CLEAN COAL TECHNOLOGIES FOR

SUSTAINABLE POWER DEVELOPMENT

Dr. V. K. SETHI
Prof. & Head
RGPV
Bhopal

WORLD SUMMIT ON SUSTAINABLE DEVELOPMENT

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

Promote CCT in countries where coal is main stay

fuel for Power Generation.

Reduce Atmospheric Pollution from Energy

Generating Systems.

Enhance productivity through Advanced Fossil Fuel

Technology.

POWER SCENARIO IN INDIA

Installed capacity in utilities

Thermal
Hydro
Nuclear
Wind
Total

(March 31, 2002)

73,274 mw
25,574 mw
2,860 mw
1,427 mw
1,03,135 mw

Total energy generation

383 billion kwh
Per Capita Energy Consumption -400 kwh

DEMAND PROJECTION
YEAR 2012 CAPACITY ADDITION BY SECTORS
Central
46,500 MW
State & IPP
41,800 MW
NCES
10,700 MW
Nuclear
6,400 MW
Total
105,400 MW
YEAR 2020 MIX OF GENERATION
Thermal
Renewable & Hydro
Nuclear
Total

326,000MW
104,000 MW
20,000 MW
450,000 MW

CLEAN COAL TECHNOLOGIES

Mining

Management & Practices

(Reduction of Extraneous
material)

Coal Preparation

Process after mining to improve

inherent & Extraneous material
(washing & beneficiation)

Conversion Technologies

Supercritical, PFBC and IGCC

Post combustion cleaning Particulate and gaseous

pollutants removal
(Environmental requirement)

VISION 2020
PROGRAM
In-combustion Clean-up
Fluidized bed
combustion (CFBC,
PFBC, AFBC)

Gasification using +
fluidized bed, moving bed
or Entrained bed Gasifiers

Post combustion Clean-upDesulfurization

(FGC systems) Supercritical

Pre combustion Cleanup beneficiation/washing

CLEAN COAL
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.

CLEAN COAL
TECHNOLOGIES

Clean

Coal
Technologies
(CCTs)
are defined
as
technologies designed to
enhance:
Efficiency

of conversion

Environmental

acceptability

of

coal

COAL FOR POWER

GENERATION

China

and India are projected

to
account
for30%
of the worlds
increase
in
energy
consumption
between 2000-2020 and 92%
of
increase in coal use.

The

key environmental challenges

facing the coal industry are related to
:
Coal

Mining
Particulate emission
Disturbance land me

INDIA AMONGST TOP

SIX EMITTERS OF CO2
Country
Total emission
Percentage of
(Million Tonnes of CO2)
emission
USA
5470
China
3121
14%
Russian Federation 1456
Japan
1173
Germany
884
India
881

world

24%

6%
5%
4%
4%

Note : Green House

inventory for India for
Energy Sector (Million
Tonnes
of
CO
)
2
Energy Sector
CO2
CO2

equivalent

(CO2+CH4+NOx)
Total Emission
total)

508
(58% of total)

565
(64% of

Source : IAE : 1999

PER CAPITA EMISSIONS OF CO2

Top 6 Polluters
World

Developed countries Developing Countries

Parties
(Tonnes of CO2 per (Tonnes of CO2 per
capita)
capita)

Qatar
44.08
Bahrain 35.23
UAE
30.11
Kuwait 25.01
Singapore 23.47
U.S.A
20.50

USA
20.50
Luxemboury 20.42
Australia 16.52
Canada
15.76
Finland
12.47
Estonia
12.47

Qatar
44.08
Bahrain
35.23
U.A.E.
30.11
Kuwait
25.01
Singapore 23.47
Saudi Arabia 13.27

Note : Per capita CO2 equivalent emissions for India in 1990 are estimated to be
1.194 tonnes or 325 kg of Carbon per capita. This contribution 58% of National
Emissions and 4% of global emission.
Source : IEA 1999 & UNDP 1998.

COST OF VARIOUS CO2

MITIGATION OPTIONS FOR
INDIAN POWER SECTOR
Potential
Technologies

Green house
gas emission
reduction (kg/kWh)

COST (Rs/Tonnes CO2)

1.
2.
3.
4.
5.
6.

1.50
0.96
0.18
0.23
0.18
0.125

480
2600
24000
16000
16000
8500

Co-generation
Combined Cycle
PFBC
IGCC
Supercritical
Coal Washing

Source: ADP 1998

Zero Emission
Technology (ZET)

This technology combines and forms a

part of :
Clean Coal Technologies
Solid to liquid fuel technology
GHG mitigation technology
Clean Development Mechanism for power
sector
Non-CFC Refrigerant and Non-CFC Aerosol
Propellant Technology
Clean Aviation Fuel or ATF for aircraft
Substitute LPG for domestic use.

