NTPC NETRA's Conference on R&D for Energy Sustainability

Transcription

1 NTPC NETRA's Conference on R&D for Energy Sustainability NETRA Presentation on Non-chemical Technology for High COC Operation with Scale Inhibition for achieving ZLD 31 st March 2016

2 SCALE-BAN TM A Sustainable solution A Non Chemical Water Treatment for Zero Liquid Discharge (ZLD) Continuously improving the possibilities to Innovate the conservation of natural resources.

3 A FACT Only 0.007% of total water available on earth is potable which is being shared by all types of Industries, Agriculture & House holds.

4 Vision To provide a Self Sustainable, Efficient and Cost Effective Zero Liquid Discharge (ZLD) solution for Industries.

5 A Sustainable Zero Liquid Discharge (ZLD) Solution MISSION Maximizing Water Conservation Optimizing Generation through Scale free operations

6 Genesis SCALE-BAN TM equipment has been developed by years of hard researches & trials and in commercial production since The technology is proven and well tested. The references of its successful running in more than 200 industries and applications have been established. SCALE-BAN TM is an online non chemical static mechanical equipment which reduces 30% to 40% water consumption in thermal power plants besides total prevention of hard water scale in condensers/heat exchangers in cooling water services.

7 Problems & Concerns Zero Liquid Discharge (ZLD) & Specific Water Consumption in Thermal Power Plants as per New Gazette Notification (7 th Dec. 2015) issued by Government of India-MOEF to be mandatorily achieved To meet above guidelines, conventional systems like RO & Multi Effect Evaporator (MEE) are very costly to install & operate. RO & MEE operations are cumbersome. SCALING IN CONDENSER/HEAT EXCHANGER Impacts of scaling: Loss of Vacuum/Generation & Increased steam consumption Increased water consumption and water pollution

8 Impact of Scale in Heat Exchangers Scale of even 0.5 mm causes an energy loss of 7% Efficiency Loss in %

9 Available methods for ZLD & Scale Prevention Conventional SCALE-BAN RO & MEE Chemical Treatment Online Ball Cleaning System Softener Plant Non- Chemical Static Mechanical Equipment

10 Limitations of Conventional Systems for achieving ZLD & Scale free Operations Restricted level of hardness (300ppm) and TDS (1500ppm) in cooling water causing Heavy Blow Down from cooling tower. Blow down water can be consumed only after treatment through RO followed by MEE. Recurring Expenses on RO+MEE operations, Online Ball Cleaning System, anti-scalant chemical dosing & softener operation in cooling tower. No guarantee for zero scale (Generation losses). Frequent de-scaling of condenser/heat exchanger.

11 Operations with SCALEBAN Cooling tower can be operated at very high hardness (10000ppm) and TDS (50000ppm), Unbelievable COC level of 15 to 20 already achieved. Reduction in blow down by more than 80% to 90% (ZLD achieved with zero recurring expenses). Elimination of RO+MEE system for achieving ZLD. Complete elimination of Online Ball Cleaning System, Softener & antiscaling chemical. Zero scale is guaranteed for 20 years. De-scaling of Condensers/heat exchangers is not required.

12 Working Principle of SCALE-BAN TM Innovation evolved from problem

13 S O L U B I L I T Y S O L U B I L I T Y SOLUBILITY CHARACTERISTICS OF WATER IN HEAT EXCHANGER IN SCALEBAN S 1 Ca ++ Mg ++ S 1 Ca ++ Mg ++ S 2 S 2 T 1 T 2 Temperature Relationship of Temperature & Solubility of Ca 2+ and Mg 2+ in Liquid P 1 P 2 ph Value Relationship of ph & Solubility of Ca 2+ and Mg 2+ in Liquid SCALEBAN GALVANIC PRINCIPLE

14 Working process of SCALE-BAN TM

15 VIDEO ON SCALEBAN AT NTPC DADRI

16 SCALE-BAN Installation In a Power Plant

17 DESIGN OF A SELF SUSTAINABLE, EFFICIENT AND COST EFFECTIVE ZERO LIQUID DISCHARGE MODEL

18 ZERO LIQUID DISCHARGE (ZLD) WITHOUT SCALEBAN CLARIFIED WATER Make up water EFFLUENT TREATMENT PLANT COOLING TOWER COC CONDENSER/ COOLERS ETP TREATED WATER CT Blow Down water CONDENSER/ COOLERS RO PLANT RO PERMEATE COOLING TOWER/PROCESS APPLICATIONS MULTI EFFECT EVAPORATOR (MEE)

19 ZERO LIQUID DISCHARGE (ZLD) WITH SCALEBAN CLARIFIED WATER Make up water EFFLUENT TREATMENT PLANT COOLING TOWER COC CONDENSER/ COOLERS ETP TREATED WATER Negligible Blow Down due to high COC. Hence can be directly taken for ash handling/ coal handling CONDENSER/ COOLERS RO PLANT RO PERMEATE COOLING TOWER/PROCESS APPLICATIONS MULTI EFFECT EVAPORATOR

20 FINAL SCHEME WITH SCALEBAN FOR ACHIEVING ZERO LIQUID DISCHARGE (ZLD) CLARIFIED WATER Make up water COOLING TOWER COC SCALEBAN CONDENSER / COOLERS Negligible Blow Down due to high COC. Hence can be directly taken for ash handling/coal handling SCALEBAN CONDENSER / COOLERS

