Clean Coal Technologies for green power in India

Transcription

1 Clean Coal Technologies for green power in India by Y P Abbi, Senior Fellow, TERI, New Delhi, INDIA February 2009 Thermal Power India-3 Conference on Present & future technologies Prospects & strategies for sustainable development, Organized by CPU & AESI, New Delhi, India

2 Contents Introduction to TERI What is clean coal technology India s power sector present and future Thermal power generation technologies Introduction of Super-critical steam cycle technology Development of IGCC Development of CCS Concluding remarks

3 The Energy and Resources Institute (TERI) An independent, not-for-profit research institute Staff strength of about 700 (450 research professionals) Working on energy, environment and sustainable development issues: Technologies: renewable energy, bio-fuels and biomass, building energy, industrial energy efficiency, waste treatment, bio-remediation, microbial enhanced oil recovery, biofertilizers, tissue culture, etc. Policy analysis and regulations: electricity, oil and gas, coal, environment, transport, etc. Field action research, pilot demonstration and implementation Academics: TERI School (University) Presence: HQ at New Delhi, 4 regional centers Overseas: Washington, London, Tokyo, Kuala Lumpur, and Dubai

4 Industrial Energy Efficiency & Sustainable Technology Division Aim: Development and diffusion of resource efficient & environment friendly technical solutions for industry Areas of work - Energy audit of industry and thermal power plants - Energy efficiency technologies development for small-scale industries (glass, foundries, brick kilns, etc. ) - Energy efficiency improvements in industrial processes - Clean coal technologies propagation for thermal power plants - CDM projects development

5 What is Clean Coal Technology? Which Gives Minimum Pollution due to Particulate Matter (PM), So x, No x, CO 2 PM,So x, No x, : Local Pollution CO 2, No x : Global Warming How to Achieve Through Improving Energy Conversion Processes

6 Clean coal technology for power generation Stipulates Improvement of efficiency of electricity generation (fuel to electricity), which reduces emissions/kwh energy produced

7 India s power sector present & future

8 National Electricity Policy Guidelines for 11 th Plan ( ) Access to electricity by all households, and minimum lifeline consumption of 1 kwh/day/household by 2012 Per capita consumption to reach 1000 kwh/yr Availability of power on demand Reliable & quality power at reasonable price Adequate (5%) spinning reserve 9% per annum growth of generation

9 India s perspective plan for electric power Power Generation Thermal (Coal and Lignite (MW) NG/LNG/Diesel (MW) Nuclear (MW) Hydro (MW) Total (MW) Installed Capacity as on March ,629 NG: 14,810 Diesel: 1,179 4,405 36, ,697 Addition Capacity required till March ,861 15,436 7,695 21, ,107 Total Capacity as on March ,490 31,425 12,100 57, ,804 Excludes power from renewables: 11,125 MW Per capita consumption: 665 kwh/yr; Shortage (Energy: 8.5%, Peak:15%)

10 Power supply in (Total GWh) 2.4% 0.8% 17.5% 79.3% Thermal Hydro Nuclear Import from Bhutan

11 Projections for Electricity Requirement by Ministry of Power, Government of India Year Generation (Billion kwh) 7% GDP 8% GDP Installed Capacity (MW) 7% GDP 8% GDP Source: Integrated Energy Policy, Planning Commission, Govt. Of India

12 Power generation capacity mix across various scenarios (Year 2031) Power Generation Capacity (GW) BAU EFF NUC REN LG HG Coal Natural Gas Hydro Nuclear Diesel Renewables Total BAU Business as usual; EFF High efficiency; NUC High nuclear capacity; REN aggressive renewable energy; LG Low growth; HG High growth Source: National Energy Map of India: Technology Vision 2030 (TERI: 2006)

13 India s Electric Power Generation Scenario Total (excluding RE): 134,697 MW Thermal (coal) : 77,629 MW (57.66%) Thermal (NG) : 14,810 MW (11.0%) Coal for power : 332 million tonne Total : 215,804 MW Thermal (coal) : 114,490 MW (53.1%) Thermal (NG) : 31,425 MW (14.6%) Total : 794,000 MW* Thermal (coal) : 466,000 MW (58.6%) Coal for power : 2 billion tonne/year * For 8% GDP Growth Coal to remain major source of electricity generation Increasing import dependence for coal likely

