Use of beneficiated coal in Thermal Power Plant-VSP Perspective

S.K.Chaurasiya AGM (R&D), V R Bapa Rao AGM (Vigillance) Abstracts The power sector has registered significant progress since the process of planned development of the economy began in 1950. Hydro -power and coal based thermal power have been the main sources of generating electricity. Nuclear power development is at slower pace, which was introduced, in late sixties. The concept of operating power systems on a regional basis crossing the political boundaries of states was introduced in the early sixties. In spite of the overall development that has taken place, the power supply industry has been under constant pressure to bridge the gap between supply and demand. Introduction Power development is the key to the economic development. The power Sector has been receiving adequate priority ever since the process of planned development began in 1950. The Power Sector has been getting 18-20% of the total Public Sector outlay in initial plan periods. Remarkable growth and progress have led to extensive use of electricity in all the sectors of economy in the successive five years plans. Over the years (since 1950) the installed capacity of Power Plants (Utilities) has increased to 89090 MW (31.3.98) from meager 1713 MW in 1950. 1. The present assessment of coal resources in India is around 205 billion tonnes, out of which 70 billion tonnes are "proved" reserves. Taking into consideration country's population and the economic growth required, the resource position is not at all comfortable as the total estimated coal resources of India are less than 1.0% of the world resources. Proven resources of 64 billion tonnes are available down to a depth of 300m, a depth to which mining is currently taking place. About 15%of the total resources are of coking variety and 85% of non-coking type. Qualitatively, 20% of non-coking coals are of superior grades (A, B & C) with ash content of 24 % or less and 80% are of inferior grades with ash content between 24-45%. The ash

content in coal as delivered to major consumers like power plants is even higher, averaging above 40%. 2. Coal sector in India has been almost totally under the State control since the early seventies. Massive development programme was undertaken since then. As a result, coal production gradually increased form 78 million tonnes in 1974-75 to 289 million tonnes at the end of 1996-97 which was also the terminal year of the Eighth Five Year Plan (1992-97). Long term coal demand is projected to grow at an average rate of over six percent per annum. 3. The demand for next 15 years as projected by a committee set up by the Planning Commission of India is as follows:
Table 1 - Projected Demand (High Case)

(in million tonnes)

1996-97 2001-02 2006-07 2009-10 Power Utilities Steel Others Total 215 40 70 325 350 63 70 513 400 80 100 716 500 179 136 815

4. In order to meet the rising coal demand for power sector an additional annual production capacity build-up of around 25 mt is required. To produce an additional 375 mt over the next 15 years, an investment of about Rs. 37, 500 crores (US $ 10bn) at current prices will be required. In view of the continuously widening resource gap, the public sector coal companies alone cannot meet the demand of coal. This situation has made private investment in the coal sector imperative and inescapable. 5. Coal Beneficiation: Since 75% of coal produced in India is coming from mechanized open cast mines, there is a pronounced degree of contamination in the coal which deteriorates the quality of coal being supplied to the power plants. Further there are very few power plants (except some pit-head super thermal power plants) getting coal from a single dedicated source. Multiplicity of supply sources further adds to the problem of inconsistency in quality of coal. At least half of the operating power stations are receiving coals from more than one

mine. With the result they are getting coals of different quality and size. In absence of proper blending facilities, it is not operationally feasible for the power plants to homogenize the feed coal. A general trend in deterioration of quality of coal consumed by the power plants is shown in the enclosed graph at annex I. 6. The quality of raw coal presently being used by the power stations is given below: 1. Ash Content: 30% to 55%, generally around 45%. 2. Moisture content: 4% to 7% except in rainy season when it goes higher in some cases. 3. Sulphur content: 0.2% to 0.7% 4. Gross Calorific Value: 3000 K Cal/kg. to 5000 K Cal/kg. (3500 K Cal/kg.) 5. Volatile matter: 18% to 25 % Unwanted non-coal materials like shales and stones are generally present with occasional presence of iron pieces like shovel teeth etc. 7. Some of the common problems of power plants due to poor and inconsistent raw coal quality are listed below: damage to conveyor belts, crusher elements and frequent choking of chutes and feeders reduced pulverising capacity of the mills, higher erosion of grinding elements and reduced availability of mills due to higher outages reduced flame stability requiring additional oil support slagging and fouling of the water walls faster erosion at the coal burners and flue gas path increased requirement of land for dumping of ash, and ash handling equipment reduced Plant Load Factor (PLF) as well as reduced station thermal efficiency higher emissions and related environmental impacts

Several other operational problems may also arise due to poor and inconsistent quality of coal. 8. Some of the well recognized benefits arising from combustion of washed coal in thermal power stations are:
Reduction in:

Emissions into the atmosphere Ash handling and disposal costs Requirement of oil support Load on transportation system Operating and maintenance costs in existing plants Capital cost of new plants

Increase in:

Thermal efficiency Plant availability Plant output

VSP has been using ROM (F Grade) from Talcher & Belpahar of Mahanadhi Coalfields Limited (MCL) for generating steam in Boilers along with other by product fuels like BFG & COG. The coal from these sources is having on an average 40% ash content. As per Ministry of Environment and Forests notification, Power Plants situated more than 1000 KMs away from mines and/or in Environment sensitie areas should use coal with less than 34% ash. In view of the above VSP decided to go for trial usage of Beneficiated Coal for evaluating the benefits of using low ash coal in TPP Boilers. 30.000 Tons of beneficiated Coal supplied by M/s Aryan Energy (P) Limited. The specification of the beneficiated coal is PARAMETER YIELD CV (kcal/kg) ASH TOTAL MOISTURE SIZE (MM) (-)2 MM SIZE DESIRED LIMITS 70% Min 30% more than raw coal supplied. 33.5 % Max. Within 1.5 % more than raw coal supplied. 0 to 50 mm 20 % Max.

RMHP stored Beneficiated Coal separately. The total coal used in TPP Boilers during the period was 24073 Tons. During study Boilers were fired with Beneficiated Coal along with BFG & COG. However one boiler (No-5) was fired with only Beneficiated Coal without any Gaseous fuel for a brief period to study the effect of only Beneficiated Coal firing. Analysis report of Beneficiated Coal S.N. 1 2 3 4 5 6 7 Parameter Rake No % Total moisture % AM % ASH % Volatile Matter % Fixed carbon % Size analysis i)+ 50 mm ii)-2 mm CV( k cal / kg) 1 13.8 9.56 26.94 28.59 34.91 2.0 8.5 3863 Test Results 2 3 14.0 14.4 9.32 6.13 28.06 30.75 29.04 29.59 33.58 33.53 2.0 8.0 3741 4.0 16.5 3810 Average 8.34 28.58 29.07 34.01 2.67 11 3804.67

Comparison of Beneficiated coal and ROM coal and the results are as given below: Boiler Fuel With ROM With Remarks No Combination COAL Beneficiated COAL BF GAS 97,000 Nm3/Hr 97,000 Nm3/Hr Difference of (+) 8 CO GAS 12,500 Nm3/Hr 12,500 Nm3/Hr Tons per 2 COAL B,C MILLS B,C MILLS hour STEAM FLOW 307 Tons/Hr 315 Tons/Hr BF GAS 97,000 Nm3/Hr 97,000 Nm3/Hr Difference of (+) 11 CO GAS 10,000 Nm3/Hr 10,000 Nm3/Hr 3 Tons per COAL A,C MILLS A,C MILLS hour STEAM FLOW 280 Tons/Hr 291 Tons/Hr BF GAS 97,000 Nm3/Hr 97,000 Nm3/Hr Difference of (+) 10 CO GAS 10,000 Nm3/Hr 10,000 Nm3/Hr 4 Tons per COAL A,C MILLS A,C MILLS hour STEAM FLOW 300 Tons/Hr 310Tons/Hr

BF GAS 5 CO GAS COAL STEAM FLOW

Nil Nil A,B,D,E MILLS 310 Tons/Hr

Nil Nil A,B,D,E MILLS 328 Tons/Hr

Difference of (+) 18 Tons per hour

OBSERVATIONS: TANGIBLE BENEFITS: From the above it is seen that on an average about 10 Tons/Hr. of steam flow increased in Boilers with beneficiated coal compared to ROM coal with same combination of fuels. Incase of Boilers No.5 where only Coal with out gaseous fuel was used, steam flow increased by 18 tons/hr. Other observations while firing beneficiated Coal: Boilers furnace is slightly brighter compared to non beneficiated coal firing. However in both cases it is seen that furnace flame scanners were stable and not flickering. 2. Not much clinkering and mill rejects are seen in both cases (i.e. with beneficiated and ROM coal firing) 3. During coal conveying dust emission in transfer points were on the higher side as compared to normal coal. 4. No significant changes noticed in flue gas outlet temperatures which indicate there is no change in Boiler efficiency. 5. The effect on ash handling system is difficult to measure and it appears there is no drastic change on ash handling noticed. 6. Similarly no significant change in visual Chimney emissions was observed during the test period. 20. Conclusions:
1.

Benefits associated with the use of washed coal in the power plants are generally accepted by all concerned. A number of studies carried out in the past have established the economic as well as environmental benefits of using coal in power house boilers. What is required is a well co-ordinate effort to put these studies together and translate the available data into practical guidelines that would help in deciding upon the use of beneficiated coal in Thermal Power Plants