CALORIFIC VALUES OF DIFFERENT FUELS USED IN THERMAL POWER STATION.

Last blogg we have come to know about the proximate analysis of coal our base fuel. Beside coal some other fuels can also be used to run a power station . The names are given below.

1. Coal ( imported and indigenous )  and lignite.

2.  Liquid fuel  heavy fuel oil , light oil , distillate no2, naptha , HSD, Super Kerosene oil and refinery residue  etc.

3. Gaseous fuel comprising of  LNG, BF ( blast furnace Gas) etc.

4. New fuels like orimulsion , di methyl ether , coal bed methane  etc.

Use of coal has already been discussed and for lignite most of our plant is pit head based in south India and North India respectively. Comparatively a new technology has been adopted to fire lignite.

In the later part we will discuss about this fuel use and their cost from a Govt report of India.

The calorific value of the coal (domestic) is        3750 KCAL/KG

After benefaction of coal at Pit head  becomes   4150 KCAL/KG.

The Calorific value of imported coal  is               5400KCAL/KG

The calorific value of  lignite  is                           2800KCAL/KG

The calorific value of  Naptha  is                        10,500KCAL/KG

The calorific value of compressed natural gas    10,000 KCAL/CUM

The calorific value of LNG is                                 9500 KCAL/CUM

The Calorific value of  Diesel                              10,860 KCA/KG

To derive the benefits of the above information the  cost of fuel and availability at destination  point is to be considered. For estimating that pit head, port , pipeline transportation etc are

also considered with assumption of our  available facilities and distances.

The capital cost of power station for different fuel comes as below.

1.  With imported coal                                             4.0  Rs/MW

2. Indigenous Coal                                                  4.0  Rs/MW

3. Lignite (pit head)                                                  4.2  Rs/MW

4. LNG/Naptha /Gas                                                 2.7  Rs/MW

7. Diesel                                                                    3.5  Rs/MW 

The above information is to be noted .

PROXIMATE COAL ANALYSIS FOR THERMAL POWER STATIONS

DETERMINATION OF ULTIMATE FROM PROXIMATE COAL ANALYSIS

Frequently in the absence of a complete analysis of a coal the proximate analysis of coal is done . In such cases a very close approximation is done by a formula provided by "GERBHARDT'.

Fixed carbon (F.C % by wt-moisture and ash free basis)

Volatile matter   V by wt ( moisture and ash free basis) 

Ash                     A by wt.

Moisture             H2O ( imperial formula of water) by wt.

                                           7.35                            

Hydrogen           H=  V (  ----------  -0.013 )

                                          V+10

Nitrogen             N = 0.07 V for anthracite and semi anthracite  coal.

                               =  2.10 -0.012 V for Bituminous coal and lignite.

Total  Carbon         =  Fixed carbon + Volatile carbon

                                =F.C. + 0.02V2 for anthracite

                         

                                 = F.C. + 0.9( V-10) for semi anthracite

                                 = F.C. + 0.9 ( V-14) for Bituminous coal

                                 = F.C. + 0.9 (V-18) for Lignite.

                            C   = % of Total Carbon in the coal.  

H,N and C as obtained from the equations are Moisture and  Ash Free Basis.

Sulphur increases the value of C hence the calculated value of  " C" is too high by practically the

sulphur content  of the coal.

Oxygen - This is determined by the difference after obtaining the value of  H,C, Ash, Moisture and

Nitrogen.

For further studies BS 1016 -- Methods of the analysis and testing of coal and coke.

                               BS  1017 --  Samples of coal and coke.

This analysis is some times required during commissioning stages when other instrument facilities and Lab was not developed. Therefore we thought to mention it in the beginning.

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FUEL USED FOR THERMAL POWER STATION.

In our earlier blogs we have understood the significance of LAND on technical issues and understand that how much land is required to set up a Thermal Power Stations. Now we will discuss about the next important aspect of the Thermal Power Station i.e. FUEL. Generally in our country as on date we have abundence of Coal supply Therefore we are using mainly Coal but FUEL oil , Light diesel oil , Naptha , LNG ( Light Natural Gas ) was also used. Petrolium products were imported from other countries then it was refined and distributed as different product all over the country. Others are mainly used for Gas turbine project.

Therefore our main discussion will be focused on Coal only. Others will be discussed  as and when topic comes.

