Qtql phone 66337000

(Hr{f, S{trR 6.T tsq$'q} ft-filrax: 26493561

qtq{ €-ftr - Rqun,O rq { qd erss,Rnl atJ,q{ ffi - 110049

Bharat Heavy Electricals Limited

(A Govt. of India Undedaking)
Power Sector - Marketing, BHEL House, Siri Fort, New Delhi - 110049

Ref : MS-1-05-0002
Dtd: 6rh Sep 2018

Chief Engineer (Generation)

TSGENCO
ll Floor, VidyutSoudha,
Khairatabad,
Hyderabad - 500082
Subject : Kakatiya Thermal Power Plant Stage | (500 MW) & ll (600 MW) -
Technical Feasibility Study for implementation of New Standards for
Stack Emissions Norms - Reg.

Dear Sir,
Kindly refer to your letter no. CEG/SEG-1/EME-III/ADE(P/F Environ norms-D NO-
04118, dated 1zl}1n}fi, regarding feasibility study for implementation of new
standards for stack emissions. We have examined the plant layout, Coal Analysis and
other inputs provided to us by Mls TSGENCO for finding the feasibility to install/
modify the equipments. Our observations are furnished as below:

1) Reduction in Suspended Particulate Mafter {SPM) to 50mg/ Nm3 from

existing 100 mg/Nm3:
The particulate matter levels of 50mg/Nm3 can be attained by adding one more
field in ESP. A write up pertaining to addition of one field is enclosed herewith
at Annexure-2"l for Kakatiya Thermal Power Plant Stage | (500 MW) &
Annexure-2.2 for Stage ll (600 MW). Along with the wri
additional Space requirements, Electrical loads and

rc-L are envisaged due to addition of one field. These requ

care as a part of BOP Package. According to our initi
changes / modiflcations are also required to be ca
system:
"1':Ttril[
SF,,,1,,,t-lvl
SL:.'(rr',rr-ii rX-
- ESP funnel outlet'Y" duct to be modified
CE{Gcn
- No, of opacity monitors to be increased

Registered ffice: BHEL House, Siri Fort, New Delhi- 110049

\fz,
 BHARAT HEAVY ELECTRICALS LIMITED

- Bus Ducts are to be modified

- U row of the columns are to be removed etc

2l Reduction SOz level to 200 mg/Nm3:

The SO2 level of 200mg/Nm3 can be achieved through introduction of FGD
(Flue Gas Desulphurisation) System. The design parameters of FGD system is
dependent on the extent of sulphur content in the coal, SO2 concentration in
Flue gases and other Coal Characteristics as well. Technical feasibility for
installation of FGD system is enclosed at Annexure-3 for Kakatiya Thermal
Power Plant Stage | (500 MW) & Stage ll (600 MW)'

3) Reduction NOx level to 300 mg/Nm3:

The reduction in NOx emissions to meet MoEF norms can be achieved through
a de-NOx systems. Which can be approached in three different ways for this
plant depending on the emission level'
In-furnace modifications like providing OFA, BOFA and Horizontal offset air
system depending on the boiler capaci$
a SNCR (Selective Non Catalytic Reduction)
a SCR (Selective Catalytic Reduction)

As a cost effective measure, the first choice would be in-furnace modification

for reducing the NOx level. This In-furnace modification method reduces the
amount of NOx emission significantly. The maximum NOx reduction of around
4Ooh can be achieved through this method.
The Technical feasibility for the reduction in NOx level of 300m9/Nm3 through
in-furnace modification "Boiler Over Fired Air (BOFA) System" is enclosed
herewith at Annexure4J tor Kakatiya Thermal Power Plant Stage | (500 MW)
& Annexure4^Ztar Stage 1l (600 MW)'

We would like to submit that implementation of new standards will have impact on the
BOP packages also along with the BTG package- Therefore, the extent of
modifications / additions required in BOP packages may be jointly decided by

TSGENCO and BHEL. We propose to discuss further course of action with you at your

Registered Office: BHEL House, Siri Fort, New Delhi - 110049

 AHARAT HEAVT ELECTRICALS L'MITED

earliest convenience, followed by submission of techno-commercial proposal for

implementation of new emission norms'
A line of confirmation is highly appreciated in this regard'
Thanking and assuring you of our best attention at all times'

