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4 th Annual “Coal Markets in India-2014”

4 th Annual “Coal Markets in India-2014”. The Imperial New Delhi 22.08.2014. Improving Coal Efficiency - Role of Coal Additives -------- ooo -------- Abhitech Energycon Limited A/1020, Oberoi Garden Estate, Chandivali Farm Road, Chandivali , Mumbai – 400072

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4 th Annual “Coal Markets in India-2014”

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  1. 4th Annual “Coal Markets in India-2014” The Imperial New Delhi 22.08.2014

  2. Improving Coal Efficiency -Role of Coal Additives--------ooo-------- AbhitechEnergycon Limited A/1020, Oberoi Garden Estate, Chandivali Farm Road, Chandivali, Mumbai – 400072 Tel (91-22) 2847 9999 Fax (91022) 2847 9988 E-Mail : abhitech@abhitechenergycon.com Visit us at : www.abhitechenergycon.com

  3. Coal Efficiency • Coal Efficiency represents the amount of Energy that can be extracted from a single unit of Coal. • So, we are essentially talking about Plant Efficiency, or more specifically Combustion Efficiency; which can be measured to see what amount of Energy is being extracted from a single unit of Coal in a particular system.

  4. Combustion Efficiency • Combustion Efficiency is a measure of how efficiently a device/system consumes fuel. Ideally, it should be 100%, meaning that the fuel is completely consumed. • In practice, this level of efficiency is impossible to achieve, but it's possible to come close. • The lower the combustion efficiency, the less efficient the device is, making it expensive to run, wasteful of fuel, and harmful for the environment.

  5. Factors affecting Combustion Efficiency and Overall Plant Performance • Poor Combustion • Excess Air control • Deviation of fuel quality from designed values • Heat Transfer Fouling • Pre-water treatment • Condenser Performance • APH Performance • Poor Operation and Maintenance of Boilers

  6. Methods used to overcome these problems • Scheduled Maintenance and AOH of Boilers. • Modification and Renovation in the Boilers • Energy Audit to keep an account of various losses in Boilers. • Different types of analysis like CFD Analysis to improve flue Gas Path.

  7. Disadvantages of employing these methods • High Capital Expenditure • Shutdown required • Complexity of these methods • Highly skilled Professionals required • For analysis purpose, expensive equipment required.

  8. Alternative ??? Then, Is there any solution which is - Simple in Application, Involves no Downtime, and Requires no Capital Expense ?

  9. Combustion Catalysts Coal Additives

  10. Effective Additive – Reduction in Losses, Impact on GUHR & Boiler Efficiency • 1% Red’n in UFA – 20 Kcal/kwh on GUHR & 0.8% in Boiler Eff. • 1% Red’n in UBA – 2.5 Kcal/kwh on GUHR & 0.2% in Boiler Eff. • 1% Red’n in Excess Air – 7.4 Kcal/kwh on GUHR & 0.6% in Boiler Eff. • 1% Red’n in FGT – 1.2 Kcal/kwh on GUHR & 0.067% in Boiler Eff. • 1TPH Red’n in S/H Attemp. – 0.03 kcal/Kwh on GUHR • 1TPH Red’n in R/H Attemp. – 0.25 kcal/Kwh on GUHR • 1 mm of soot deposit Red’n – 0.83 % savings in Coal (Ref :- BEE , NTPC, IGEN, BS 2885) • Thus, due to improvement in all above parameters, with the use of an effective Additive, 2 to 4 % savings in coal can be achieved.

  11. Bureau of Energy Efficiency – BoilersTypes, Combustion in Boilers, Performance evaluation, Analysis of Losses, Feed Water Treatment, Blow down, Energy conservation opportunities

  12. Bureau of Energy Efficiency - Boilers

  13. NTPC-USAIDHeat Rate Improvement Guidelines for Indian Power Plants

  14. Saving Potential • All India Yearly Coal Consumption for Power Generation (Utilities) : 454 MMT • Coal that can be saved @ 2 % using Additive : 9.09 MMT • Total Generation possible from the amount of Coal saved @ 0.75 kg/kWh : 12.1 MMWHr • Average Power Consumption per Annum for a Single Household in India : 3.11 MWHr • No. of Households that can be enlightened for whole year in India with the amount of Coal Saved: 38.97 Lacs

  15. Current Status • The Coal Additive Market is in its infancy, although the outlook is bright. • There aren’t many Companies in the market producing Coal Additives as yet. • Abhitech is doing the Leadership work – • Creating Awareness • Developing a Model for Evaluation • Establishing Additives as an Alternative • Creating an Industry • Serving the National Cause of Fuel Conservation

  16. Abhitech - Mission Efficiency Abhitech’s aim is to not only save the Coal and other Carbon based Fuels by increasing the Boiler Efficiency using specially formulated Additives, but also lend a helping hand in making the environment pollution free and making this Planet a better place to live in.

  17. Combustion Catalyst THERMACT

  18. Technology Collaboration with IIT-Bombay. Abhitech Energycon Ltd. Abhitech Energycon Ltd.

  19. Established across various Sectors • Large Capacity Power Plants from 60 MW to 800 MW • Sugar Industry ( Co-generation ) • Steel Plants (Coke making & Blast Furnace) • Captive Power Plants (AFBC Boiler) • Biomass fired IPPs. Abhitech Energycon Ltd. Abhitech Energycon Ltd.