14 Comparison of Indian coal with imported Coals Australia China S Africa Indian Coal (Dadri) INDONESIA Type A Type B Type C Total Moisture (AR) % max 20 max Inherent Moisture (AD) % max 12 typical Ash Content (AD) % max 8 max 7-8 Volatile Matter (AD) % Sulphur (AD) % max Fixed Carbon (AD) % 45 approx Gross Calorific Value, kcal/kg (AD)% HGI Ash Fusion Temperature (deg C)

15 Emission standards for coal fired power plants in India Particulate matter (PM) Generation capacity 210 MW or more 150 mg/nm 3 Generation capacity less than 210 MW 300 mg/nm 3 SOx No standard NOx No Standard

16 Environmetal standards for gas/naptha based thermal power plants I. Limit for emission of NOx (a) For existing units 150 ppm (v/v) at 15% excess oxygen. (b) For new units with effect from Total generation of gas turbine limit for Stack NOx emission (v/v), at 15% excess oxygen 400 MW and above o 50 ppm for the units burning natural gas. o 100 ppm for the units burning naphtha Less than 400 MW but upto 100 MW o 75 ppm for the units burning naphtha o 100 ppm for the units burning naphtha Less than 100 MW 100 ppm for units burning natural gas or naphtha as fuel For the plants burning gas in a conventional boiler: 100 ppm II. Limit for enission of SOx: No standard

17 Coal Beneficiation Coal beneficiation capacity was 90 million tonnes per annum, and the Planning Commission, Government of India, has set a target of 163 million tonnes per annum capacity addition during the 11 th plan period ( ). In 1997, Ministry of Environment and Forest (MoEF), Government of India had issued a circular that the power plants located more than 1000 km away from the coal mines should use only washed coal for power generation. However, this directive has not been fully implemented, as adequate washing capacity does not exist presently.

18 Thermal power generation technologies

19 Energy efficiency improvements for power generation from coal Sub-critical steam cycle Renovation & Modernation, and life extension of old plants Supercritical steam cycle Ultra-supercritical steam cycle Integrated gasification combined cycle (IGCC) Carbon capture and sequestration (CCS)

20 Sub-critical to Supercritical Steam Cycle Technology in India Unit Rating (MW) Steam Parameters Plant Heat Rate (kcal/kwh) Gross Generation Efficiency (%) 60 / ata/ 535 o C, non-reheat / ata / 537 o C / 537 o C / ata /537 o C/537 o C ata/537 o C/537 o C (Sipat) Supercritical: 246 ata/537 o C/ 565 o C (North Karanpura) Supercritical: 246 ata/ 565 o C/ 565 o C (Ultra Mega Projects) Ultra-supercritical: 306ata/598 o C/ 598 o C Note: Considering boiler efficiency of 85%

21 Introduction of supercritical steam cycle

22 Supercritical projects planned during 11 th Plan ( ) 3x660 MW at Sipat; first unit to be commissioned in 2008 and 2 nd & 3 rd units with a gap of 6 months each 3x660 MW at Barh Stage I, first unit to be commissioned in 2009 and 2 nd & 3 rd units with a gap of 6 months each 3x660 MW at North Karanpura, first unit to be commissioned in x660 MW at Sasan UMPP, to be commissioned in 2012 Total during 11 th Plan: 5,940 MW

23 Supercritical/Ultra-supercrical projects planned during 12 th Plan ( ) Supercritical and ultra-supercritical: 42,480 MW Sub-critical : 20,450 MW Total : 62,930 MW

24 Development of design and mfg. capacity in India for SC plants Boilers JV of MHI & L&T; BHEL with technical collaboration of Stein Steam Turbines JV of Toshiba & JSW; BHEL with technical collaboration of Siemens JV of Bharat Forge & Alstom

25 Development of IGCC

26 IGCC for India IGCC have potential for 10-12% improvement in heat rate for coal based power plants; also potential for reduction of water consumption by 40% Indian coals have high ash (40 to 45%) and low calorific value ( kcal/kg) Pressurized Fluidized Bed Gasification (PFBG) is most suitable for Indian coals as per two independent studies conducted by BHEL (Bharat Heavy Electricals Ltd) and Nexant/ IGT (Study funded by USAID)

27 IGCC with PFBG World Status Only one 107 MW IGCC demonstration plant at Pinon Pine, USA (cost US $ 306 million) was operated for a short time in 1998 using low ash coal. This plant was owned by Sierra Pacific Utility and funded partly by USDOE Reasons for closure were both technical and financial support. Technology not yet established commercially

