By S D Prasad, Sr Chemist Sandip Mitra, Chemist Kajal Acharyya, Chemist & Hiranmoy Misra, Chemist
A Study of Mill Reject Utilization at NTPC-Kahalgaon Using Circulating Fluidized Bed Technology
59.2 17.8 2.5 20.2 Coal Hydro Nuclear oil & Gas Other INDIAN ENERGY SCENARIO COAL IS THE BACKBONE OF INDIAN ENERGY SECTOR IT WOULD BE HIGHLY UNREALISTIC TO ENVISION A FUTURE WITHOUT INDIA BURNING COAL Need of the hour is any upcoming, state of the art, advanced and environment friendly technology aiming at fuller resource utilization. FUTURE CONCERNS Though India is the 3 rd largest coal producer in the world, both quality and availability of coal is a matter of concern.
WASTES GENERATED IN APOWER PLANT Waste Gaseous Waste Solid Waste CO 2 SOx NOx SPM Other Bottom Ash Fly Ash & Mill Reject Most Ignored Bowl Mill throws out particle Having density >1.8 g/cc as reject.
Very low grade coal may be thrown out from the system.
Mill reject amounts 1-2% of total coal feed.
Reject amount may vary with unit age and coal quality.
Instant and irregular change in input increases mill rejects both in quantity & quality
Mill Reject Characteristics Mill Reject Characteristics At Kahalgaon Moisture Ash Sulphur VM GCV 1-2% 65-85% 6-8% < 6% ~800 Kcal/Kg At Kahalgaon Daily Mill Reject Generation ~ 600 MT PROBLEM WITH THIS REJECT
Do not find any use except as filling material
Problem of disposal.
Pile up in plant premises taking up expensive real estate.
High ash & sulphur leaching damages the vegetation & agro field.
Results fugitive dust emission.
IT IS NOT REJECT BUT BYPRODUCT OF THE SYSTEM
LEAVES NO OPTION EXCEPT TO UTILISE IT
IF UTILISED A potential source of power. Sulphur can be extracted.
Waste to Wealth through Circulating Fluidized Bed Technology A Clean Coal Technology Initiative Circulating Fluidized Bed Technology CFB is a fairly known technology today.
Winkler is credited with describing the first fluidized bed in 1921.
Flourished mostly in the decade of 90s. What is a fluidized bed?
Packed Bed U < U mf A Fluid Bed , uniform expansion U = U mf Bubbling Fluid Bed U > U mf B C Fluidized Bed Behaviour A B U< U mf No flow U > Umf Fluid flow Circulating Fluidized Bed : Combination Of Fluidized Bed and Gas/Solid Separation and Recycle System Fuel Fluidizing Gas Cyclone separator Flue exhaust Fluidized bed combustor CHEMICAL ASPECTS OF CFB TECHNOLOGY EFFICIENT SULPHUR REMOVAL Limestone(CaCO 3 ) and Dolomite(CaCO 3 ,MgCO 3 ) used for absorption of SO 2 in CFB combustors.
Calcination: CaCO 3 CaO + CO 2
Sulphation: CaO + SO 2 +1/2 O 2 = CaSO 4
Industrial CFB boilers show 90% S-capture. H LOW NOx EMISSION Reducing zone contains only 50-60% of the stoichiometric air requirement In reducing zone fuel N 2
does not find O 2 to produce NOx. Limited opportunity for the formation of NOx in oxidizing zone at 800- 900 o C Fluidizing Gas Oxidizing zone Reducing zone Sec.air Fuel Advantages Of CFB Boilers Fuel Flexibility Simpler Fuel Handling And Feeding System High Combustion Efficiency Good Load Following Capability High Availability PC Volatiles CFB O% 40% PC Ash Softening Temp CFB 1150 0 C 1370 0 C PC Heating Value CFB 500 Kcal/Kg
5000 KCal/Kg PC HGI CFB 40 110 Available Technologies Fuel Sensitivity SIMPLER FUEL HANDLING AND FEED SYSTEM Single feeding point & No need of pulverizers.
CFB Boiler : An innovative solution of mill reject problem A self sustaining, environment friendly, inexpensive and practical process for mill reject utilisation.
Application of CFB:Very bright future to Indian power plants Canada -India Boiler Emission upgrade project has build an advanced CFB boiler at Kolaghat Thermal Power Station for research and demonstration. OPPORTUNITIES AT NTPC KAHALGAON Daily Mill reject Generation: 600 MT (~380Mt from stage-I and ~220MT from Stage-II at full load)
A CFB Boiler may be erected utilizing mill rejects as fuel.
Steam generable in CFBC = 30 MT/hr considering avg GCV of rejects 800 Kcal/Kg = 8 MW (aprx)
SPACE REQUIRED FOR CFB BOILER The space needed for a CFB Boiler (Including TG and ESP) as approx 40M 2 /MW
For proposed scheme at Kahalgaon it needs only boiler island (Excluding TG and ESP)
Furnace of Bataan CFB project, Philippines, (35 MW), is located only on 50M 2 area
Proposed CFB Boiler may be erected adjacent to the mill reject silo area of Unit-I (Stage-I)
CASE STUDY AT NTPC KAHALGAON
This CFBC boiler may be executed with existing ID Fan, ESP & stack.
Stage-I rejects may be transported to the CFB site by the existing reject conveyor system
Generated steam can be used for different auxiliary purpose like PRDS,FOPH, steam ejector, oil burners.
Fluidizing Gas Fluidized bed combustor ESP ID Fan Turbine & Generator Blr Drm Main Stm Header High Pressure Steam PRV PRDS,FOPH, steam ejector, oil burners and other utilities Mill reject A Proposed schematic for generation of power from mill rejects at NTPC-Kahalgaon Revenue Generation Projected Investment : ` 10.0 Crore Steam generable in CFBC = 30 MT/hr = 8 MW electricity generation (approx) Considering 80% PLF Annual savings = ` 8x24x365x0.8x2 = ` 11.2 Cr Projected Annual O&M Expenses = ` 1.5 Cr (Fuel cost almost free) Depreciation + Interest @14%= ` 1.4 Cr Projected Annual Return= ` 8.3 Cr (PBT) Profit after Tax = ` 7.5 Cr Projected Pay back period = 16 Months only
NTPCLightening Every Third Bulb of India NTPC contributes ~ 30% of total power generation with 20% of the total national capacity In order to combat the forthcoming challenge of competitive bidding, we have to innovate in all directions. NTPCFuture Ahead NTPC Innovate and Lead Innovative utilization of Mill Reject using CFB Boiler: A step to turn NTPC vision into reality. References
WASTE TO ENERGY process : paper by Mr.Prabir Basu, DalhousiUniversity, Canada. Website of BHEL Mr._S.Lakshmanan: CFB- The Technology for India Energy carbonminus: India and Low Carbon Economy Greenhouse gas control technologies ; Google Books CFB Technology & Boiler; Google Books THANK YOU OPEN SESSION THANK YOU