Future Coal Power Plants Projects Till 2035

Author(s)

Abdul Matin 15-ME-166

 
  
  
  
  
  
 
 
 
 

DEPARTMENT OF MECHANICAL ENGINEERING

FACULTY OF MECHANICAL & AERONAUTICAL ENGINEERING
UNIVERSITY OF ENGINEERING AND TECHNOLOGY
TAXILA
July 2018

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 ABSTRACT

Future Coal Power Plants Projects Till 2035

Pakistan has vast resources of energy potential. there's estimated 1,540 MTOE of coal within

the country. When it comes to diversifying the energy combine, coal

is a choice that Pakistan is exploring, and this report recommends that ultra-

super critical plants be installed within the country to realize bigger units of power generated,

in respect to fuel consumed, once more underscoring the principle of efficiency that forms the

umbrella of Pakistan’s Energy Vision 2035. Increase in efficiency of Coal-based power

plants so as to curtail environmental footprint and guarantee most utilization of fuel. The

advice is to maneuver towards higher efficiency and lower emissions (HELE), and ultra-

super crucial power plants would be the approach forward. This report

shall cover the upcoming coal fired power plants of the country until 2035.

Keywords:

 Ultra-super critical

 HELE

 Coal fired

 Resources

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 UNDERTAKING

I certify that project titled “ Future Coal Power Plants Projects Till 2035”

is my own work. The work has not been presented elsewhere for assessment. Where material

has been used from other sources it has been properly acknowledged / referred.

  
 

   

Abdul Matin

15-ME-166

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 ACKNOWLEDGEMENTS

We are thankful to our honorable Professor Dr. Abid Hussain Who provided us a chance to

enhance our knowledge, gave us the opportunity and guided us during our project assignment. We

really praise to his great efforts. We again extended our deep gratitude and heartiest thanks to all

of them whose creativity, experience, wisdom, skill, constructive criticism, scholastic approach

and valuable suggestions guided us throughout the preparation of report.

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 TABLE OF CONTENTS

ABSTRACT ………………………………………………………………………………...…….ii

UNDERTAKING…………………………………………………………………...……iii

ACKNOWLEDGEMENT……………………………………………………………………...…...iv

TABLE OF CONTENT …..…………………………………………………………………...…..v

LIST OF FIGURES …………………………………………………………………………...…viii

LIST OF TABLES ………………………………………………………………………………...ix

ABBREVATIONS……………………………………………………………………………...…..x

CHAPTER 1: Energy ...................................................................................................................... 9

1.1 Background .......................................................................................................................... 9

1.2 Existing Projects .................................................................................................................. 10

CHAPTER 2 : List of Proposed Projects ....................................................................................... 12

2.1 KCP Complex Coal Power Plant ......................................................................................... 12

2.2 K-Electric Coal Power Plant ................................................................................................ 13

2.3 Engro Thar Power Plant) ..................................................................................................... 13

2.4 Hub Coal Power Project....................................................................................................... 13

2.5. ThalNova Power Pvt Ltd..................................................................................................... 14

2.6. Thar Energy Ltd .................................................................................................................. 14

2.7. Lucky Electric Power.......................................................................................................... 15

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 2.8 Siddiqsons Energy Ltd ......................................................................................................... 15

2.9 Gwadar Coal Power Project ................................................................................................. 16

2.10 Oracle Coalfields PLC ....................................................................................................... 16

CHAPTER 3 : Processing and Working ........................................................................................ 18

3.1 Processing of Coal ............................................................................................................... 18

3.2 Working of a Coal-Fired PP ................................................................................................ 19

Conclusion ..................................................................................................................................... 20

REFERENCES .............................................................................................................................. 21

                                             

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                                                          LIST OF FIGURES

Number Page

Fig 1.1 Sahiwal Coal Power Plant….………..………………………..……………..1

Fig 2.1 KCP Power Plant…….…………….……………………..…...………..…..10

Fig 3.1: HUBCO PP Project Details …………………..………………...……..…...…..14

Fig 3.2: Working of coal fired PP …...………………………………………….......8

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 LIST OF TABLES

Number Page

Table 1.1: Primary Energy Mix of Pakistan…..……………………………………………………...………..10 

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 ABBREVIATIONS:

HELE: Higher Efficiency and Lower Emissions

MTOE: Million Tonnes of Oil Equivalent

PP: Power Plant

MW: Mega Watt

KW: Kilo Watt

PAEC : Pakistan Atomic Energy Comission

GTs : Gas Turbines

KCP: Karachi Nuclear Power

HP : High Pressure

USD : United States Dollar

CPEC: China Pakistan Economic Corridor

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 CHAPTER 1

Energy

1.1 Topic Background

Energy, being lifeline of socio-economic development of a country, occupies a dominant position

in the Plan as ensuring energy security is one of the important themes of the Vision. Pakistan is

facing a formidable challenge of energy shortages with the demand outweighing its supply. The

energy shortage has adversely affected all sectors of the economy resulting in an annual loss of up

to three per cent of the GDP. Pakistan’s existing energy mix is highly dependent on expensive

fuels, like oil and gas, instead of coal and hydel. In this context, gas accounts for 48 per cent,

followed by oil 33 per cent, hydel 11 per cent, coal six per cent, nuclear two per cent and a small

fraction from imported electricity. Disproportionate reliance on the imported oil, that is 85 per cent

of the total supply, is exerting a strain on the balance of payments besides making the energy mix

unfavourable. The total commercial primary energy mix for 2012-13 was 64.59 MTOE of which

26.5 per cent was from imports and 73.5 per cent was from local indigenous resources. The current

energy mix is heavily based on the subsidised indigenous gas, which is depleting and is left with

useful life of 17 years at the current consumption level. The future demand of primary energy is

projected to surge up to 92 MTOE during the Plan period.

