for

THERMAL POWER PLANTS

By JVD RAO BE,MBA

ADE / Coal Coordinator/E&P
Dr.NTTPS

APGENCO Mobile :9493120449

Contents
Coal Facts
1. Formation, Mining & Uses 2. Classification 3. Calorific Values of Fuels 4. Classification 5. Influence of coal nature 6. Fuels Grades & GCVs 7. Analysis

..... .. .. .. .. .. ..

Coal Handling at Dr. NTTPS

1. Introduction 2. Coal Preparation 3. Coal Linkages. 4. Typical Coal analysis Results 5. Bunker Levels 6. Boiler Design Values

.. .. .. .. .. .. . .. ..

7. Delegation of powers APGENCO 8. Penalty calculations

9. Environmental standards 10. Free loading/unload timings 11. Demurrage charges

12. Delegation of powers-Railways

Appendix
1. Performance Calculations 2. Boiler Efficiency Calculations.

.. .. . ..

3. Air pre-heater performance

4. Conversions.

Annexure-Dr.NTTPS
1. CHP schematic diagram
2. Belt conveyors specifications 3. Wagon tipplers specifications 4. Crushers specifications 5. Stacker/Reclaimers specifications

PREFACE
The coal hand book covers up with coal related topics such as Coal formation, types, grades and prices, which also provides various coal analyses with typical test results. It is more important to provide coal information with typical test results. This book may provide important and valuable information related to coal handling plants of thermal plants (especially Dr.NTTPS) such as coal linkages, grades, prices. It also provides major equipment details such as wagon tipplers, belt conveyors, crushers and stacker/reclaimers. In the last two and half years of my service in coal plant, DR.NTTPS as ADE/COAL COORDINATOR, I have gone through major portion of the CHP system and I also visited various sea ports to inspect and study the type of coal received for APGENCO. As I had interest to get the knowledge on coal handling system, I concentrated and studied more on coal and coal handling system by regular observation and involvement and I also gone through the system during interruptions and breakdown time gaps. Finally my opt to think to inscribe this coal hand book is to provide information regarding coal and CHP system of DR.NTTPS to the people whoever eagerly searching for information on COAL and CHP System. I have had considerable help and advice from many engineers, friends and colleagues during the preparation of the various editions of this book. So, I must thank to all for their valuable suggestions and guidance, especially thanks to Er.G.Sampath Kumar, DE/E&P-IV/DR.NTTPS for his valuable support and involvement during the editing and designing of this valuable edition. imported

-JVDRAO

COAL FACTS
Coal Formation:
Fossil fuels are derived from plant and animal matter. They formed naturally over millions of years. These energy-producing fuels are the remains of ancient life that have undergone changes due to heat and pressure. The primary fossil fuels are coal, petroleum and natural gas. Together they account for 85% of the world's energy consumption. Coal is a dark, combustible material formed, through a process known as coalification, from plants growing primarily in swamp regions. Layers of fallen plant material accumulated and partially decayed in these wet environments to form a spongy, coarse substance called peat. Over time, this material was compressed under sand and mud, and heated by the earth to be transformed into coal. Some scientists refer to coal as sedimentary rock. Coal is primarily composed of carbon, hydrogen, oxygen and nitrogen. There are several classifications of coal, which are rated according to their carbon content and heating value. The heating value of coal is expressed in Kcal/Kg.

Coal Mining
The two main types of coal mining are 1. Surface (strip) mining and 2.underground mining.

Strip mining
It involves the removal of coal deposits close to earth's surface (usually no more than 100 feet from the surface). Topsoil and rocks are removed from the surface to expose the coal deposits. Explosives and heavy machinery are used to break up and remove layers of coal. Underground mining It involves the removal of coal deposits, often hundreds of feet below the earth's surface. (Some mines may be close to 2,000 feet deep.) Shafts or tunnels are dug into the coal layers and widened to allow room for the miners and coal cars or conveyor belts. Additional shafts may be excavated to increase air ventilation for the miners.

Coal Uses
Coal is used to generate heat, produce electricity, and make steel and industrial products. It is used worldwide as a fuel, second only to petroleum as the most consumed energy resource.

