A techno-economic feasibility study has been conducted to investigate revamping two 32 MWe pulverized-coal (PC) boilers with circulating fluidized bed (CFB) firing. The steam generators at Panki Thermal Power Station in Kanpur, Uttar Pradesh, are owned by Uttar Pradesh Rajya Vidyut Utpadon Nigam Limited (UPRVUNL), supplied by Waagner Biro, Austria, and commissioned in 1967–68. The study reveals that: (i) CFB revamping of the boilers is technically feasible and economically viable; (ii) Performance improvement of the plant is significant in terms of such indices as plant load factor, forced outage and a auxiliary oil consumption, among others. The expected performance improvement is due in large part to the elimination of key outage-prone components such as pulverizers (mills) and burners. (iii) Significant improvement in emissions performance due to the reduction in emissions of NOx and fly ash is projected. (iv) The financial analysis indicates that the CFB revamping option gives the highest return on investment compared to alternatives. Finally, to demonstrate the technical soundness and viability of the special design used in this revamping a sub-scale CFB boiler has been design and built at another power plant.

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