NETRA

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NETRA Presentation On Carbon mitigation
technologies 20th Dec. 2011 Prakash D Hirani
NTPC Energy Technology Research Alliance
Developing Economic and Green Energy Technologies
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• Presentation Outline
• NTPC overview (5 slides)
• About NETRA (12 slides)
• Carbon sequestration (26 slides)

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NTPC Overview
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35 Years since Inception and Energizing India
PAN India Presence
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Performance Highlights - Operational
Consistently Delivering
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Capacity Addition by 2017
Long Term Corporate Plan prepared for next 21
years upto GW by 2032 to position NTPC as the
Worlds largest and best power producer and
leader in Green Power
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Global Stature
Number 1 independent power producer in Asia in
2010 (by Platts, a division of McGraw-Hill
companies)
1 in the world in capacity utilization 3 in
Asia in electricity output and 10 in the
world 3 in the world in plant availability
10th largest generator in the world
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Environmental Initiatives
More than 30 Million tons of CO2 has been avoided
in NTPC
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About NETRA
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Focus Areas of NETRA
Efficiency and Availability Improvement Cost
reduction
NETRA
New Renewable Energy
Climate Change
Support to Stations
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Feasibility of CO2 capture technology by aqueous
carbonation of ash at Ramagundam
Principle Ramagundam fly ash contains 4.5 CaO
(i.e. 1 T/Hr. per 200 MW unit) which requires
0.78 T CO2 for carbonation Lab. Studies
conducted and established carbonation by mixing
CO2 in ash Slurry with Ramagundam fly ash.
Chimney
Objectives 1. CO2 Utilization 2. Reduction in
scaling in ash pipelines 3. Reduction in acid
consumption 4. Reduction in acidic gases from
flue gas 5. Reduction in maintenance cost 6.
Carbonated ash for construction purposes or
Agriculture use
Schematic of trials

• Further Activities (Ramagundam)
• Design of a pilot plant for 1 T/hour of Ash
  Slurry
• Fabrication Installation at site
• Trials at Ramagundam
• Feasibility Report

Carbonated fly ash after 2 days in air
Tests with Dadri Flue gas
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Installation of integrated biodiesel pilot unit
from Pomognia fruit at Dadri
Objective Demonstrating utilization of 83 of
energy from Pomognia fruit in form of
Biodiesel and power instead of existing 15
(total)

• Benefit Unique technology, self powered useful
  in remote areas
• Technique
• Previous set up produces only raw oil from fruit
  using expeller. Cake and shells were used as
  manure (Utilization 15 energy)
• Now, Shell and cakes are gasified and power is
  also generated to make the system self driven
  (Utilization 83 energy)
• Status Pilot setup is demonstrated at Dadri
  and surplus power is also generated for lighting.
  Patent filed

Integrated biodiesel pilot plant at Dadri
From 65 Kg Pomognia Fruit Biodiesel
8kg Electricity production 24Kwh
From 1 Hectare plantation Biodiesel 1
Ton Electricity gen 4800 Kwh Saving Power
3800Kwh Payback 5 Years
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Waste Heat Recovery System FGHR-AC Pilot Plant

• Objective-
• Waste heat from flue gas for 100TR Air
  Conditioning at Ramagundam
• Benefit-
• Utilizes Waste heat instead of electrical power/
  steam to generate Air Conditioning
• Green house gas free Air conditioning.
• Auxiliary Power Saving of 0.4 MU per year (266
  ton of CO2)
• Initial cost of demonstration pilot plant is
  high, but expected to come down after large scale
  deployment

Comparison with vapor compression FGHR VAM Demo Vapour compression system
Capital cost (Mn 34.2 8.5
Auxiliary power (kWe) 86 137
NPV of Operating cost for 25 year Mn 13.8 22.1
C Credit _at_ 10 USD / ton of CO2 in Lacs 70 ---
Chimney
Fan
Status Technical specification for Ramagundam
STPS completed, NIT by Apr2011
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Aqua Ammonia Power Cycle
Objective

• More efficient utilization of low grade/waste
  heat from flue gases, LP steam, solar energy for
  increasing cycle efficiency and power generation