Coal Classification
As geological processes apply pressure to dead biotic material over time, under suitable conditions it is transformed successively into Peat: It is considered to be a precursor of coal, has industrial importance as a fuel in some regions, for example, Ireland and Finland. In its dehydrated form, peat is a highly effective absorbent for fuel and oil spills on land and water. Lignite: It is also referred to as brown coal, is the lowest rank of coal and used almost exclusively as fuel for electric power generation. Jet is a compact form of lignite that is sometimes polished and has been used as an ornamental stone since the Upper Paleolithic. Sub-bituminous coal : This coal properties range from those of lignite to those of bituminous coal is used primarily as fuel for steam-electric power generation. Additionally, it is an important source of light aromatic hydrocarbons for the chemical synthesis industry. Bituminous coal : its look like a dense sedimentary rock, black but sometimes dark brown, often with well-defined bands of bright and dull material, used primarily as fuel in steam-electric power generation, with substantial quantities also used for heat and power applications in manufacturing and to make coke. Steam coal: It is a coal having grade between bituminous coal and anthracite, once widely used as a fuel for steam locomotives. In this specialized use it is sometimes known as sea-coal in the U.S. Anthracite : it is the highest rank; a harder, glossy, black coal used primarily for residential and commercial space heating.

Graphite : It is technically the highest rank, but difficult to ignite and is not so commonly used as fuel: it is mostly used in pencils and, when a powdered, as a lubricant.

CALORIFIC VALUE OF FUELS

Calorific value (CV)
The calorific value is defined as the quantity of heat liberated on the complete combustion of a unit weight or unit volume of fuel, at constant pressure and under the conditions known as normal of temperature and pressure (i.e. to 0C and under a pressure of 1 .013 mbar). It is measured in units of energy per unit of the substance, usually mass, such as: kcal/kg, kJ/kg, J/mol, Btu/m.

Gross Calorific Value (GCV)

The higher calorific value (or) Gross calorific value (GCV) which supposes that the water of combustion is entirely condensed. The heat contained in this water is recovered.

Net Calorific Value (NCV):

The lower calorific value (or) Net calorific value (NCV) which supposes that the products of combustion contain the water of combustion in the vapor state. The heat contained in this water is not recovered.

Heat Rate (HR):

The amount of heat input required per unit of power generated (kcal/kwh) for specific fuel being fired and specific site conditions. A measure of generating station thermal efficiency, generally expressed in btu per net kwh. It is computed by dividing the total btu content of fuel burned for electric generation by the resulting net kwh generation.

Dulongs formulae for GCV calculation : According to Dulong's formula

GCV = ((35.5 x C + 114.8 x H + 9.5 x S 14.5 x O) x 1000) (100 x 4.1868)

Measurement of GCV in different basis

The variables are measured in weight percent (wt. %) and are calculated in several basis, they are AR (as-received) basis is the most widely used basis in industrial applications. AR basis puts all variables into consideration and uses the total weight as the basis of measurement.
AS RECEIVED BASIS (AR) = TM+IM+ASH+VM+FC+S (Includes all moistures)

AD (air-dried) basis is to neglect the presence of moistures other than inherent moisture while DB (dry-basis) leaves out all moistures, including surface moisture, inherent moisture, and other moistures.
AS DRIED BASIS (AD) = 0+IM+ASH+VM+FC+S (Includes Inherent moisture)

DAF (dry, ash free) basis is to neglect all moisture and ash constituent in coal
AS DRY ASH FREE (DAF) = 0+0+0+VM+FC+0 (Excludes all moisture & Ash)

DMMF (dry, mineral-matter-free) basis leaves out the presence of moisture and mineral matters in coal, for example: quartz, pyrite, calcite, etc. Mineral matter is not directly measured but may be obtained by one of a number of empirical formula based on the ultimate and proximate analysis.
AS DRY BASIS (DB) = 0+0+ASH+VM+FC+S (Excludes all moisture)

(TM=Total Moisture, IM=Inherent Moisture, VM=Volatile Matter, FM=Fixed

Carbon, S=Sulphur)