Tongarh
DGM / PS Marketing

Enclosure:
Annexure - 1 lnputs received from TSGENCO
Annexure - 2.1 Technical Feasibility of Reduction of suspended Particulate
Matter KTPP - I
Annexure * 2.2 : Technical Feasibility of Reduction of suspended Particulate
Matter KTPP - ll
Annexure -3 Technical Feasibility of SOx Reduction of KTPP - | & KTPP-ll
Annexure - 4.'l Technical Feasibility of NOx Reduction at KTPP - |
Annexure - 4.2 Technical Feasibility of NOx Reduction at KTPP - ll

Registered Ofiice: BHEL House, Siri Fort, New Delhi - 110049

-t\l | ,-,)L/
'l
I
 Annzv,"^Xt {

TEL.ANGANA STATE POWER GENERATION CORPORATION

LIMITED
KAKATIYA THERMAL POWER PROJ ECT-CH ELPUR

PROXIMATE ANALYSIS
Unit Date -F-ree
Inherent Total Volatile Fixed Ash GCV
moisture moisture Moisture matter carbon Cont€nt cal / gr
o/o olo o/o 'o/o
9/o oy'o

4.03 4.76 8.79 L9.49 27 -48 44.25 JJOO

W Carbon GCV
o/o
cal/gr
KTPP-I lq rn 17

uefr|7c),. 1,o18
CHIEF CHEMIST
KTPP STAGE-I

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Unit
W Date Free Inherent Total Volatile Fixed Ash 6CV
nroistur* moisture Moisture matter carbon Content callgr
o/a 6/a qh o/o q/o P/d
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 1x500 Mw KAKATfYA THERMAL powER pLANr
Krpp srAGE- i,lffili'; ,' '
TECHNICAL FEASIBILITY TO MEET pARTtcuLATE
EMtsstoN 50 mg/Nm3
l. Preamble:
Kakatiya Thermal Power Project tras
installed
stages' 1x500 MW unit which is commissioned capacity of 1xs00 MW & 1x600 MW in two
to explore the possibility to bring down gsp oi tq.og.z010. BHaL m.ade feasibility study
emission level or unit * 1 meeting
MoEF norms. the latest

ll. Existing ESp detaits:

(i) ESP size: 4XFAA_9x37.SM- 2X96135_2

(ii) No. of fierds in each stream: 9 Nos.
(ail with 400mm pitch)
(iii) Designed outlel emission: 100 mgiNm3
(with one fierd in each stream
out of service)

lf l' For meeting 50 mg/Nm3with

one field in each stream out of service
parameters enclosed (Annexure-l with present coal
):

(i)
New ESP size: 4XFAA-9x37.5M +1x37.5M-
2x96135-2 (Addition of one fierd in
stream) each
(i') No. of fierds in each stream: 10 Nos. (ail with 400mm
pitch)
(iii) Revised emission level : 50 mg/Nmr qwith
one iieio in each stream out of service)
(iv) Additional length required atong gas
flow for new field: 5650mm (Duct
ducuduct supporting structure to be foundation &
modified to obtain clear space in rear
of ESp)

lV. Feasibility Study:

To examine the feasibility of field addition,
BHEL official visited Kakatiya site
During site visit' it is noted that addition on 0g.02.201g.
of one field may be envisaged in rear
suitably modifying ESP outlet duct and side of ESp by
duct supporting structure as follows.

Each ESP outlet duct to be connected

' directly to common bus duct instead
of converging
as 'Y', duct. Thereby'y' piece after ouilet
funnerwiil be eriminated.
' common bus duct to be modified to suit outlet ducr connection from each funnel.
I Location of existing U-row and last row of additional
ESp field column will interfere. Hence
U-row columns & its foundation need
to be removed to accommodate foundation
for new row
of ESP columns.

' Additional 4 nos' of opacity monitors will be required at ESp

ouget for modified
arrangement.