Technique

• Use of ammonia-water mixture as working fluid
  instead of water taking advantage of variable
  temperature boiling and condensation

Benefits
Efficiency improvement by around 1 compare to
Rankine cycle in low temperature range source
(150oC Sink-32oC)
Status
S.No Activities Status / Schedule
1 Development of 5kW test loop and Experimentation Completed in Dec 2010
2 Analysis of results and report 15.03.11
Based on analysis of 5kW results Technical specifications for 100 kW Pilot plant shall be prepared for deployment in one of NTPC station. Based on analysis of 5kW results Technical specifications for 100 kW Pilot plant shall be prepared for deployment in one of NTPC station. Based on analysis of 5kW results Technical specifications for 100 kW Pilot plant shall be prepared for deployment in one of NTPC station.
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Solar Platform
S.No Project Deliverable
1 8-sensor Solar Radiation Station Ground Level Solar Radiation Data Global, Diffuse, DNI, UV, IR, Albedo, Sun Shine Duration
2 Setting up of Solar based HVAC system 1. GHG free, low CO2 Solar HVAC 2. Thermal storage for lean/non-solar period operation 3. Can be replicated in power plants
3 Setting up of 1 MW Solar RD Project at NETRA Proofing of solar thermal technology for low cost solar power CLFR RD test bed for component prototype testing Insight feedback for OM issues of solar thermal power plant
4 Setting up of Solar PV Multi-technology test bed and measurement lab 1. Solar PV RD test bed of five different technology for performance assessment. 2. Related Test and measurement equipment
5 In-house development of two axis solar tracker for heliostat application Can be used for Mounting measuring instruments Photovoltaic module to harness more energy. Heliostat for natural lighting/solar tower
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In-house development of two axis solar tracker
for heliostat application

• Solar tracker, tracks the movement of sun
• Used for focusing
• Various measuring instruments to the sun.
• Photovoltaic module to the sun for harnessing
  more energy.
• heliostat for natural lighting/solar tower

Microcontroller Unit
Motor Driving Circuit
Real time clock
Stepper motor
Power supply unit

• Features
• Microprocessor controlled
• Track the sun with 0.072 Deg of accuracy.
• Power Consumption 28 Watt

Cost - Rs. 30,000/- approximately (Market cost
Rs. 5 lacs)
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Why MSW to Energy ?
MSW
Contains 70 organic content, suitable material to be used as a fuel resource (presently considered as a waste, creates pollution)
Advantages of using MSW
Represents a renewable energy source Considered as carbon neutral fuel (CO2 neutral fuels) Pollutant emissions are lower than coal Can be exploited for their energy instead of destined to landfill
Energy content of typical treated Indian MSW
3766 Kcal/kg
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Waste to Energy
Technology Using high pressure steam to
convert municipal solid waste (MSW) into solid
fuel, and it may be used as a co-firing fuel in
boiler / stand alone system.

• Comparison with other technologies
• Use of Saturated steam for treatment (All in one
  process)
• (other technology uses 1. Dry 2. Shred 3.
  Compress with binders to produce pellets Energy
  intensive process)
• Requires low energy consumption (only steam is
  required)
• Produce grounded fuel with uniform properties
• Moisture removal is easy (Inherent moisture is
  removed)
• (Others Only surface moisture is removed)
• Increase the shelf life of the fuel (fuel becomes
  non hygroscopic)
• (others Moisture will be reabsorbed by the
  fuel)
• Removes bad / stinky odor (Sterilize the waste)

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Treatment Performance
Kitchen Waste
Paper Waste


Proposed Usage of MSW
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Plant schematic
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Proposed steam treatment
Improves drying performance
Suitable for mixed MSW
It can produce uniformly grounded fuel Fuel with uniform properties
Higher density Removes stinky odor Removal of inherent moisture
Requires 39 less energy compared to traditional
methods
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Carbon Sequestration
Carbon Capture Technologies
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CO2 Management
Single source CO2 Emission
CO2 Capture
Utilization
Storage