Influence of Coal Properties

Properties effect on Specific Coal Consumption
The effect of various coal properties like ash content, moisture content, fixed carbon and calorific value on specific coal consumption in a typical thermal power station in India is analyzed. It is observed that the specific coal consumption is a strong function of moisture content, ash content and fixed carbon. For the known Thermal Power Station (as considered in the present analysis), it is observed that, for an increase in moisture content by 2%, the specific coal consumption increases by about 8%. If, however, the ash content is increased by 2%, the specific coal consumption increases by about 5%. It is also observed that, for a 4% increase in fixed carbon, the specific coal consumption decreases by about 25%.

Coal Boulders on performance

Delay in unloading, which also pay demurrage charges to railways. More labor required to clear off boulders. Damage of conveyers and equipments. Damage of crushers Jamming of chutes and hoppers. No coal flows at bowl mills. Loss of generation. Wastage men & machine running hours.

Coal Wetness on performance

Delay in unloading, which also pay demurrages to railways. More labor required to clear off wet coal. Damage of conveyers and equipments. Jamming of chutes, hoppers and crushers. Due to wetness loss of generation. No coal flows at bowl mills. Formation of clinkers in boilers. System troubles.

FUELS GRADE & GCV S

I.COAL GRADES
The gradation of non-coking coal is based on Useful Heat Value (UHV), the gradation of coking coal is based on ash content and for semi coking / weakly coking coal it is based on ash plus moisture content , as in vogue as per notification.
Grades of Coking Coal: Grade Steel Grade I Steel Grade -II Washery Grade -I Washery Grade -II Washery Grade -III Washery Grade -IV Ash Content Not exceeding 15% Exceeding 15% but not exceeding 18% Exceeding 18% but not exceeding 21% Exceeding 21% but not exceeding 24% Exceeding 24% but not exceeding 28% Exceeding 28% but not exceeding 35%

Grades of Non-coking Coal: Grade Useful Heat Value (UHV) Corresponding Gross Calorific Value(GCV) (Kcal/Kg) Ash% + Moisture % (Kcal/ Kg) UHV= 8900-138(A+M) at (60% RH & 40O C) (at 5% moisture level) Exceeding 6200 Not exceeding 19.5Exceeding 6454 Exceeding 5600 but not 19.6 to 23.8 Exceeding 6049 exceeding 6200 but not exceeding 6454 Exceeding 4940 but not 23.9 to 28.6 Exceeding 5597 exceeding 5600 but not exceeding. 6049 Exceeding 4200 but not 28.7 to 34.0 Exceeding 5089 exceeding 4940 but not Exceeding 5597 Exceeding 3360 but not 34.1 to 40.0 Exceeding 4324 exceeding 4200 But not exceeding 5089 Exceeding 2400 but not 40.1 to 47.0 Exceeding 3865 exceeding 3360 but not exceeding. 4324 Exceeding 1300 but not 47.1 to 55.0 Exceeding 3113 exceeding 2400 but not exceeding 3865

A B C D E F G

Grades of Semi-coking and Weakly Coking Coal: Grade Semi coking grade I Semi coking grade II Ash + Moisture Content Not exceeding 19% Exceeding 19% but not exceeding 24%

Grades of NEC Coal :

10

Grades A B

UHV (Kcal/Kg) 6200-6299 5600 6199

Corresponding Ash% + Moisture %age 18.85 19.57 19.58 23.91

II.BIO-MASS FUELS:
SNo

Fuel

1 2 3 4 5 6 7 8 9 10

Wood Cattle dung Bagasse Wheat and rice straw Cane trash, rice husk, leaves and vegetable wastes Coconut husks, dry grass and crop residues Groundnut shells Coffee and oil palm husks Cotton husks Peat

Approx heating value Kcal/Kg Natural Dry State state 1500 3500 1000 3700 2200 4400 2400 2500 3000 3000 3500 4000 4200 4400 6500 3500 4000 4200 4400 6500

III.FOSSIL FUELS:
1 2 3 4 5 6 7 8 9 10 11 12 Coal Coke Charcoal Carbon Fuel oil Kerosene and diesel Petrol Paraffin Natural gas Coal gas Electrical (Kcal(KW) Bio gas(Kcal/cu mtr) (12 kg of dung produces 1 cu. Mtr gas) 4000-7000 6500 7000 8000 9800 10000 10800 10500 8600 4000 860 4700-6000

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IV.OILS
LDO (As Per IS 1460-1974) : It is generally used for start up of boiler.

