Project Formation Research On High-efficiency Coal Utilization Systems .

Project Formation Research onHigh-efficiency Coal Utilization SystemsFeasibility Study on An Urban-located, Eco-friendly,High-efficiency Coal-fired Power Project in IndiaSponsored byNew Energy and Industrial Technology Development Organization (NEDO)Kyushu Electric Power Co., Inc.June 2016Prepared byJapan Coal Energy CenterElectric Power Development Co., Ltd.Kyushu Electric Power Co., Inc.

Executive SummaryGovernment of India introduced a new environmental norms for new and all existing thermal powerstation (TPS) in December 2015. Power sector’s current top concern is how to address the new normsfor achieving higher thermal efficiency of TPS and mitigating environmental impacts. In this point ofview, NTPC’s Badarpur TPS has been selected as a model site, where feasibility is studied onadopting the latest USC technologies to the existing TPS along with the comprehensive environmentalmeasures.In the study, empowering, technical specification, construction schedule, economic feasibility GHGreduction and mitigation of environmental impact by replacement have been considered. ThisJapanese technologies based study will provide a good example for future new power project as wellas making concrete replacement planStudy Items are conceptual design, O&M plan, construction cost, financial analysis, environmentaland social considerations, business plan, project plan, ash utilization, CO2 reduction, project structureand steering committee. Site survey and technical meetings with Badarpur TPS have been conductedto complete above study items.Size of new USC unit is 660 MW, its steam pressure, main steam temperature and reheat steamtemperature are 26.48 MPa, 600 degC and 600 degC, respectively. In a turbine island, optimization ofsteam flow on turbine blade, long turbine blade at the last stage, and high performance sealtechnology are adopted.As latest environmental technologies, low-low temperature ESP, SCR and wet limestone-gypsumFGD are selected. By adopting these new technologies, emission of new plant is kept low enough,such as 30 mg/m3N SPM, 100 mg/m3N NOx, 100 mg/m3N SO2. Diffusion simulation of thesepollutant materials is also conducted and confirmed that surrounded ambient environment is keptclean. Plant water consumption is lower than 2.5 m3/MWh to meet new norms. Plan based onJapanese experience is proposed. Capital cost of new plant is estimated as 1,210 USD/kW, (withoutenvironmental facilities: 1,049 USD/kW） with construction period of 5 years.CO2 reduction effect was studied by comparing several baseline of efficiency guideline (SC),emission coefficient of grid, PAT target and current TPS emission. Annual emission reduction was20% from each baseline. Ash demand in Delhi region is found to be very high in constructionindustries such as cement and blocks. As for future viding, participation by the consortium ofJapanese manufactures are most considerable.Because of the postpone of the replacement implementation at Badarpur TPS, only 1st steeringcommittee has been held and the main purpose of this FS is changed as “to apply this result for futurenew project / replacement project”. In view of the comment by NTPC board member, this feasibilitystudy was thought to show a good outcome for future opportunities.

TABLE OF CONTENTSCHAPTER 1 OUTLINE OF FEASIBILITY STUDY1.1Background .1-11.2Purpose of Study .1-11.3Study Fields .1-11.4Period of Study .1-41.5Study Schedule .1-41.6Study Team Structure .1-51.7Counterpart .1-61.8Study team members .1-7CHAPTER 2 CURRENT SITUATION IN INDIA POWER SECTOR2.1Capacity addition plan .2-12.1.1Power situation in Delhi Capital Territory .2-22.1.2Power demand forecast, long term power development plan .2-3CHAPTER 3 FUEL SUPPLY PLAN AND ASH UTILIZATION FOR NEW PLANT3.1Fuel supply plan .3-13.2Ash Utilization .3-2CHAPTER 4 GENERAL DESCRIPTION OF POWER PLANT4.1Selection of Construction Site .4-14.2General Configuration of Power Plant .4-24.3General Features of Power Plant .4-24.3.1Primary Fuel.4-24.3.2Applicable Emission Standards .4-34.3.3Boiler Type .4-44.3.4Selection of Steam Conditions .4-54.3.5Introduction of Ultra-Supercritical Pressure High Efficiency PowerGenerating Technology .4-64.3.6Air Quality Control Systems (AQCS) .4-12CHAPTER 5 CONCEPTUAL DESIGN OF COAL-FIRED POWER PLANT5.1Basic Design .5-15.2Power Plant Design .5-15.2.1Boiler and auxiliary Equipment .5-15.2.2Steam Turbine Generator and Auxiliary Equipment .5-145.2.3River Water Supply System .5-24-i-

