Please visit us at: www.just-chemicals.

com
Mr. Soumitra Banerjee

Mr. Soumitra Banerjee is a seasoned power plant and water treatment professional with in-hand experience of more than
26 yrs. He is a Post Graduate from Government Engineering College, Jabalpur in year 1995, did M.Sc. in Applied
Chemistry. He has worked with India’s Giant Private Power Generators in India viz., The Tata Power Company Limited
(handling multi-location Power plants in eastern India), Adani Power Limited, Jindal Power Limited, and Lalitpur Power
Generation Co. Ltd as HOD Power Station Chemistry and Environment. He has experience in both sub and super critical
power stations in India. He is the founder of Juschem Solutions Pvt. Ltd, Bangalore as a consultant, troubleshooter and
Trainer for both sub critical and super critical power stations. He was also associated with a prestigious Institute of Power
Technology as a guest faculty on Power Plant Chemistry. He has presented few papers on power plant chemistry and
water management in national seminars and magazines. Mr. Soumitra Banerjee has also a book titled “Practical Guide to
Thermal Power Station chemistry”, which includes Coal, Water and Oil for learning entire gamut of Power Station
Chemistry. He is currently serving as Consultant/Trainer/Advisor for JSW Energy Limited (3 Locations), L&T Power, Tata
Power, etc.,
 Our Capabilities cum offering
With extensive experience in the thermal and co-generation industries, We have conducted numerous
extensive site cycle chemistry reviews, audits and benchmarking studies at plants in India and Indonesia. We
have a team of retired NTPC and Big Private power plant professionals.
Audit for Power Plant Chemistry and Thermodynamic Efficiency:
• Recommending best practices and helping to create GCV Balance. Correct sampling and analysis is one
of the significant key in power plant efficiency
• Water Management and Water Balance including their treatment practices and recommend optimization
• Processes related to steam-water cycle chemistry and its systems, reporting, frequency and data control
• Efficiency and effectiveness measures of Cooling water treatment, DM Plant and Boiler water treatment
The technical process used by Thermal Chemistry is proven, robust and detailed. It clearly identifies key areas
of cycle chemistry risk for any plant. Practical, proven and detailed recommendations are then made to lower
the plants ongoing risk for future deposition and corrosion related failures.
 What we do to improve at IPPs & CPPs and Other Water Treatment Plants
Audit – Efficiency, effectiveness of process of Heat Balance, thermodynamics and power plant Chemistry
as boiler efficiency, condenser efficiency, Cooling tower efficiency, coal sampling-analysis and boiler
water chemistry contributes significantly to power plant economics

Audit criteria – what should be and what is

Audit finding – what is compared with what should be

Determine the causes and effects of the finding – recommend in audit report

Training on aspects, How, What, why, When, Where, Who/Whom on area of concern

Defining process, SWOT and Planning improvement projects

Estimate likely impact of Improvements

 Process Improvement Activities
Introduce
process change
Analyse Identify Tune
process improvements process changes
Train
engineers

Process Process change Training Feedback on Revised process

model plan plan improvements model
 Improvement Assessment
Process
Select projects Distribute Analyse Clarify
for assessment questionnair es responses responses

Identify issues Interview Interview Interview

for discussion project managers engineers mana gers

Brief managers Present Write report

and engineers assessment
 Present’s
Coal Quality Monitoring+ (CQM+)
A Value Added Service Proposal

Heat Balancing and Modelling Coal Quality Impacts on

Power Generation Costs
Dan Eyre, SGS Technologies Ltd
Power-Gen India & Central Asia, New Delhi, 18 May 2017
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 Coal quality expertise is required along the power generation value chain
New Build Fuel offer Load/Disport Delivery Utilisation Compliance

• Lab scale • Coal suitability • Coal sampling • Coal sampling • Combustion & • Data
testing review / advice & analysis & analysis emissions management
analysis
• Work as per • Coal switching • Supplier data • Coal stock • Emissions
Design and blending challenge management, • Boiler monitoring &
Specifications stock audit performance
• Out-of-spec / • Portfolio study
compliance
• Performance low cost coals optimization • Coal blending • Emissions
guarantees optimization • Problem Trading
solving

• CQM+ assessment

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• Coal quality, that is the properties of coal, has an impact on many parts of a power
plant including
• Unloading point weighment, sampling, sample preparation, analysis and storage
• Coal handling facilities and stacking + PV
• Pulverizing mills – performance with respect to LOI and VM
• Boiler – efficiency and 7 losses
• Air heater – efficiency and fluid dynamics
• ESP – Ash content, fluid and Resistivity
• Ash - % C content
• Stack emissions - losses
• Coals have different characteristics and heat content.
• The behavior of a coal in a boiler is strongly influenced by its rank and by the mineral matter and other impurities associated
with it.
• Coal properties can affect the efficiency, reliability and availability of both the boiler and the emissions control units.

