Super Critical Technology In NTPC India A brief overview

Presentation Outline

A Brief Introduction to Indian Power Scenario / NTPC Super Critical Technology in NTPC

Currently India has Power Generating Capacity of about 127,925 MW

Generating Capacity (MW)
Thermal Hydro Nuclear Renewable TOTAL 84,024 33,810 3,900 6,191 127,925* 66 % 26 % 3% 5% 100.0%
Private Sector 12% Central Sector 32% State Sector 56%
(70,821 MW)

About 88% of Capacity is owned by Central/State Governments

*Excluding Captive generation capacity of appx. 15000 MW

Thermal:Fuel Mix (MW)

Coal Gas Diesel Thermal 69,408 13,582 1,202 84,024 82.5% 16.1% 1.4% 100.0%

(15,431 MW)

(41,673 MW)

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Source: Ministry of Power, GOI

A Brief Introduction to NTPC

The largest power generation company in India under Central Government Current installed capacity 29,144 MW 18 coal based and 8 gas based power plants Setting up hydro power plants, developing coal mines for captive use, and exploring oil / gas blocks in consortium with partners Subsidiary & JV companies for taking up power generation, trading, and distribution business and for setting up of small hydro plants Setting up coal based power plant in Srilanka
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A Brief Introduction to NTPC

HYDEL POWER ~9,000 MW BY 2017 NUCLEAR POWER 2000 MW BY 2017 RENEWABLES~1000 MW BY 2017
LATERAL INTEGRATION GLOBALISATION SETTING UP OF POWER PLANTS ABROAD INTERNATIONAL CONSULTANCY FORWARD INTEGRATION

POWER TRADING POWER DISTRIBUTION

RELATED DIVERSIFICATION

SIX COAL MINE BLOCKS (~47 MTPA CAP.) ALLOCATED ONE OIL/GAS BLOCK ALLOCATED.

SECTORAL SUPPORT PIE APDRP RURAL ELECTRIFICATION TRAINING UNDER DRUM

R&M OF POWER STATIONS JV FOR CAPTIVE POWER

Clean Coal Technologies in NTPC

Efficiency Improvement

New Technologies

Green Power

Environment Management

Renewable

Clean Coal Technologies in NTPC

Mature

Clean Coal Technologies

Supercritical/Ultra Supercritical Circulating Fluidized Bed Combustion

Clean

Coal Technologies under Development

Integrated Gasification Combined Cycle

Environmental

Impact Mitigation Technologies

NOx,SOx and SPM control

Clean Coal Technologies in NTPC

Sl No 1 2 3 4 5 Technology Efficiency Improvement Environmental benefit Super critical /USC Technology FBC Technologies IGCC Low NOx burners, Over Fire Air Environmental mitigation Technologies (ESP, DeNOx, DeSOx, Ash Utilization etc)

Super Critical Technology will improve efficiency

6000C/6000C (eff = 39.9 %)

6000C/6000C (eff = 39.4%) 5650C/5930C (eff = 39.1%)

Efficiency %

5650C/5650C (eff = 38.8%) 5370C/5650C (eff = 38.5%) 5370C/5370C (eff = 38.2%)

5370C / 5370C

Base Efficiency=37.6 % (Gross, GCV) 170 246 MS Pressure Kg/cm2 316

Efficiency figures corresponds to boiler efficiency of 85% on GCV basis

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SUPERCRITICAL ADVANTAGES
Enhancements Plant efficiency Fuel tolerance Reductions Coal Consumption Ash production CO2 SO2 Nox Improvements Startup time Sliding Pressure Operation Load following capability 0.69% to 1.64% More tolerant to coal quality changes

1.79% to 4.24%

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ENVIRONMENTAL ASPECTS

Reduction in CO2, SO2 and NOx between 1.79% to 4.24% Reduction for 500 MW at 68.5% PLF per year is - CO2 78300 tons - SO2 365 tons - Nox 71 tons