V. SCOPE OF SUPPLY FOR ADDITONAL

FIELD OF REVISED ESP SIZE:
one set of complete Mechanical and Electrical
system will be provided for the additional
field (last
field) as required in line with the original
offer"

l*f su
V (a) MECHANICAL: columns'
supporting structure, for additionar fierd, consisting of pre-fabricated
1. set of preciprtator
bolts
cross ties, foot plates and foundation
take care of casing thermal expansions'
2. set of slide supports, for additional columns, to
3.ExtensionofEsPcasings,foradditiona|fie|ds,consistingofprefabricatedwa||androof-panels
thickness'
fabricated steel plate of adequate of ESP
fabricated from chequered prate on top
4. Extensionof ESp outer roof, for additionar fierds,
casing. per bus of the
each set consisting of four support insurators
5. set of Insurators, for additionar fierds,
insulator for direct
insulator for each emitting rapping mechanism and one bushing
field, one shaft
connecting to the transformer/rectifier'
6.setofinsulatorhousings,foradditionalinsulators,completewithHTductingforconnecting
transformer.
T.Setofhighvo|tageemittingsystemconsistingofframeworksupportedfromsupportinsu|ators,
shaft insulators' angularly
mechanism including rapping shafts'
emitting electrodes and rapping
arrangements and geared motor'
displaced tumbling hammers' drive
8'Setofco|lectinge|ectrodesystemconsistingofsupportingarrangement,co|lectinge|ectrodes
bar, rapping shafts,
shock
fabricated from ro*_formed sheets
of steer, rapping mechanism incruding

anguIarlydisplacedtumb|inghammers,drivearrangementandgearedmotor.
g.setofpyramida|ashco|lectionhoppersfabricatedfromstee|plateofadequatethickness'
doors and walkways beneath
outlet flanges' poke holes' access
complete with ss lining (as required),
the hoPPer
10. Set of gas screening
plates for casing and hoppers'

11.Therma|insulationfortheprecipitatorwa|ls,roofpane|sandhopperswithsuitab|ecladding
other fixing materials like studs'
retainers' etc '
material and

v (b) ELECTRICAL CONTROL INSTRUMENTATION:

;;;r;i" uo*rg" & current rating with associated control
1. set of transformer rectifier units of
cubicles.Eachtransformerrectifiersetisinsta||edwithonenumberofthe|atestversionof
controller)'
controller (inbuilt rapping and TR set
Microprocessor based ARECA-Il
the high voltage
between the transformer rectifier and
2. High vohage bus duct connections
Emittingsystemcompletewithbushinginsutatoranddisconnectingswitches.
heaters for
for hopper and tubular type electrical
3^ set of suitable type of electrical heaters
heaters for shaft insulators'
support insulators with thermostats and electrical tubular type
stations & junction boxes'
4. Set of local start /stop push button
for high and low level in each hopper'
5. set of ash level indicators of RF type
as required'
6. Extension of LT distribution board
of ESP'
7. Additional 4 Opacity monitors at the outlet duct

8. Extension of Auxiliary control panel (ACP) as required' \ll"tU

 traY suPPorts required
of suitabre type and cable tray and
g. LT power and contror
cabres

between:
board and ACPs/EC Panets
'ESP LT distribution sets
controllers and transformer reclifier
' Electronic ln ESP
mounted components
control panels and field
'Auxiliary
of EC panels'
lnter connection communication cables
'
and tray supports'
10. Set of cable trays

:
OF SUPPLY AND SERVICES
VI. IMPACT ON SCOPE
ld in series as
"ffionalfrelds
DescriPtion
in Section-V above'
per per scope of suppty "Lt"a
in"iJi*t i-e 8 Electricalfields
@dg aooiiion. of fields'
si
miiltro_6nt load on EsP
ffiffiopo*"': wiil be
iil;;;;
\- - ^ tYll':n'^f^1w9r)
finalized Dqryglg--
tailed

g details
ffili;;)ments fi:!ti1-i with
i"unAairo-t''onTtm'rn
o"
ffiffi ;ti r o gi!11 1'as;T.:*,::""
ndatro n
ro u
i:l",;i't'"o ?;1'p t"p " ti n
n n
1', 3:'
ioom tot additional EC
Space in ESP tontioi additional
panels and sectiott it lirtlsB-&-lcl
at ESP' Ventilation' Air
iietos. ESP, llluminltion
conditioning ;iplicable for additional
"tt'"t
fields in E91guI9[99!L collectton
system (BoP
:-i:h same as
A5fiffidffis \eill;;;oin fietd shall be considered
ScoPe): 9th field.
-@missioning
fo r a d d itiorr a | -!!e-lQs'