Measures to achieve
Sustainable
Development

Promoting

CCTs, including
carbon sequestration is essential
to a balanced cost effective climate
change response
Developing

countries where coal

combustion
efficiencies are low
CCT promotion a need of the day.

Super Critical PC Power Plant (15 oC Amb.)

Net Thermal Efficiency (%)

60

Super Critical PC Power Plant (Indian Condition)

IGCC (15 oC Amb)

55

IGCC (Indian Condition)

50
45

566 oC

Sub Critical PC Power Plant (Indian Condition)

1500 oC
1300o C
623 oC
600o C

40
1184o C

650o C

35
30
1990

Ceramic gas
turbine

540oC
1995

2000

2005

2010

Year of commercial use

EFFICIENCY IMPROVEMENT FORECAST

CONVENTIONAL Vs IGCC ( Courtesy BHEL)

POLLUTANT GENERATION FROM PC PLANTS

MMT

150
100

128
85
13.3 20

50

Specific Coal Consumption

0
1997 2002

MMT

1997

10

10

2002

=0.75 KG/KWH

ASH

15

No Change Scenario

2.8

Coal

6.6

4.3

1997 2002

1997

Ash

43%

Sulphur :

0.6%

2002

SO2

500
MMT

400

Ideal Scenario

570

600

380

384

=0.35 KG/KWH

256

300

Coal

200

Ash

100
0

Specific Coal Consumption

1997

2002

CO2

1997

2002

Sulphur :

15%
3%

PERCENTAGE OF PC PLANTS

RELATIVE EMMISSION
120
110
100
90
80
70
60
50
40
30
20
10
0

PC
PC+FGD
PFBC
IGCC

SOx

NOx Particulates

SUPER CRITICAL UNITS

Standardized Unit Size 660 MW, 246 ata, 537 oC
Station Size 2x660 MW (Minimum)
Common Off site facility
FW Temperature 270 oC 275 oC with 6 Heaters.

Total Capacity Planned

Number of Units

14,560 MW *
22 Units

* Includes 6x720 MW and 2x500 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
Pressure
Temperature
Efficiency -

Power Generation Plants

300 bar
600oC
45% (LHV Basis)

Nickel based alloys allows

By the year 2005 By the year 2020 Cycle Efficiency -

up 650oC
620 oC
650-700 oC
50-55%

R&D IN
SUPERCRITICAL
TECHNOLOGY

Main Thrust Areas :

Materials & Metallurgy for components

of boiler &
turbine subjected to high
temperature and high
pressure.
Supercritical cycle optimization
-incremental heat rate
improvement
Retrofit of supercritical boiler to
subcritical PC boiler
Fluidized bed supercritical steam cycles
Once through HRSGs with supercritical
parameters

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 BASED COMBINED CYCLE PLANT

Routes
Combustion

Gasification

Hot Flue gas under pressure

drives the G.T.

Pressurized gasification
process produces fuel for
G.T.

Pressurized
Fluidized BED
Combustor (PFBC)

Options Available

Moving BED

Fluidized BED

Entrained BED

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 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 4448%.

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 ...

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 FOR IGCC

To utilize Indias low grade coal for power generation

with improved plant efficiency.

To introduce coal gas in Natural Gas based Combined

Cycle Plants in a phased manner.

To increase power generation capacity at the level of

present emission.

To develop state of Art Technology for Indigenous and

Export Markets.

IGCC
Gas
Clean Up
Fuel

COAL
Raw Gas
Cooler

Steam

Combustion
Chamber

Air

Gasifier

Alternator

Booster

Comp.

Ash

Turb.

Air
Steam

Alternator
ST

Exhaust
Gases
Condenser
WHB

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, lignite, etc.
CFBC Technology is superior to PC
Power Plant Technology:

Lower NOx formation and the ability to

capture SO2 with limestone injection
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
Coal Feed
Hopper

Ash Cooler

Back-Pass
Furnace
ESP

External
Heat-Exchanger
HP Air

CFBC Vs Other Clean

Coal Technologies
CFBC

PF+FGD/SC
R

IGCC

34.8

36.7

41-42

Relative Capital
Cost/kW

1.0

1.03-1.19

1.151.42

Relative O&M
Cost/kW

1.0

1.49

0.8-0.98

ITEM
Cycle Eff. %

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.

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.

SUMMERY

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

SUMMERY

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.