Typical analysis of coals of the some o f  countries being used  in India  w ith or HMV/MF,without Indian coal.

Country                                       M        VOL         F.C    ASH    SUL       HHV/M/KG

AUSTRALIA                            2.58     30.09       52.80  14.55   0.72         27.03

CHINA                                     2.50     29.90       44.40   25.70   0.66         23.94

INDIA                                       14.64  22.87       28.55    33.94   0.45        14.57

M== MOISTURE % , VOL = VOLATILE MATTERS , F.C =FIXED CARBON, ASH =ASH SUL= SULPHUR %.

The above values are typical  for a coal block not representing any  country. There are other places where ash % is as low as 3to10 %.

Typical ash analysis for Indian coal for power station.

SiO2        56.66

Al2O3     27.46

Fe2O3       6.40

CaO           1.81

MgO          0.96

Na2O         3.40

K2O           3.40

TiO2          1.94

P2O5         1.10

SO3           0.27

THIS PROPERTIES OF ASH WILL DETERMINE WHERE THE SAME WILL BE USED . THESE ASH CAN BE USED FOR MAKING BRICKS , CONSTITUENTS OF CEMENT , CAN BE USED TO FILL UP THE EXCAVATION SPECIALLY PIT HEAD STATION AND UNDERGROUND MINING. ALSO THIS ASH CAN BE USED FOR  ROAD MAKING AND FILL UP OF LAND.

      

                                                      

LAND REQUIREMENT FOR THEMAL POWER PLANT FINAL

Till date we have discussed various aspect of land requisition and indicated the requirement as per expert committee. Final tabular form is given below.

1. Pit head/load centre stations with indian coal

SLNO     DESCRIPTION    2X500     3X660     5X660     6X660     4X800     5X800

  1.           MAIN PLANT        520          680          920         1030         940        1040

  2.           ASH DISPOSAL     250          495          825          990          800        1000

  3.       CORRIDORS MISC   220          240         250           250          250         250

  4.          TOWNSHIP              100          100         150           150          150         150 

  TOTAL AREA                      1090       1520        2145        2420         2140       2440 

2. Coastal stations with imported coals              

The area varies from  590 acre to 785 acre depends upon the criteria about coal transportation  and cooling tower. for 3x660 MW plant.

The area varies 925 acrs to 1230 acres for 5x800 MW. Area varies due to coal transportation  ( MGR or coal conveyor and with or without cooling water.  

India we have only 3x660 MW or 5X800 MW stations in India therefore data therefore some data is available . No other data is available in open market.

A situation will arise whther we can use Blended coal i.e. mixture of indigenous coal and imported coal. It is seen frequently that blended coals were used to maintain the genration and plf od the fact. Therefore 3rd option of land requirement with blended coal is also given to readers for their views. However references were drawn from the expert committee land report which was plublished in 2007 and same was reviewed recently.  To get into third option land requirment per MW is to be derived from the available data.

SLNO     DESCRIPTION       2X500       3X660       5X660       6X660       4X800       5X800

pit head  Area/mw                    1.09           0.77           0.65             0.61          0.67           0.61

coastal Area /MW varies from 0.3 to 0.4 depends againg on coal transportataion & CT.

Number assumption was made to arrive a value on Land requirement. Some of the crteria are being mentioned here. Some of the assumptions are common but some other are locality specific.

- Coal storage capacity is to be planned depending upon their location and availabilty of coal certainty.

- Type of transportatation like by Rail , MGR ( Merry Go Round) or by conveyor from port of unloading or from pit.

- Water storage capacity is planned depending upon availability of water source , rainfall in that area etc.

- Type of condenser cooling choosen i.e cooling tower . Area calculation mentioned above contains IDCT but  if NDCT is being used then area requirement will be more.

-Regarding water system following data based assumptions were made.

i) Consumption rate was assumed as 3.5 metre cube/MW/hr.

ii) Storage capacity of 10days plant requirement considered.

iii) Depth of reservoir considers as maximum 8m.

-For switchyard only 400kv /765 kv switchyard considered. 33kv ,11 kv yard if required are beyond this land requirement,

-Laydown area , pre-assembly area, steel yard , construction storage yard etc no additinal land is cosidered . It is assumed that this area will be turned into "GREEN BELT;' Construction people may note this change . It may put erection of SG slightly out of gear as pre-assembly yard will be away from the location required.  

