th
4
Annual
“Coal Markets in India-2014”
The Imperial
New Delhi
22.08.2014
Improving Coal Efficiency Role of Coal Additives
--------ooo--------
Abhitech Energycon Limited
A/1020, Oberoi Garden Estate, Chandivali Farm Road,
Chandivali, Mumbai – 400072
Tel (91-22) 2847 9999 Fax (91022) 2847 9988
E-Mail : abhitech@abhitechenergycon.com
Visit us at : www.abhitechenergycon.com
Coal Efficiency
• Coal Efficiency represents the amount of
Energy that can be extracted from a single
unit of Coal.
• So, we are essentially talking about Plant
Efficiency, or more specifically Combustion
Efficiency; which can be measured to see
what amount of Energy is being extracted
from a single unit of Coal in a particular
system.
Combustion Efficiency
• Combustion Efficiency is a measure of how
efficiently a device/system consumes fuel.
Ideally, it should be 100%, meaning that the
fuel is completely consumed.
• In practice, this level of efficiency is impossible
to achieve, but it's possible to come close.
• The lower the combustion efficiency, the less
efficient the device is, making it expensive to
run, wasteful of fuel, and harmful for the
environment.
Factors affecting Combustion Efficiency
and Overall Plant Performance
•
•
•
•
•
•
•
•
Poor Combustion
Excess Air control
Deviation of fuel quality from designed values
Heat Transfer Fouling
Pre-water treatment
Condenser Performance
APH Performance
Poor Operation and Maintenance of Boilers
Methods used to overcome
these problems
• Scheduled Maintenance and AOH of Boilers.
• Modification and Renovation in the Boilers
• Energy Audit to keep an account of various
losses in Boilers.
• Different types of analysis like CFD Analysis to
improve flue Gas Path.
Disadvantages of employing
these methods
• High Capital Expenditure
• Shutdown required
• Complexity of these methods
• Highly skilled Professionals required
• For analysis purpose, expensive
equipment required.
Alternative ???
Then,
Is there any solution which is Simple in Application,
Involves no Downtime, and
Requires no Capital Expense ?
Combustion Catalysts
Coal Additives
Effective Additive – Reduction in Losses,
Impact on GUHR & Boiler Efficiency
• 1% Red’n in UFA – 20 Kcal/kwh on GUHR & 0.8% in Boiler Eff.
• 1% Red’n in UBA – 2.5 Kcal/kwh on GUHR & 0.2% in Boiler Eff.
• 1% Red’n in Excess Air – 7.4 Kcal/kwh on GUHR & 0.6% in Boiler Eff.
• 1% Red’n in FGT – 1.2 Kcal/kwh on GUHR & 0.067% in Boiler Eff.
• 1TPH Red’n in S/H Attemp. – 0.03 kcal/Kwh on GUHR
• 1TPH Red’n in R/H Attemp. – 0.25 kcal/Kwh on GUHR
• 1 mm of soot deposit Red’n – 0.83 % savings in Coal
(Ref :- BEE , NTPC, IGEN, BS 2885)
• Thus, due to improvement in all above parameters, with the use of an
effective Additive, 2 to 4 % savings in coal can be achieved.
Bureau of Energy Efficiency – Boilers
Types, Combustion in Boilers, Performance evaluation, Analysis of Losses, Feed Water
Treatment, Blow down, Energy conservation opportunities
Bureau of Energy Efficiency - Boilers
NTPC-USAID
Heat Rate Improvement Guidelines for Indian Power Plants
Saving Potential
• All India Yearly Coal Consumption for Power
Generation (Utilities) :
454 MMT
• Coal that can be saved @ 2 % using Additive :
9.09 MMT
• Total Generation possible from the amount of Coal
saved @ 0.75 kg/kWh :
12.1 MMWHr
• Average Power Consumption per Annum for a
Single Household in India :
3.11 MWHr
• No. of Households that can be enlightened for
whole year in India with the amount of Coal Saved:
38.97 Lacs
Current Status
• The Coal Additive Market is in its infancy,
although the outlook is bright.
• There aren’t many Companies in the market
producing Coal Additives as yet.
• Abhitech is doing the Leadership work –
• Creating Awareness
• Developing a Model for Evaluation
• Establishing Additives as an Alternative
• Creating an Industry
• Serving the National Cause of Fuel Conservation
Abhitech - Mission Efficiency
Abhitech’s aim is to not only save the
Coal and other Carbon based Fuels by
increasing the Boiler Efficiency using
specially formulated Additives, but
also lend a helping hand in making
the environment pollution free and
making this Planet a better place to
live in.
