RAMAKRISHNA ENERGY AUDIT & CONSERVATION TECHNIQUES IN POWER INDUSTIRES

1. RAMAKRISHNAENERGY AUDIT & CONSERVATION TECHNIQUES IN POWER INDUSTIRES Scope of Discussion Numerical Example & Case Study Bandel Thermal Power Station IISWBM References

2. Part 1: Definition and Types

3. Power Plants • Thermal • Coal Based Conventional • Coal Based with CFBC • Coal Based with IGCC • Biomass in place/along with coal in above three cases • Blast Furnace/Corex/Coke Oven Gas in place/along with other fuel as above • Nuclear Reactor producing thermal energy for boiler • Solar Thermal; Geothermal • Hydro-Electric • Wind • Solar Photovoltaic • Ocean Thermal Energy Conversion

4. Relevant Designated Consumers (from EC Act) • Thermal power stations, hydel power stations, electricity transmission companies and distribution companies. • Commercial buildings or establishments. * The list of energy intensive industries specified in the Schedule can be altered based on energy intensity and quantity of energy consumption as per Clause of the EC Act.

5. Part 2: Scope of Discussion • Brief Description of the Process • Material and Energy Flow Diagram • National Practice • International Best Practice • Energy Conservation Measures – Cases • Concluding Remarks with References

6. Areas for Energy Audit in Power Plants • Boiler Efficiency Test • Air Heater Leakage Test • Mill Performance Test • Furnace Efficiency Test • Turbine Performance Test • Condenser Performance test • HP Cylinder Efficiency Test • Regenerative System Performance Test • Lighting Illumination Test • DM Water flow study • Ash / Coal Handling Plant Study (Optimum coal path) • Cooling Tower Performance Test

13. AIR & FLUE GAS (FG) PATH GENERATION: 55MW DATE:17.10.06 ECO INLET (FG) 0 Temp. ( C ) 400.6 O % 1.9 2 CO % 17.0 2 COAL CO OOR 25.4% Ash Flow 259.6 35.13 T/hr WATER OUT 5266 Kcal/ Kg ECO WATER IN ECO OUTLET (FG) 0 Temp. ( C ) 336.1 /APH INLET(FG) O % 3.4 2 APH CO % 15.9 2 CO 637.0 Flow 278.5 APH INLET APH OUTLET ESP INLET (FG)/APH OUTLET ESP OUTLET (FG)/ID INLET 0 0 0 0 Temp.( C ) 32.4 Temp. ( C ) 282.5 Temp. ( C ) 177.5 Temp. ( C ) 139.4 O % 21 O % 20.9 O % 6.8 O % 10.735 2 2 2 2 Flow 226.3 CO % 0 CO % 12.8 CO % 0 2 2 2 CO (ppm) 6.7 CO 7971 CO OOR Flow 336.5 Flow 446.5 Note: Assumtions: Air :Coal (Stoiciometric) = 5.8 OOR Out Of Range Excess Air= O X100%/(21-O ) 2 2 Acuracy Upto 1st decimal place Fly Ash in Total Ash = 80% ID ESP FD

19. Cont….

20. Indian Scenario • India is going to invest US$ 1.25 trillion in energy infrastructure between now and 2030 • Best coal based thermal power plant in India is having thermal efficiency of 32% - world’s best (supercritical) is 36% • India’s supercritical under construction by NTPC at Seepat, Chhattisgarh and Behr, Bihar. Other agencies are also setting up such plants in Sasan, MP; Akaltara, Chattisgarh; Mundra, Gujrat; Girye, Maharashtra and Tadri, Karnataka.

21. IGCC in India • 6.2 MW IGCC Pilot Plant has been developed by BHEL at Tiruchirapalli, Tamil Nadu • This plant uses coal with over 40% ash and • Uses both Pressurized Moving Bed Gasifier (PMBG) and Pressurized Fluidized Bed Gasifier (PFBG). Based on this, • A similar plant of 100 MW by NTPC jointly with BHEL is under construction at Aurya, Uttar Pradesh

23. 250 MW IGCC demo plant at Nakoso Power Station

24. Block Diagram of 250 MW demo plant of MHI

25. IGCC demonstration plant at Nakoso Power Station, Japan • 250 MW • Heat Rate : 7109 Btu/kWh • Thermal Efficiency (based on HHV) = 48% World-wide Average of IGCC: • 18 – mostly Ultrasupercritical (USC) • 15,400 MW • Heat Rate : 8125 Btu/kWh • Thermal Efficiency (based on HHV) = 42%

26. An Artist’s Impression of a Future Fully Commercial IGCC Power Plant

27. IISWBM • IISWBM-Indian Institute of Social Welfare and Business Management is the first Management Institute in India established in 1953. • Government of India in recognition of 50 years of glorious existence of the Institute released a Commemorative Postage Stamp on IISWBM on 25th April, 2004 in New Delhi. • The National Bureau of Accreditation (AICTE) accredited the Institute for its various programmes with its highest rating.

28. AN OVERVIEWOF IISWBM ACTIVITIES • The only Government accredited full-time post-graduate Energy Management course in Eastern Region of India since 1993. • IISWBM is the preferred Energy Consultant Government of West Bengal, number of industries and municipalities. • Energy Club, AEE-India Chapter & EGA Cell at Work – The AEE India Chapter, the only Chapter of the Association of Energy Engineers (AEE), USA in India at IISWBM, has succeeded in securing the international awards in different categories in each year since 2003. • This helps the senior managers in energy intensive industries in the region to share with the counterparts in India and abroad on state-of-the-art technology and practices in Energy Management.

29. Seminar of Energy Management Department with AEE-India Chapter Mr. Mrinal Banerjee, Power Minister of West Bengal addressing delegates and participants at a National Seminar on New Electricity Act.

30. Observance of National Energy Conservation Day 2008 Dr. R K Agrawal, ED, SAIL; Mr. Malay De, IAS, CMD, WBSEDCL & WBSETCL; Mr. D Majumdar, CMD, IREDA and Dr. B K Choudhury, IISWBM at Observance of the National Energy Conservation Day on 14th December, 2008.

31. REFERENCES • Detailed Energy Audit Reports by IISWBM, particularly conducted at Bandel Thermal Power Station • BEE Study Materials : Book 2, Book 3 and Book 4 • www.energymanagertraining.com • http://en.wikipedia.org/ • www.powermag.com • Tata Energy Data Directory and Year-book (TEDDY) 2005-2006

32. ACKNOWLEDGEMENTS: REFERRED BOOKS, BEE & IISWBM Questions? THANK YOU