Thermal coal upgradation and conversion in india ibc asia, jakarta april 25, 2012 sent

THERMAL COAL
UPGRADATION AND CONVERSION
IN INDIA 2012
TOWARDS A MORE SUSTAINABLE ENERGY FUTURE FOR INDIA

DR. HIMADRI BANERJI,
Ex CEO RELIANCE ENERGY
MD ECOURJA

AT THE 2ND ANNUAL COAL UPGRADATION AND
CONVERSION, IBC ASIA , JAKARTA, 25TH APRIL 2012

DR HIMADRI BANERJI EX CEO RELIANCE ENERGY IBC ASIA JAKARTA 24-26 APRIL 2012

COAL CONVERSION AND UPGRADATION IBC ASIA

PRIORITIES ON ENERGY GENERATION SECTOR:
– Increased use of Advanced Fossil Fuel Technology.

– Promote CCT where coal is main stay fuel for Power
Generation.

– Reduce Atmospheric Pollution from Energy
Generating Systems.

– Ensuring energy security


Total Thermal generation 2012 700 billion kwh
Total Coal Based 2012-13 518 billion kwh
Target Coal based 2012-2013 560 billion kwh
Generation Loss Coal Shortage: 8.7 billion kwh


DEMAND PROJECTION

YEAR 2020 MIX OF GENERATION
• Thermal 326,000MW
• Renewable & Hydro 104,000 MW
• Nuclear 20,000 MW
• Total 450,000 MW

DR HIMADRI BANERJI EX CEO
RELIANCE ENERGY IBC ASIA
JAKARTA 24-26 APRIL 2012

COAL FOR POWER GENERATION
China and India are projected to account for 30%
of the world’s increase in energy consumption
between 2000-2020 and 92% of increase in coal use.

The key challenges facing the coal industry in India
are related to :

Obsolete Coal Mining Technology
Frequent Disruptions Due to Flooding
Forest and Environmental Clearances
Regulated and Unrealistic Prices

Coal Production Data 2008-2012
Coal Production Coal India Ltd
Grades
Fiscal

2008 2009 2010 2011 2012

Raw coal % of Raw coal % of Raw coal % of Raw coal % of Raw coal % of
production Raw coal production Raw coal production Raw coal production Raw coal production Raw coal
Mill Te production Mill Te production Mill Te production Mill Te production Mill Te production

Non
Coking 353.30 93.1 377.19 93.4 395.13 91.6 389.97 90.4 413.70 90.7
Coal 1

Coking
26.16 6.9 26.54 6.6 36.13 8.4 41.35 9.6 42.40 9.3
Coal 2

Total 379.46 100.0 403.73 100.0 431.26 100.0 431.32 100.0 456.10 100.0


Coal Reserves India 2012

SOURCE: ANNUAL REPORT 2011 MINISTRY OF COAL

(in Million Tonnes)

LIGNITE RESERVES INDIA 2012

SOURCE: ANNUAL REPORT 2011 MINISTRY OF COAL

COAL CHARACTERIZATION
COAL QUALLITY IN INDIA


COAL RANK, GAS GENERATION AND ADSORPTION
THERMAL
MATURITY GAS GENERATION &
COAL RANK (ASTM)
(Ro%) ADSORPTION BARMER, CAMBAY,
LIGNITE BIOGENIC & MANNARGUADI LIGNITE GROUP C
0.4% MIXED GAS
SUB BITUMINOUS BASINS
A.B.C.
RANIGANJ FM.
HIGH 0.5% OF RANIGANJ & JHARIA
B
I VOLATILE C ADSORPTIO
0.6% N CAPACITY COALFIELDS
T HIGH GROUP B
U BARAKAR FM.
M VOLATILE B OF SATPURA, SOHAGPUR,
I 0.8%
HIGH WARDHA, GODAVARI,
N
O VOLATILE A THERMAL SONHAT COALFIELDS
U GENERATION
S
1.1% BARAKAR FM.
MEDIUM OF JHARIA, RANIGANJ, EAST
R VOLATILE BOKARO & KARANPURA GROUP A
A 1.5%
N COALFIELDS
LOW
K
S VOLATILE
2.0%
SEMI ANTHRACITE
2.6%
ANTHRACITE

META 0 2000 6000 SCF / T
ANTHRACITE

COAL QUALLITY IN INDIA

INDIAN COALS HIGH ON ASH

As equipment for hauling and mining gets larger, there is also more opportunity
for dirt bands to get into the mined coal. Furthermore, current coal resource
assessments are limited to within 300 m, which implies that opencast mining is
expected to dominate production over the next 20-30 years, and thus, coal
quality might not improve much without additional cleaning and
beneficiation). Furthermore, the current grading system of coals in India does
not provide a proper pricing signal for coal producers to improve coal quality
(see footnote 196).