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V. SCOPE OF SUPPLY FOR REVISED ESP SIZE WITH

ONE FIELD ADDITION:
one set of complete Mechanical and Electrical system will be provided
for the additional field (last
field) as required.
V (a).MECHANICAL:
1' Set of precipitator supporting structure, for additional field,
consisting of pre-fabricated columns.
cross ties, foot plates and foundation bolts
2' Set of slide suppotls, for additional columns, to take care
of casing
thermal expansions.
3' Extension of ESP casings, for additional fields, consisting
of prefabricated wall and roof-panels
fabricated steel plate of adequate thickness..
4' Extension of ESP outer roof, for additional fields, fabricated
from chequered plate on top of ESp
casing.
5. Set of Insulators, for additional fields, each set consisting
of four support insulators per bus of the
field' one shaft insulator for each emitting rapping mechanism
and one bushing insulator for direct
connecting to the transformer/rectifier.
6' set of insulator housings, for additional insulators, complete with HT
ducting for connecting
transformer-.
7 ' set of high voltage emitting system consisting of frame work supported
from support insulators,
emitting electrodes and rapping mechanism including rapping
shafts, shaft insulators, angularly
displaced tumbring hammers, drive arrangements and geared
motor.
B' set of collecting electrode system consisting of supporting arrangement,
collecting electrodes
fabricated from roll-formed sheets of steel, rapping mechanism
including shock bar, rapping shafts,
angulady displaced tumbling hammers, drive anangement
and geared motor.
9' set of pyramidal ash collection hoppers fabricated from steel plate
of adequate thickness,
complete with SS lining (as required)., outlet flanges, poke
holes, access doors and walkways
beneath the hopper.
10 Set of gas screening plates for casing and hoppers

11 Thermal insulation for the precipitator walls, roof panels and

hoppers with suitable claddino
material and other fixing materials like studs, retainers, etc.
v (b). ELECTRTCAL CONTROL TNSTRUMENTATTON:

1' set of transformer rectifier units of adequate voltage & current rating
with associated control
cubicles' Each transformer-rectifier set is installed with one
number of the latest version of
microprocessor based Areca-ll Controller (inbuilt rapping and
TR set controller).
2- High voltage bus duct connections between the transformer
rectifier and the high voltage emitting
system comprete with bushing insulator and disconnecting
switches.
3- Set of suitable type of electrical heaters for hopper and tubular
type electrical heaters for support
insulators with thermostats and electrical tubular gpe heaters
for shaft insulators.
set of local stad /stop push button stations & junction boxes.
5. set of ash level indicators of RF type for high and low level in
each hopper
o- Extension of LT distribution board as required.
Additional 4 Opacity monitors at the ouilet duct of ESp.
\slrz
 B. Extension of Auxiliary controlpanel (ACp)
as required.
9' LT power and control cables of suitable
type and cable tray and tray supports required
. ESp LT distribution board and ACps/EC panets
between

' Erectronic controters and transformer rectifier

sets
' Auxiriary controrpaners and fierd mounted
components in ESp
. Inter connection communication cables
of EC panels.
10. Set of cable trays and tray supports.

VI. IMPACT ON SCOPE OF SUPPLY AND

SERVICES :

S tpply ofEsFior add rTiona I fbtds

in series i.e. 8 Electricalfields per
Supplyotesp@riesas
per scope of supply stated in Section_V
boiler. above.
Supply_o_f A_nos o-f_q_C-HVR sets ired for additioniiiietOi
Additional load on ESp 720 lKllA aaO
additionat 8 fietds (190 KVA for each LSp pass)

t modification
Civil works a SpaCe nequirements *e9[g9qaE_Aaditionat Fietd AsFer ptot pta;
Revised esR fou
(preliminary) with 10 field
shall be
"rr"ngl*"nt
required for preparing foundatio-n drawing.
Space in ESP controi room for additional
EC
panels and sections in LTMSB &
ACp additional
fields. ESP, lllumination at ESp, Ventilation,
Air
conditioning etc.as applicable for additional
fields in ESP control room.
Ash Handting sysiem (BOp Additional 'l6 nos o
Scope): data for 1Oth field shall be considered same
as
ESP erection and commEsioru'G
for additionat fields.

