Feasibility Study Report (1) ESP
Feasibility Study Report (1) ESP
Feasibility Study Report (1) ESP
Ref : MS-1-05-0002
Dtd: 6rh Sep 2018
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:
\fz,
BHARAT HEAVY ELECTRICALS LIMITED
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
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
-t\l | ,-,)L/
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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
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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TELAN SAHA-{:IIY powrE GFH HRATTOil csRpo nATroN Lr M rTED
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2
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
rfipp-rl 06,11,17 3,70 4,80 8,50 24.93 26,55 44.42 3409
,
06.r1.17
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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
(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)
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
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
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finalized Dqryglg--
tailed
g details
ffili;;)ments fi:!ti1-i with
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ndatro n
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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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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
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. Preamble
2. Feasible Study
3. Fuel Analysis
5. FGD Technology
6. FGD Overview
8. Design Criteria
9. Recommendation
\811'-
1.0 Preamble
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
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,
tq13>
3.0 Fuel Analysis
Ultimate Analysis
I
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* l.'fi
y,v15 /-,
4,0 FGD DESIGN PARAMTERS
4
Boiler Load in MWe BMCR BMCR
a) % 4.457 4.536
c) HzO o/o
7.779 7.720
e) Nz % 73.647 73.603
(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
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
Limestone Slurrv-
Storage Tank
E-1-*
3r Gyprum
Filtrate Water
Tank
"a^
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/-) / 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.
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.
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)
z-sf su
8.1 COMMON SYSTEM FOR Unit-1
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
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'
Bypassed
Over Fire Air
Main Windbox
Air
Burners
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.
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Bypassed
Over Fire Air
Main Windbox
Air
Burners