West Bengal Power Development Corporation Limited (WBPDCL), the state’s largest power generation utility, has emerged as one of India’s most efficient coal-based power producers in recent years. With a strong focus on operational excellence, fuel self-sufficiency and gradual diversification into renewable energy, the corporation has significantly improved its performance metrics while expanding its generation portfolio.
WBPDCL’s generation portfolio
WBPDCL currently operates a total installed capacity of 4,265 MW across five thermal power plants (TPPs) in West Bengal. In addition, a 660 MW supercritical unit at the Sagardighi TPP achieved full load operation in December 2025 and is moving towards commercial operation. The company’s thermal fleet has been built over several decades and includes the 275 MW Bandel thermal power station (TPS), the 500 MW Santaldih TPS, the 840 MW Kolaghat TPS, the 1,050 MW Bakreswar TPP and the 2,260 MW Sagardighi TPP, including the new supercritical unit. The commissioning of the 660 MW unit represents a significant step in WBPDCL’s transition towards more efficient and advanced generation technologies.
Alongside its thermal fleet, WBPDCL has begun expanding into renewable energy. The company currently operates 62 MW of solar capacity and has an additional 21.5 MW under installation. One of the key projects under planning is a 200 MW floating solar plant at the Bakreswar dam, which will be integrated with battery storage systems. This project reflects WBPDCL’s strategy of gradually diversifying its generation mix while continuing to rely on coal-based generation for baseload supply.
Captive coal and fuel self-reliance
Fuel security is a cornerstone of WBPDCL’s operational strategy. The corporation operates five captive coal mines with a combined capacity of about 25 million tonnes per annum (mtpa). These include the Pachhwara North coal mine with a capacity of 15 mtpa, the Barjora (North) coal mine with 3 mtpa, the Gangaramchak Coal Mine with 3 mtpa, and the Tara East and West coal mines with a combined capacity of 4 mtpa.
A major milestone was achieved in 2024-25, when WBPDCL met 100 per cent of its coal requirement through its captive mines, thereby eliminating its dependence on Coal India Limited. This move has significantly strengthened the company’s supply reliability and cost stability. By ensuring assured coal availability, the company has been able to maintain high plant load factors (PLFs) and consistent generation levels.
Operational performance and key achievements
WBPDCL has recorded impressive operational performance in recent years. According to the Central Electricity Authority (CEA), the corporation achieved a PLF of 88.9 per cent in 2024-25, significantly higher than the national average of around 70 per cent for coal-based power plants.
The Santaldih TPS emerged as the best-performing coal-based plant in the country, recording a PLF of 94.38 per cent during the year. In addition, four WBPDCL stations ranked among the top 10 coal-based TPSs in India in terms of efficiency parameters during 2024-25. Santaldih secured the first position, while Bakreswar ranked second, Sagardighi fourth and Bandel ninth.
The company also achieved its highest-ever electricity generation of 33.2 billion units (BUs) in 2024-25, surpassing the previous record of 31.8 BUs. This represented a growth of 1.4 BUs or about 4.4 per cent compared to the previous fiscal. Operational improvements were also reflected in lower specific oil consumption, which declined to 0.22 ml per kWh, well below normative levels.
Another major operational milestone was achieved at Bakreswar Unit 2, which ran continuously for 505 days from May 28, 2024 to October 14, 2025, demonstrating exceptional reliability and maintenance practices. These achievements collectively highlight WBPDCL’s strong operational discipline and focus on efficiency.
Strategy for performance improvement
The improvements in WBPDCL’s operational indicators were driven by a structured tenfold strategy implemented during 2024-25. The strategy prioritised strengthening safety and environmental practices, enhancing human resource development and improving stakeholder engagement.
Other important elements included adopting best operational practices, ensuring uninterrupted coal supply from captive mines and strengthening quality assurance and coal unloading systems. The company also focused on improving maintenance practices, better planning of unit overhauls and centralised monitoring of critical operational parameters. Special attention was given to improving the performance of older generating units.
As a result of these initiatives, several key operational indicators improved significantly. The PLF increased from 82.22 per cent in 2023-24 to 88.90 per cent in 2024-25, while the plant availability factor rose from 83.42 per cent to 91.15 per cent. Auxiliary power consumption declined from 8.72 per cent to 8.44 per cent, and specific oil consumption decreased from 0.35 ml per kWh to 0.22 ml per kWh. For the first time, WBPDCL achieved 100 per cent recovery of fixed costs against normative parameters for all its units.
Coal-based power in India’s energy mix
Despite the rapid expansion of renewable energy, coal-based power continues to play a dominant role in India’s electricity system. As of 2024-25, India’s total installed power capacity stood at about 509.64 GW, of which 246.9 GW was thermal capacity, accounting for nearly 48 per cent of the total installed capacity. However, in terms of actual electricity generation, thermal power contributed nearly 70 per cent of the total generation at around 1,340 BUs, as against the country’s total generation of 1,829.7 BUs. This underscores the continued importance of coal-based power plants in ensuring a reliable baseload electricity supply.
Electricity consumption in India has also been growing steadily. Per capita electricity consumption reached 1,460 kWh in 2024-25, representing an increase of over 52 per cent compared to a decade ago. Nevertheless, this figure remains significantly lower than the global average of around 3,670 kWh, and far below consumption levels in developed economies such as the US, Germany and Japan. This indicates significant scope for further growth in electricity demand.
Power demand outlook for West Bengal
Electricity demand in West Bengal has also been increasing steadily in recent years. The state recorded a peak power demand of around 12,495 MW in September 2025. According to projections under the West Bengal Clean Energy Transition Roadmap 2030, electricity demand in the state is expected to increase from around 62,957 MUs in FY 2026 to over 81,354 MUs by FY 2030.