- As discussed earlier ash content in Indian and imported coal considered as 45% and 10 %. It is also assumed that ash will be evacuated in 04 years (100%) from ash pond. 

-Ash slurry pipeline corridor is taken as 10km lenght and 10m wide.

- For MGR the assumption is taken as 20km in length with 30/35m width.

- For Raw water pipeline corridor 10km length and 14m width considered.

For our land calculation IDCT is only been considered if NDCT ( Natural draft cooling Tower )

is used then land requirment will be more.

- If we use GIS in switchyard the land requirement will be less.

I hope i am able give you the importance of land in thermal power station. From tomorrow onwards we will be discussing other prime topic like fuel and air.

If any body requires detail of the topic mentioned above they may free to write in my blog or in my mail dguha1952@gmail .comm. We expect a detail discussion on above subject from the developed countries.  

    

EXPERT VIEWS ON LAND REQUIREMENT A GUIDE LINE FOR ALL

Till yesterday we have discussed various aspect of Land requirement for Thermal Power Station . Day by day the problem of getting Land at required location becomes acute . Study is already on to reduce the area by re engineering , using superior technology , using fuel mixture etc . A few aspect is now being given for viewers for their knowledge and comment pl.

a.  Power stations classified as Pit head / load centre oriented. but using indigenous coal

Power station size 2x500MW  to 5X800MW( UMPP) the area requirement varies from 20 to 100 acre. All other power stations  like 3x660MW, 4X660, 4X800MW etc falls in between the above

limit.

b. Power station classified as Coastal based using imported coal 

India is having a vast coast line and due to economic and financial reasons IPPs tend to use coastal stations with large capacity ( 5x800 MW/6x660MW etc) with imported coal near coast line.

The limit sets by expert committee for 3x660MW to 5x800MW is 30 to 65 acre. It is observed that the land requirement due to category  (b) is much lesser than the  (a ) mainly due ash content of coal.

It is assumed that indigenous coal having 45% and imported coal is 10% . These values were taken

for Land area calculation..

Above limit value was given only for  Main Power House area. Coal storage and handling also requires considerable area . Same was categorised again with the above concept .

For pit head station of 2x500MW to 5x800MW  with indigenous coal the land requirement varies from 220 to 250 acres. Variation is much less .

For coastal stations  having imported coal  the land requirement varies  from 150 acres to 200 acres

for 3x660MW to 5x800 MW with MGR ( Merry Go round ) rail but the requirement is much less for

coal conveyor system . The value for same size power stations is 108 to 150 acres.

Next day we will summarise the total land issues and move into our next topic.

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COMPARISON OF LAND REQUIREMENT FOR DIFF. SIZE OF PLANT

CONTINUED FROM 6.

LET US GO TO TABULAR FORM FOR UNDERSTANDING THE MATTER.

--------------------------------------------------------------------------------------------------------------------------
DESCRIPTION                                              FOR INDIAN COAL               FOR IMPORTED COAL
--------------------------------------------------------------------------------------------------------------------------
                                                                         AREA            %                          AREA           %
                                                                       ---------------------------------------------------------------------

1. MAIN PLANT PKG ( CHIMNEY TO
   TRANSFORMER YARD INCLUDING
    SG AND TG )                                                 92              3.321                            70            4.575


2. COAL STORAGE AND HANDLING          250              9.02                            200          13.07

3. WATER SYSTEM AND RESERVOIR         310             11.191                         154          10.06

4.  SWITCHYARD                                             106              3.826                          106           6.928

5.  MISC BALANCE OF PLANTS PKG,
     DM,ASH FOPH SYS,COMP, ETC, ROADS
     DRAINS, STORES ETC.                               139                 5                              110            7.189

6.  GREEN BELT                                                408              14.729                        273        17.843

7.  ASH DISPOSAL AREA                                1080              38.989                        327        21.372

8. TOWNSHIP                                                      150                 5.415                       150          9.803

9. MISC CORRIDOR TO BE USED FOR
    ASH ,WATER, TRANSPORT SYSTEM          235                 8.483                       140          9.15

                                                          TOTAL       2770                                                1530
------------------------------------------------------------------------------------------------------------------------

The above figure was arrived by a team of experts appointed as committee member to finalise land requirement of UMPP ( ultra Mega power plant ) having size of 5x 800 MW at India. To overcome
the power crisis in INDIA five to six numbers to be established on tariff based tendering.