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 Annexure 3
Kakatiya Thermal Power Plant Unit-1 (500 MW) & Unit-2 (600MW)
Technical Feasibility Report for
FLUE GAS DESULPHURIZATION SYSTEM

GONTENTS

1.1 FGD system

1. Preamble

2. Feasible Study

3. Fuel Analysis

4. FGD Design Data

5. FGD Technology

6. FGD Overview

7. Principle of FGD System

8. Design Criteria

9. Recommendation

\811'-
1.0 Preamble

a. Kakatiya ;r;;;"; ";;;;;

in"rrnrr power nrolect nu, tn" of rx50o MW
& 1x600 MW in two stages. Stage-l comprises of 1x500 MW Unit & Stage-ll
comprises of 1x600MW.

b. In line with M/s TSGENCO's request to meet the new MoEF norms vide ref:
CEG/SEG-1/EME-llliADE(PyF Environ norms-D NO-04/18, dt 1 2101t2018,
a team from BHEL visited Kakatiya TPS to find feasibility for implementation
of new environmental norms for Sox, NOx. SpM

2.0 Technical Feasiblity Report

a ,rrl ,.n"o* i'r'i ,,u; ";;";; ,;; ;;rr;i tv t" o, rn ;;; r;;
.iou
emission level of Unif# 1 & 2 meeting the latest MoEF norms. Based on
layout study, it is found that within the available space it is feasible to install
the Wet Limestone based FGD system to meet SOz emission as per MoEF
norms.

b. BHEL Proposes Wet Limestone Based FGD System for Kakatiya TPS for
unit-1 & unit-2,

FGD System is designed considering the following

. One FGD Absprber system per boiler

. common Limestone slurry pieparation system for all the boilers

r Common Gypsum Dewatering System for all the boilers

Preliminary Layout for Kakatiya Unit-1 & Unit-2 is attached in Annexure-1

tq13>
3.0 Fuel Analysis

Unit-1 {1x500MW) Unit-2 (1x600MW)

Proximate Analysis
(G14 Grade Coal) craa:"":""11
!clr
Fixed carbon % 27.48 26.55

Volatile matter % 19.49 20.93

Moisture % 8.79 8.5

Ash % 44.24 44.02

Total % 100 100

Ultimate Analysis

Carbon % 39.61 40.06

Hydrogen % 1.50 1.53

Sulphur % 0.55 (FGD Design) 0.58 (FGD Design)

Nitrogen % 0.61 0.65

Oxygen % (by difference) 4.7 4.66

Total Moisture % 8.79 8.5

Ash % 44.24 44.02

I
,l
r-4
* l.'fi
y,v15 /-,
4,0 FGD DESIGN PARAMTERS

Sl. No Description Unit Unit-1 Unit-2

(s00 Mw) (600 Mwl

4
Boiler Load in MWe BMCR BMCR

2. Gas flow at FGD inlet m3/s 719.4 894

3. Gas Temperature at FGD lnlet Deg C 126 142

Flue Gas Composition at FGD system Inlet

a) % 4.457 4.536

b) COz Yo 14.045 14.065

c) HzO o/o
7.779 7.720

d) SOz % 0.073 0.076

e) Nz % 73.647 73.603

f) Inlet SOz Concentration (Wet) mg/Nm3 21 80 2270

5.0 FGD TechnologY
agreement with MITSUBISHI
BHEL has on-gorng collaboration / Technology licensing
H|TACHIPowERSYSEMS(MHPS),JapanforwetLime/LimestoneFGDandsea
system (Double contact Flow
water FGD Technology. MHPS has supplied wet FGD
units around the world and has
Scrubber Technologylio t"r" than 100 commercial
high reliability' high
got a global reputation in terms of economic performance'
lperanitity due to its proven design and simplified construction.
Treated Gas