5.2.4Plant water system .5-255.2.5Wastewater treatment system .5-295.2.6Electric Equipment.5-315.2.7Instrumentation and Control System.5-365.2.8Instrumentation Equipment and Control Systems.5-415.2.9Coal Handling and Storage Facility .5-435.2.10 Ash Handling Plant: .5-475.2.11 Air Quality Control Systems (AQCS) .5-515.3Conceptual Design of Civil & Architectural Works .5-665.3.1Site Preparation .5-665.3.2Intake structures .5-675.3.3Ash Disposal area .5-685.3.4Coal Storage Yard .5-695.3.5Buildings and Other Facilities.5-705.3.6Chimney .5-715.3.7Ancillary Building .5-71CHAPTER 6 ORGANIZATION6.1New Power Station Structure .6-16.1.1Organization .6-16.1.2Main work contents of each organization and establishment ofmanagement techniques .6-16.2Examination concerning Operation and Maintenance of the New PowerStation.6-36.2.1Operation Management .6-36.2.2Maintenance department .6-56.2.3Performance management .6-66.2.4Environmental management .6-76.2.5Safety management .6-76.2.6Education .6-7CHAPTER 7 CONSTRUCTION PLANNING7.1Construction Schedule .7-17.2Pre-construction Schedule .7-17.3Project Milestones .7-27.4Replacing Experience at J-Power’s Isogo Thermal Power Plant .7-27.4.1Overview of Replacement Process .7-4CHAPTER 8 EPC COST ESTIMATION8.1EPC Cost Assumptions .8-1- ii -

8.2EPC Cost .8-18.2.1Turnkey EPC Cost.8-18.2.2Estimation Basis .8-2CHAPTER 9 ENVIRONMENT & SOCIAL ASSESSMENT9.19.2Existing Environmental Policies/Standards, Applicable laws, and regulations .9-19.1.1Introduction .9-19.1.2National Environment Policy .9-19.1.3Environmental Standards, Regulations etc. .9-2Present Environmental and Social Status .9-39.2.1Site and Surrounding.9-39.2.2Land Use .9-59.2.3Social Environment .9-89.2.4Cultural and Heritage aspects .9-159.2.5Community Health .9-159.2.6Hydrology .9-169.2.7Water Use .9-209.2.8Geology .9-229.2.9Soil .9-239.2.10 Water Quality .9-299.2.11 Meteorology and Climatology .9-349.2.12 Ambient Air Quality .9-379.3Pollution Reduction & Social Benefits.9-539.4Anticipated Impacts & Mitigation .9-549.5Presence / Absence of Anticipated Problems .9-549.6Atmospheric Dispersion Simulation.9-549.7Environment and Social Assessment Points as per JICA Guidelines .9-72CHAPTER 10 FINANCIAL ANALYSIS10.1 Financing & Project cost estimate .10-110.1.1 Financing.10-110.1.2 Project cost .10-210.2 Financial evaluation .10-310.2.1 Assumptions.10-310.2.2 Profitability of the project .10-3CHAPTER 11 INFLUENCE OF ENVIRONMENTAL IMPACT11.1 Greenhouse gas (CO2) reduction effect .11-111.1.1 Greenhouse gas (CO2) reduction effect.11-111.1.2 Existing Methodology for Calculating CO2 Reduction Effect .11-1- iii -

11.1.3 Domestic or international policies related to coal fired power plant .11-911.2 Calculation of CO2 Emission Reduction Effect.11-1311.2.1 Conditions for calculation .11-1311.2.2 Calculation of the Effect of CO2 Emission Reduction .11-1411.3 Calculation Results of the Effect of CO2 Emission Reduction.11-1711.4 Calculation of the potential of environmental impact mitigation .11-1811.4.1 New Environmental Norms .11-1811.4.2 Emission value after replacement .11-1811.4.3 Current emission value.11-1811.4.4 Estimation of environmental value by replacement .11-2011.4.5 Estimation of Environmental impact by replacement .11-22CHAPTER 12 STEERING COMMITTEE12.1 1st Steering committee in Delhi .12-112.2 2nd Steering committee .12-112.3 Debriefing Meeting .12-212.3.1 Debriefing Meeting .12-212.3.2 Issues to be addressed if in the case that replacement of Badarpur isimplemented.12-2CHAPTER 13 CONCLUSION13.1 Conclusion of this feasibility study .13-113.2 Way to the implementation .13-2- iv -