• Geological storage
• Oceanic storage

Physical chemical methods
Biological methods

• Fuel
• Chemicals

• Absorption
• Adsorption
• Membrane
• Cryogenic distillation

• Bacteria
• Algae
• Other related items

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The Energy-Carbon Conflict

• There are three option to control the CO2
  emission without severely or negatively changing
  the standards of living
• - Increase in energy efficiency
• - Switching over to less carbon intensive source
  of energy
• - Carbon sequestration

• Major steps for carbon sequestration
• Capture -CO2 separation from flue gases
• Transport -Probably in liquid form at high
  pressure
• Fix -Back to mother Earth- storage in
  geological formation

The Separated gas may also be used for - Use
for enhanced coal bed methane ECBM recovery -
Use for enhanced oil recovery EOR - Making
value added products
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Carbon Emission Reduction Technologies
Efficiency Enhancement
Pre-combustion

• Combustion efficiency
• improvement in conventional
• power plant
• Low grade heat utilization
• IGCC
• Super critical Ultra super
• critical technology
• Advanced class gas turbine
• Hydrogen technology
• fuel Cell

CO2 Capture
During Combustion
Post combustion
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CO2 Capture Technologies
Pre-Combustion
During -Combustion
Post-Combustion

• IGCC
• Gas turbine
• Hydrogen separation
• for Fuel Cell
• CFBC
• PFBC

• Oxy- fuel
• Combustion

• Pulverized coal
• fired based plant

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Fuel
Pulverized coal based Power Plant
Flue gas
CO2 Separation
Air
CO2
Post Combustion approach
Pre-combustion approach
Oxy-fuel Combustion
Fuel
CO2
Oxygen
Air Separation
Air
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Major steps for carbon sequestration
Fundamental Research is required to develop Cost
Effective Technology
CO2 Capture
Fundamental RD may not required as Options are
known
Major Issues are
CO2 Transport

• Environmental and Safety
• CO2 piping network
• Long Term Integrity of CO2 storage
• Monitoring and Verification
• Legal Frame Work

• CO2 Fixation

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Technologies for CO2 Separation
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Carbon Capture Technologies
CO2 Capture Technology

• The Separated CO2 may also be used for
• Use for enhanced coal bed methane ECBM
  recovery
• Use for enhanced oil recovery EOR
• Making value added products

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Challenges in Carbon Capture
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Challenges in Carbon Capture
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Challenges in Carbon Capture
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Challenges in Carbon Capture
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Challenges in Carbon Capture
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Chemical Absorption Process

• Flue gas is cooled and scrubbed
• in a direct contact cooler
• CO2 is adsorbed in 15-20 aqueous
• solution of MEA at 40-45 ºC in a
• Absorption Tower
• The absorbed CO2 is regenerated
• by stripping around 120-130 ºC
• Steam (3 kg/cm2) required for
• regeneration is supplied by a reboiler
• Regeneration, the most energy
• intensive process, requires 2 ton of
• steam per ton of CO2
• Corrosion is a major issue

Absorption Process most widely used Technology
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Solvent Development
Pri. Amine High Regeneration Energy
Waste Heat Utilization of flue Gas for
Reboiler
Regeneration Target 100 C
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Chemical Process for CO2 Separation

• Major Concerns
• In amine process, 80-90of total energy
  required, is consumed in solvent regeneration
• For a 210 MW coal fired boiler the total energy
  requirement is about 65 MWe of power.
• This will bring down total efficiency by at
  least 30.
• This will approximately double the power
  generation cost

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Efficiency Enhancement The IGCC Technology
The IGCC Cycle

• CO2 Emission
• CO2 Emission 0.80-0.85 Ton/MW
• For 200 MW Size Unit 160-170 T/Hr
• For 500 MW Size Unit 400-425 T/Hr

Improvement of overall efficiency would reduce
the CO2 emission level.
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Carbon Capture Technologies Membrane
Membrane process
The Cycle
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Carbon Capture Technologies Membrane
Membrane process

• Absorbents
• Ionic Liquids
• Non-Corrosive molten organic salts
• Alkyl ammonium, Phosphonium, Imidazolium and
  pyridinium halide salt
• Aqueous solution of KOH, NaOH, Na2CO3, NH3 etc.