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In 1999 NTPC appointed an International consultant EPDC, Japan to study for adoption of super critical technology in NTPC EPDC evaluated supercritical technology from technical, economical and environmental point of view for Indian perspective. EPDC recommended supercritical technology for India and suggested following parameter. Main steam pressure 246 kg/cm2, Temperature-538/566 deg C NTPC implemented supercritical technology for two plants i.e Sipat-I (3X660MW) and Barh-I (3X660MW) with above parameter.
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Implementation of Supercritical Technology NTPC

Supercritical Technology Analysis

Technology - Mature and established Availability - Same as sub-critical Project Implementation- Essentially same as sub-critical O&M - By & large same as sub-critical Reduced Environmental Impact Most preferred parameters- 246 Kg/cm2-538oC/566oC Materials proven and already in use Indigenous Supplier of Supercritical Technology are under developing stage.

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SUPERCRITICAL VS SUBCRITICAL MAJOR DESIGN DIFFERENCE

Boiler- Once Through instead of drum type and use of superior material in certain pressure parts Piping- Reduced diameter. Superior Material. Turbine- Increase in thickness of various parts to suit higher parameters Feed Heaters-Increased thickness of tubes, water boxes and tube plate BFP-Increased motor rating. Higher thickness of certain parts Boiler Control- Change in philosophy Water Chemistry- No blow down. 100% flow CPU. Different chemistry control. No new superior material is used. Only the quantity of superior material increases.

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Super Critical Technology - Efficiency Improvements

Sub - critical units Old Unit Size MS Pressure kg/cm2 MS Steam Temp(O C) RH Steam Temp (O C) 500 MW 170 537 537 Recent 500 MW 170 537 565 38.26 Plant-I 660 MW 247 537 565 38.84
CO2 Emission / MW

Super - critical units Plant-II 660 MW 247 537 565 39.14 Plant-III 660 MW 247 565 593 39.96

Gross Efficiency (HHV) % 38.00

Plant 500 MW (170 bar/537 C/537 C) 500 MW (170 bar/537 C/565 C) 660 MW (246 bar/537 C/565 C) 660 MW (246 bar/565 C/593 C)

Turbine Heat Rate

SO2 Emission / MW

BASE 0.7% 2.6% 5.1%

BASE 0.7 % 2.6 % 5.1 %

BASE 0.7 % 2.6 % 5.1 %

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NTPC is adopting Super Critical Technology

NTPC adopted supercritical technology for unit size over 500 MW in steps as under: PLANTS IN ADVANCE STAGE OF CONSTRUCTION 3 x 660 MW Sipat STPP Stage-I 3 x 660 MW Barh STPP Stage-I UPCOMING PLANTS Barh-II, Bihar 2x660 MW (Order Placed) North Karanpura, Jharkhand 3x660 MW Darlipali, Orissa 4x800 MW Lara, Chattisgarh 5x800 MW Cheyyur, Tamilnadu 3x800 MW Marakanam, Tamilnadu 4x800 MW Tanda-II, Uttar Pradesh - 2x660 MW Meja, Uttar Pradesh - 2x660 MW
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Heat Rate Improvement Efforts in NTPC

16.00 14.00
HR Improvement (%)

12.00 10.00 8.00 6.00 4.00 2.00 0.00 200 LMZ (1978) 200 KWU 500 KWU 500 KWU 500 High RH (2006) (1979) (1982) Mod (1998) 660 SC (2004) 660/800 SC (2008)
P = 130 ata MST = 537 RHT = 537 P = 150 ata MST = 537 RHT = 537) P = 170 ata MST = 537 RHT = 537) P = 170 ata MST = 537 RHT = 537 P = 170 ata MST = 537 RHT = 565 P = 247 ata MST = 537 RHT = 565 P = 247 ata MST = 565 RHT = 593

P = 280 ata MST = 600 RHT = 620)

660/800 USC (2012)

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Impact of Local Conditions on Reported Efficiency

