ENERGY CONCLAVE 2006
TECHNOLOGY FRONTIERS AND
MODERNISATION
ENERGY R&D
BHEL ROLE & CONTRIBUTION
PRESENTATION
BY
RAVI KUMAR
DIRECTOR (POWER)
BHEL, NEW DELHI
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Bharat Heavy Electricals Limited
R&D – WORLD STATUS
Expenditure on R&D per capita
(IN US $)
INDIA
CHINA
S. KOREA
AUSTRALIA
UK
USA
JAPAN
-
5.5
11.7
241
285
460
705
978
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Bharat Heavy Electricals Limited
R&D – BHEL
TARGETS
2006-07
EXPENDITURE ON R&D
NO. OF PATENTS TO BE
FILED
COMMERCIALISATION OF
IN HOUSE DEVELOPED
PROJECTS
2005-06
RS. 150 CR. RS. 125 CR.
55 NOS.
45 NOS.
RS. 700 CR. RS. 650 CR.
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Bharat Heavy Electricals Limited
BHEL-R&D EXPENDITURE AS % OF T.O.
History of R & D Expenditure as % of T.O.
1.6
1.4
R & D Expenditure
1.2
1
0.8
0.6
0.4
0.2
0
199293
199394
1994- 199595
96
199697
1997- 199898
99
1999- 200000
01
200102
2002- 200303
04
200405
200506
Year
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Bharat Heavy Electricals Limited
TECHNOLOGY TRENDS
POWER SECTOR
 Lower Cost of Generation
 Environment Friendly
 Higher Efficiency
 Higher Reliability
 Compatible to Local Conditions
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Bharat Heavy Electricals Limited
CENTRE OF EXCELLENCE SETUP BY BHEL
 Center Of Excellence For Simulators
 Center Of Excellence For Computational
Fluid Dynamics
 Center Of Excellence For Permanent
Magnet Machines
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Bharat Heavy Electricals Limited
STATE OF ART TECHNOLOGIES / PRODUCTS INTRODUCED
BY BHEL

Low Nox Oil/ Gas Burners

Large Capacity Atmospheric FBC

High Efficiency Pelton Turbine

Controlled Shunt Reactor (CSR)

Flexible AC Transmission System (FACTS)

Space Grade Solar PV Panels

Phase Shift Transformer

145 KV Gas Insulated Switchgear

India’s Largest Vertical AC Motor (6 MW, 6.6 KV)

Micro Controller Based Flame Scanner

Performance Analysis, Diagnostics and Optimization
(PADO) Package

91 Ton/hr BHEL 280 Bowl Mill
Bharat Heavy Electricals Limited
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TECHNOLOGIES SUBSTANTIALLY DEVELOPED
 Supercritical Thermal Power Plants

Circulating Fluidised Bed Combustion

Coal Based Combined Cycle Plants


IGCC

PFBC
Nuclear Power Generation with Fast Breeder
Technologies

Fuel Cells

Solar Photo Voltaic
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Bharat Heavy Electricals Limited
SUPERCRITICAL THERMAL POWER PLANTS
 The supercritical cycle offers a ‘burn less
fuel for the same output’ approach
 Involves economical use of energy
resources resulting in higher efficiency and
low emissions
 BHEL is equipped to supply Supercritical
Power Plants upto 1000 MW
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Bharat Heavy Electricals Limited
Cycle Efficiency benefits of supercritical units are derived
from higher pressures and temperatures of steam
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Bharat Heavy Electricals Limited
Super Critical R&D Projects
Areas identified
R&D Actions Taken
Heat Transfer Correlations
Joint Project with
IIT-Chennai
DNB, Tube Dry-out
Flow Instability
Spiral to Vertical Transition Piece
Joint Project with AU FRG
Load Transfer Attachment
Dynamics, Temperature Control
BHEL Corp R&D
Ripple Effect
BHEL In-House
Chemical Lab
FW Oxygenated Treatment
Low NOx Burner
BHEL In-House
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Bharat Heavy Electricals Limited
CFBC TECHNOLOGY





Burns low grade fuels like lignite
No pulverising
Low NOx & Low SOx emissions
Higher efficiency
BHEL commissioned 2x390 TPH
boilers for Surat Lignite Power
Project
 Number of 125 MW CFBC based
power plants are under execution
 Order received for 2x250 MW NLC,
the largest CFBC technology based
power plant in the country
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Bharat Heavy Electricals Limited
ENVIRNOMENTAL ASPECTS – ROAD MAP
Area of focus
-
NOx control in pulverized coal fired boilers
NOx emission scenario of Indian plants while firing different fuels:
Unit capacity, MW
fuel
NOx emission, ppm at 3.0 % O2
500
gas
73
500
oil
129 to165
500
coal
271 to 434
250
coal
266 to 322
210
coal
247 to 478
210
lignite
242 to 280
120
coal
389
Development of low NOx wall fired coal burner
Establishment of SCR demo plant
Commercialisation of wall burner
Commercialisation of SCR system
- 2006
- 2007
- 2008
- 2010
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Bharat Heavy Electricals Limited
IGCC POWER GENERATION - DEVELOPMENT IN BHEL
 6.2 MW IGCC Pilot Plant at its Trichy Complex.
 Technical feasibility of upgrading the 6.2 MW Combined
Cycle Demonstration Project of BHEL to ~100 MW had
been established