Combustion Catalyst
THERMACT
Technology Collaboration with IIT-Bombay.
Abhitech Energycon Ltd.
Established across various Sectors
• Large Capacity Power Plants from 60 MW to
800 MW
• Sugar Industry ( Co-generation )
• Steel Plants (Coke making & Blast Furnace)
• Captive Power Plants (AFBC Boiler)
• Biomass fired IPPs.
Abhitech Energycon Ltd.
Abhitech - Background
 THE LARGEST MANUFACTURER OF COMBUSTION
CATALYSTS IN INDIA
 INDIAN TECHNOLOGY
 GLOBAL PRESENCE
 ONE OF THE FEW COMPANIES WORLD WIDE,
WITH PRODUCTS FOR SOLID & LIQUID FUELS
 TECHNICAL MANPOWER : 266 ENGINEERS
Abhitech Energycon Ltd.
Global Presence
Baddi (HP)
Delhi
Raipur
Kolkatta
Bhubaneshwar
Head
office
Head office
Vijayawada
Manufacturing unit
Belgaum
Zonal offices
Bangaluru
Chennai
Export
Abhitech Energycon Ltd.
Manufacturing Unit at
Baddi, Himachal Pradesh
THERMACT
A Multifunctional Catalyst for
COAL
IIT, Bombay
Abhitech
Energycon
Ltd.
Abhitech
Energycon
Ltd., INDIA
Product Specifications
Manufacturer
ABHITECH ENERGYCON LTD
Name
THERMACT
Packing
20 Kg Silsack Bag
Appearance
Black Colour
(Powder Form)
Odour
Odourless
Dosage
1:15,000 on Kg/Kg basis
(1 Kg of THERMACT for 15 Tons of Coal)
Abhitech Energycon Ltd.
Special Features of THERMACT
 THERMACT is a multifunctional combustion improver
manufactured by Abhitech Energycon Ltd, with collaboration of IIT,
Mumbai.
 No capital expenses (NO CAPEX)
 “NO SHUTDOWN” required for installation of Dosing equipment.
 Tested and approved by –





Indian Institute of Technology, Bombay
CMRI (Central Mining Research Institute)
CMERI (Central Mechanical Engineering Research Institute)
Jadavpur University, Ostrava University
SGS, USA - Toxicity Characteristic Leaching Procedure
(TCLP) test
Abhitech Energycon Ltd.
SCHEMETIC OF THERMACT DOSING
DOSING
MECHANISM
Two Vibro or Screw
Feeders opposite
corners
1 kg of THERMACT is
added with 15 Tons
of Coal
No shutdown required
for installation of
Dosing equipment
F
Regulator
AC Supply
Apparatus
Power
Consumption
AC Supply
Vibro-feeder +
Thyristor Control Panel
1.8 kWh/day
240 V. single
phase, 50 Hz
DOSING MECHANISM
1 kg of THERMACT
is added to
15 Tons of Coal.
Abhitech Energycon Ltd.
Working Principle
Carbon
Particle
THERMACT
Catalyst 1
H2O
C + H2 O
CO + H 2
CO +1/2 O2
CO2
Catalyst 2
Fixed Moisture
C + H2
CH4
CH 4
heat given
THERMACT
Catalysts
Reduction in coal
consumption / GUHR
Abhitech Energycon Ltd.
Activation Energy
 THERMACT
reduces
the
activation energy required for
various
reactions
aiding
combustion.
with
THERMACT
 The rate
increased.
of
reactions
are
Abhitech Energycon Ltd.
Benefits
 Reduction in Unburnts in Ash
 Reduction in Excess Air
 Reduction in O2%
 Reduction in Flue Gas Temperature
 Reduction in Slag and Clinker
 Reduction in R/H and S/H Attemperation
 Reduction in GUHR
 Reduction in Coal consumption
 Reduction in Soot blowing frequency
 Improved Generation
 Reduction in Secondary Fuel Consumption
Abhitech Energycon Ltd.
