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ENERGY CONCLAVE 2006 TECHNOLOGY FRONTIERS AND MODERNISATION

ENERGY CONCLAVE 2006 TECHNOLOGY FRONTIERS AND MODERNISATION. ENERGY R&D BHEL ROLE & CONTRIBUTION. PRESENTATION BY RAVI KUMAR DIRECTOR (POWER) BHEL, NEW DELHI. R&D – WORLD STATUS. Expenditure on R&D per capita (IN US $). INDIA - 5.5 CHINA - 11.7 S. KOREA - 241

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ENERGY CONCLAVE 2006 TECHNOLOGY FRONTIERS AND MODERNISATION

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  1. ENERGY CONCLAVE 2006 TECHNOLOGY FRONTIERS AND MODERNISATION ENERGY R&D BHEL ROLE & CONTRIBUTION PRESENTATION BY RAVI KUMAR DIRECTOR (POWER) BHEL, NEW DELHI

  2. R&D – WORLD STATUS Expenditure on R&D per capita (IN US $) INDIA - 5.5 CHINA - 11.7 S. KOREA - 241 AUSTRALIA - 285 UK - 460 USA - 705 JAPAN - 978

  3. R&D – BHEL TARGETS

  4. BHEL-R&D EXPENDITURE AS % OF T.O.

  5. TECHNOLOGY TRENDS POWER SECTOR • Lower Cost of Generation • Environment Friendly • Higher Efficiency • Higher Reliability • Compatible to Local Conditions

  6. CENTRE OF EXCELLENCE SETUP BY BHEL • Center Of Excellence For Simulators • Center Of Excellence For Computational Fluid Dynamics • Center Of Excellence For Permanent Magnet Machines

  7. STATE OF ART TECHNOLOGIES / PRODUCTS INTRODUCED BY BHEL • Low Nox Oil/ Gas Burners • Large Capacity Atmospheric FBC • High Efficiency Pelton Turbine • Controlled Shunt Reactor (CSR) • Flexible AC Transmission System (FACTS) • Space Grade Solar PV Panels • Phase Shift Transformer • 145 KV Gas Insulated Switchgear • India’s Largest Vertical AC Motor (6 MW, 6.6 KV) • Micro Controller Based Flame Scanner • Performance Analysis, Diagnostics and Optimization (PADO) Package • 91 Ton/hr BHEL 280 Bowl Mill

  8. TECHNOLOGIES SUBSTANTIALLY DEVELOPED • Supercritical Thermal Power Plants • Circulating Fluidised Bed Combustion • Coal Based Combined Cycle Plants • IGCC • PFBC • Nuclear Power Generation with Fast Breeder Technologies • Fuel Cells • Solar Photo Voltaic

  9. SUPERCRITICAL THERMAL POWER PLANTS • The supercritical cycle offers a ‘burn less fuel for the same output’ approach • Involves economical use of energy resources resulting in higher efficiency and low emissions • BHEL is equipped to supply Supercritical Power Plants upto 1000 MW

  10. Cycle Efficiency benefits of supercritical units are derived from higher pressures and temperatures of steam

  11. Super Critical R&D Projects

  12. CFBC TECHNOLOGY • Burns low grade fuels like lignite • No pulverising • Low NOx & Low SOx emissions • Higher efficiency • BHEL commissioned 2x390 TPH boilers for Surat Lignite Power Project • Number of 125 MW CFBC based power plants are under execution • Order received for 2x250 MW NLC, the largest CFBC technology based power plant in the country

  13. ENVIRNOMENTAL ASPECTS – ROAD MAP Area of focus - NOx control in pulverized coal fired boilers NOx emission scenario of Indian plants while firing different fuels: Development of low NOx wall fired coal burner - 2006 Establishment of SCR demo plant - 2007 Commercialisation of wall burner - 2008 Commercialisation of SCR system - 2010

