 Mining & Quarrying 38 0.68

14 Other Industries 1360 8.82

Total 13932 100.00

Investors Manual for Energy Efficiency

PROCESS, TECHNOLOGY AND TRENDS

2.1 Technology Trends

Table 4: Turbine Sizes and Pressure Parameters

Unit Size Steam Flow Super Heater Super heater

60/70 MW 260 96 540

110/120 MW 375 139 540

200/210 MW 690 137/156 540

250 MW 805 156 540

500 MW 1670 179 540

Confederation of Indian Industry - Energy Management Cell

Table 5: Turbine Sizes and Heat Rate

Unit capacity Turbine inlet Turbine Heat Rate

60/100 MW 90 ata 535oC 2315

110/120 MW 130 ata 535oC 2180

200/210 MW 130 ata 535oC 2025

210/250 MW 150 ata 535oC 1975

500 MW 170 ata 535oC 1950

• Flexibility to use depending on availability and price

• To address environmental issues like Nox and Sox reduction

2.2 Clean Coal Technologies

Investors Manual for Energy Efficiency

2.2.1 AFBC Boilers

The advantages of AFBC boilers are

• Suitable to burn variety of fuels

• Combustion efficiency is higher

• It can completely burn fine particle (Fuel size range:6-12 mm)

• Losses due to unburnt are avoided

• Simple auxiliaries i.e., Lower operating cost

2.2.2 CFBC Boilers