Needs large efforts on development of Membrane
with right permeability selectivity.
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Carbon Capture Technologies Adsorption
The Cycle
Works on a Pressure Temperature / Vacuum swing
process
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Technology Development for post-combustion
capture of CO2 by Adsorption
Netra Research on CO2 Capture
CSMCRI, BHAVNAGAR ADSORBENT DEVELOPMENT
CSIR (IIP), DEHRADUN PROCESS DEV OPTIMIZATION
IIT, MUMBAI SIMULATION MODELING PROCESS DESIGN
NEERI, NAGPUR ADSORBENT DEVELOPMENT
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Pressure Swing Adsorption (PSA) process for CO2
capture from flue gas

• Conventional amine based CO2 capture process is
  cost and energy intensive
• PSA process is being developed as an alternative
  process
• In PSA process
• CO2 is selectively adsorbed on adsorbent under
  moderate pressure
• Adsorbed CO2 is recovered under vacuum

• Research components in process development
• Development of materials for CO2 adsorption
• Development of PSA process using the materials
  
• Modeling and simulation of PSA process
• Experimentation in PSA test unit and
• process optimization

Synthetic Flue Gas CO2 12- 13 Moisture
4- 5 Oxygen 3-4 Nitrogen 78-81
Temperature 50-55 C
PSA Unit
CO2 purity 85 recovery 75

• Three Indian and PCT patent application filed on
  CO2
• selective zeolite based adsorption materials
• The PSA unit has been shifted to NETRA from
  IIP for
• further development of the process
• Pilot scale development of the process in
  collaboration
• with GNFC and CSMCRI is under active
  consideration

PSA test unit
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Outcome
Highly selective adsorbent developed at CSMCRI
superior to conventional adsorbents
Novel VSA cycle devised and tested at IIP
Over 92 CO2 purities at 80 recoveries achieved
at 55 0C from CO2 levels of 11 in flue
gas. Simulation model validated
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Highlights

• Over 80 recovery of high purity (gt90) CO2 from
  flue gas at moderate temperature and low pressure
• Preliminary estimates of Power requirements 0.30
  Kw-hr/kg CO2 recovered at 550C , lower than
  current amine based absorption processes
• Base adsorbent material is commercially available
• Process does not generate any waste stream
  requiring further treatment

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CO2 Fixation Initiative

• Carbon Sequestration
• CO2 Capture and its geological storage is
  energy cost intensive (60-80USD/Tonne CO2),
• uncertain and not yet proven
• Indias focus for CO2 mitigation is directed
  towards biological fixation/utilization of
• CO2 in addition to efficiency improvement and
  use of renewable

• CO2 to Bio-oil Micro Algal Process
• Able to produce bio-oil, neutraceuticals, cattle
  food, etc.
• Oil content upto 40
• Potential algal species are Dunaliella,
  Nannochloris, Spirulina
• 30 times more oil production than other energy
  plantations for same land
• No need for agricultural land may avoid
  bio-oil crop conflict
• Typical CO2 consumption 100 gm/m2/day
• Requirement of land for algal cultivation is an
  issue
• Commercial process for algae to bio-oil using CO2
  from power plant yet to establish
• Extensive global RD for development of the
  process

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Micro-Algal process for mitigation of CO2

• Algae commercially grown for nutritional, feed
  and specialty
• products
• Lipid / oil content 2 to 40
• Algae generate 7-30 times more oil than
  bio-plants like Jathropa,
• Ratanjot etc
• Global RD for development of the process in
  open pond and
• photo-bioreactorsystem
• Typically for a open pond system
• CO2 consumption rate 100 gm/ square
  meter/ day
• Dry algae production rate 20 gm / square
  meter / day
• Oil production 30

Algae
1000 sq. meter algae based pilot plant
IOCL-RD NETRA through MoU between IOCL NTPC
Process Open race way pond
Major steps Process development in Lab. scale 1000 m2 open pond pilot study at NTPCs power station
Present status Lab. scale developed has been started Area of app 1500 Sq M identified at Faridabad Gas Power Plant

• Benefit The pilot study will help in assesing
  the feasibility of using flue gas as CO2
• source the possibility of
  producing bio-diesel

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TRASFORMING LIVES
THANK YOU
Email hiraniprakash_at_yahoo.co.in
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