  14. IGCC POWER GENERATION - DEVELOPMENT IN BHEL • 6.2 MW IGCC Pilot Plant at its Trichy Complex. • Technical feasibility of upgrading the 6.2 MW Combined Cycle Demonstration Project of BHEL to ~100 MW had been established • Preliminary assessment made for 400 MW IGCC Plant • Plan to set up 125 MW IGCC Demonstration plant

  15. IGCC POWER GENERATION - DEVELOPMENT IN BHEL PFBG SCALE - UP

  16. A glimpse of Fuel Cell Developments at BHEL(Inter-disciplinary approach followed for Fuel Cells Development)

  17. Indigenous Fuel Cell R&D - Achievements • Phosphoric Acid Fuel Cells (PAFC) • BHEL R&D:1 kW (1991), 5 kW (1995) & 50 kW (2000, 2 stacks of 25 kW each) - with data acquisition and display system & inverter have been demonstrated. • Performance of a state-of-the-art 200 kW FCPP (PC 25 C, procured from M/s IFC / ONSI / Toshiba) also evaluated, using LPG as fuel. • Polymer Electrolyte Membrane Fuel Cells (PEMFC) • Single cells & small stacks for evaluating electro-catalysts. Also tested Direct Methanol FCs – Basic Tech acquired fromIISc, B’lore • High Temperature Fuel Cells (SOFC) • BHEL R&D & CTI, Bangalore:Materials, processes & components developed. Assembled & tested single cells of planar SOFC.

  18. Over two decades experience in Photovoltaics Manufacturing capacity of 3MW Single crystalline (mono) cells upto 2.3W (15% efficiency) PV modules range is from 10W to 160W PV systems integration capabilities- have supplied PV power plants ranging from 1 KWp to 150 KWp PV modules internationally certified to IEC 61215 standards Cumulative shipments from BHEL over 20 MWp BHEL IN PHOTOVOLTAICS

  19. Future outlook for PV in BHEL • Automatic manufacturing capacity over 30 MW planned • Plan for improving solar cell efficiencies to over 18% by 2010 • Capability to process both mono & multi crystalline wafers • Opportunities for backward integration into silicon wafer manufacturing • Large scale deployment of PV power plants • Explore alternate technologies like Thin film cells, multijunction cells etc

  20. BHEL - R&D DEVELOPMENT OF 765 KV TRANSMISSION SYSTEM 2006-07 TARGETS • DESIGN & MANUFACTURE OF 765 KV, 500 MVA TRANSFORMER • DESIGN & MATERIAL PROCUREMENT FOR MANUFACTURE OF 765 KV 80MVAr SHUNT REACTOR • DEVELOPMENT OF COMPOSITE INSULATORS FOR TRACTION & TRANSMISSION WITH NANO ADDITIVES

  21. POWER PLANT PERFORMANCE IMPROVEMENTSAUXILIARY POWER CONSUMPTION REDUCTION • Power plant consumes nearly 7 to 9% of energy generated • Auxiliary power can be brought down by proper selection of technology, equipments and cycle parameters • Power consumption of BHEL manufactured equipment has been recently reduced from 7% (of total power consumption) to 6.65% for 250 MW & from 4% ( with turbine driven boiler feed pump) to 3.8%

  22. POWER PLANT RENOVATION & MODERNISATION LEADING PLAYER IN R&M AND UPRATING • R&M and LE of Large No. of Units in India and Abroad • Uprating of 110 MW Czech Units to 120 MW - Replaced Internals of HP, MP & LP Turbines with Reaction Type Blading - Boiler Upgrades to Ensure Rated - FlowModernize C&I and Balance of Plant • Improvised Blade Profiles for 210 MW LMW Sets - Reaction Type Blades for HP Turbine yield an additional 2.5 MW - New Monoblock LP Rotor with Reaction Blading Leading to additional 3.7 MW

  23. PERFORMANCE OF BHEL THERMAL SETS

  24. THANK YOU Committed to make a better world http://www.bhel.com

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