(DGFS) Technology
Unique features of Double Contact Flow Scrubber
. Simple absorber with minimal internals - Easy Maintenance
. Low pressure nozzles - Reduced power consumption than conventional spray
tower.
.Sing|eStagese|f-washingnozzles&SinglestageSprayheaders-Easy
OPeration
. & Lower Investment
compact Layout with GGH over absorber - Smallfootprint
Cost
. concentration unlike conventional spray tower
- Reduced
Increased slurry
cyclones in Gypsum dewatering
absorber tank volume and elimination of hydro
sYstem.
. blower capacity'
lnnovative Jet Air sparger (JAS)- Reduces the oxidation
. Flexible design to meet a wide range of lnlet so2 concentration from 400
mg/Nm3 to 22000 mg/Nm3'
. which can be
The DCFS is based on a modular rectangular configuration
scaled uP easilY
n ,. 1l
/- Ll) u
-.,
6.0 FGD SYSTEM OVER VIEW

FGD OuUet Gate

Booster Fan
f| T,'ur*d
[] Flue Gas

I
a

Absorber
Ii"i:
oxidation Air Btower iiii
. ,,1{_____l

Limestone ,li
I Slurry Recirculation
,\pumps
-aJ
Ash Pond

Secondary Hydro
cyclone

Primary
cyclone
Vacuum Belt Filter

i r+m-r '!i|i!?',,,, .-,,, -,.,,,

Limestone Slurrv-
Storage Tank
E-1-*
3r Gyprum

Filtrate Water
Tank

"a^
L'
/-) / t'/
7,0 Principle of FGD System

FGD technology is used to remove Sulfur dioxide (SO2) from exhaust flue gases of
power plants & industries. BHEL offers Wet FGD (Limestone based) Systems for both
Greenfield and R&M Projects of Power plants & industries to meet the SO2 emission
norms & regulations.
* Limestone is used as a reagent for the removal of SOz from the exhaust flue
gas. The SO2 laden flue gas reacts with the limestone slurry sprayed in the
absorber.
* The removal of SO2 takes place in the Absorber system and Gypsum is
collected as final product. Treated flue gas passes through the mist eliminator
to remove moisture & gets reheated in Gas to Gas Heater (GGH) and then
discharged to chimney. The collected FGD Waste water is neutralized and
then discharged.

L\lgL
 8.0 FGD Sub-system
Flue Gas System
a' Flue Gas from the boiler is tapped off at the lD Fan ouflet common
discharge duct to Chimney. The total gas pressure loss in
the FGD plaht is
compensated by Booster Fans.

b. Bypass Damper is provided to permit isolation FGD plant of flexible

operation of boiler and FGD plant

There will be 2 numbers of Booster Fan per FGD system

along with drive
Motor and relevant Accessories

Gas-Gas Heater (GGH)

d' one number of Rotary Regenerative type GGH will be provided for each
absorber along with associated accessories.

e' The GGH will be designed so that the flue gas temperature
at GGH ouilet to
stack shail be >95 Deg c under guarantee point condition.

t' The GGH components shall be made up of corrosion resistant

materials to
withstand the acidic atmosphere encountered in FGD operation.

Absorber
g' one number of Absorber system complete with internals Spray pipes,
Spray Nozzles, Jet Air Sparger (JAS), Agitator and Mist
eliminator will be
provided for each boiler. (Total 2 Nos of Absorber)

h' Absorber Recirculation Pumps for each absorber will be provided

to spray
the slurry inside the absorber and absorb SO2.

The Absorber Recircuration Tank wiil be provided with side

mounted
Agitators for thorough mixing of recirculation slurry.

oxidation Air Blower for each absorber will be provided for

oxidation of
Calcium sulphite to Calcium sulphate

z-sf su
 8.1 COMMON SYSTEM FOR Unit-1

BALL MILL SYSTEIIII

k' Limestone of <250 mm size is stored in
Limestone storage shed and is
crushed to 25mm under and conveyed
till the inlet of 2 numbers of
Limestone storage silo hoppers.

l. 2 numbers (2x100 %, 1w+1s) wet Bail Miil system

arong with comprete
accessories wi, be provided for grinding
of Limestone.
m' Each Ball Mill shall be designed to meet maximum
rimestone requirement of
two (2) units at Design point.

