SEIL Power India Restricted, the one coal plant to win a POWER High Plant award this yr, stands out for its superior supercritical know-how, distinctive operational efficiency, and dedication to sustainability.
India, a longtime financial powerhouse, has been fielding huge energy demand progress lately—outpacing the worldwide common a number of instances over. In fiscal yr 2023 (FY23, April 2022–March 2023), “India witnessed its highest ever year-on-year progress in energy consumption,” marking a “exceptional improve of 9.6% each year, reaching 1,512 [billion units (BU)] in comparison with 1,380 BU in FY22,” Raghav Trivedi, CEO of SEIL Power India Restricted, an unbiased energy producer (IPP), informed POWER. In FY24, demand spiked once more to achieve 1,627 BU. Some forecasts counsel demand may attain a staggering 2,474 BU inside a decade—a rise of greater than 50%.
The fast improve is pegged partly to India’s sturdy gross home product (GDP) progress (of seven.2% each year in FY23 and eight.2% in FY24), in addition to scorching summer season temperatures, corresponding to these through the summer season of 2022, Trivedi famous. On the similar time, as in different international locations, India has made leaps in reaching common entry to electrical energy and electrification, notably for transportation. The facility sector “has turn out to be a catalyst for varied different sectors, together with manufacturing, agriculture, healthcare, and training, fostering financial growth and a greater high quality of life,” he mentioned.
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1. The SEIL Power India Restricted energy plant, a 2.64-GW supercritical coal-fired facility in Andhra Pradesh, India, options 4 660-MW models that ship excessive operational effectivity, superior emissions management, and progressive seawater cooling techniques. Courtesy: SEIL |
Demand progress, which is regionally decided, is about to soar, notably in Andhra Pradesh, certainly one of India’s most quickly creating states. In keeping with state planning paperwork, the state’s power necessities will develop at a compounded annual fee of 6.64%, fueled by fast urbanization and industrial progress pushed by the enlargement of Particular Financial Zones (SEZs) like Kakinada SEZ and Sri Metropolis SEZ, alongside large-scale infrastructure tasks such because the Vizag-Chennai Industrial Hall. In keeping with Trivedi, these circumstances pose a major alternative for SEIL, a 2.64-GW coal-fired energy plant (Determine 1) that’s strategically positioned on the japanese shoreline of Nellore district in Andhra Pradesh.
Leveraging Expertise to Enhance Efficiency
SEIL Power India Restricted’s energy plant stands out for its superior options, which give it an edge over different coal crops in India. Developed in two phases—Section 1 was accomplished in 2015, and Section 2 was accomplished in 2016—the plant boasts 4 660-MW supercritical coal-fired models that function at greater temperatures and pressures to maximise power extraction. Initially owned by Sembcorp, SEIL was acquired by Tanweer Infrastructure SAOC, an Oman-based infrastructure funding firm, in 2023.
“SEIL is poised to guide responsibly by persevering with to innovate and adapt to evolving power wants. By sustaining our give attention to sustainability and reliability, we intention to set new benchmarks within the provision of best-in-class power options for India’s future,” mentioned Trivedi.
On the coronary heart of the plant are two Dongfeng Electrical-supplied coal-fired steam boilers outfitted with entrance and rear wall firing burners. One other two Harbin-supplied coal-fired steam boilers are geared up with nook firing burners. The boiler system, outfitted with trendy metallurgy designed for 600C at reheat, allows the plant to burn even low-grade coal with steady flame circumstances. A key function of the boiler system is the usage of low nitrogen-oxide (NOx) burners, which successfully scale back emissions to fulfill environmental requirements. However, as well as, the system employs superheater spray tapping after the economizer coils, which permits for the restoration of warmth from the flue gasoline and considerably boosts the plant’s power effectivity.
SEIL famous it collaborated with the Nationwide College of Singapore to develop its advanced boiler mannequin, utilizing finite particle evaluation to grasp coal combustion behaviors for completely different grades of coal firing in mixing. The mannequin, which additionally consists of erosion sample evaluation, combustion effectivity, and emission evaluation, was used to improve SEIL’s operation procedures for essentially the most environment friendly firing.
The steam turbine configuration is a condensing tandem compound, single-reheat, 3,000-rpm steam turbine generator set. The design incorporates three casings: a high-pressure (HP) turbine, an intermediate-pressure (IP) turbine, and two double-flow low-pressure (LP) generators. A key innovation contributing to the plant’s efficiency is the Heater Above Reheat Strain (HARP) cycle. “The benefit of the HARP cycle is that it permits optimizing the ultimate feedwater heater temperature unbiased of the reheater strain, which reduces moisture on the LP exhaust,” SEIL defined, noting that the ultimate feedwater temperature is 284C.
SEIL has additionally made important strides in digitalization by creating and implementing varied in-house, real-time monitoring instruments aimed toward enhancing plant effectivity and sustainability. The plant, for instance, deploys Good Efficiency Evaluation (SMART), a real-time key efficiency indicator (KPI) device developed in-house that leverages Microsoft Azure cloud-based software program to observe the plant’s warmth fee. SPARK supplies real-time targets based mostly on dynamic working circumstances and controllable losses, serving to operators optimize efficiency, SEIL famous.