Coal Quality
Indian Power Plants vs US and China

EFFECT OF HIGH ASH
1. damage to conveyor belts, coal crushers,

2. blockage of chutes and feeders,

3. damage to, and high erosion of, pulverizers,

4. reduced availability of coal mills,

5. reduced flame stability,

6. slagging and fouling of water walls,

7. high boiler erosion,

8. increased requirement for land for dumping,

9. higher emissions The high ash content AND HIGH ALPHA
QUARTZ also leads to technical difficulties for
utilizing the coal, as well as lower efficiency
and higher costs for power plants.

EFFECT OF HIGH ASH

1. corrosion of boiler walls and fouling of economizers,

2. high fly ash emissions (IEA, 2002a).

3. The high silica and alumina content in Indian coal ash is another problem, as it
increases ash resistivity that reduces the ESP’s efficiency and increases
emissions

4. although the high ash fusion temperature (>1100 DegC) of Indian coals is
helpful for reducing slagging in boilers.

5. However, the high ash fusion temperature does eliminate the use of Indian
coals in entrained-flow gasifiers –
The high ash content also leads to technical
difficulties for utilizing the coal, as well as
lower efficiency and higher costs for power
plants

COAL WASHING &UPGRADATION
Ash in Indian coals is generally finely intermixed into the coal structure
and the distribution of materials across different relative density
fractions is uniform.

Hence, coal washing using physical methods is difficult, as coal must be
crushed to small sizes for effective washing.

There are various options for removing of
impurities / reduction of Ash from the coal.

Coal Extraction Stage:
1. Judicious Mining – Removal of dirt bands separately.
2. In Situ Gasification or UGC – Still at Infancy stage

Post Coal Extraction Stage:
1. Washing / Processing the Coal
2. Blending high Ash Indian Coal with Low Ash Imported Coal
3. On Surface Gasification – adoption of IGCC – Attempts are
underway

Coal Beneficiation
India is endowed with 276 billion Tonnes of Coal Reserves.

The proven reserves stand at about 110 billion tonnes, corresponding to 10% of
world’s total proven reserves.

84% of the country’s coal production is from Open Cast Mines.

75% of the total Coal produced in the country is consumed by the Power Sector.

Indian Coals is that they are low in sulphur, however, they have very high Ash
Content.

Indian coals have high Ash (30% to 45%, compared to Ash in coal at Developed
countries (7 to 20%).

When compared on energy terms, it may be misnomer to state these reserves as
huge.

Cleaning of Coal (Coal beneficiation) assumes importance from environment & long
distance transportation point of view

Coal Beneficiation

In 1997, the MoEF mandated the use of beneficiated coals with ash content of 34% (or
lower) in power plants located beyond 1000 km from their coal source, and plants located in
critically polluted areas, urban areas, and ecologically sensitive areas (CPCB, 2000b).

This notification was based on a recommendation from a committee headed by the
chairman of CPCB. Although this rule was to be enforced from June 2000, it is not clear how
well the rule is being is met.

According to the CEA, more than 40 plants (about 24 GW of capacity) needed better quality
coals and the estimated annual cleaner coal consumption was expected to be about 87 MT
(CPCB, 2000b). On the other hand, the thermal coal washery capacity in 1999-00 was only
about 24 MT.

Coal Beneficiation
Hence, a key option available for power plants was the use of blended coals using better
quality foreign sources or a small quantity of well-cleaned domestic coal (CPCB, 2000b).

With rising demand for better quality coals, the private sector has taken an increasing
interest in building washeries in the last few years.

The current washery capacity is nearly 110 MT of thermal coal. The share of the private
sector is about 78%, and the share of CIL (which account for about 22%) is primarily from
converted-coking-coal washeries (Ministry of Coal, 2005a; Kanchan, 2006).