LTMESTONE SLURRY SToRAGE SysTEM

(LSSS)
n' Two numbers of Lime stone slurry tanks
each designed for a storage
capacity of 8 hours' continuous limestone
requirement of Two (2) units.
o' Each slurry Tank will be provided with one number of centre mounted
Agitator

p Each slurry Tank will be provided with 2 numbers of Limestone slurrv

pumps.

GYPSUM DEWATERING SYSTEM

q' There wiil be two stages of Gypsum dewatering
system consisting primary
stage of sets of hydro-cyclones and secondary
stage of vacuum belt filters
for dewatering of Gypsum.

r' There will be 2

numbers of vacuum Belt Filters (2x100 o/o,
1w+1s) for
Gypsum dewatering.

s' The overfrow of primary hydro cycrones wiil

be fed to one number of
Secondary

t' Neutralization tank is provided to control pH

of waste water slurry before
discharging to ash pond.

u' The Gypsum cake from the belt filter will

be discharged through a Hopper to
a Belt conveyor.

v' The Bert conveyor wiil transport the Gypsum

to the Gypsum storage shed.

zt{*
 I

Recommendation:

1. BHEL recommends Wet Limestone Based FGD system for Kakatiya Plant,
BHEL proposes to use Limestone as a reagent for the removal of SOz from the
exhaust flue gas. The SO2 laden flue gas reacts with the limestone slurry
sprayed in the absorber.
2. Based on the layout study, it is feasible to install the FGD system for both units
without any space constraints.
3. BHEL proposes one FGD Absorber system per boiler (Total 2 Nos of
Absorber), Common Limestone Slurry Preparation System & Gypsum
Dewatering System for all the boilers

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 fn-furnace modification (combustion
mitigation in TsGENco, Kakatiya
modification) #ffiff"'
Tpp, 500r,,rw Boirer
M/s TSGENCO, Kakatiya Thermar power
prant has unit 1,500
supplied by BHEL' This boifer MW boirer
was commissioned in the year
is of radiant reheat, controlled z11o.This boifer
circufation, singfe drum, baranceo draft,
type unit' designed far 10ao/o outdoor
coal firing and stafi up with
This boiler is originafly designed oil with HEA ignitors.
for Nox emission of 260 grlcl
but now has to meet the nlw (750 mgiNmr),
emission norm_s_ brought in
through the gazette notification by the MoEF & cc
dated 07.12,15. mL noitein"u
to meet Nox
ror oeing .l**irsioned
:;;X? ffi ffi;i:,irJfu in the period between

[?:r*'ff::T."#,:;r"H;ached in three dirrerent ways ror this prant

' fn-furnace modifications like providing oFA, BOFA and Horizontaf
air system depending on the offset
boiler capacity
. SNCR (Selective Non Catalytic Reduction)
, SCR (Selective Catalytic Reduction)
As a cost effective measure
the first choice wourd be
reducing the Nox level' f n-furnace in-furnace modification for
modification produces staged
diverting a portion of the secondary combustion by
air to above the firing zone,
which in turn
oxvsen in tfre main combustion
f3::nff,;Hil:oroavailable zone, where

BHEL's In-furnace modification.

technique envisages minimum
wind box to incorporate f ntegral modification of
oFA rr"t"gr"iover fired air)
BOFA (Bypass over Fire
Aii system. n pJ*ion.?f^lgondary and instarfation of
the furnace through (a) fntegrat air
over Fi;; Ai; {r-oFA) nfrjro is admined to
rocated in the
Giili xT,n:i:::,ff j;ffJ
ff ';:l
r, ,v , I ra, IffiJ
( b ;;;;..
) ro u s ;
th ove r r re e r
the four corners. wrnq t
ooxes,
i

at a higher elevation, in
i

all
This In-furnace modification
method reduces the amount
Nox reouction
-o-r of Nox emission
il:il|"fl|ti: Jff#aximum d 40o/o can be achieved
",'oun
Requirement of sNcR and
scR wit be considered onry
reduction achieved-after irnplementation based on Nox
meet the MOEF&CC norms of In-furnace
" modification in order to
of 300 mg/Nm3.