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 TABLE 1.1 Primary Energy Mix of Pakistan

1.2 Existing Projects

Fig 1.1: Sahiwal Coal Power Plant

 Lakhra Power Plant, located in Jamshoro, Sindh. It is capable of producing 150 MW of

power.

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  Sitara Chemical Industries Ltd. Power Plant, located in Faisalabad, Punjab. It is capable

of producing 40 MW of power.

 Fauji Fertilizer Power Plant, located in Karachi, Sindh. It is capable of producing 118

MW of power.

 Sahiwal Coal Power Plant, located in Sahiwal, Punjab. It is capable of producing 1320

MW of power.

 Maple Leaf Power Plant, located in Mianwali, Punjab. It is capable of producing 40 MW

of power.

 Port Qasim Coal Power Plant, located in Karachi, Sindh. It is capable of producing 1320

MW of power.

 DG Cement Power Plant, located in DG Khan, Punjab. It is capable of producing 30 MW

of power.

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 CHAPTER 2

List of Proposed Projects

 2.1 KCP Complex Coal Power Plant

PAEC is setting up an indigenous coal-based generation facility/thermal power plant to meet

electricity requirement of the KCP complex. Total installed capacity of the plant will be 50MW
and two units of 25MW each will be installed. Local sub-bituminous coal will be used as primary
fuel while imported sub-bituminous coal will be utilised as an alternative.The expected
commercial operation date of the project is December 2017 while useful life of the generation
facility will be 30 years.The electric power from the coal-based generation facility will be
transmitted to the load centre of Fesco.

Pakistan Atomic Energy Commission (PAEC) has submitted an application to the National
Electric Power Regulatory Authority (Nepra) seeking power generation licence for the said
power plant.

                                                                 

Fig 2.1: KCP PP

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 2.2 K-Electric Coal Power Plant

K-Electric signed an agreement with Chinese companies to set up 700 megawatts of coal-fired

power plants. China Datang Overseas Investment Corporation (CDTO) and China Machinery

Engineering Corporation (CMEC) entered into a joint development agreement to develop two

350MW of coal-based power plant with a cost of one billion dollars at Port Qasim. The energy

generated by this project shall be sold to KE under a long term contractual arrangement as allowed

by the Interim Power Procurement Regulations 2005.

2.3 Engro Thar Power Plant

It is located in Mithi, Thar. Seventy per cent work on both mining and power projects have been

completed ahead of schedule and the first electron from Thar Coal Block-II will start generating

power by the end of this year, according to Sindh Engro Coal Mining Company (SECMC) chief

executive officer. The company is just 20 meters away from the first steam coal to supply coal to

660MW mine-mouth power plant. SECMC is a joint venture between Sindh government and

Engro Powergen Ltd. The power plant will be operational in May, 2019.

2.4 HUB Coal power project  

The second coal-fired power plant of Hubco will generate 1,320 megawatts from two 660MW
units. Coal will be imported from Indonesia and South Korea.

Hub Power Company (Hubco) will have a 24% stake in the power plant while a Chinese
company will have 74% shareholding. Additionally, 2% stake has been reserved for the

 
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Balochistan government. Most of the finances are offered by Chinese banks. It is expected to be
operational by August, 2019.

Fig 3.1: Hubco power Project details.

2.5 ThalNova Power Ltd.

ThalNova Power Thar Private Ltd (TNPTL) has signed the Engineering, Procurement, Construction

(EPC) contract with China Machinery & Engineering Corporation (CMEC) in Beijing recently to develop

the 330 MW Power project in Thar, Sindh. ThalNova is a CPEC power project based on Thar lignite

coal to be located at the power park site within Block II, Thar Coalfields, District Tharparkar, Sindh.

The capacity is 330 MW and is expected to be operational by March, 2021.

2.6 Thar Energy Ltd.

Plant construction will involve site clearing, preparation, grading, excavations and construction

of foundations, excavation of water storage and evaporation pond, construction of roads and other

structures. Power plant turbine’s main equipment and associated parts will be imported to Pakistan

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and shipped to site on flat bed trailers. Auxiliary machinery, components and structures from

Pakistan will be manufactured and fabricated outside the plant and shipped to the site on flat bed

trailers. These parts will be fabricated and installed on site. Typical activities during the plant

fabrication will include, site preparation and erection of equipment, machinery and structures.

Placement of the vessels and equipment on the foundations, laying of pipes, welding, joining,

electrical and instruments installation, painting and finishing.