Description Relative Density @15oC/15oC Flash Point PMCC oC min Kinematic Viscosity CST Sulphur %by weight max Ash weight max Gross calorific value Kcal/Kg(Average)

Values 0.85 38oC 2 to 7.5 1% 0.02 10720

LSHS/HFO (As Per IS 1593-1971) : It is generally used for Warm up & flame stabilization of boiler.

Description Relative Density @15oC/15oC Flash Point PMCC oC min Kinematic Viscosity CST Pour Point oC max Sulphur %by weight max Sediment % by weight Max Ash weight max Water content % Vol .Max Gross calorific value Kcal/Kg(Average)

Values 0.9579 66oC (min) 120oC (min) 500 CST max 72oC 4.5% 4.5% 0.1 1.0 10000

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Analysis of Coal
There are two methods 1. Proximate analysis and 2. Ultimate analysis.

Proximate Analysis
The objective of proximate analysis indicates the percentage by weight of the Fixed Carbon, Volatiles, Ash, and Moisture Content in coal. The amounts of fixed carbon and volatile combustible matter directly contribute to the heating value of coal. Fixed carbon acts as a main heat generator during burning. High volatile matter content indicates easy ignition of fuel. The ash content is important in the design of the furnace grate, combustion volume, pollution control equipment and ash handling systems of a furnace. The definition, importance and measure of coal parameters are explained as follows

Moisture
Moisture is an important property of coal, as all coals are mined wet. Groundwater and other extraneous moisture is known as adventitious moisture and is readily evaporated. Moisture held within the coal itself is known as inherent moisture. Typical range of Moisture content is 0.5 to 10%. Moisture may occur in four forms within coal: Surface moisture: Water held on the surface of coal particles or minerals. Hydroscopic moisture: Water held by capillary action within the micro fractures of the coal Decomposition moisture: Water held within the coals decomposed organic compounds Mineral moisture: Water which comprises part of the crystal structure of hydrous silicates such as clays.
Measurement: Determination of moisture is carried out by placing a sample of powdered raw coal of size 200-micron size in an uncovered crucible and it is placed in the oven kept at 108+2 C along with the lid. Then the sample is cooled to room temperature and weighed again. The loss in weight represents moisture.

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Volatile Matter
Volatile matter in coal refers to the components of coal, except for moisture, which are liberated at high temperature in the absence of air. This is usually a mixture of short and long chain hydrocarbons, aromatic hydrocarbons and some sulfur. Typical range of volatile matter is 20 to 35%.
Measurement: Fresh sample of crushed coal is weighed, placed in a covered crucible, and heated in a furnace at 900 + 15C. For the methodologies including that for carbon and ash, refer to IS 1350 part I:1984, part III, IV. The sample is cooled and weighed. Loss of weight represents moisture and volatile matter. The remainder is coke (fixed carbon and ash).

Ash and Fixed Carbon

The Ash content of coal is the non-combustible residue left after coal is burnt. It represents the bulk mineral matter after carbon, oxygen, sulfur and water (including from clays) has been driven off during combustion. Analysis is fairly straightforward, with the coal thoroughly burnt and the ash material expressed as a percentage of the original weight. Typical range Ash content is 5 to 40%. The fixed carbon content of the coal is the carbon found in the material which is left after volatile materials are driven off. This differs from the ultimate carbon content of the coal because some carbon is lost in hydrocarbons with the volatiles. Fixed carbon is used as an estimate of the amount of coke that will be yielded from a sample of coal. It gives a rough estimate of heating value of coal.
Measurement: The cover from the crucible used in the last test is

removed and the crucible is heated over the Bunsen burner until all the carbon is burned. The residue is weighed, which is the incombustible ash. The difference in weight from the previous weighing is the fixed carbon. (In actual practice Fixed Carbon or FC derived by subtracting from 100 the value of moisture, volatile matter and ash).

