“The earth, the air, the

land and the water are

not an inheritance from
our fore fathers
but on loan from our
children. So we have to
handover to them at
least as it was handed
over to us.”
- Mahatma Gandhi
Biggest challenge in the 21st century

Rising Oil price

Increasing Pollution Depleting Oil reserve

 Present scenario

 India depends on Gulf countries for 70% of its oil needs

 India ranks among the top 10 largest oil-consuming

countries (consumption is 2.2 million barrels per day)

 Stringent environmental norms.

 Weakening of INR vis-a-vis foreign currencies

 Tariff-based bidding in Indian Power Sector.

 Welcome to
Presentation
 A PRESENTATION ON

PLASMA ENERGY
TECHNOLOGY
( Eliminating use of oil in coal based power plant through PET)

Presented by
A S GUPTA Supdt(O)
D.S.RAO Dy Supdt (O)
 CONTENTS
Disadvantages of using oil

Available Technologies

Plasma Energy Technology

Economic feasibility

Advantages

Conclusion
Disadvantages of using oil

High cost involved (Oil, steam) & Additional capital cost.

Maintenance considerations.

Prone to fire accidents.

Specific problems related with oil (APH fires, ESP, etc)

Pollution issues.
AVAILABLE TECHNOLOGIES FOR OIL FREE BOILER
START UP OR STARTUP WITH LESS OIL

LIGHTUP WITH NATURAL GAS

CORONA DISCHARGE IGNITION

TINY OIL IGNITION TECHNOLOGY

PLASMA ENERGY TECHNOLOGY

PLASMA ENERGY TECHNOLOGY
 WHAT IS PLASMA???

A state of matter similar

to gas in which a certain
portion of the particles
are ionized.
After sufficient heating a
gas dissociates
its molecular bonds,
rendering it into
constituent atoms. It may
lead to ionization
BASIC PRINCIPLE OF THE PLASMA-ENERGY TECHNOLOGY(PET)

Pulverized coal + syn gas Plasma torch

Reactor

Furnace
Sketch of Plasma-Fuel System (PFS).
Pulverized coal

PET uses high-temperature plasma for the thermal-

chemical preparation of the coal-air mixture for
combustion = partial coal gasification
BASIC PRINCIPLE: ZELDOVICH MECHANISM

The list of the chemical reactions used in the model consists of

116 reactions

The starting chemical stage of coal conversion is the evolution

of volatile matter (CO, CO2,CH4, H2, H2O, C6H6, C5H5N, C4H5N,
CH3SH, C4H4S).

Two more stages: Char carbon and nitrogen gasification (seven

reactions with H2O, CO2, CO, O2, NO, H2S)

The 1st reaction step is the conversion of HCN to NH3 by an

attack of an oxidizing agent. The NH3 forms and destructs NO
within a pair of competitive parallel reactions.
 Temperature profile

100 kW

plasma flame: measured isotherms

 BASIC PRINCIPLE OF PET

• Temperature of a plasma flame

reaches 4000-6000 K.
• PET provides thermo-chemical
treatment of rich coal/air mixture (0.4-
0.6 kg of coal per one kg of air). It
corresponds to 30 - 40% of air
theoretically needed for complete coal
combustion.

Concentrations of gaseous and solid

components in dependence on
temperature in reactor
COMPONENTS OF PLASMA IGNITION SYSTEM

Plasma torch operated with DC power

Rectifier unit to supply the required DC power

Coal burner which can withstand high temperatures

Cooling water for cooling of plasma torch

Instrument air for purging and ionisation.

 DC PLASMA TORCH
Dimensions:
Length: 0.5 m
Diameter: 0.25 m

weight:30 kg

Cathodes and anodes are made

with special anti oxidative alloy
COMPONENTS OF PLASMA IGNITION SYSTEM

Plasma torch operated with DC power

Rectifier unit to supply the required DC power

Coal burner which can withstand high temperatures

Cooling water for cooling of plasma torch

Instrument air for purging and ionisation.

 PLASMA REACTORS – THE CORE ELEMENT OF PET

Direct flow
Reactor

Air-coal mixture

Plasma torch

Tangential
flow Reactor
COMPONENTS OF PLASMA IGNITION SYSTEM
 MOUNTING OF PLASMA TORCH

Plasma
reactor

Plasma
reactor

For a 550 MW Boiler, 4 nos of torches are required.

 DC PLASMA TORCH
Power consumption ranges
between 50 kW and 350 kW

Hybrid torches of 1.4 MW

are also available.

Actual power supplied

depends on:

Quality & Volatility of the coal.

LABORATORY PERFORMANCE TEST
Implementation of Plasma Energy Technology

Courtesy: Yantai Longyuan

Capital cost for a 2x500 MW plant
 As per the CERC guidelines capital cost of FOPH for a

2X500 MW plant = Rs 50 Cr. (0.05Cr/MW*)

 As per vendor information, capital cost for providing PICS

for 2x500MW plant = Rs 13.8 Cr.

 Savings in capital cost ~ Rs 36 Cr.

 Courtesy : CERC benchmarks . Vendor Information.

Cost-Benefit Analysis for New Units & for Commissioning
(For 2X500 MW Plant)

Savings in capital cost of Rs. 36 Cr.

Oil Consumption during commissioning ~ 4,000 KL LDO

16,000 KL HFO

Cost of Oil ~ Rs. 87.2 Cr.

Equivalent Coal (CV of Oil / CV of Coal) ~ 65866 T

Cost of coal = Rs. (65866 X 2340) ~ Rs.15.41 Cr

Cost of Pulverization = Rs 2.4*(20*65866) = Rs.31.6 Lacs

Cost-Benefit Analysis for New Units & for Commissioning
(For 2X500 MW Plant) Contd..