The government has also encouraged the building of private washeries with its
“build-own-and-operate (BOO)” policy.


Cost
Grades and Prices of Indian Coal. The lowest range of prices is from
Mahanadi Coalfields Limited and the highest is from Eastern Coalfields
Limited and Western Coalfields Limited. Source: (Ministry of Coal,
2005a) and CIL website.

These costs are for run-of-mine and they do not include royalty, tax, and cost of transport.
The cost of transportation is another important part of the final cost of delivered coal to
consumers. Considering the calorific value of coal, the weighted average free-on-rail price of
coal for power plants is under $5/million kilocalories, inclusive of royalty of tax; however, the
price of delivered coal is about $12-16/million kilocalories, as freight and handling add about $7-
$11, depending on distance and mode of transport (Ministry of Coal, 2005a).227 In contrast, the
cost, insurance and freight (cif) price of imported coal is about $13 per million kilocalories at
coastal locations. The prices have increased by over 50% by 2012

India’s Concerns and Strategies
for a Clean Environment


INDIA RANKS 3RD ON TOTAL CO2
EMISSIONS
Country CO2 emissions[14] Area (in km2) Population

World 33,508,901 148,940,000 6,852,472,823

China 8,240,958 9,640,821 1,339,724,852

United States 5,492,170 9,826,675 312,793,000

India 2,069,738 3,287,263 1,210,193,422

Russia 1,688,688 17,075,400 142,946,800

Japan 1,138,432 377,944 128,056,026

Germany 762,543 357,021 81,799,600

Green House inventory for India for
Power Sector (Million Tonnes of
CO2)
Energy Sector CO2 CO2 equivalent
(CO2+CH4+NOx)

Total Emission 1200 1324

(58% of total) (64% of total)

Source : IAE : 2010
Total Emissions India:2069 Million Tonnes

PER CAPITA EMISSIONS OF CO2

Top 6 Polluters


COST OF VARIOUS CO2 MITIGATION OPTIONS FOR
INDIAN POWER SECTOR

Potential Green house COST (Rs/Tonnes CO2)
.

Technologies gas emission
reduction (kg/kWh)

1. Co-generation 1.50 480
2. Combined Cycle 0.96 2600
0.18 24000
3. PFBC 0.23 16000
4. IGCC 0.18 16000
5. Supercritical 0.125 8500
Source: ADP 1998
6. Coal Washing

DR HIMADRI BANERJI EX CEO RELIANCE ENERGY IBC ASIA JAKARTA 24-26
APRIL 2012

CLEAN COAL TECHNOLOGIES
• Mining Through better Management
Practices
(Reduction of Extraneous
material)

• Coal Preparation Process after mining to improve
Inherent & Extraneous material
(washing & beneficiation)

• Conversion Technologies Supercritical, CFBC, PFBC, CTL,
Coal Gasification and, IGCC

• Post combustion cleaning Particulate and gaseous
pollutants removal
(Environmental Requirement)

VISION 2020
PROGRAM

Gasification using + In-combustion Clean-
fluidized bed, moving up Fluidized bed
bed or Entrained bed combustion (CFBC,
Gasifiers PFBC, AFBC)

Pre combustion Clean-up Post combustion
beneficiation/washing Clean-up-
Desulfurization
(FGC systems)
CLEAN COAL Supercritical
TECHNOLOGIES

Technologies for utilization of Coal for Power Generation with minimal pollutants discharged
to the atmosphere (Reduced CO2, Sox, Nox, SPM) at high conversion efficiency……….World
Coal Institute.