Customers using THERMACT in
PF Fired Boilers
CLIENT NAME
LOCATION
CAPACITY
Mundra, Gujrat
3 X 800 MW
Sanjay Gandhi TPS
Birsinghpur
2 X 210 MW
Santaldih Thermal Power Plant
West Bengal
1 x 250 MW
Bandel Thermal Power Station
West Bengal
1 x 210 MW; 4 x 62.5 MW
Sagardighi Thermal Power Project
West Bengal
2 x 300 MW
Bakreswar Thermal Power Station
West Bengal
5 x 210 MW
Tenughat Thermal Power Station
Lalpania
1 x 210 MW
Kolaghat Thermal Power Station
West Bengal
6 x 210 MW
Durgapur
1 x 110 MW
Satpura TPS, Sarni
Sarni
1 x 210 MW
CSEB – Korba TPS
Korba
2 x 120 MW; 4 x 50 MW
Chachai
2 x 120 MW
Tata Power ,Mundra
The Durgapur Projects Ltd.
Amarkantak Thermal Power Station
Abhitech Energycon Ltd.
Savings Achieved (in %)
Performance at Various
Thermal Power Plants
Savings (%)
7
6
5
4
3
Less than
110 MW
More than
250 MW
3.8
4.18
3.5
5.92
210 MW
3.19
5.16
4.2
2.78
2
1
0
Clients Name
Abhitech Energycon Ltd.
Case Study – I
SANJAY GANDHI TPS,
BIRSINGHPUR
(MPPGCL)
(Savings shown by Indirect Method)
4 x 210 MW,1 x 500 MW
Comparison: Pre-Trial & Post-Trial
Parameters
Unit
Pre-Trial
Post-Trial
Difference
Difference %
Average Load
MW
146.1
162.61
16.48
11.28%
GCV of Coal
Kcal/kg
3756
3725
Unburnt in Bottom Ash
%
8.89
3.69
5.20
58.51%
Unburnt in Fly Ash
%
4.73
2.43
2.30
48.59 %
O2 @ APH I/L
%
6.96
5.73
1.23
16.19%
CO @ APH I/L
PPM
943.18
617.26
255.32
27.07%
Boiler Efficiency
%
81.08
84.12
3.04
3.75%
Boiler Efficiency after
GCV Correction
%
81.08
84.19
3.11
3.84%
Turbine Heat Rate
Kcal/Kwh
2369.2
2322.58
46.66
GUHR
Kcal/kwh
2922
2758.7
163.37
5.59 %
GUHR after THR
Correction
Kcal/Kwh
2922
2805
116.71
3.99 %
Effect of THERMACT on
Bottom Ash
Pre-Trial
Post-Trial
Effect of THERMACT on Fly Ash
Pre-Trial
Post-Trial
Effect of THERMACT on Clinker
Pre-Trial
Post-Trial
Effect of THERMACT on FLAME
Pre-Trial
Post-Trial
Case Study – II
TENUGHAT THERMAL POWER
STATION.
(TVNL)
(Savings shown by both Direct and
Indirect method)
3 x 210 MW
Case Study – III
COASTAL GUJARAT POWER LTD.
(A TATA Group of Company)
(Savings shown in terms of reduction in slag
and clinker and reduction in Heat Rate)
An Ultra Mega Power Plant
4 x 800 MW
THERMACT - DOSING MECHANISM
CLINKER PHOTOS DURING THERMACT USAGE
Near Sootblower 175
Before THERMACT
With THERMACT
Abhitech Energycon Ltd.
CLINKER PHOTOS DURING THERMACT USAGE
Near Sootblower 176
Before THERMACT
With THERMACT
Case Study – IV
CENTURY PULP AND PAPER, LALKUAN
100 TPH, AFBC PLANT
(Savings shown in terms of reduction in LOI)
Case Study – V
STATKRAFT , GERMANY
(A Biomass Based Unit)
Reduction in Fly and Bottom Ash
Case Study: STATKRAFT Germany
A few customers using THERMACT on
regular basis in AFBC Boilers.
S.No.
Customer
Equipment Details
1
KSK Energy Ltd.
90 TPH X 2 – AFBC
2
Birla Cement
70 TPH X 2 - AFBC
3
J. K Cement
89 TPH - AFBC
4
Vasavadatta Cement Ltd
80 TPH - AFBC
5
Madras Cement Ltd
70 TPH - AFBC
6
Century Pulp & Paper Ltd
100 TPH X 2 - AFBC
7
Jubilant Life Sciences Ltd.