14

TYPICAL RESULTS:
PARAMETRS MOISTURE ASH VOLATILE MATTER FIXED CARBON INDIAN (F) 5.98% 38.63% 20.70% 34.69% INDONESIAN 9.43% 13.99% 29.79% 46.79% SOUTH AFRICA 8.50% 17.00% 23.28% 51.22%

Ultimate Analysis
The objective of ultimate analysis is to determine the amount of carbon (C), hydrogen (H), oxygen (O), sulfur (S), and other elements within the coal sample. The determination of the carbon and hydrogen in the material, as found in the gaseous products of its complete combustion, the determination of sulfur, nitrogen, and ash in the material as a whole, and the estimation of oxygen by difference. The carbon determination includes that present in the organic coal substance and any originally present as mineral carbonate. The hydrogen determination includes that in the organic materials in coal and in all water associated with the coal. All nitrogen determined is assumed to be part of the organic materials in coal. For practical reasons, sulfur is assumed to occur in three forms in coal: as organic sulfur compounds, as inorganic sulfides, which are mostly the iron sulfides pyrite and marcasite, and as inorganic sulfates. The total sulfur value is used for ultimate analysis.

TYPICAL RESULTS: PARAMETRS MOISTURE MINERAL MATTER CARBON HYDROGEN NITROGEN SULPHUR OXYGEN INDIAN(F) 5.83% 38.63% 41.11% 2.76% 1.22% 0.41% 9.89% INDONESIAN 9.43% 13.99% 58.96% 4.16% 1.02% 0.56% 11.88%

15

COAL HANDLING AT Dr NTTPS

Introduction
The Dr.Narla tatarao Thermal power station is one of the biggest power plant in India which is having an installed capacity of 1760 MW running under the control of well known organization i.e., APGENCO. For running this power plant coal is receiving from various places/mines such as Talcheru (Orissa), Singareni Collieries (Andhra) and Indonesia. The details of mines and their coal grades are here with furnished for information.

Storage and Handling of Coal

Uncertainty in the availability and transportation of fuel necessitates storage and subsequent handling. The main aim of coal storage is to minimize carpet loss and the loss due to spontaneous combustion. Formation of a soft carpet, comprising of coal dust and soil causes carpet loss. On the other hand, gradual temperature builds up in a coal heap, on account of oxidation may lead to spontaneous combustion of coal in storage. Stocking of coal has its own disadvantages like build-up of inventory, space constraints, deterioration in quality and potential fire hazards. Other minor losses associated with the storage of coal include oxidation, wind and carpet loss. A 1% oxidation of coal has the same effect as 1% ash in coal, windage losses may account for nearly 0.5 1.0% of the total loss. Methods to reduce carpet losses: 1. Preparing a hard ground for coal to be stacked upon. 2. Preparing standard storage bays out of concrete and brick

16

Preparation of Coal
Preparation of coal prior to feeding into the boiler is an important step for achieving good combustion. Large and irregular lumps of coal may cause the following problems: 1. Poor combustion conditions and inadequate furnace temperature. 2. Higher excess air resulting in higher stack loss. 3. Increase of unburnts in the ash. 4. Low thermal efficiency. Therefore, it is compulsion to make proper sizing of coal by different ways

Sizing of Coal:
Proper coal sizing is one of the key measures to ensure efficient combustion. Proper coal sizing, with specific relevance to the type of firing system, helps towards even burning, reduced ash losses and better combustion efficiency. Coal is reduced in size by crushing and pulverizing. Pre-crushed coal can be economical for smaller units, especially those which are stoker fired. In a coal handling system, crushing is limited to a top size of 6 or 4mm. The devices most commonly used for crushing are the rotary breaker, the roll crusher and the hammer mill. It is necessary to screen the coal before crushing, so that only oversized coal is fed to the crusher. This helps to reduce power consumption in the crusher.