To settle the land requirement expert committee views were taken for cost consideration and calculation.

Further options on land w

ill be discussed in next day blogg.


  

CONTINUED FROM PAGE -5. TOPIC LAND FOR THERMAL POWER STATION.

In my earlier discussion it was mentioned  about the situation and preliminary boundary conditions prevailed in INDIA about LAND for thermal plant. Now a days land acquisition has become a serious businees and can be bone of contention between political parties . Sometimes it has been observed that ruling GOVT lost its election due to this. Therefore Government at centre has become very wise and they have set up different committes to limit the requirement of land as per technolodgy , as per coal ( Indian or imported ) , Size of units , Configeration of units  etc. A birds eye view will now be written for construction personnel for their knowledge for setting up a power station.

Expert commitee of GOI consist of GOVT representative of Power field , Power plant equipment manufacturer , Power plant electricity producers etc.  The size of units firing Indian coal comparitively bigger than firing Imported coal. It is seen that coal requirement is double than the imported coal and the ash generation is eight times more than the imported coal. This is because the gross calirofic value of Indian coal used for power station is 3000 to 4000 kcal/kg with ash contain is as high as 35- 45% where as the imported coal from Indonesia ,austrelia , south africa etc having Gross Calirofic value of 6000kcal/kg with ash content < or equal to 10%. Due to this the size of unit with indian coal will be bigger because more amount of coal is requried to be burnt for same power output. Therefore it can be concluded that type coal is to be decided before we decide for the land. Coal can be indenigous /indian /blending of both to get the required value.

standard land requrement will be given in my next post  having classification on unit size and also type of coal to be used.
contd to pg 7

Continued from page -4.

Till date we have discussed about the major criteria about finalisation  of location of thermal power station in

India. Those criteria  are very basics and observed that it depends mostly on EIA ( ENVOIRNMENTAL

IMPACT ASSESSMENT)  studies  of the locations and other important issues. Land is disputable

commodity in INDIA now a days . Recently it is news  that a dispute has arisen between two Public Sector

undertakings about the location of 1980 MW super thermal power station. After completion of all other

studies it has been alleged that plant is coming over the coal  reserve of that place hence it was opposed  by

coal ministry. That project is now in suspended animation but considerable amount was spent for developing

the project. Such type of mistake could have been avoided and project could have been started in time. I

like to know the basic norms of other developing countries like USA, UK , GERMANY ,FRANCE, etc

Also for the developing countries like CHINA , MALAYSIA, PAKISTAN etc. Readers may help in this .


continued to page-6

LAND FOR THERMAL POWER STATION

Continued from previous day on the above subject " Land for thermal power station ".

Site is chosen such a way that chimneys of power plants does not fall within the approach funnel of the runway of the nearest platform. Chimney height has  already been standardised  by GOI according to unit size . Minimum that height to be followed.The same will be elaborated at the appropriate time.

Site should be at least 500M away from flood zone of river system 

-Location of sites are avoided near ( at least 10 km away from ) archaeological , historical ,historical ,cultural /religious/tourist importance and defence installation.

-Forest and prime agricultural are avoided for thermal power or ash disposal.

All the new TPP industrial projects including R & M  require prior environmental  clearance as per the norms of GOI ( Govt of India ) . The projects are classified as below.

- Category A. - All projects above 500MW ( fuel -coal,lignite,naptha, Gas etc) 

                       - All projects above 50MW ( pet Coke, diesel and all other fuels)

- Category B  - All projects less than or equal 500 MW on above fuel

                        -  All projects less than or equal 50MW but greater than 05 

                           MW( Pet coke ,diesel and all other fuels.)

Guide lines and norms publicised by Agency of GOI.

Land requirement for large capacity power house for the main power plant is about 0.2 sq km  / 100 MW. (approximately) without water reservoir , housing and ash ponds.

The land for housing is 0.4sq km for the entire project .

Land for ash pond is 0.2 sq km /100 MW considering 50% ash utilisation and also above 40% to 45% ash contain in the coal.

Water requirement is about 40 cusecs per 1000 MW.  

              

 continued to pg 5.                       

LOCATION OF THERMAL POWER STATION.