LIST OF TABLESTable 1.5-1Study Schedule .1-5Table 1.8-1Study Team Members .1-7Table 2.1-1Energy wise Capacity (as of April, 2016) .2-1Table 2.1-2State/region wise supply/demand gap .2-2Table 2.1-3Energy wise capacity trend in India .2-3Table 3.1-1Fuel supply plan and issues to be considered .3-1Table 4.3-1Design Coal Specification .4-3Table 4.3-2Emission Standards .4-4Table 4.3-3Experience List of Ultra-Supercritical Once-through Boilers in Japan(600ºC Class).4-6Table 4.3-4Concept of Drum Boiler and Once-through Boiler .4-8Table 4.3-5Operation Characteristics of Drum Boiler and Once-through Boiler .4-10Table 4.3-6Criteria of Water Quality for Drum Boiler and Once-through Boiler .4-11Table 5.2-1Basic Specification of the Boiler .5-1Table 5.2-2Candidate Materials for the Boiler Pressure Parts.5-5Table 5.2-3Steam Turbine Basic Specifications .5-14Table 5.2-4List of Turbine Protective Circuits .5-16Table 5.2-5List of Steam Extraction.5-21Table 5.2-6Example of Generator Specifications .5-23Table 5.2-7Example of Main Transformer Specifications.5-23Table 5.2-8Example of Raw Water Quality .5-28Table 5.2-9Plant Interlock Items (Example) .5-38Table 5.2-10CHP Capacity/No. Of Tips Per Hour For Tandem Tippler.5-45Table 5.2-11Belt Speed & Width Selection for belt conveyors of CHP .5-46Table 5.2-12Stockpile Details .5-47Table 5.2-13AHP Design Parameters .5-47Table 5.2-14Basic Specification of Scr System .5-53Table 5.2-15Basic Specification of Esp.5-55Table 5.2-16FGD design Conditions .5-59-v-

Table 5.2-17Equipment Specifications in Absorption/Oxidation Process.5-60Table 5.2-18Equipment Specifications in Flue Gas Reheating Process .5-61Table 5.2-19Equipment Specifications in Gypsum Recovery Process.5-62Table 5.2-20Equipment Specifications in Limestone Supply Process .5-64Table 5.2-21Equipment Specifications in Other Utility System .5-65Table 6.2-1Comparison of JIS B8223 and NTPC Standards.6-4Table 6.2-2General Periodic Inspections in Coal-fired Thermal Power Stations inJapan.6-6Table 8.2-1Comparison in Costs with and without DeNOx & DeSOx Systems .8-1Table 9.2-1Land Use/Land Cover of the Study Area Based on Satellite Imagery(November 2006) .9-6Table 9.2-2Summary of Land Use Pattern in the Study Area .9-8Table 9.2-3Distribution of Population in Study Area .9-9Table 9.2-4Distribution of Gender Ratio in the Study Area .9-9Table 9.2-5Distribution of Population by Social Structure .9-10Table 9.2-6Distribution of Literates and Literacy Rates .9-10Table 9.2-7Profile of the Workers in the Study Area.9-11Table 9.2-8Classification of the Workers in the Study Area.9-11Table 9.2-9Percentage-wise Classification of the Workers in the Study Area .9-11Table 9.2-10Educational Facilities in the Study Area .9-12Table 9.2-11Higher Educational Facilities in the Study Area .9-12Table 9.2-12Health Facilities in the Study Area (Continued.) .9-13Table 9.2-13Health Facilities in the Study Area .9-13Table 9.2-14Banking Facilities in the Study Area .9-14Table 9.2-15Available Water Resources in Delhi .9-21Table 9.2-16Ground Water exploration/sources for Delhi.9-21Table 9.2-17Soil Sampling Locations .9-24Table 9.2-18Soil Characteristics in the Study Area .9-26Table 9.2-19Rating Chart for Available Nutrients in Soil .9-27Table 9.2-20Infiltration Testing Sites .9-28- vi -