90 TPH X 2 – AFBC
8
Delta Paper
50 TPH - AFBC
9
Siddharth Paper
35 TPH - AFBC
10
Merino Industries
25 TPH - AFBC
11
KRBL
25 TPH - AFBC
12
India Glycols Limited
80 TPH X 2
Customers in Sugar Sector using
THERMACT-B on regular basis.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Customer
Location
Modi Sugar
SBEC Sugar
Yadu sugar
Neoli sugar
Indian Sucrose
Bhagwanpura
A B Sugar
Chadha Sugar
Wahid Sugar
Ramala Coop
Morna Coop
Sarsawa Coop
Semikhera Coop
Anoopshar Coop
Belrayan Coop
Nanauta Coop
Modi Nagar
Baraut
Bisauli
Kasganj
Punjab
Punjab
Punjab
Punjab
Phagwara
Ramala
Morna
Sarsawa
Semikhera
Anoopsahar
Belrayan
Nanauta
Effective in all types of Boiler
• Depending on the Boiler type, size, age,
operational conditions, fuel used ,
maintenance practices, renovations done
with time, its Efficiency varies.
• In a set of ideal conditions it may also be
close to Designed efficiency.
• But still, with Additive use, there is always
scope of improvement in its Efficiency and
in turn reduction in Coal Consumption.
Business Model
Abhitech Energycon Ltd.
Plant visit & Assessment
Submission of Technocommercial Proposal
TRIAL ORDER
Pre Trial (without THERMACT) 15 days
Installation of Hopper Feeder Assembly
Trial (with THERMACT) 30 days
Submission of Technical Report
Regularisation of Product
Abhitech Energycon Ltd.
Trial Methodology
Pre Trial (Without THERMACT) :
Initial studies of the boiler and all parameters will be
conducted for 15-20 days
Trial (With THERMACT):
THERMACT dosing will be done at appropriate location.
The same study conducted earlier will be repeated & GUHR
calculated.
Pre GUHR – Post GUHR
% Savings = ------------------------------------------------ X 100
Pre GUHR
Multiple Coal samples will be collected from feeder & composite
sample will be prepared for analysis of calorific value
Abhitech Energycon Ltd.
Savings : Increase in ŋB (Boiler Effiiciency),
Reduction in UHR (Unit Heat Rate)
Contributed by
Inherent moisture latent heat
absorption prevention
Formation of useful combustible
products
Covered by
Direct Method
[ using gravimetric feeder ]
Reduction in unburnts in fly ash
Reduction in unburnts in bottom ash
Reduction in excess air requirement
for same power output
Covered by
Indirect Method
[ BS2885 ]
Reduction in APH temperature.
Abhitech
Energycon
Ltd.
Abhitech
Energycon
Ltd., INDIA
SAFETY
ASPECTS
Abhitech Energycon Ltd.
Credentials of THERMACT –
Govt. & Pvt. Institutes
INSTITUTES
Indian Institute of Technology, Mumbai
Central Mining Research Institute,
Dhanbad
Central Mechanical Engineering Research
Institute, Durgapur
CERTIFICATIONS
Fully safe for industrial applications, as all the ingredients in
preparation of THERMACT are organic in Nature.
Decomposition of coal was faster with THERMACT with less
residual matter.
Effect of prolonged used of THERMACT on Boiler Tubes.
SGS, USA
Conducted Toxicity Characteristic Leaching Procedure
(TCLP) test.
American Electric Supply (AES), Hungary
For positive effects of THERMACT on their 210 MW Unit.
CEZ, Czech Republic
For reduction in Heat Rate
Bandel TPS
For reduction in GUHR on their 210 MW x 1, 67.5 MW x 4 units.
Durgapur Projects Ltd
For reduction in GUHR on their 77 MW x 1, 130 MW x 1 units.
Santaldih TPS
For reduction in GUHR on their 250 MW unit
Tenughat Thermal Power Station
For reduction in GUHR on their 210 MW unit
Sagardighi Thermal Power Station
For reduction in GUHR on their 300 MW unit
Abhitech Energycon Ltd.
SGS TEST REPORT
Test Significance:
This is a statutory test required for products being used/ imported
into USA which detects the presence of potential hazardous chemicals
to human/ environment/ ground water. About 95 different elements
are identified as hazardous to humans, environment and ground
water.
Test Results:
The test conducted by SGS Lab on THERMACT confirms that none of
the 95 identified hazardous chemicals are present in THERMACT.
