The Kudgi thermal power plant located in the Bijapur District of Karnataka, India, is the first super-critical coal-fired power project to be undertaken by India’s state-owned electricity generator NTPC.
The 4GW thermal power facility is being developed in two stages. The first stage comprising three 800MW super-critical generating units was declared commercial in September 2018. The second stage will consist of two more 800MW super-critical generating units.
The Kudgi thermal power project stage one broke ground in June 2012 and the first generating unit of the plant was commissioned in December 2016.
The second and third units were commissioned in March 2017 and March 2018, respectively.
Kudgi thermal power project development history
A memorandum of understanding (MoU) was signed between NTPC, Power Company of Karnataka Limited (PCKL), and the Energy Department of Karnataka to construct the super-critical thermal power plant on a 4,100ha site at Kudgi in January 2009.
The designated coal block for the power plant received forest clearance in September 2010.
Kudgi thermal power plant make-up
Built on a 2,440ha site, the stage one comprises three supercritical once-through coal-fired boilers supplied by Doosan and three 800MW Toshiba steam turbines.
Each boiler is capable of producing 2,550t of high-pressure steam an hour, operating at 271kg/cm² pressure and 569°C temperature.
The plant has a 275m-high flue stack and is fitted with electrostatic precipitators (ESP) for pollution control.
It is estimated to require 7,380m³ of water an hour, which is supplied through a pipeline from Almatti Dam on Krishna River, located 18km away from the project site. The power plant has an onsite water reservoir facility to store the water.
The power plant employs high-concentration slurry disposal (HCSD) system to dispose the ash generated during power production.
Coal supply for the Kudgi power plant
The Kudgi power project is estimated to require up to 12 million tonnes (Mt) of coal a year, which is being initially met through domestic coal supply from NTPC’s Pakri Barwadih Coal Block in Jharkhand.
The plant is expected to use blended coal in future.
Power transmission from the Kudgi thermal power plant
The electricity generated from the Kudgi power plant is evacuated to India’s Southern grid through 400KV transmission lines.
Karnataka is entitled to receive 50% of the total generated power from the plant.
NTPC signed a $350m term loan agreement with the Japan Bank for International Cooperation (JBIC ) for the Kudgi power project stage one in January 2014.
Toshiba JSW was awarded a $470m contract for supplying three 800MW supercritical steam turbines and generators for the stage one of Kudgi thermal power project in February 2012.
Doosan Chennai Works, a subsidiary of Doosan Heavy Industries and Construction, was awarded the contract for the supply of supercritical coal-fired boilers for the stage one in the same month.
Dosan engaged Sunil Hitech and Edac Engineering for the erection, testing and commissioning of the boilers.
JSW Severfield Structures (JSSL), a joint venture between JSW Steel and Severfield, was subcontracted by Dosan for the primary and secondary structures of the boilers.
Torishima Pump was subcontracted for providing three boiler circulation pump units for the stage one.
IDPL was contracted for the detailed engineering, survey, civil works, installation, testing and commissioning of the four interconnected power transmission lines to evacuate power from the Kudgi power plant.
Petron Engineering Construction was contracted for the supply, installation, testing and commissioning of the electrical equipment.
Unity Infraprojects was awarded a contract worth Rs2.48bn ($39m approximately) in February 2014, for the construction of the township at the Kudgi project site.
IVRCL was responsible for the steam generator area and other offsite civil works for the project.
Mantec Consultants was hired to conduct the environmental impact assessment study for the Kudgi thermal power plant.