42.6% LCV /GCV 9% over base 40.2% Un-burnt Carbon Loss 39.8% Vacuum 39.0%

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Salient Features of the Steam Generator

Type

Supercritical, suitable for variable pressure or rifled/plain water wall tubing Tower type or two pass type Flow (T/Hr)

operation with spiral

Rating At SH Outlet At RH Outlet

Flue

Temperature Deg C 540 568

Pressure Kg/Cm2(a) 256 52.0

2225 1740

gas temperature at air-heater outlet- 125 Deg C

Fuel

GCV range 3000 to 4000 Kcal/kg with 10-16% moisture and 32 to 48% ash

Start up system

Start up system with one no. circulating pump is with alternate drain flow to condenser through flash tank .

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Major Furnace Sizing Criteria

Net Heat Input/Plan Area Heat liberation rate Burner zone heat release rate Heat input per burner Furnace cooling factor Furnace residence time 4.75X106 Kcal/hr/m2 (Max) 106920 Kcal/hr/m3(max 1.36x106 kcal/hr/m2 (Max) 600X 105 kcal/hr (Max) 1.8X105 kcal/hr/m2(Max) 2.0 Sec(Min)

Boiler Pressure Parts Material

Up to 400 Deg C Up to & including 550 deg C Up to & including 605 deg C Above 605 Deg C Carbon steel to ASME A-106 Gr. B/C or SA 210C or equivalent Alloy steel to ASME SA-335:P-11/P-12/P-22/P-23; ASME SA-213:T-11/T-12/T-22/T-23 or equivalent. Alloy steel to ASME SA-213:T-91/T-92 and ASME SA335:P91 or approved equivalent. Austenitic stainless steel, SUPER 304H, TP 347H or approved equivalent.

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TURBINE COMPONENTS MATERIAL

Components 246 ata /537 0 C /5370 C

Material
246 ata /537 0 C /5650 C 246 ata /565 0 C / 5650 C -- ata /600 0 C/ 6200 C

HP inner casing HP stop and control valves IP inner casing IP stop and control valves

15Cr1Mo1V 15Cr1Mo1V 15Cr1Mo1V 15Cr1Mo1V 25Cr1Mo1V 25Cr1Mo1V 18Cr11MoNiVNb 18Cr11MoNiVNb

15Cr1Mo1V 15Cr1Mo1V G-X12CrMoVNbN9-1 G-X12CrMoVNbN9-1 25Cr1Mo1V 25Cr1Mo1V 18Cr11MoNiVNb 18Cr11MoNiVNb

G-X12CrMoVNbN9-1 G-X12CrMoVNbN9-1 G-X12CrMoVNbN9-1 G-X12CrMoVNbN9-1 25Cr1Mo1V 25Cr1Mo1V 18Cr11MoNiVNb 18Cr11MoNiVNb

9-10% Cr Steel

9-10% Cr Steel

HP Rotor IP Rotor HPT Blades (Few initial stages) IPT Blades (Few initial stages)

10% Cr Steel 10% Cr Steel

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NEW MATERIAL
In addition to conventional material the following new materials are being adopted on recent-660MW supercritical units and to take care of higher temperature of steam parameters: Super 304H SA-213 T23 SA-335 P23 SA-213 T92 SA-213 P92 SA 302 C

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Typical Tubing for 568 / 595 C Steam Temperatures

OR AUSTENITIC

Primary SH Final RH

Final SH

Primary RH

SUPER 304

Economiser

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Adoption of Clean Coal Technology: Conclusions

NTPC has already gone for adoption of higher size ( 660 MW) supercritical units and moving towards higher steam parameter for coming projects. Adoption of further higher size Ultra supercritical units with higher steam parameters for efficiency improvement is under study. Detailed feasibility for adoption of IGCC technology for high ash Indian coal (For a demonstration plant of 100 MW capacity) is already completed. Increasing Operational Efficiency and introduction of reusable energy sources

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Thank You

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