INNOVATIVE ENERGY EFFICIENCY SCHEMES FOR

NET HEAT RATE REDUCTION IN CPP IN OPM

Dr T.G. Sundara Raman

Vice-President- EnERG TEkH &
Consultant –Energy & DeCarbonization
Orient Paper & Industries Ltd – Amlai
Dr C.S. Kashikar
Chief Operating Officer
&
Anjani Kumar Srivastava
General Manager ( Power Plant )
Orient Paper & Industries Ltd – Amlai

CII Conference on Energy Efficiency in

Captive & Waste Heat Recovery Power Plants

Hyderabad
23rd May 2024

Enhance. Enrich.
 Net Heat Rate Reduction Concept - CPP

• Gross Heat Rate is direct function of Performance of STG & Boiler

• Gross Heat Rate [GHR] = 86000 / Cycle Efficiency

• Overall Cycle Efficiency = Boiler η * Turbine η * Generator η

• Net Heat Rate is directly related to connected Auxiliary Energy

Consumption viz., APC,ASC & IC.

• Net Heat Rate [NHR] = Gross Heat Rate [GHR] / [100 – APC]/ 100]

NHR shall be reduced by :

• [Effecting GHR reduction]
• Lowering APC & ASC as also
• Interconnecting [IC] Boiler -Turbine Energy Transfer losses

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Orient Paper Mills –Amlai is presently having HP Cogeneration Plants in Operation

1 No. 150 TPH AFBC Coal fired Boiler [ Steam Pressure /Temperature: 87 ksc/
510ºC] AFBC Boiler with Feed water temperature at 190ºC connected to 30MW
Multi-extraction [ MHP, LP, LLP] Condensing [ Water cooled condenser] Steam
Turbo-Generator.

1 No. 82 TPH Chemical Recovery Boiler [ Steam Pressure/Temperature: 64 ksc/

450ºC] alongwith 90 TPH Stoker Coal fired Boiler connected to 25 MW Multi-
Extraction [ MP, LP,LLP] Condensing [ Water Cooled Condenser] Steam Turbo-
Generator.

Both condensers are related to cooling water in closed circulation connected

to a Common Spray Pond.

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 AFBCB & CRB HP COGEN BATTERY IN OPM

HPS HPS
• . ~G
• . STG ~G
STG

MP 25 MW
MP 30 MW
LP
LP EXH
EXH

C
C
Spray Pond

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INNOVATIVE ECS # 1 FOR NHR REDUCTION

CONCEPT OF VARYING COOLING WATER FLOW IN

CONDENSERS FOR NET POWER ENHANCEMENT

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CW Pumps Power Optimization with Both Extraction Condensing STGs in operation

STANDARD PRACTICE IN ALL STEAM TURBINES WITH CONDENSERS

Constant Cooling water flow rate designed for Rated Condensation ( max.) flow is
being maintained all along –irrespective of exhaust steam condensing flows.

Cooling water Pump(s) hence are designed for maximum condensing flows with
design margin on flow & head necessitating constant high auxiliary Power
Consumption at all [Low/Medium /High] Condensing loads of operation.

INNOVATIVE ECS FORMULATION & IMPLEMENTATION

Innovative energy scheme had been developed for adjusting cooling water loads to
suit varied condensing flows . Hence it was proposed to reduce the circulating
cooling water load to condenser at lower condensing loads to suit. This has in
principle approval & acceptance of Siemens.
Hence cooling water flow to condensers shall be lowered at lowered condensing
loads for effecting reduction in MCW Pump power consumption [APC].

Enhance. Enrich.
 High APC of CW Pumps in [Extraction] Condensing STG Battery

- Exhaust Steam Condensing Flows are being split between the 2 Steam Turbines

- Constant flows [ designed for rated condensation ] in both the Condensers

irrespective of condensing flows

- Invariably in Cogen units, Extraction steam for process is very high with
balance only for condensing steam

- APC Very High at 1.05 MW with 2 CW pumps in operation even with Condensing
flows < 50 % of rated value.

- Moreover, the CW Pumps had been designed for 1.3 times Design load.

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CW Pumps Optimization with Both Extraction Condensing STGs in operation

EARLIER

2 CW pumps of very high flow rate [5300 m3/h each] had been in operation all
along. As the requirement of CW flows for the 2 Condensers are far less [~3800
m3/h] even at rated high condensing loads of 57 to 64 TPH, Power consumption is
uniformly high at around 1.0 to 1.1 MW.

RECOMMENDATORY ADVISE & PRACTICE

It was decided to put in practice the innovative concept of varying the cooling
water flow to condenser as under :
As the condensing loads in each of the turbines are very low viz., 25 to 30 TPH, it
had been decided to operate 1 CW pump catering water flows to both the
condensers.[ As & when the condensing loads go up > 30/35 TPH on a sustained
period, both the CW pumps need to be operated].