Therefore they affect the economics as well as the short- and long-term operation of the plant.

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• A ‘CQM+’ is a systemic approach that involves the judgement which has technical knowledge and a great deal of accumulated
experience.
• CQM+ typically looks at the information and evidence available, and uses both technical knowledge and past experience to judge the
optimum operating conditions for a plant at a particular time.
• CQM+ system seeks to priorities and apply such knowledge, using a Analytics. It generally contains a knowledge base which
formalizes the accumulated experience, together with a set of methods for applying these as new conditions arise.
• Such systems can be applied to specific parts of an operating plant, and may also be used to determine overall operating
characteristics in such a way as to optimize long-term plant performance.
• A critical input variable for coal-fired plant will always be the quantity and quality of the GCV being fed to the boiler.

The operation of coal-fired power plants involves multiple variables which have different levels of importance. Thus
different systems need development and validation in different locations, also taking into account the many possible
variations in plant design.
We hereby define our role, joint efforts in following charts, which is made to improve the overall system of Coal
sampling – analysis – efficiency with scope of continual improvement

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 A typical layout of a pulverized coal fired power plant

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 For Heat Balancing: The stages that require monitoring in a coal-fired power generating plant
(as shown in Above Slide)
# Location/Equipment
1 Rail car unloading – sampling and Analysis* (Analytics)
2 Reclaim conveyor – Crosscheck for coal loss* (Analytics)
3 Coal storage conveyors– Crosscheck for coal loss* (Analytics)
4 Stockpiles – Sampling, Analysis and PV* (Analytics)
5 Mill silo feed conveyor (coal bunker conveyor)* (Analytics)
6 Mill silo (coal bunker) – Daily level-stock* (Analytics)
Applications for stages 1–6 include:
– weigh feeders** (Analytics)
– on-line coal analysers
– coal blending software
– conveyor belt monitoring and protection controls
7 Pulveriser (coal mill) and primary blower
– preheat air to pulverisers - monitoring
– coal flow distribution measurement and control
- coal fineness analysis and report

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 For complete Heat Balancing: The stages that require monitoring in a coal-fired power generating plant
# Location/Equipment
8 Boiler (coal-fired furnace)
- Boiler Efficiency Calculation loss method
– bottom ash removal – C%
– Ash slurry density and flow monitoring
– fly ash hopper level monitoring
– opacity monitors
– primary and secondary combustion air monitoring
- Boiler Blowdown Quantity and Temperature
– sampling probes
– gaseous pollutant monitors (CO, CO2, NOx, SO2)
– stack gas flow monitors
10 Particulate matter measurement (ESP)
– bottom ash slurry measurement
– fly ash level measurement
– carbon in fly ash
14 – cooling water system – heat transfer data (Optional)

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 • Since there are significant limitations on what can be established and on the interpretation and use of
the data obtained. SGS proposes help in the analytics and bringing out useful information from it as
value added service to Adani:

Commonly adopted approaches to controlling key specified parameters in the coal chain
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Scope of Work: Important and essential measurements:
1. Check - Right weighment at loading and unloading points
2. Check - Correct Sampling at loading, unloading and as fired
3. Check - Correct weighment at Coal Feeders/as fired
4. Audit - Correct analysis at all the above samples
5. Use -Algorithms and Functions to get the weighted average Data
6. Check - Correct PV and Correct Quantity Assessment – monthly
7. Check - Representative Samples during monthly PV, sampling and its analysis
8. Check and use - Past Data required for analytics
9. Check and use - Research Data and source of coal with precedence
10. Perform: Final Analytics using all the above to arrive at the gap (if exists)
11. Perform: Use Quality tools to find the cause of variation if any
12. Provide: Prescription and follow-up to reduce the variation and gap
 Summary
 SGS has extensive experience in all aspects of coal
supply and power plant operation

 CQM+ assessment is a powerful tool to deliver added Laboratory scale testing

Sampling and analysis
value to generation assets

 Identify best value coals and combustion

 Predict or characterize coal-related plant performance
problems
Full-scale testing Plant optimization
 Optimize coal blending strategy
 Tracking of GCV loss and prescription
 Determine coal quality adjustments (sulphur, ash, moisture
etc) Emissions management Risk management
 Evaluate fuel flexibility requirements for new build plant
 Evaluate low-cost / off-spec fuels

Coal suitability advice CQM+ assessment

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Reach us,
Juschem Solutions Pvt. Ltd
A108, SV Heights, Whitefield, Bangalore – 560066. KA
Email: [email protected]
Phone/WhatsApp: +91 7985635683, 9907203621
website: www.just-chemicals.com

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Visit us at www.just-chemicals.com