Cooperation project for the renovation of existing coal-fired power plants in China

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RM in Japan and Our Experiences under the
CEA-JCOAL Cooperation
Japan Coal Energy Center (JCOAL) at Round Table
Meeting on Thermal Power Energy Efficient
Rehabilitation and Modernization (EERM) by
WBPDCL, Kolkata April 4, 2016
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Overview

1. Philosophy and practices of coal fired power
   station management in Japan
2. Our experiences in India
3. Summary

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• Philosophy and practices of coal fired
• power station management in Japan

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Concept of full plant economic life in Japan
Source Kyushu Electric Power
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Maintaining the designed efficiency over 45
years
O M is a crucial key to excellent and
sustainable efficiency management of power
station throughout its lifetime.
Comparison of an old power plant in Japan with
its counterpart power plant in country X
X?????????
?? ???
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Takasago coal-fired power plant (250MW X 2 units)
Working efficiently over 45 years
Gross Output Net Output 250,000kW2 233,000kW2
Fuel Coal (Heavy Oil) (Start-up only light oil)
Boiler ManufacturerBoiler Type Boiler output(?MCR)SteamFlowPressureTemperature Mitsubishi,CE Forced Circulation, subcritical pressure Drum Type Boiler Corner Firing System 825 t/h SH out 17.2MPa SH out 571? RH out 543?
Turbine ManufacturerTurbine Type Main steam Pressure Main steam TemperatureReheat steam Temperature Mitsubishii, Westinghouse Regenerative,reheat, condenser 16.6MPa 566? 538?
MW
MW
Unit 1 COD in Jul 1968 Unit 2 COD in Jan 1969
?MCRmaximum continuous rating
Source J-POWER
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Plant management timeline
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2. Our experiences in India under the CEA-JCOAL
Cooperation
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Japan Coal Energy Center (JCOAL)

• Established as a foundation in 1990, with its
  origin back to 1948
• Covers all coal related issues from upstream to
  downstream of the coal value chain
• Members 119 incl. major public-listed companies
  and main players in energy and relevant sectors
• Supervision by METI (Ministry of Economy, Trade
  and Industry of Japan)

Facilitation and promotion of cleaner utilization
of coal
Mining Preparation
Exploration
Coal utilization technology development
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Our major partner institutions
IEA-Clean Coal Energy CentreA
IEA-GHGA
Provincial Government of Saskachewan
Government of Ukraine
Government of Poland
China Electricity Councila
Government of Canada
CEA, Government of India
State Mining Exploration Company of Mozambique
ASEAN Centre for Energy
Government of Australia
State Government of Victoria
Government of Indonesia
State Government of Queensland
Indicated are JCOALs major partners only.
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Diagnostic studies for RM

• JCOAL conducted diagnostic studies for RM
  implementation at 3 (three) state power stations
  and at 5 (five) NTPC power stations.
• At Dr. NTTPS of APGENCO the study was done at the
  time of shut-down and cost-benefit analysis was
  made.

2015 Dadri
2012 Unchahar
2012 Badarpur
2011 Kahalgaon
2012 Durgapur
2010, 2011 Wanakbori
2010, 2011, 2012 Dr. Narla Tata Rao (Vijayawada)
2010 Ramagundam
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Proposed options of RM (1)
Plan-ALE Replacement of worn parts only
Plan-BRM Replacement of worn parts Reuse of
casing, replacement of HP,IP,LP turbine, D-EHC
improvement and ESP rehabilitation
Plan-CRM Plan-B generator improvement
Plan-DRM Plan-C condensor and feedwater heater
improvement
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Proposed options of RM (2)
Plan Policy (Effect) Specification Upper Capacity(MW)/Lower Heat rate(Kcal/kWh) Upper Capacity(MW)/Lower Heat rate(Kcal/kWh) Upper Capacity(MW)/Lower Heat rate(Kcal/kWh) Analysis
Plan Policy (Effect) Specification Design Actual After RM Analysis
A (LE only) Keep the status quo with 20 years LE Replacement of worn parts only 2102350 2002420 ?? Required cost for 20 years LE
B Keep rated capacity 210MW with heat consumption rate improvement by 5 and 20 years LE Reuse of casing, replacement of HP,IP,LP turbine, D-EHC improvement and ESP rehabilitation 2102350 2002420 2102300 High FIRR with environmental improvement
C Uprate of rated capacity to 225MW heat consumption rate improvement by 5 and 20 years LE Plan Bgenerator improvement 2102350 2002420 2252300 Good FIRR with environmental improvement even with LE
D Uprate of rated capacity to 225MW heat consumption rate improvement by 5 and 20 year LE Plan Ccondensor and feedwater heater improvement 2102350 2002420 2252280 Environmental improvement and low FIRR with current price level of electricity
10 -120
25 -120
25 -140
RM proposal of Plan B,C and D are found to be
effective for efficiency and environmental
improvement as well as economically beneficial.
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Environmental Improvement by ESP Rehabilitation
Expected Outcome by ESP Rehabilitation
Dust Concentration (mg/Nm3)
NTPC has introduced MEEP at two units of Rihand
TPS.
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manufacturers-how it works to enhance economy of
a unit
Maritsa East III Bulgaria (210 MW x 4 units, age
20-30 yrs) increased the capacities
Liddell PS turbines with increased capacities
210MW
Renovation
500MW
Renovation
Capacity uprate by 10 (225-245MW) with 15-20 yrs
life extension
(1) Original LP turbine(GEC)
?improved section
520MW

• Modernization of LMZ(K-200-130) to 226-230 MW
  with the same heat rate (By Toshiba)
• Rehabilitation of boiler, generator auxiliaries
  incl. transformers and ESP
• BOP was also in the scope
• Newly added equipment FGD (By IHI) De-NOx s

(2) Retrofitted by Hitachi (now MHPS)
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Efforts for HELE (High Efficiency Low Emmissions)
application through RM Feasibility Study on
Replacement of Badarpur TPS, NTPC
Ultra Super Critical, Efficiency 45
Sub-Critical, Efficiency 40
Old Isogo COD in1967

Current Badarpur TPS
New Isogo COD Unit 1 in 2002, Unit 2 in 2009
Capacity 530MW (265MW2 )
Capacity 1,200MW (600MW2 )
Increasing Power supply
Efficiency Improvement
Unit1
Unit1
Unit1
Unit2
Unit2
Unit2
Cleaner Environment
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Outline of Combustion Test of Indian Coal
SourceMHPS
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HRD Activities through CCT Transfer Program
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High Efficiency Coal Washery Plant (NEDO)

• High efficiency coal preparation plant in Odisha
• High efficiency coal preparation plant was
  commissioned on July 25th, 2014 in Angul, Odisha
  using latest vari-wave jig technology with
  processing capacity of 350t/h.

Source NEDO website
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Summary
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We look forward to working with you

• Website
• http//www.jcoal.or.jp/index-en.html
• Contacts
• Mr. K. Murakami (kzmurakami_at_jcoal.or.jp)
• Ms. Yamada, F. (fyamada_at_jcoal.or.jp)