SERIAL NO.3.

Site selection for coal based thermal power station is very important job. It needs number of important criteria to be considered before arriving into a conclusion. It requires clearance from GOI ministries such as Ministry of Power, Ministry of water resources, Ministry of  endearment and Forest , Ministry of Coal etc to get the location approved.

 

Before we move to the selected topic we should understand the life cycle of the project and few process. Every project is unique because of variation but process it pass through is common . Those macro process are listed below.

 

1. Project Concept :- When project is conceptual stage ,

 

2 Pre- feasibility study :- Whether concept is feasible or not .There may be changes after conceptual

                                          stage to make the project feasible.

 

3. Feasibility study:- That is after made all the changes and incorporating all the inputs from different

                                  group a feasibility report attaching all the relevant documents required as per

                                  norms of GOI ( GOVT. OF INDIA) feasibility report has been prepared and

                                  distributed to concerned authorities for acceptance.

 

4. Design ,Engineering, procurement and manufacturing:- In this stage simultaneously all the 

                                                                                              activities start .

 

5. Implementation of Project:- At this  stage construction , erection and commissioning  activities 

                                                  start . The blog  is now being written for those people but all the back

                                                -ground is given to understand the project implementation totally.

 

6. Monitoring and Evaluation :- After  completion of the project evaluation has been done to do the

                                                    variance analysis with concept/feasibility/design regarding 

                                                     financial parameters and technical parameters.

 

Our topic "location" belongs to process 1.     

 

As per the Guidance provided by Ministry of Enviorment and Forest, building of thermal should be  build at least 25 to 30 KM away from outer  periphery of the following places.

 

1. Metropolitan cities.

 

2. Wildlife sanctuaries. Open Zoos, National forest, Bird Sanctuaries etc.

 

3. Ecological  sensitive area, lakes , coastal area having coral plants.

 

CONTD; PAGE-4 

   

INTRODUCTION 2.

serialno.2.

Serial no.1 describe the general idea about construction of Thermal Power Station and dilemma exists in this field .From now onwards we will be touching technical matters along with other aspect of thermal power station. As already explained we will discuss about only pulverised fuel plants in the beginning.

Let us assume  group named  "AABB LTD" wants to build a power station in India . We also assume that they have already tied up with financial company for fund we generally calls it financial closure of the project. It generally happens during project execution time due to various reasons. These matters  itself a specialised subject needs to be studied by finance executive with project management . However it is helpful if an idea in macro form is kept in mind like definition of financial terms etc. We need not to discuss further on this and leave the same for others.

While the group tied with Financial institution ( those who give loans to company) then they will look out for other aspect of building a thermal power plant.According to their strength they will look out for a suitable location.

Location depends on following technical criteria.

A. Power plant location should be near the pit head ( it means transportation cost of coal is minimum.

B. Source of water is nearby ( River , Dams etc)

C. Disposal of ASH to the mines where coal comes from and part of the same for other use.

D. Near state GRID or National GRID. 

      

The above conditions are ideal to build a thermal power plant but in reality may be one criteria can be achieved for which laid down procedures and norms are exiting..

serial no 2 completed.  (to be continued) 

INTRODUCTION OF TOPIC

I spent 35 yrs on building thermal power stations with sub critical and super critical technology in India. I felt we need a common documentation to build a power station with above technology.In India the power stations are built by construction worker ,supervisors and engineers.Most of them moves place to place to erect the plants. In power field India has opened their market to global players therefore new technology,methods etc are setting in.If we move twenty years back only a PSU is having monopoly in the power market and the construction workers , supervisors and engineers were familiar with product and line of action to build the plant. But now a days situation has been changed . You may be working with Indian technology now but next day you may be engaged to build a Chinese plant or an American plant. This change requires the change of mindset regarding QUALITY, HEALTH SAFETY , CONSTRUCTION METHOD LOGY, CRITERIA ,LIMIT ETC.

This blog I have started to focus on supervisors , technicians ,  young engineers who are directly supervising  the job and those who are recently come out from colleges without having an Idea of how a power plant look like.

I will go through the topic serially so that same will be understood by the mass . I will touch upon

only if needed otherwise I will narrate the topic with ground realities with the help project management.I need all your support on my endeavour . I expect constructive comments from all of you. thanks..  SERIAL -1. DTD 18.12.12.