Thermal power continues to dominate the state’s generation mix, accounting for nearly 90 per cent of the electricity supply, while hydropower, pumped storage and solar contribute relatively smaller shares. To meet the growing demand, several new projects are being planned in the state. These include a 4×800 MW coal-based project by JSW Energy at Salboni, an 800 MW thermal project at Durgapur under the public-private partnership model and another 800 MW unit planned at Bakreswar. In addition, two 800 MW units are proposed at Santaldih. On the renewables side, projects such as the 200 MW floating solar plant at Bakreswar with battery storage and a 100 MW solar project extension at Goaltore are being planned. A 1,900 MW pumped storage hydroelectric project in Purulia district is also under preparation.
Demand drivers
Several structural factors are expected to drive electricity demand growth in the coming years. One of the major drivers is rising domestic electricity consumption, particularly due to the increasing use of appliances such as air conditioners, refrigerators, pumps and heating equipment. Cooling appliances alone are expected to account for nearly one-third of India’s peak electricity demand by 2030.
Another important factor is the rapid expansion of new-age sectors such as data centres and electric vehicles (EVs). Data centre capacity in India is expected to grow at around 20 per cent annually, adding significantly to baseload demand. At the same time, the electrification of transportation through EV adoption will further increase electricity consumption.
Industrial growth under the Make in India initiative is also expected to increase demand. Sectors such as semiconductors, chemicals, food processing and green hydrogen are expanding rapidly and require reliable and continuous power supply. In this context, WBPDCL views coal-based generation as the backbone of state’s energy security, while gradually integrating renewable sources to complement its generation portfolio.
Key challenges
Despite its strong operational performance, WBPDCL faces several operational and structural challenges. One of the key challenges is the increasing requirement for the flexible operation of TPPs as they must ramp up or ramp down generation to accommodate the variability of renewable energy sources. Operating units at lower loads can reduce equipment life and increase maintenance costs. Coal logistics also remain a concern. Even with captive coal mines, transporting coal from mines to power plants can be difficult due to limited rail infrastructure and environmental concerns associated with road transport.
Financial challenges persist due to delayed payments from distribution companies, which create liquidity constraints for generation companies and impact future investments. Environmental compliance requirements also pose significant financial challenges. Technologies such as flue gas desulphurisation (FGD) and selective catalytic reduction systems increase operational costs and require substantial capital expenditure.
Water management is another important issue. Revised norms impose stricter limits on raw water consumption, requiring investment in zero liquid discharge systems and sewage treatment plants. In addition, ash utilisation remains a challenge due to the limited availability of ash consumers and transportation infrastructure.
WBPDCL faces several challenges in the development and execution of new power generation projects. One of the primary constraints is the limited manufacturing capacity for key thermal power equipment within India, which often results in longer procurement timelines. This is further compounded by import dependence for critical components such as alloy steel-and semiconductor-based systems, exposing projects to global supply chain disruptions and cost fluctuations. The sector is also witnessing a shortage of experienced manufacturing and erection vendors, impacting construction schedules and quality assurance. In addition, the long gestation period of thermal power projects, often caused by demand-supply mismatches and regulatory approvals, can lead to project delays and escalation in capital costs.
Land acquisition for TPPs, solar projects, mining infrastructure and railway connectivity remains a major hurdle. Furthermore, implementing environmental compliance measures, particularly desulphurisation projects such as FGD at plants like Sagardighi and Kolaghat, requires significant capital and operational expenditure, adding to the financial burden of new and ongoing projects.
Emerging technological requirements
To remain competitive in the evolving power sector, WBPDCL is focusing on technological upgrades and digital transformation. The company is exploring ultra-supercritical and advanced ultra-supercritical technologies for future capacity additions in order to improve efficiency and reduce emissions.
Digital technologies are also being adopted to enhance operational efficiency. Tools such as artificial intelligence, machine learning and predictive analytics are being used for predictive maintenance and plant performance optimisation. Advanced monitoring platforms and digital twin technologies are being deployed to enable real-time monitoring and improve asset reliability. Another emerging focus area is energy storage integration, where pilot projects are being explored to combine battery storage systems with TPPs. Such systems can help stabilise the grid and balance fluctuations in renewable energy generation.
Future outlook and strategic priorities
Looking ahead, WBPDCL aims to maintain its leadership position as one of the top-performing power generation utilities in the country. Operational excellence remains a central priority, with continued emphasis on maintaining high PLFs and strengthening plant information systems for real-time monitoring.
Strategic expansion will focus on transitioning towards more supercritical thermal units, supported by complete fuel self-sufficiency through captive coal mines. The commissioning of the 660 MW supercritical unit at Sagardighi, expected to achieve commercial operation in early 2026, represents a key milestone in this direction. The company is also planning additional capacity additions, including two 800 MW units and another 660 MW unit.
At the same time, WBPDCL aims to expand its renewable energy portfolio through projects such as the 200 MW floating solar plant at Bakreswar and other solar installations. Environmental compliance initiatives, including the installation of FGD systems at Sagardighi and the modernisation of electrostatic precipitators at Kolaghat, are also being prioritised.
Conclusion
WBPDCL’s recent achievements highlight the continued importance of efficient coal-based generation in India’s evolving power sector. Through a combination of operational improvements, captive fuel security and selective adoption of new technologies, the company has established itself as one of the country’s top-performing generation utilities.
While the energy transition is accelerating, coal will continue to play a critical role in ensuring reliable baseload power for states such as West Bengal, where electricity demand is rising rapidly. By maintaining high operational standards while gradually integrating renewable energy and digital technologies, WBPDCL aims to sustain its leadership position and support the state’s long-term energy security.
Based on a presentation by A.K. Mukherjee, Director (Projects), WBPDCL, at a recent Power Line conference.