Test Inference:
The use of THERMACT is safe and does not cause any
detrimental effect on humans/ environment.
Abhitech Energycon Ltd.
CENTRAL MECHANICAL ENGINEERING RESEARCH INSTITUTE,
DURGAPUR (CMERI)
CMERI has investigated the effect of prolonged usage of THERMACT
(5 years and above) on boiler tubes at Bandel TPS.
Test Results:
CMERI has studied the conditions of the boiler tubes at BTPS after
THERMACT was used for more than 6 years. They have carried out
dimensional measurements of boiler tubes by various methods like
Visual Inspection, Chemical Analysis of the 2 Metallographic
Examination and Hardness Measurement, Tensile Property Evaluation,
Stress Test and Fractographic Examination.
Test Conclusion:
CMERI has confirmed that even after a prolonged usage of
THERMACT for more than 5 years, there is no detrimental effect on
the metallurgy of the boiler tubes and various pressure parts.
Abhitech Energycon Ltd.
CENTRAL MECHANICAL ENGINEERING RESEARCH INSTITUTE,
DURGAPUR (CMERI)
CONCLUSION:
In view of all the investigations completed as per scope of work (mainly visual
examination, dimensional measurement, chemical analysis, metallographic
analysis, hardness and tensile test results), no noticeable material degradation of
the exposed tubes supplied) under the influence of THERMACT is being observed.
Apart from that long term behavioral study from stress rupture tests also do not
reveal an significant abnormality. Moreover, attempts were made to confirm the
effect of “THERMACT” on the surface and sub-surface characteristics of the tubes
using SEM and EDS analysis (as an optional test) also did not depict any harmful
effects.
Hence, it seems to be prudent to declare that THERMACT, as a compound to
enhance the heat efficiency within the furnace, does not loose any detrimental
threat to the life of boiler tubes. However, it is wise to state that this is valid
only when all the mandatory inspection schedule of boiler tubing is maintained
as per the guidelines.
Abhitech Energycon Ltd.
CENTRAL MINING RESEARCH INSTITUTE, DHANBAD
(CMRI)
Test Significance:
This test states the impact of THERMACT on the combustion
characteristics of coal.
Test Results:
Confirm that addition of THERMACT catalyst improves the
combustibility of coal.
Abhitech Energycon Ltd.
CENTRAL MINING RESEARCH INSTITUTE, DHANBAD
(CMRI)
Differential Scanning calorimeter Results
Abhitech Energycon Ltd.
CENTRAL MINING RESEARCH INSTITUTE, DHANBAD
(CMRI)
CMRI–Dhanbad has confirmed that due to THERMACT ;
 Ignition behavior of Coal is changed
 Decomposition of Coal is faster
 Catalytic effect on Coal combustion
 Residual matter after coal combustion decreases with
THERMACT.
Abhitech Energycon Ltd.
Cost Benefit Analysis For 1 x 660 MW
Coal Consumption / day
:
12,000 Tons
Savings in coal with THERMACT usage (@ 2%) :
240 Tons
Cost of Coal
:
4000 Rs./Ton
Gross Monetary Savings / day
:
Rs. 9,60,000
THERMACT required / day
(1 kg for 15,000 kgs of Coal)
:
800 kgs
Cost of THERMACT
:
Rs. 330/kg
Investment in THERMACT / day
:
Rs. 2,64,000
Net Monetary Savings / day
:
Rs. 6,96,000
Net Monetary Savings / month
:
Rs. 208.8 Lacs
Net Monetary Savings / annum (330 days)
:
Rs. 22.97 Crs
No Capital Expenditure or Additional manpower cost to be incurred by TPS
Abhitech Energycon Ltd.
All truth passes through three
stages. First, it is ridiculed.
Second, it is violently opposed.
Third, it is accepted as being selfevident.
Arthur Schopenhauer
Thank you!
Abhitech Energycon Ltd.
Contact Us
ABHITECH ENERGYCON LIMITED
Regional Office : B-1/564, First Floor, Janak Puri,
New Delhi - 110 058; Telefax - 011 25521884,
Mob No - 8130774999, 9350039580
Mail – abhitech_north@yahoo.in
Head Office : A/1020, Oberoi Gardens,
Chandivali Farms Road, Chandivali, Mumbai - 400 072.
Tel - +91-22-2847 9999 ; Fax - +91-22-2847 9988
Mail – abhitech@abhitechenergycon.com
Website - www.abhitechenergycon.com