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Slide 1:

1 ENERGY CONCLAVE 2006 TECHNOLOGY FRONTIERS AND MODERNISATION ENERGY R&D BHEL ROLE & CONTRIBUTION PRESENTATION BY RAVI KUMAR DIRECTOR (POWER) BHEL, NEW DELHI

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2 R&D – WORLD STATUS Expenditure on R&D per capita (IN US $) INDIA - 5.5 CHINA - 11.7 S. KOREA - 241 AUSTRALIA - 285 UK - 460 USA - 705 JAPAN - 978

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3 R&D – BHEL TARGETS 2006-07 2005-06 EXPENDITURE ON R&D RS. 150 CR. RS. 125 CR. NO. OF PATENTS TO BE FILED 55 NOS. 45 NOS. COMMERCIALISATION OF IN HOUSE DEVELOPED PROJECTS RS. 700 CR. RS. 650 CR.

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4 BHEL-R&D EXPENDITURE AS % OF T.O.

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5 Lower Cost of Generation Environment Friendly Higher Efficiency Higher Reliability Compatible to Local Conditions TECHNOLOGY TRENDS POWER SECTOR

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6 Center Of Excellence For Simulators Center Of Excellence For Computational Fluid Dynamics Center Of Excellence For Permanent Magnet Machines CENTRE OF EXCELLENCE SETUP BY BHEL

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7 Low Nox Oil/ Gas Burners Large Capacity Atmospheric FBC High Efficiency Pelton Turbine Controlled Shunt Reactor (CSR) Flexible AC Transmission System (FACTS) Space Grade Solar PV Panels Phase Shift Transformer 145 KV Gas Insulated Switchgear India’s Largest Vertical AC Motor (6 MW, 6.6 KV) Micro Controller Based Flame Scanner Performance Analysis, Diagnostics and Optimization (PADO) Package 91 Ton/hr BHEL 280 Bowl Mill STATE OF ART TECHNOLOGIES / PRODUCTS INTRODUCED BY BHEL

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8 TECHNOLOGIES SUBSTANTIALLY DEVELOPED Supercritical Thermal Power Plants Circulating Fluidised Bed Combustion Coal Based Combined Cycle Plants IGCC PFBC Nuclear Power Generation with Fast Breeder Technologies Fuel Cells Solar Photo Voltaic

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9 The supercritical cycle offers a ‘burn less fuel for the same output’ approach Involves economical use of energy resources resulting in higher efficiency and low emissions BHEL is equipped to supply Supercritical Power Plants upto 1000 MW SUPERCRITICAL THERMAL POWER PLANTS

Cycle Efficiency benefits of supercritical units are derived from higher pressures and temperatures of steam:

10 Cycle Efficiency benefits of supercritical units are derived from higher pressures and temperatures of steam

Super Critical R&D Projects:

11 Super Critical R&D Projects Areas identified R&D Actions Taken Heat Transfer Correlations Joint Project with IIT-Chennai DNB, Tube Dry-out Flow Instability Spiral to Vertical Transition Piece Joint Project with AU FRG Load Transfer Attachment Dynamics, Temperature Control BHEL Corp R&D Ripple Effect BHEL In-House Chemical Lab FW Oxygenated Treatment Low NOx Burner BHEL In-House

CFBC TECHNOLOGY:

12 CFBC TECHNOLOGY Burns low grade fuels like lignite No pulverising Low NOx & Low SOx emissions Higher efficiency BHEL commissioned 2x390 TPH boilers for Surat Lignite Power Project Number of 125 MW CFBC based power plants are under execution Order received for 2x250 MW NLC, the largest CFBC technology based power plant in the country

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13 ENVIRNOMENTAL ASPECTS – ROAD MAP Development of low NOx wall fired coal burner - 2006 Establishment of SCR demo plant - 2007 Commercialisation of wall burner - 2008 Commercialisation of SCR system - 2010 Area of focus - NOx control in pulverized coal fired boilers Unit capacity, MW fuel NOx emission, ppm at 3.0 % O 2 500 gas 73 500 oil 129 to165 500 coal 271 to 434 250 coal 266 to 322 210 coal 247 to 478 210 lignite 242 to 280 120 coal 389 NOx emission scenario of Indian plants while firing different fuels:

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14 6.2 MW IGCC Pilot Plant at its Trichy Complex. Technical feasibility of upgrading the 6.2 MW Combined Cycle Demonstration Project of BHEL to ~100 MW had been established Preliminary assessment made for 400 MW IGCC Plant Plan to set up 125 MW IGCC Demonstration plant IGCC POWER GENERATION - DEVELOPMENT IN BHEL

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15 PFBG SCALE - UP IGCC POWER GENERATION - DEVELOPMENT IN BHEL

A glimpse of Fuel Cell Developments at BHEL (Inter-disciplinary approach followed for Fuel Cells Development):

16 A glimpse of Fuel Cell Developments at BHEL (Inter-disciplinary approach followed for Fuel Cells Development)

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17 Indigenous Fuel Cell R&D - Achievements Phosphoric Acid Fuel Cells (PAFC) BHEL R&D: 1 kW (1991), 5 kW (1995) & 50 kW (2000, 2 stacks of 25 kW each) - with data acquisition and display system & inverter have been demonstrated. Performance of a state-of-the-art 200 kW FCPP (PC 25 C, procured from M/s IFC / ONSI / Toshiba) also evaluated, using LPG as fuel. Polymer Electrolyte Membrane Fuel Cells (PEMFC) Single cells & small stacks for evaluating electro-catalysts. Also tested Direct Methanol FCs – Basic Tech acquired from IISc, B’lore High Temperature Fuel Cells (SOFC) BHEL R&D & CTI, Bangalore: Materials, processes & components developed. Assembled & tested single cells of planar SOFC.

BHEL IN PHOTOVOLTAICS:

18 BHEL IN PHOTOVOLTAICS Over two decades experience in Photovoltaics Manufacturing capacity of 3MW Single crystalline (mono) cells upto 2.3W (15% efficiency) PV modules range is from 10W to 160W PV systems integration capabilities- have supplied PV power plants ranging from 1 KWp to 150 KWp PV modules internationally certified to IEC 61215 standards Cumulative shipments from BHEL over 20 MWp

Future outlook for PV in BHEL :

19 Future outlook for PV in BHEL Automatic manufacturing capacity over 30 MW planned Plan for improving solar cell efficiencies to over 18% by 2010 Capability to process both mono & multi crystalline wafers Opportunities for backward integration into silicon wafer manufacturing Large scale deployment of PV power plants Explore alternate technologies like Thin film cells, multijunction cells etc

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20 BHEL - R&D DEVELOPMENT OF 765 KV TRANSMISSION SYSTEM 2006-07 TARGETS DESIGN & MANUFACTURE OF 765 KV, 500 MVA TRANSFORMER DESIGN & MATERIAL PROCUREMENT FOR MANUFACTURE OF 765 KV 80MVAr SHUNT REACTOR DEVELOPMENT OF COMPOSITE INSULATORS FOR TRACTION & TRANSMISSION WITH NANO ADDITIVES

POWER PLANT PERFORMANCE IMPROVEMENTS AUXILIARY POWER CONSUMPTION REDUCTION:

21 Power plant consumes nearly 7 to 9% of energy generated Auxiliary power can be brought down by proper selection of technology, equipments and cycle parameters Power consumption of BHEL manufactured equipment has been recently reduced from 7% (of total power consumption) to 6.65% for 250 MW & from 4% ( with turbine driven boiler feed pump) to 3.8% POWER PLANT PERFORMANCE IMPROVEMENTS AUXILIARY POWER CONSUMPTION REDUCTION

POWER PLANT RENOVATION & MODERNISATION:

22 LEADING PLAYER IN R&M AND UPRATING R&M and LE of Large No. of Units in India and Abroad Uprating of 110 MW Czech Units to 120 MW - Replaced Internals of HP, MP & LP Turbines with Reaction Type Blading - Boiler Upgrades to Ensure Rated - FlowModernize C&I and Balance of Plant Improvised Blade Profiles for 210 MW LMW Sets - Reaction Type Blades for HP Turbine yield an additional 2.5 MW - New Monoblock LP Rotor with Reaction Blading Leading to additional 3.7 MW POWER PLANT RENOVATION & MODERNISATION

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23 PERFORMANCE OF BHEL THERMAL SETS

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24 THANK YOU Committed to make a better world http://www.bhel.com

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