Preliminary assessment made for 400 MW IGCC Plant
 Plan to set up 125 MW IGCC Demonstration plant
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Bharat Heavy Electricals Limited
IGCC POWER GENERATION - DEVELOPMENT IN BHEL
PFBG SCALE - UP
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Bharat Heavy Electricals Limited
A glimpse of Fuel Cell Developments at BHEL
(Inter-disciplinary approach followed for Fuel Cells Development)
Skid Design
(Renewable
Energy Systems
Lab)
Inverter System
(Power
Electronics Lab)
Anodes, Cathodes,
Membrane Electrode
Assemblies etc
(Fuel Cells Lab)
Fuel Cell
Development
Data Acquisition,
display & Controls
(Control
Instrumentation Lab)
Stack Heating
& Cooling
(Heat Transfer
Lab)
Bipolar &
Cooling plates
(Fuel Cells Lab)
Stack Hardware
& Assembly
(Design Analysis &
Value Engg)
Reactants &
Coolant Supply
(Turbo Machinery
Lab)
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Bharat Heavy Electricals Limited
Indigenous Fuel Cell R&D - Achievements
Phosphoric Acid Fuel Cells (PAFC)
BHEL R&D: 1 kW (1991), 5 kW (1995) & 50 kW (2000, 2 stacks of 25 kW
each) - with data acquisition and display system & inverter have been
demonstrated.
Performance of a state-of-the-art 200 kW FCPP (PC 25 C, procured
from M/s IFC / ONSI / Toshiba) also evaluated, using LPG as fuel.
Polymer Electrolyte Membrane Fuel Cells (PEMFC)
Single cells & small stacks for evaluating electro-catalysts. Also tested
Direct Methanol FCs – Basic Tech acquired from IISc, B’lore
High Temperature Fuel Cells (SOFC)
BHEL R&D & CTI, Bangalore: Materials, processes & components
developed. Assembled & tested single cells of planar SOFC.
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Bharat Heavy Electricals Limited
BHEL IN PHOTOVOLTAICS
 Over two decades experience in Photovoltaics
 Manufacturing capacity of 3MW
 Single crystalline (mono) cells upto 2.3W (15%
efficiency)
 PV modules range is from 10W to 160W
 PV systems integration capabilities- have supplied PV
power plants ranging from 1 KWp to 150 KWp
 PV modules internationally certified to IEC 61215
standards
 Cumulative shipments from BHEL over 20 MWp
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Bharat Heavy Electricals Limited
Future outlook for PV in BHEL
 Automatic manufacturing capacity over 30 MW planned
 Plan for improving solar cell efficiencies to over 18% by
2010
 Capability to process both mono & multi crystalline
wafers
 Opportunities for backward integration into silicon wafer
manufacturing
 Large scale deployment of PV power plants
 Explore alternate technologies like Thin film cells,
multijunction cells etc
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Bharat Heavy Electricals Limited
BHEL - R&D
DEVELOPMENT OF 765 KV TRANSMISSION SYSTEM
2006-07 TARGETS

DESIGN & MANUFACTURE OF 765 KV, 500 MVA
TRANSFORMER

DESIGN & MATERIAL PROCUREMENT FOR
MANUFACTURE OF 765 KV 80MVAr SHUNT
REACTOR

DEVELOPMENT OF COMPOSITE INSULATORS
FOR TRACTION & TRANSMISSION WITH NANO
ADDITIVES
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Bharat Heavy Electricals Limited
POWER PLANT PERFORMANCE IMPROVEMENTS
AUXILIARY POWER CONSUMPTION REDUCTION
 Power plant consumes nearly 7 to 9% of energy
generated
 Auxiliary power can be brought down by proper
selection of technology, equipments and cycle
parameters
 Power consumption of BHEL manufactured equipment
has been recently reduced from 7% (of total power
consumption) to 6.65% for 250 MW & from 4% ( with
turbine driven boiler feed pump) to 3.8%
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Bharat Heavy Electricals Limited
POWER PLANT RENOVATION &
MODERNISATION
LEADING PLAYER IN R&M AND UPRATING
 R&M and LE of Large No. of Units in India and Abroad
 Uprating of 110 MW Czech Units to 120 MW
- Replaced Internals of HP, MP & LP Turbines with Reaction Type
Blading
- Boiler Upgrades to Ensure Rated
- FlowModernize C&I and Balance of Plant
 Improvised Blade Profiles for 210 MW LMW Sets
- Reaction Type Blades for HP Turbine yield an additional 2.5 MW
- New Monoblock LP Rotor with Reaction Blading Leading to
additional 3.7 MW
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Bharat Heavy Electricals Limited
PERFORMANCE OF BHEL THERMAL SETS
Performance Trend
(Thermal sets in India)
90
85
80
%
75
PLF-BHEL
OA-BHEL
PLF-ALL INDIA
70
65
60
55
50
9091
9192
9293
9394
59
62.8 61.2 63.1 64.6 65.6 65.7 68.3 70.5 71.3 74.1 74.3 75.7 74.9
PLF-BHEL
55.8 56.6
OA-BHEL
71.7 72.7 74.6
77
PLF-ALL INDIA 53.8 55.3 57.1
61
9495
9596
9697
9798
9899
9900
0001
0102
0203
0304
0405
0506
77.5 79.9 80.7 79.8 78.9 80.4 81.8 81.7 83.9 83.9 84.3 83.4
60
63
64.2 64.7 64.2 66.7 68.5 69.9 72.2 72.7 74.8 73.6
year
Bharat Heavy Electricals Limited
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THANK YOU
http://www.bhel.com
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Bharat Heavy Electricals Limited