pwr_october-2024 - 31

COAL TOP PLANT
tal impact. " Being a coastal thermal
power plant, SEIL has developed procedures
to utilize domestic coal and imported
coal in any blend to achieve the
lowest fuel cost and improve top-line
profitability, " Trivedi noted.
As an additional notable economic
strategy, SEIL has secured commodity
exposure for its power purchase agreements
" through annual
contracts
1. The SEIL Energy India Limited power
plant, a 2.64-GW supercritical coal-fired facility
in Andhra Pradesh, India, features four
660-MW units that deliver high operational
efficiency, advanced emissions control, and
innovative seawater cooling systems. Courtesy:
SEIL
plant, for example, deploys Smart Performance
Assessment (SMART), a realtime
key performance indicator (KPI)
tool developed in-house that leverages
Microsoft Azure cloud-based software
to monitor the plant's heat rate. SPARK
provides real-time targets based on dynamic
operating conditions and controllable
losses, helping operators optimize
performance, SEIL noted.
Additionally, SEIL's in-house-developed
Energy Management System
offers detailed insights at both the
system and equipment levels so operators
can monitor auxiliary power consumption
in real time. VISTA, a critical
tool developed by EPRI, simulates and
analyzes various coal blends and identifies
potential issues such as slagging,
overheating, and steam/flue gas temperature
imbalances. SEIL also notably
continuously monitors and benchmarks
its greenhouse gas emissions.
A Dynamic Fuel Management
Strategy
But SEIL's reliability also relies on a
dynamic fuel management strategy,
which leverages a blend of local and
imported coal to ensure continuous
and efficient operations. The approach
circumvents fluctuations in coal quality,
a detriment affecting many coal generators
in India. A crucial advantage SEIL
leverages is its location on the southern
Indian coastline (about 250 kilometers
[km] from Chennai). " Subbituminous
coal, purchased on the global market, is
transported to the plant's transfer tower,
from which it is distributed across
the coal pile, " SEIL explained.
To transport imported coal efficiently
from the nearby port, the power facility
utilizes a 15-km state-of-the-art pipe
conveyor system, reducing transportation
costs and minimizing environmenOctober
2024 | POWER
for
non-escalable energy components, " a
move that guarantees stable and predictable
returns, SEIL said. The strategy
ensures SEIL's revenue stream remains
sustainable, even in a volatile market.
A Focus on Environmental
specific
Sustainability and Safety
Yet,
another
POWER POINTS
Winning Attributes
✔ SEIL's four 660-MW coal-fired
supercritical units employ advanced
technology that significantly
enhances efficiency and reduces
emissions.
✔ The project's plant load factor is
consistently above 80%, and its
annual availability rate is 92.79%.
✔ SEIL has implemented several
sustainability initiatives, including
an innovative seawater cooling
system and 100% fly ash utilization.
innovation
that
stands out relates to its seawater cooling
system, which significantly reduces
freshwater consumption-a critical factor
in a region where water scarcity is an
ongoing concern. " The SEIL plant is one
of the rare plants in India to use seawater
cooling towers, " the company noted.
About 12,000 cubic meters/hour of
seawater are supplied from a seawater
makeup pumping station with siphon
and submarine discharge pipe. " This
pumping station also supplies seawater
to the desalinization plants to produce
boiler makeup water, firewater,
potable water, service water, and water
for other facility uses, " SEIL added.
In addition, advanced demineralized
water is produced by a " multiple effect "
distillation system. " Desalinated
water is next treated in a new demineralization
plant using electro-deionization
units to produce boiler-quality
makeup water. Given the arid location,
this water system is cost-effective and
sustainable for a plant located close to
the ocean, " it said.
While a major regional coal plant, SEIL
also pursues a strong commitment to environmental
sustainability. The plant, for
example, has achieved 100% fly ash utilization,
repurposing the byproduct for use
in the construction industry. The fly ash is
processed into raw materials for cement
and other building products, a practice
that both reduces waste and minimizes
environmental impact. And, in addition to
efficient ash handling, SEIL is equipped
with low-NOx burners and tall stacks that
help minimize NOx emissions and keep
the plant compliant with local and international
environmental standards. Continuous
emissions monitoring systems are
also installed to track particulate matter
and other pollutants in real-time.
www.powermag.com
✔ Real-time digital tools optimize
plant operations and drive
continuous improvements in
performance.
✔ The plant has a stellar safety
record.
Safety is another top priority at SEIL.
Since its commissioning, the plant has
logged an impressive 10.45 million safe
man-hours, reflecting its strong commitment
to operational safety. SEIL
has earned recognition from numerous
industry bodies, including the National
Safety Council and the Golden Peacock
Awards.
Trivedi said SEIL's plant load factor
(PLF) consistently hovers above
80%, with an average PLF of 81.11%,
demonstrating its ability to operate at
high capacity while producing positive
profit-after-tax results. " Among Indian
IPPs, SEIL continues to be one of the
most dependable power providers
with an annual availability of 92.79%
on a complex basis, " he said. Trivedi
attributes the stellar performance to
dedicated teamwork and strong visionary
leadership. But that, too, demands
a carefully executed approach. " We
developed an extensive integrated
sheet to facilitate collaborative working
between the coal and operations
teams, " he noted.
Looking ahead, " SEIL is poised to
lead responsibly by continuing to innovate
and adapt to evolving energy
needs. By maintaining our focus on
sustainability and reliability, we aim to
set new benchmarks in the provision of
best-in-class energy solutions for India's
future, " he said. ■
-Sonal Patel is a POWER senior editor.
31
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