Aux Consumption for plasma guns = 1097 * 2 * 0.2 MWh

Power consumption for plasma guns = Rs. 10.53 Lacs

Total power consumption for coal firing =

Cost of Coal + Cost of Pulverization + Cost of energy by Plasma
= Rs (15.41 + 0.31 + 0.10) = Rs. 15.83 Cr.

Savings = Cost incurred with oil - Cost with coal

= Rs. (87.2 – 15.83) Cr. = Rs. 71.36 Cr.

Total savings on fuel cost during commissioning = Rs. 71.36

Cr.
 Cost-Benefit Analysis: Oil Savings
(Last 3 years Average)

Consumption: LDO - 409 kl; HFO – 759 kl

Cost of oil: Rs. ( 58000*409 + 40000*759) = Rs. 5.41 cr.

Equivalent coal = 1390 + 2480 T = 3870 Tons

Cost of coal = Rs.(3870*2340) = Rs. 90,55,800.

Cost of pulverization= 2.40*(20*3870) = Rs. 1,85,760.

Assumptions: LDO Calorific value: 10200 kCal/kl

HFO Calorific value: 9800 kCal/kl
Coal calorific value: 3000 kCal/kg
 Cost-Benefit Analysis: Oil Savings
(Last 3 years Average) Contd..

Energy requirement of plasma guns = 64.5hrs * 2 Nos* 0.2 MWh

= 25.8 MWh

Cost of energy consumed by Plasma Guns = Rs (25800*2.40)

= Rs 61,920.

Total cost incurred in coal light-up =

Cost of Coal + Cost of Pulverisation + Cost of Addl. APC

= Rs. (90,55,800 + 1,85,760 + 61,920)

= Rs. 93.03 lacs

Proposed annual savings = Rs(5.41 – 0.93) Cr. = Rs. 4.5 Cr.

 Cost-Benefit Analysis: Steam
On an annual basis

Daily Aux Steam consumption for HFO tracing ~ 150 T

Cost of DM water per ton = Cost of water +

Cost of chemicals + Overhead
= Rs. (8+7+15)
= Rs. 30.

Annual cost of DM water for HFO tracing Steam

= Rs(30*150*365)
= Rs 16,42,500.
 Cost-Benefit Analysis: Steam
On an annual basis Contd..

Annual cost of DM water for HFO tracing = Rs 16,42,500

Improvement in Heat Rate:

For 1% reduction in DM Make Up, HR savings = 20.72kCal/kWh
Present DM Consumption = 0.497% of MCR
Eliminating 150 T Aux Steam Consumption = 0.310% of MCR

So, proposed HR savings = 0.187*20.72 = 3.874 kCal/kWh.

For 1kCal/kWh reduction in HR, savings ~ Rs 5000/day
So, proposed savings = Rs (3.874*5000) per day
(due to reduction in HR) = Rs 19,370 per day
= Rs 70,70,050 per year.

Annual savings = Rs.(16,42,500 + 70,70,050) = Rs 87.12 lacs

 Cost-Benefit Analysis: Other benefits
 With Plasma guns, un-burnt carbon can be reduced from 1.4% to
1.0%
 So, un-burnt coal reduced from 3.5% to 2.5%
 Reduction in NOx by 15%.
 Savings in FOPH and boiler front maintenance costs.
 ADVANTAGES
 PET eliminates the need for the use of any supplemental
fuel.

 PET enables unit to operate at ~10% load with stable flame

with a variety of coal qualities.

 PET improves boiler efficiency and decreases harmful NOx

emissions

 ESP can be put into service during startup and hence

damage to ID fan Blades and Black Smoke can be avoided.

 After retrofitting we will get CDM benefits due to reduction in

GHG emissions.
Roadmap
Power requirement in coming decades

India’s India’s
 ROAD MAP
 Implement PET in any of existing units in different
regions, to study its performance and reliability for Indian
conditions.

 Further implement this technology in all upcoming plants.

 Will help India to maintain Energy security.

 CONCLUSION
 Plasma Energy Technology is a “READY TO GO”
alternative solution for cleaner energy from coal.

 Return on investments does not exceed 18 to 30

months.

 Potential solution to the stringent environmental

norms.
CONCLUSION
THANK YOU
 REFERENCES
• Simulation of Coal Plasma Ignition and Combustion in a Furnace
Chamber by A.Askarova, E.Karpenko, V.Messerle, A.Ustimenko.

• 5th International Workshop and Exhibition on Plasma Assisted

Combustion (IWEPAC), 15-18 September 2009, Hilton Alexandria Mark
Center, Alexandria, Virginia, USA

• Mr. Srinivasan S, Mr. Jogesh Singh - M/S Jasubhai Industries

• M/S Gondian Power Corporation, China

• CERC website.

• www.energy-tech.com
 Assumptions and clarifications
• All calculations are for Simhadri St-I (2*500 MW) units.

• 4 nos of 200 kW plasma guns for each 500 MW unit.

• CV of LDO = 10200 kCal/kl, cost = Rs 58,000/kl

• CV of HFO = 9800 kCal/kl, cost = Rs. 40,000/kl
• CV of coal = 3000 kCal/kg, cost = Rs. 2,340/T

• Power required for pulverisation of coal = 20 kWh/ ton

 Vendors:
The Yantai Lonyuan Power Technology Co. CHINA.

In India, M/s Jasubhai Industries are the sole vendor of

Plasma Ignition Combustion System (PICS)

 PLASMATRONICS™
New York, USA www.plasmatronicsllc.com

 Beijing Compass Technologies Co Ltd.

Email: bjkompass@gmail.com
Beijing, P.R China

 Welford Technology Holdings Limited

Hong Kong. http://www.welford.com.cn