2.7 Lucky Electric Power

Port Qasim Lucky power station is a 660-megawatt (MW) coal-fired power station proposed by

Lucky Electric Power Company Limited in Port Qasim, Pakistan. In March 2016, the Pakistan

Power Infrastructure Board approved the project. The project would cost $1 billion, and would be

financed on a 75:25 debt:equity ratio. Construction work would be performed by SEPCO III

Electric Power Construction. In November 2016, Lucky Electric announced that the plant would

run on domestic coal from the Thar lignite mine, rather than imported coal, in line with government

policy to increase reliance on domestic coal. At the time, Lucky stated that it planned to achieve

financial close by March 2017, and to begin commercial operations by the end of 2019; as of June

2017, however, there had been no announcement of financial close. In December 2016, Lucky

signed an engineering, procurement, and construction (EPC) contract with SEPCO III. In July

2018 it was reported GE Power will provide the boiler and steam turbine technology for the plant,

which is ultra-supercritical.

2.8 Siddiqsons Energy Lt

Engro Corporation on Monday announced its board had approved an investment of $21,375

million by way of subscription of ordinary shares in Siddiqsons Energy Limited. Siddiqsons

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Energy Limited is a special purpose vehicle (SPV) established to develop around 330 megawatts

of Thar coal-fired power generation facility in Block II, district Tharparkar Sindh on a build,

operate and own basis. the company was carrying cash amount of Rs65bn (USD 565mn) as of Mar

2018 and it has also applied for “letter of intent and rights” to develop 350MW of wind and solar

power plant in Balochistan. The project is expected to be operational by June 2021.

2.9 Gawadar Coal Power Project

It is an imported coal based power project, situated at Gwadar, in the province of Balochistan,

Pakistan. The primary energy input will be imported coal. It is to have an installed capacity of 300

MW. The estimated cost will be 600 Million USD. China Communications Construction Company

(CCCC) is the project executing company. Gwadar port authority and Gwadar Development authority are

to supervise the project.

2.10 Oracle Coalfields PLC

It initially was a 660Mw plant, rising eventually to 1,320Mw

The idea behind Oracle’s 4Mtpa mine and a first stage 660MW power plant at the mouth is based

on a current shortfall in Pakistan of generating capacity of 8,000Mw, a number that if anything is

going to rise.

The cost of realising this project is expected to be US$1.6bn, of which US$1bn will be debt.

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The firm has agreements and contracts, including an EPC (engineering, procurement

and construction) term sheet and contracts with its Chinese partner SEPCO for both mine and

plant.

A ‘no objection’ letter from the Central Power Purchasing Agency Guarantee Limited (CPPA)

- which buys electricity on behalf of Pakistan’s state-owned electricity grid operator NTDC means

power from the Thar project can be transmitted into the grid. Oracle’s site was recently put on the

priority list on the China-Pakistan Economic Corridor (CPEC), which should result in the fast-

tracking of debt-funding for the project.

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 CHAPTER 3

Processing & Working 

3.1 Processing of Coal

Coal is prepared for use by crushing the rough coal to pieces less than 2 inches (5 cm) in size. The

coal is then transported from the storage yard to in-plant storage silos by conveyor belts at rates

up to 4,000 short tons per hour.

In plants that burn pulverized coal, silos feed coal to pulverizers (coal mills) that take the larger 2-

inch (51 mm) pieces, grind them to the consistency of talcum powder, sort them, and mix them

with primary combustion air which transports the coal to the boiler furnace and preheats the coal

in order to drive off excess moisture content. A 500 MWe plant may have six such pulverizers,

five of which can supply coal to the furnace at 250 tons per hour under full load.

In plants that do not burn pulverized coal, the larger 2-inch (51 mm) pieces may be directly fed

into the silos which then feed either mechanical distributors that drop the coal on a traveling grate

or the cyclone burners, a specific kind of combustor that can efficiently burn larger pieces of fuel.

3.2 Working  

Coal-fired plants produce electricity by burning coal in a boiler to produce steam. The steam

produced, under tremendous pressure, flows into a turbine, which spins a generator to create

electricity. The steam is then cooled, condensed back into water and returned to the boiler to start

the process over.

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 Fig 3.2 Working of a Coal- Fired Power Plant

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 Conclusion

From the above analysis and my working experiences in coal-fired power plants. I can easily say

that the power plant is modern day techniques in operation and in working. As we know that

renewable energy is the result to our crisis in electrical power sector. The last government has

achieved a lot, yet there’s a long way to go. If we need to end this power crisis, we all has to play

our part and each government has to dedicate itself to eliminating the crisis. No power plant in the

world is free from problem. It is the responsibility of management to cope with the problems and

resolve them for the growth of the power plant. Sometimes, the management of power plant

realizes the problems but they have not given proper opportunity to implement their strategies in

their respective departments. China collaboration and CPEC proves as a golden opportunity for us

to develop in the said sector.

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 REFERENCES

 Web Links:

[1] CPEC project details

http://cpec.gov.pk/project-details/5
[2] Tables, diagrams, Info from
           https://www.pc.gov.pk/

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