21lg>
TSGENCO approached BHEL (OEM) vide Lr.No.CEG/ SEG-I/ EME-llI/ADE(P)/
F.Environ Norms/D.No.04/18, dated 12.01.2018 for suitable NOx mitigation
with in-
measures in this boiler. BHEL has studied the boiler towards retrofitting
furnace combustion modification for reducing Nox and proposes the following'

Maior scoPe of work:

. Installation of BOFA sYstem
. New redesigned Nozzle tips for Coal, Oil, Air, CCOFA compadments
. Associated Controls and instrumentation for BOFA system

Tvpical Boiler with BOFA duct arrangement

Bypassed
Over Fire Air

Main Windbox
Air
Burners

Furnace Air $taging- Vsrtical

Bypassed Over Fire Air {BOFA) System

3aleL
 Annexure4.2
In-furnace modification (Combustion modification) for NOx
mitigation in TsGENco, Kakatiya Tpp, 600MW Boirer
M/s TSGENCO, Kakatiya Thermal Power plant has Stage ll, 600 MW boiler
supplied by BHEL. This boiler was commissioned in the year 2A15. This boiler
is of radiant reheat, controlled circulation, single drum, balanced draft, outdoor
type unit, designed for 100% coal firing and start up with oil with HEA ignitors.
This boiler is originally designed for NOx emission of 260 gm/GJ (7S0 mg/Nm3),
but now has to meet the new emission norms brought in by the MOEF & CC
through the gazette notification dated 07.12.15. This boiler has to meet NOx
emission less than 300 mg/Nm3 for being commissioned in the period between
Jan 2AA4 and December 2016.
NOx mitigation can be approached in three different ways for this plant
depending on the emission level.
r ln-furnace modifications like providing OFA, BOFA and Horizontal offset
air system depending on the boiler capacity
. SNCR (Selective Non Catalytic Reduction)
. SCR (Selective Catalytic Reduction)
As a cost effective measure the first choice would be in-furnace modification for
reducing the NOx level. ln-furnace modification produces staged combustion by
diverting a portion of the secondary air to above the firing zone, which in turn
reduces the amount of available oxygen in the main combustion zone. where
NOx is mostly generated.

BHEL's ln-furnace modification technique envisages minimum modification of

wind box to incorporate Integral OFA (lntegral over fired air) and installation of
BOFA (Bypass Over Fire Air) system. A portion of secondary air is admitted to
the furnace through (a) Integral Over Fire Air (|-OFA) nozzles located in the
main windbox above the top coal elevation and (b) through Bypass Over Fire Air
(BOFA) nozzles located above the main wind boxes, at a higher elevation, in all
the four corners.
This In-furnace modification method reduces the amount of NOx emission
significantfy, The maximum NOx reduction of aroun d 4Aoh can be achieved
through this method.
Requirement of SNCR and SCR will be considered only based on NOx
reduction achieved after implementation of ln-furnace modification in order to
meet the MOEF&CC norms of 300 mg/Nm3.

'z> tt l..^
l5L
 \

TS6ENCO approached BHEL (OEM) vide Lr.No.CEGi SEG-li EME-lll/ADE(Py

F.Environ Norms/D.No.04118, dated Q.A1.2018 for suitable NOx mitigation
measures in this boiler. BHEL has studied the boiler towards retrofitting with in-
furnace combustion modification for reducing NOx and proposes the following.

Maior scope of work:

. lnstallation of BOFA system
. New redesigned Nozzle tips for Coal, Oil, Air, CCOFA compartments
. Associated Controls and instrumentation for BOFA system

Tvpical Boiler with BOFA duct arranqement

Bypassed
Over Fire Air

Main Windbox
Air
Burners

Furnace Air $taging- Vertical

Bypassed Over Fire Air {BOFA) $ystern