Super Critical PC Power Plant (15 oC Amb.)
60
Super Critical PC Power Plant (Indian Condition)
IGCC (15 o Amb)
C
Net Thermal Efficiency (%) 55
IGCC (Indian Condition)
Sub Critical PC Power Plant (Indian Condition)
50 1500 oC
1300o C
623 o C
45 600oC
566 oC

40 Ceramic gas
1184o C turbine
650o C
35
540oC
30
1990 1995 2000 2005 2010
Year of commercial use

EFFICIENCY IMPROVEMENT FORECAST
CONVENTIONAL Vs IGCC ( Courtesy BHEL)

POLLUTANT GENERATION FROM PC PLANTS
128
150
85
100
MMT

20 No Change Scenario
50 13.3
0
Specific Coal Consumption
1997 2002 1997 2002
ASH
=0.75 KG/KWH
15
10 Coal
10
MMT

4.3
6.6 Ash : 43%
5 2.8
Sulphur : 0.6%
0
1997 2002 1997 2002

SO2
570 Ideal Scenario
600

500 Specific Coal Consumption
400
380 384
=0.35 KG/KWH
MMT

300 256
Coal
200

100 Ash : 15%
0 Sulphur : 3%
1997 2002 1997 2002
CO2

RELATIVE EMMISSION

120
PERCENTAGE OF PC PLANTS

110
100
90 PC
80
PC+FGD
70
60 PFBC
50
40 IGCC
30
20
10
0
SOx NOx Particulates


SUPER CRITICAL UNITS

• Standardized Unit Size 660 MW, 246 ata, 565 oC
• Station Size 2x660 MW (Minimum)
• Common Off site facility
• FW Temperature 270 oC – 275 oC with 6 Heaters.

Total Capacity Planned 44,560 MW *
Number of Units 40 Units

* Includes 6x800 MW and 2x600 MW Imported sets.


Main advantages of
Super-Critical Steam Cycle

• Reduced fuel cost due to improved thermal efficiency
• Reduction of CO2 emissions by 15% per unit of Power
generated compared to sub-critical
• Very good part load efficiencies
• Plant costs are comparable with sub-critical units


Current State-of-Art

Super-critical Steam Power Generation Plants
Pressure - 300 bar
Temperature - 600oC
Efficiency - 45% (LHV Basis)

Nickel based alloys allows up 700oC
By the year 2005 - 620 oC
By the year 2020 - 650-700 oC
Cycle Efficiency - 50-55%

R&D IN SUPERCRITICAL TECHNOLOGY
Main Thrust Areas :
Materials & Metallurgy for components of boiler &
turbine subjected to high temperature and high pressure

Adv-USC Materials

Nickel based alloys have been developed for 700 ° C
application: IN 617, IN740, Alloy 263 and their variants

Development is also in progress to develop improved
materials to meet specific objectives:

12-15%Cr Advanced Martensitic Steels for temperatures up to 650 °
C

Z Phase strengthening steels up to 650 °
C

Low Nickel alloys for 700 °C to 710 °
C

SUPER CRITICAL SCENARIO

EXPECTED BENEFITS:

• Coal Saving 1,565,200
Tonnes

• Co2 Emission Reduction 1,909,544 ”

• SO2 Emission Reduction 11,648 ”

• Ash Reduction 661,752 ”


COAL GASIFIERS
Just as conventional solid-fuel boilers may be divided into three
basic types (namely pf-fired, fluidised bed and grate-fired),
gasifiers fall into three groups: entrained flow, fluidised bed and
moving bed (sometimes called, somewhat erroneously, fixed
bed).

Fluidised bed gasifiers are exactly analogous to fluidised bed
combustors; entrained flow gasifiers are similar in concept to
pf-firing; and moving bed gasifiers bear some resemblance to
grate firing.


COMPARISON OF GASIFIER TYPES


COAL BASED COMBINED CYCLE PLANT

Routes

Combustion Gasification

Hot Flue gas under pressure Pressurized gasification
drives the G.T. process produces fuel for
G.T.

Pressurized Options Available
Fluidized – BED Moving – BED
Combustor (PFBC) Fluidized – BED
Entrained – BED

The BGL gasifier (courtesy of BG plc)


COAL BASED
COMBINED CYCLE POWER GENERATION

• Offers Plant efficiency over 44% with advanced GT

• Has Lower emission of gaseous and solid pollutants

• Accept Inferior and varying quality of coals

• Lower water requirement

• Capability of phased construction and retrofitting


IGCC


IGCC TECHNOLOGY ...
– Gasification of coal is the cleanest way of utilization of coal,
while combined cycle power generation gives the highest
efficiency.

– Integration of these two technologies in IGCC power
generation offers the benefits of very low emissions and
efficiencies of the order of 44-48%.