Enhance. Enrich.
REDUCTION IN APC WITH 1 of 2 MCW PUMPS OFF

Chart Title : 12300units/d [ 515 kW ]

APC Reduction–MCWP

25000 24050

20000

15000
12678
11512 11522 11378 11476

10000

5000

0
Aug-23 Nov Dec Jan-24 Feb Mar
2 Pumps on 1 MCW Pump on

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Innovative Concept of Varying Cooling water flow with Condensing Loads

PLANNED –TAKING THE CONCEPT FURTHER

• New Energy Efficient lower duty CW pumps [200 kW] one with Fixed
speed & the other with Varying speed alongwith IE3/IE4 motors. The
proposed cooling water pump shall be with VFD so as to vary the
cooling water flow to condenser to suit the varying condensing steam
flows. Through this process, APC from CW pump(s) shall be lowered-
resulting in increase in net power available for process.

• Though Cooling water flow through the condenser tubes had been
designed for exhaust steam condensation rated capacity, the CW flow
rate shall be reduced suitably with lowered condensing loads with
Varying speed of the 2nd CW pump in operation.
• APC is expected to be reduced further by 100 to 150 kW
• Net Heat rate reduction is ensured.

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 ENERGY GAINS & DECARBONIZATION
APC reduction & Net Heat Rate Improvement

Reduction in CW pump power consumption ………………………….. : 0.515 [+0.15] MW

Reduction in APC achieved/planned is of the order of ………………………………: 2.5 %

[ 0.65 MW out of ~24 to 26 MW total power generation].

Alongside Turbine Net Heat Rate shall be lowered by ………………………………: ~ 2.5 %.

Carbon Emission Reduction

Existing [Planned]

Through effecting power consumption reduction of ………: 12380 [+3600] units/day ,

Carbon Emission Reduction accrued is …………….…….:~ 500 [+150] tCO2e/month .

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 MULTI-EXTRACTION CONDENSING STG
30 MW ES DF MONITORING
STG

HPS
~G
STG

• . .
MP

LP C
EXH

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 HEAT RATE & CYCLE EFFICIENCY– 30 MW STG - ILLUSTRATION

Parameter Flow Pressure Temperature Enthalpy Energy

TPH ksca Deg C Kcal/kg MKcal/h

A HPS in 143.9 84 505 814 117.13
B HMP Ext1 30.54 20.81 338 743 21.68

C LP Ext 2 64.26 5.0 181 672 43.18

D LLP Ext 3 4.4 1.14 102 626 2.75
E Exh-Condsn 44.7 0.091 44 44 1.97

F Power Output 25.65 MW

GHR = [A-(B+C+D+E)]/F 1850 Kcal/kWh

Cycle Effy 86000/GHR 47 %

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STEAM TURBINE EXTRACTION/EXHAUST ON HEAT RATE
30MW STG Multi-stage Extraction -Exhaust steam condensation with Cooling water
35
32

30
Power Conversion [%]

25 23

20 18

15
15

10 9

0
Extraction / Exhaust Stage of 30 MW Steam Turbine
HPE MP LP LPH C

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 INNOVATIVE METHODOLOGY FOR SUSTAINED HEAT RATE IMPROVEMENT

• Turbine exhaust steam flow, Vacuum, Cooling water flow rate alongwith
inlet & outlet temperatures to 30 MW STG Condenser shall be measured
with on-line temperature sensors on line & transferred to DCS for
continuous recording.

• Exhaust steam condensing flow rate is already being measured with

vacuum on a continuous basis.

• With all of the above in place, turbine exhaust steam enthalpy shall be
computed [ with the developed Innovative Algorithm ].

• Exhaust steam enthalpy shall be Dovetailed with CW flow of MCW

Pump.

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 INNOVATIVE METHODOLOGY FOR SUSTAINED HEAT RATE IMPROVEMENT

• Cooling water flow rate shall be adjusted with VFD of CW pump

relating to NHR reduction & minimize exhaust steam enthalpy with
Condenser vacuum subject to dryness fraction limit set at 0.88-0.89
[using Generative AI tool].

• Integrating Steam inlet conditions with the above, Objective is to

maximize steam enthalpy difference between Turbine inlet & exhaust
& thereby maximize Power generation.

• Plan to use IoT 5.0 concept through ensuring sustained uniform

operation especially during change of shift.

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INNOVATIVE ECS # 2 FOR NHR REDUCTION

Waste Heat from Condenser lukewarm water discharge

for preheating Boiler make-up water-
Deaerator Steam Consumption Reduction

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STG Condenser Lukewarm Cw return for preheating DM Water

LP Steam

CFB
Deaerator

PHE 1
CW Ret-
DMW DM
Water

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MEE Cw Cdsr return [Cooling tower divert] preheating DM Water

LP Steam
MEEC

CRB
Deaerator

PHE
CW Ret-
DMW DM
Water

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 Impact of Wide Seasonal Temperature range related to
LPS saving with heat in warm water return from Condensers
Coal Fired Boiler Chemical Recovery Boiler
DM Water Flow : 20 m3/h DM Water Flow : 50 m3/h
Season Winter Summer
Season Winter Summer

Time Day Night Day Night Time Day Night Day Night

DM DM
Water 20-24 16-20 29-32 26-29 Water 20-24 16-20 29-32 26-29
ᵒC ᵒC
Temp. Temp.
LPS TPH 0.45 0.6 0.3 0.4 LPS TPH 1.1 1.5 0.75 1.0
Saving- Saving
Deaer -Deaer
Temp. ᵒC 16-24 26-32 Temp. 16-24 26-32
range range

CER tCO2e
120 80 CER tCO2e
/month 200 300
/month

Enhance. Enrich.
With PHE installation, DM water Pump pressure had been
reduced with VFD from ………………………….: 12 ksc to 5 ksc.

