Team Kahalgaon

International O&M Conference

February 13-14, 2011
New Delhi

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 boilers receive fairly coarse (0-6mm) solid
fuels.

Fluidized nature and height of the bed allows
high degree of particle mixing.



HIGH COMBUSTION EFFICIENCY
Superior mixing

Large reaction space

Long residence time

Independent of ash properties
HIGH AVAILABILITY
The availability records of CFB boilers are
more than 90%.
MAJOR DISADVANTAGES
Erosion of reactor wall

complexities of hydrodynamics

Higher start-up and shut down time

Indian Experience -CFBC
18 boilers Installed

Operating maximum capacity 125 MW

Contracted maximum capacity 250 MW firing Neyveli Lignite
for M/s Neyveli Lignite Corpn

Fuels used -Gujarat Lignite, NeyveliLignite, Rajasthan Lignite ,
KutchLignite , Petcoke, Coal , Washery Rejects, Char
Source: BHEL


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
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SESSION
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