– The comparative indices show that in case of IGCC, emission
of particulate, NOx and SOx are:
7.1%, 20% and 16%, respectively, of the
corresponding emissions from PC plant.


IGCC Technology Contd...
– Environmental performance of IGCC plants far exceeds that of
conventional and even supercritical plants.

– Three major areas of technology that will contribute to
improvements in IGCC are :
• hot gas de-sulfurisation
• hot gas particulate removal
• advanced turbine systems


DEVELOPMENTAL GOALS and CHALLENGES FOR IGCC

• To utilize India’s low grade coal for power generation
with improved plant efficiency.

IGCC plant are still at the demonstration stage and
nearly all of the projects so far have required some
form of Government support.
• The technology has three major deficiencies that
need to be remedied before it becomes widely used
• IGCC plant are expensive to build, costing significantly more than conventional
coal-fired plant with environmental protection equipment.
• IGCC plant have so far suffered from relatively poor reliability.
• iThe operational flexibility of IGCC plant at least those with oxygen (O2) plant -
has yet to be fully proven; in particular, the start-up times for IGCC plant are
measured in days rather than hours.

IGCC DEVELOPMENT PROGRAM IN INDIA

MAJOR MILE STONES:
• Choice of gasification for high ash coals by BHEL
• 6.2 MW IGCC demonstration plant established by BHEL both with
Moving Bed and Fluidized Bed.
• Coal Characterization by BHEL & IICT for gasification application.
• Intensive data generated by IICT on oxygen-steam gasification in their
Moving Bed gasifier.
• Task force CEA, CSIR, NTPC & BHEL constituted to assess
technological maturity & Financial requirement for a green field IGCC
plant of 100 MW capacity at Dadri (NTPC).
• BHEL, CSIR & NTPC prepared proposal for setting up of this 100 MW
IGCC demonstration plant.


Circulating Fluidized Bed Combustion

• Circulating Fluidized Bed Combustion (CFBC)
technology has selectively been applied in
India for firing high sulphur refinery residues,
pet coke, lignite, etc.

CFBC Technology is superior to PC Power Plant
Technology:

– Lower NOx formation and the ability to capture
SO2 with limestone injection in the furnace.

Circulating fluidized Bed Combustion

• Good combustion efficiencies comparable to PC
Power Plants.

• The heat transfer coefficient of the CFB furnace is
nearly double that of PC which makes the furnace
compact.

• Fuel Flexibility: The CFB can handle a wide range of
fuels such as inferior coal, washery rejects, lignite,
anthracite, petroleum coke and agricultural waste
with lower heating.


Circulating Fluidised Bed Boiler

Steam to Super Heater

Cyclone
Back-Pass
Coal Feed
Furnace
Hopper
ESP

External
Heat-Exchanger
Ash Cooler
HP Air


CFBC Vs Other Clean Coal Technologies

ITEM CFBC PF+FGD/SCR IGCC

Cycle Eff. % 34.8 36.7 41-42
41-

Relative Capital
1.0 1.03-
1.03-1.19 1.15-
1.15-1.42
Cost/kW

Relative O&M
1.0 1.49 0.8-0.98
0.8-
Cost/kW

At present pulverized fuel firing with FGD are less costly than
prevailing IGCC technology. However, firing in CFB Boiler is
still more economical when using high sulfur lignite and low-
grade coals and rejects.

SUMMARY

• Renovation & Modernization (R&M) and Life
Extension (LE) of old power plants is a cost-
effective option as compared to adding up
green field plant capacities.

• Growing environmental regulations would force
many utilities within the country to go for
revamping these polluting old power plants
using environmentally benign CFBC technology.

SUMMARY

Sustainable Power Development calls for
adoption of Clean Coal Technologies like
Supercritical cycles, IGCC and FBC
technologies

Supercritical Power technologies may
selectively be used for Pit Head power
generation using washed coal


SUMMARY
• IGCC can revolutionize the power generation scenario
in India, once the commercial viability of technology
with high ash coals is established at the proposed
100 MW plant.

• The success of the project will largely depend on
maturity of Fluidized bed gasification technology for
high ash Indian Coals.

• CFBC technologies are particularly useful for Boiler
Emission reduction through revamping of old
polluting plants. DR HIMADRI BANERJI EX CEO

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