DM Water Flow Rate……………………….: 45 to 50 m3/h

Power Consumption reduction …………...: 15 kW.[0.015 MW]

Green Power increase …………………….: ~360 units/day

Emission reduction credit …………………: 120 tCO2e/yr

Reduction in Absolute Stack Pollutants discharge : Traces

Enhance. Enrich.
With PHE installation, DM water Pump pressure shall be
reduced with VFD from ……………………….: 12 ksc to 5 ksc.

DM Water Flow Rate……………………….: 15 to 20 m3/h

Power Consumption reduction …………...: ~8 kW.[~0.01 MW]

Green Power increase …………………….: ~200 units/day

Emission reduction credit …………………: 70 tCO2e/yr

Reduction in Absolute Stack Pollutants discharge : Traces

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 ENERGY GAINS & DECARBONIZATION
ASC +APC Reduction & Net Heat Rate Improvement

Reduction in LP Steam Consumption in Deaerators .. : 1.1 TPH+ 0.4 TPH

Reduction in ASC achieved/planned is of the order of ………………………..…: 0.3%

[ 1.5 TPH LPS out of 250/300 TPH HP steam].

Reduction in both DM water pumps power consumption : 15 +8 = 23 kW

Reduction in APC achieved/planned is of the order of ………………………: 0.1%

[ 23 kW of 25 MW].

Overall Turbine Net Heat Rate shall be lowered by ……………………..……: ~0.4 %.

Carbon Emission Reduction -Existing & [Planned]

Carbon Emission Reduction Accrual ……………………………….………..:~ 3600 tCO2e/yr .

Enhance. Enrich.
 NET ENERGY AVAILABLE & NOT GROSS ENERGY GENERATION
OTHERS

APC ASC
Centre Unit Reduction Scheme Centre Unit Reduction Scheme

Boiler BFP • High η [77% ]with Low DP Boiler Deaerator • Hot Process Condensate
CV return total &
• Hot Condensate Polishing
Boiler Fans • High η [> 80%]
with/without VFD Boiler SCAPH • Optimizn of Steam
pressures,
Boiler ESP • Energy efficient • Condensate air heating &
Transformers, • Effective Insulation
• Design & Optimization of
rapping Boiler Blow-down & • Minimization & Avoidance
Leaks
CPP Air Compressor • Waste heat[80%] to
Steam for Power gen. Boiler Soot-blowing • Optimization &
• HPS fm Blr to MPS from ST
STG CW Pump • Avoid CV throttling &
High η CWP STG Generator Air • CW to DM water &
[>86%]+Optimization Cooler • Turbine return condensate

NPA = Power Gen[GP]- APC NSA= Gross Steam Gen- ASC

Enhance. Enrich.
 NHR –APC+ASC- Reduction Tips

 Feed water temperature increase due to Pressure rise in BFP increasing steam
economy

 In duct Combustion Air drawl increases combustion air temperature

 Low DP Control Valve relates to lowered BFP Power consumption

 CBD reduction –Advanced Boiler water conditioning

 Boiler –Turbine Interconnection Pipe Insulation strengthening to minimize steam

temperature drop

 Generator Air Cooling with Boiler make-up water & turbine condensate

 CPP Air Compressor- Waste heat recovery -Boiler make-up water heating

Enhance. Enrich.
 CONCLUSIONS & ADVISORY
INNOVATIVE ECS # 01 [ APC-Redn.]
With Cooling water flow lowered distribution in the 2 Condensers, through stoppage & running of 1
of 2 CW Pumps, significant APC reduction/Energy savings are being accrued on a sustained basis.

With this demonstration, stage is now set for varying the cooling water flow in line with varied turbine
exhaust steam condensing flow by going in for proposed Energy efficient smaller CWP with VFD
alongwith existing MCW Pump in place. With VFD in place, reduction in MCW Pump Power shall be
ensured at all condensing loads –high [35 to 50 TPH], medium [ 30 to 35 TPH & low [ 20 to 30 TPH].
Recommendation is one of varying Cooling water flow with condensation steam rate, CW conditions
[ ambient ], condenser exhaust steam state , so as to minimize ST exhaust steam enthalpy so as to
reduce NHR on a sustained basis.

INNOVATIVE ECS # 02 [ ASC –Redn.]

Diverting partly waste lukewarm water from Turbine Condenser & MEE Condenser outlet for
preheating DM feed water through PHEs, Steam consumption is being/shall be reduced in both the
Deaerators- more so during Winter Season as compared to Summer.

Both of the above Innovative ECS contribute to reduction in NHR of CPP complex;
The schemes can be replicated in all CPP/TPP so as to achieve NHR reduction on a
continuous basis.

Enhance. Enrich.