28 GTI (U-Gas) Gasifier Dry feed system Coal and coal/biomass blends Highly efficient Air or oxygen blown Non-slagging/bottom ash Fluidized bed gasifier 30 year license agreement with Synthesis Energy Systems (SES) 20+ years experience including plants in Shanghai and Finland 2 Plants in operation 520 MWth Syngas COAL AIR / O 2 / STEAM AIR / O 2 / STEAM GASIFIER SYNGAS CYCLONES FLUIDIZED BED BOTTOM ASH REMOVAL

29 IGCC development in India 6.2 MW IGCC: R&D plant being operated at BHEL, Trichy. Operated for approx hrs. 125 MW demo plant being designed by BHEL for installation at APGENCO, Vijaywada (AP) (Foundation stone laid on 01 July 2008) Cost of demo plant 80 to 100% more than the conventional PC plant. Principal Scientific Advisor to PM, Govt. of India has recommended the Govt. to fund the differential cost.

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34 Carbon Conversion Efficiency 85 % Cold Gas efficiency 71 % Gross Efficiency 39% Gas Calorific Value Kcal/NM 3 Broad Operating range with good availability factor, long term operating experience A working group was constituted to validate the 125 MW design of BHEL with representatives from DAE, NTPC and BHEL

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36 Development of Carbon Capture & Sequestration (CCS)

37 CCS Technology Development in India Basic R & D stage on identification of geological sites suitable for carbon sequestration. Basalt rocks in Deccan Volcanic Plateau are possible sites for CCS Kutch (Gujarat), Jabalpur (MP), Belgaon (Karnataka), Igatpuri (Maharashtra) DST (Dept. of Sci. & Tech.), Govt. of India has started a Pilot Study Geological CO 2 sequestration in Basalt Formations in Western India by National Geographical Research Institute, Hyderabad Projected capital costs for CCS are very high; very high auxiliary power requirement (approx. 700 MW for a 4000 MW plant); projected increase in cost of power generation is approx. 100%

38 Results of IEA Study on assessment of potential for CO 2 Storage in India Science of storage in basalt formation (a major potential area in India) is relatively un-developed. There is a good correlation between basalt formation and point sources of CO 2 Deep coal seams storage potential is 345 Mt (max) and none of the fields have potential to store more than 100 Mt. Oil and gas fields around India are small-scale, and their potential for storage is small. Recent offshore discoveries of gas resources could provide opportunities in future. Potential for CO 2 injection for EOR exists; but to be explored further. Considerable potential for storage in deep saline aquifers surrounding Assam and shallow off-shore areas in Gujarat.

39 Economic Profile of CCS (a study by Mott MacDonald, 2008, UK) Study was feasibility on CO 2 capture ready Ultra Mega Power Projects (UMPPs) in India Three most favourable UMPPs sites Krishnapatnam, Cheyyur, and Griye offer the lowest abatement cost of US$ 33 / tco 2 A CO 2 abatement incentive of US$ 35 to 42/t CO 2 would be required for other inland site of UMPPs

40 Clean coal technology choices for imported coals Low ash, high HCV, low ash melting point Steps 1. Ultra super critical 2. IGCC based on Pressurized Entrained Bed Gasification (proved on demo plants up to 250 MW in USA) 3. Demonstration for CCS for Enhanced Oil/NG Recovery (EOR) or under-ground/under-sea sequestration Combination of steps 2 and 3 to produce electric power and chemicals simultaneously, would be most economical

41 FutureGen, 2012, USA Zero emissions plant 275 MW (Estimated cost 950 million $) India has contributed US$ 10 million as Observer Member/ Partner for this project Project is shelved, presently Recently, DOE/USA has invited the bids again for this demo plant based on Oxy-fuel combustion or IGCC

42 Concluding remarks Clean coal technologies being developed for both economic and cleaner electricity generation Supercritical steam cycle technology being introduced for heat rate improvement in the range of 2 5 % PFBG based IGCC technology for high ash Indian coals being developed indigenously Every candidate technology for IGCC has to be demonstrated in a semi-commercial demo plant, & then evolve scaled-up designs Commercial IGCC plants not matured yet. Main issues/risks are cost, guaranteed performance, & guaranteed availability CCS is at initial R&D stage in India

43 Thank you