  20. Abhitech - Background • THE LARGEST MANUFACTURER OF COMBUSTION • CATALYSTS IN INDIA • INDIAN TECHNOLOGY • GLOBAL PRESENCE • ONE OF THE FEW COMPANIES WORLD WIDE, • WITH PRODUCTS FOR SOLID & LIQUID FUELS • TECHNICAL MANPOWER : 266 ENGINEERS Abhitech Energycon Ltd. Abhitech Energycon Ltd.

  21. Global Presence Nepal Baddi (HP) Czech Republic Delhi Germany Slovenia Raipur Kolkatta Bhubaneshwar Head office Head office Vijayawada Manufacturing unit Sudan Belgaum Brazil Zonal offices Export Bangaluru Chennai Srilanka Abhitech Energycon Ltd. Abhitech Energycon Ltd.

  22. Manufacturing Unit at Baddi, Himachal Pradesh

  23. A Multifunctional Catalyst for COAL THERMACT IIT, Bombay Abhitech Energycon Ltd., INDIA Abhitech Energycon Ltd.

  24. Product Specifications Manufacturer ABHITECH ENERGYCON LTD Name THERMACT Packing 20 Kg Silsack Bag Appearance Black Colour (Powder Form) Odour Odourless Dosage 1:15,000 on Kg/Kg basis (1 Kg of THERMACT for 15 Tons of Coal) Abhitech Energycon Ltd. Abhitech Energycon Ltd.

  25. Special Features of THERMACT • THERMACT is a multifunctional combustion improver manufactured by Abhitech Energycon Ltd, with collaboration of IIT, Mumbai. • No capital expenses (NO CAPEX) • “NO SHUTDOWN” required for installation of Dosing equipment. • Tested and approved by – • Indian Institute of Technology, Bombay • CMRI (Central Mining Research Institute) • CMERI (Central Mechanical Engineering Research Institute) • Jadavpur University, Ostrava University • SGS, USA - Toxicity Characteristic Leaching Procedure (TCLP) test Abhitech Energycon Ltd. Abhitech Energycon Ltd.

  26. SCHEMETIC OF THERMACT DOSING DOSING MECHANISM Two Vibro or Screw Feeders opposite corners 1 kg of THERMACT is added with 15 Tons of Coal No shutdown required for installation of Dosing equipment F Regulator AC Supply

  27. DOSING MECHANISM 1 kg of THERMACT is added to 15 Tons of Coal. Abhitech Energycon Ltd.

  28. Working Principle C + H O CO + H 2 2 Carbon Particle THERMACT Catalyst 1 H O CO2 CO +1/2 O2 2 C + H CH 2 4 Catalyst 2 THERMACT Fixed Moisture Catalysts CH4 heat given Reduction in coal consumption / GUHR Abhitech Energycon Ltd. Abhitech Energycon Ltd.

  29. Activation Energy THERMACT reduces the activation energy required for various reactions aiding combustion. The rate of reactions are increased. with THERMACT Abhitech Energycon Ltd. Abhitech Energycon Ltd.

  30. Benefits • Reduction in Unburnts in Ash • Reduction in Excess Air • Reduction in O2% • Reduction in Flue Gas Temperature • Reduction in Slag and Clinker • Reduction in R/H and S/H Attemperation • Reduction in GUHR • Reduction in Coal consumption • Reduction in Soot blowing frequency • Improved Generation • Reduction in Secondary Fuel Consumption Abhitech Energycon Ltd. Abhitech Energycon Ltd.

  31. Customers using THERMACT in PF Fired Boilers Abhitech Energycon Ltd. Abhitech Energycon Ltd.

  32. Performance at Various Thermal Power Plants Less than 110 MW More than 250 MW 210 MW Savings Achieved (in %) (1 x 210 MW 4 x 62.5 MW) (2 x 210 MW) (6 x 210 MW) (1 x 250 MW) (2 x 300 MW) (5 x 210 MW) (1 x 62.5 MW) 110 x 1 MW) Clients Name Abhitech Energycon Ltd. Abhitech Energycon Ltd.

  33. Case Study – I SANJAY GANDHI TPS, BIRSINGHPUR (MPPGCL) (Savings shown by Indirect Method) 4 x 210 MW,1 x 500 MW

  34. Comparison: Pre-Trial & Post-Trial

  35. Post-Trial Effect of THERMACTon Bottom Ash Pre-Trial

  36. Post-Trial Effect of THERMACTon Fly Ash Pre-Trial

  37. Post-Trial Effect of THERMACTon Clinker Pre-Trial

  38. Post-Trial Effect of THERMACTon FLAME Pre-Trial

  39. Case Study – II TENUGHAT THERMAL POWER STATION. (TVNL) (Savings shown by both Direct and Indirect method) 3 x 210 MW

  40. Case Study – III COASTAL GUJARAT POWER LTD. (A TATA Group of Company) (Savings shown in terms of reduction in slag and clinker and reduction in Heat Rate) An Ultra Mega Power Plant 4 x 800 MW

  41. THERMACT - DOSING MECHANISM

  42. CLINKER PHOTOS DURING THERMACT USAGE Near Sootblower 175 Before THERMACT With THERMACT Abhitech Energycon Ltd.

  43. CLINKER PHOTOS DURING THERMACT USAGE Near Sootblower 176 Before THERMACT With THERMACT

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