Moreover, SEIL’s in-house-developed Power Administration System affords detailed insights at each the system and gear ranges so operators can monitor auxiliary energy consumption in actual time. VISTA, a vital device developed by EPRI, simulates and analyzes varied coal blends and identifies potential points corresponding to slagging, overheating, and steam/flue gasoline temperature imbalances. SEIL additionally notably repeatedly screens and benchmarks its greenhouse gasoline emissions. The improvements, notably, received SEIL a Nationwide Award for Excellence in Power Administration in 2024 from the Confederation of Indian Trade (CII).
A Dynamic Gasoline Administration Technique
However SEIL’s reliability additionally depends on a dynamic gas administration technique, which leverages a mix of native and imported coal to make sure steady and environment friendly operations. The strategy circumvents fluctuations in coal high quality, a detriment affecting many coal mills in India. A vital benefit SEIL leverages is its location on the southern Indian shoreline (about 250 kilometers [km] from Chennai). “Subbituminous coal, bought on the worldwide market, is transported to the plant’s switch tower, from which it’s distributed throughout the coal pile,” the corporate defined.
The corporate notably makes use of drones to measure coal heap quantity and photogrammetric mapping of coal yard means. The apply, which it pioneered in 2018, supplys a number of benefits, together with quicker and extra correct knowledge assortment. It permits operations “to preserve precise account of stockpiles and optimize coal mixing operations. Moreover, drones drastically scale back the danger and errors related to guide measurements, thereby enhancing security and accounting requirements,” Trivedi mentioned.
To move imported coal effectively from the close by port, the facility facility makes use of a 15-km state-of-the-art pipe conveyor system, lowering transportation prices and minimizing environmental influence. “Being a coastal thermal energy plant, SEIL has developed procedures to make the most of home coal and imported coal in any mix to attain the bottom gas value and enhance top-line profitability,” he famous.
As a further notable financial technique, SEIL has secured commodity publicity for its energy buy agreements “by way of annual contracts for non-escalable power parts,” a transfer that ensures steady and predictable returns, SEIL mentioned. The technique ensures SEIL’s income stream stays sustainable, even in a unstable market.
A Give attention to Environmental Sustainability and Security
Yet one more particular innovation that stands out pertains to its seawater cooling system, which considerably reduces freshwater consumption—a vital consider a area the place water shortage is an ongoing concern. “The SEIL plant is among the uncommon crops in India to make use of seawater cooling towers,” the corporate famous.
About 12,000 cubic meters/hour of seawater are provided from a seawater make-up pumping station with siphon and submarine discharge pipe. “This pumping station additionally provides seawater to the desalinization crops to supply boiler make-up water, firewater, potable water, service water, and water for different facility makes use of,” SEIL added. As well as, superior demineralized water is produced by a “a number of impact” distillation system. “Desalinated water is subsequent handled in a brand new demineralization plant utilizing electro-deionization models to supply boiler-quality make-up water. Given the arid location, this water system is cost-effective and sustainable for a plant positioned near the ocean,” it mentioned.
Whereas a significant regional coal plant, SEIL additionally pursues a robust dedication to environmental sustainability. The plant, for instance, has achieved 100% fly ash utilization, repurposing the byproduct to be used within the building business. The fly ash is processed into uncooked supplies for cement and different constructing merchandise, a apply that each reduces waste and minimizes environmental influence. And, to additional improve its fly ash utilization and produce “value-added merchandise” geared for exports, SEIL famous it has applied bagging facility, storage sheds and container loading amenities. “A devoted group, with direct reporting to the CEO, was formed to monitor and improve ash utilization,” Trivedi famous. The positive aspects have been tangible: Up to now, it has exported fly ash to 16 international locations, together with Australia, Saudi Arabia, and Sri Lanka. As well as, SEIL says it’s the first Indian energy producer to be accredited for fly ash provide within the U.S.
Along with environment friendly ash dealing with, SEIL is supplied with low-NOx burners and tall stacks that assist reduce NOx emissions and preserve the plant compliant with native and worldwide environmental requirements. Steady emissions monitoring techniques are additionally put in to trace particulate matter and different pollution in real-time.
As one more side of its environmental and group dedication, SEIL says it has planted over 1.1 million saplings on 900 acres, put in photo voltaic panels in native establishments, and offered photo voltaic streetlights for 730 households. The corporate additionally companions with Apollo Hospitals to supply medical providers and operates reverse osmosis water crops in surrounding villages.
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Security is one other prime precedence at SEIL. Since its commissioning, the plant has logged a powerful 10.45 million secure man-hours, reflecting its robust dedication to operational security. SEIL attributes this achievement to a “behavior-based” security tradition that extends to all its property. The hassle has earned SEIL recognition from quite a few business our bodies, together with the Nationwide Security Council and the Golden Peacock Awards.
Trivedi mentioned SEIL’s plant load issue (PLF) constantly hovers above 80%, with a median PLF of 81.11%, demonstrating its skill to function at excessive capability whereas producing constructive profit-after-tax outcomes. “Amongst Indian IPPs, SEIL continues to be one of the vital reliable energy suppliers with an annual availability of 92.79% on a fancy foundation,” he mentioned. Trivedi attributes the stellar efficiency to devoted teamwork and powerful visionary management. However that, too, calls for a rigorously executed strategy. “We developed an intensive built-in course of to facilitate collaborative working between the coal and operations groups,” he famous.
Trying forward, “SEIL is poised to guide responsibly by persevering with to innovate and adapt to evolving power wants. By sustaining our give attention to sustainability and reliability, we intention to set new benchmarks within the provision of best-in-class power options for India’s future,” he mentioned.
—Sonal Patel is a POWER senior editor (@sonalcpatel, @POWERmagazine).
