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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. R&D – WORLD STATUS. Expenditure on R&D per capita (IN US $). INDIA - 5.5 CHINA - 11.7 S. KOREA - 241

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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


R&D – WORLD STATUS

Expenditure on R&D per capita

(IN US $)

INDIA - 5.5

CHINA - 11.7

S. KOREA - 241

AUSTRALIA - 285

UK - 460

USA - 705

JAPAN - 978


R&D – BHEL

TARGETS



TECHNOLOGY TRENDS

POWER SECTOR

  • Lower Cost of Generation

  • Environment Friendly

  • Higher Efficiency

  • Higher Reliability

  • Compatible to Local Conditions


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


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


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


  • 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


    Cycle Efficiency benefits of supercritical units are derived from higher pressures and temperatures of steam



    Cfbc technology
    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


    ENVIRNOMENTAL ASPECTS – ROAD MAP

    Area of focus - NOx control in pulverized coal fired boilers

    NOx emission scenario of Indian plants while firing different fuels:

    Development of low NOx wall fired coal burner - 2006

    Establishment of SCR demo plant - 2007

    Commercialisation of wall burner - 2008

    Commercialisation of SCR system - 2010


    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



    A glimpse of Fuel Cell Developments at BHEL (Inter-disciplinary approach followed for Fuel Cells Development)


    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 fromIISc, B’lore

    • High Temperature Fuel Cells (SOFC)

      • BHEL R&D & CTI, Bangalore:Materials, processes & components developed. Assembled & tested single cells of planar SOFC.


    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

    BHEL IN PHOTOVOLTAICS


    Future outlook for pv in bhel
    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


    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


    Power plant performance improvements auxiliary power consumption reduction
    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%


    Power plant renovation modernisation
    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



    THANK YOU

    Committed to make

    a better world

    http://www.bhel.com


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