21 SCALEBAN V/S CONVENTIONAL SYSTEM FOR ZLD AND SCALE PREVENTION SCALEBAN SOLUTION It can handle very high hardness (10,000 PPM) & very high TDS (50,000 PPM). No effect of seasonal or annual variation of water quality. Life time zero recurring cost for operation and maintenance. Zero Scale Guarantee in Condensers. Better life of Condenser Tubes. Additional Plant availability of days enhancing PLF by 3% to 4%. Minimum 1% steam saving as condenser vacuum maintained at higher side. No land space for installation. No power Consumption. ROI Maximum 2 years. No need of EVAPORATORS for achieving ZLD CONVENTIONAL SYSTEM Restricted low level of hardness (300 PPM) & TDS (1500 PPM). Chemical treatment and RO are water quality dependent. Daily recurring expenses, Heavy opex for MEE & life of RO Membrane maximum 3 years. No Guarantee of Zero Scale. Acid and High Pressure jet cleaning shorten the life of tubes. Downtime required for condenser/heat exchanger de-scaling. Vacuum deteriorate over time leading to plant shutdown. Large shed required for RO & MEE Plant. Minimum 2 MWH power consumption. Only Expenses, No ROI EVAPORATORS are required for achieving ZLD

22 Working Parameters of SCALE-BAN TM ph value of re-circulating water should be maintained between 7.0 to 8.5

23 Started as a concept in late 90 s - Now a proven technology and continuously proving the potential as the most efficient, cost effective & sustainable solution for Zero Liquid Discharge (ZLD) with Zero Scaling. 200 Plus Satisfied Clients Year 2014: NTPC 1000MW power plant Year 2000: SEP

24 SCALEBAN CASE STUDY AT NTPC, DADRI 2X490MW TPP

25 BACKGROUND The ground work for the implementation of Scaleban at NTPC power plants started in 2012 by approaching to the then RED Mr. A. K. Jha (Director Technical), who advised to demonstrate Scaleban technology to NETRA.

26 Introducing Scaleban Presentation made to NETRA in May 2012 followed by NETRA s visit to 3X130MW CPP of Bhushan Power and Steel ltd. Sambalpur (Orissa) to study Scaleban performance. After satisfactory visit to BPSL Sambalpur, NTPC formed a team consisting of members from NETRA, OS & Dadri station.

27 Project Implementation NTPC Dadri issued work order to Scaleban in November Scaleban was commissioned in April 2014 on all the heat exchangers of Unit -5 and on Unit-6 in May 2015.

28 2X490MW NTPC, DADRI TPP SCALEBAN INSTALLATION IN 490MW POWER PLANT CONDENSER (NTPC DADRI)

29 Scaleban offered all the equipment for unit-5 and unit-6 free of cost as a salute to our Nation

30 Performance Evaluation From October 2014 Plant COC started increasing from average 2.5 to average 6 till December 2014 and passed bore well water circulation test. Performance comparison was carried out by opening a Plate heat exchanger (PHE -5b) of Unit-5 which is fitted with Scaleban and a PHE of Unit-6 which was then operating without Scaleban.

31 No scale Very hard Scale UNIT 5 PHE PLATE - After Scaleban UNIT 6 PHE PLATE Without Scaleban

32 Impressed with the 10 months of performance, NTPC Dadri showcased the Scaleban Technology at their annual O&M conference during 13 th to 15 th February, 2015 and had presented a paper.

33 NTPC DADRI STALL AT NTPC O&M CONFERENCE 13 th -15 th FEBRUARY 2015

34 One pass of Unit 5 condenser opened on July 22, 2015 and found Scale free after 15 months. Unit 5 condenser tube condition before installation of Scaleban

35 Final Performance Test Parameters 1. Average 8 COC to be maintained during the month of December ph to be maintained beyond 8.3 during the entire month. 3. Vacuum loss due to dirty tube was recorded as mm Hg on The Criteria for success of Scaleban performance is if vacuum loss due to dirty tube remains within 3 mm of Hg.

36 Before Concluding on PHE 5b Opened for physical inspection

37 SCALEBAN PERFORMANCE RESULTS 1. With Installation of Scaleban no scale has been observed during the complete test. 2. Calculated water saving of 31.44%, anti-scaling chemical saving of 100% and considerable reduction in sulfuric acid consumption and pumping power. 3. NTPC Dadri shall further increase COC to 10 in next 3 months for achieving ZLD.

38 Conclusion In line with the environment (protection) amendment rule 2015 and the goal of National Water Mission for Increasing water use efficiency by 20% in existing and upcoming Power Plants, SCALE- BAN EQUIPMENT is the only technology available on self sustainable basis for achieving Zero Liquid Discharge along with ensuring Zero Scaling in Condensers/Heat Exchangers with lucrative ROI without any recurring cost. With Scaleban, the cost of water can be reduced up to 40%, associated water treatment cost, electricity cost will be reduced & saving on chemical consumption. Scaleban is environmentally sustainable & helps achieving NATIONAL GOALS OF WATER CONSERVATION.

39 BHUSHAN POWER & STEEL LTD., Sambalpur (Orissa) Power Plant : P.O.Date : 01 May MW X 3 Nos MW X 1 No MW X 1 No. 4. 8MW X 2Nos. CSP Plant : P.O.Date : 01 May 2011 Oxygen Plant : P.O. Date : 01 May 2011

40 Bengal Energy Ltd., Kharagpur (WB) 40MW CPP (Installation in March 2014) Condenser tubes at 15 COC

41 Thank You!