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ENERGY CONCLAVE 2006 TECHNOLOGY FRONTIERS AND MODERNISATION ENERGY R&D BHEL ROLE & CONTRIBUTION PRESENTATION BY RAVI KUMAR DIRECTOR (POWER) BHEL, NEW DELHI 1 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 2 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. 3 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 4 Bharat Heavy Electricals Limited TECHNOLOGY TRENDS POWER SECTOR Lower Cost of Generation Environment Friendly Higher Efficiency Higher Reliability Compatible to Local Conditions 5 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 6 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 7 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 8 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 9 Bharat Heavy Electricals Limited Cycle Efficiency benefits of supercritical units are derived from higher pressures and temperatures of steam 10 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 11 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 12 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 13 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 14 Bharat Heavy Electricals Limited IGCC POWER GENERATION - DEVELOPMENT IN BHEL PFBG SCALE - UP 15 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) 16 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. 17 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 18 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 19 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 20 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% 21 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 22 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 23 THANK YOU http://www.bhel.com 24 Bharat Heavy Electricals Limited