Recommended practices in coal crushing are

1. Incorporation of a screen to separate fines and small particles to avoid extra fine generation in crushing. 2. Incorporation of a magnetic separator to separate iron pieces in coal, which may damage the crusher.

17

APGENCO COAL LINKAGES :

1. Mahanadhi Coal Fields, Talcher(Orissa) Talcheru mines 2. Singareni Collieries Limited , Kothagudem (A.P) Manugur Manchiryala badrachalam Road Ramagunadam-I Ramagunadam-II Rudrampur. Uppal. Mandamarri Kothagudem Yellandu Bhoopalapalli Bellampalli Srirampur Apa 3. PEC LTD (Imported Coal) Indonesia South Africa

4.

MSTC LTD (imported Coal) Indonesia

South Africa

5.

NCCF LTD (imported Coal) o Indonesia

o South Africa

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Mahanadhi Coal Fields Ltd,Talcher

Talcher is the major coal loading point of the Division and commands the status of being the biggest coal loading point served from one station in the whole of Asia. Talcher area consists of 9 coal loading sidings of M/s Mahanadi Coal Fields Ltd., from where coal gets transported to the thermal power plants of NTPC at Talcher and Kaniha, and other power houses of South India via rail routes and the sea route through Paradip (via coastal shipping). Talcher coalfield, located in the district of Angul of Orissa State, is one of the major coalfields containing huge reserves of power grade noncoking coal. The total area of the coalfield is 1860 sq.Kms. where as potential area is 1580 sq.km. The total geological reserve is 36868.12 million tonns, which constitutes 18.7% of the countrys total reserve. Talcher -18 private sidings: Three sidings (Talcher) Five sidings (Paradip) Three sidings(Khurda Road) Eight other private sidings (Gopalpur Port, Ganjam,Sukinda Road,Ghantikal Nidhipur,Charbatia,Budhapank ,Byree,Meramandali)

19

Talcheru Coal mines: At present there are 7 nos. of opencast mines and 3 nos. of underground mines in operation with manpower of 10,220.

A. Open Cast Mines

Sl.No. 01. 02. 03. 04. 05. 06 07. Hingula Lingaraj Kalinga Name of the Area Jagannath Name of the Open Cast Balanda Jagannath Ananta Kalinga Bharatpur Hingula Lingaraj

B. Under Ground Mines

Sl.No. 01. 02. 03. Name of the Area Talcher Name of the Under Ground Deulabeda Talcher Nandira

Talcher Coal mine Properties

MINE PLACE (GRADE)

VOLATILE MATTER (%)

31.60 25.26 34.67 25.98 24.69 21.88 26.70 39.20

ASH (%)

FIXED CARBON (%)

32.23 31.58 43.59 34.89 23.27 31.77 34.12 44.95

JAGANATH(F) ANANTHA(F) BHARATHPUR(D) BELPAHAR(F) DHERA(F) KALINGA(F) NANDIRA(F) LINGARAJ (D)

36.17 43.16 21.74 39.13 52.04 46.35 39.18 15.93

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SINGARENI COAL FIELDS Ltd, Kothagudem

The Singareni Collieries Company Limited (SCCL) is a Government coal mining company jointly owned by the Government of Andhra Pradesh and Government of India on a 51:49 equity basis. The Singareni coal reserves stretch across 350 Km of the Pranahita Godavari Valley of Andhra Pradesh with a proven geological reserves aggregating to whopping 8791 million tonnes. SCCL is currently operating 13 opencast and 42 underground mines in 4 districts of Andhra Pradesh with a man power around 78,000. The recent studies of Geological Survey of India attribute as much as 22016 million tonnes of coal reserves in the Godavari valley coalfield. The inventory covers up to a depth of 1200 meters and it includes reserves proved, indicated as well as inferred. The coal extracted by SCCL in the Godavari valley coalfield up to the year 2009-10 was about 929.12 million tonnes.

SCCL Coal Definitions:

ROM COAL: Run of Mine coal is coal comprising of all sizes which come out of the mine without any crushing or screening. Steam coal: The fraction of the Run of Mine coal as is retained on a screen when subjected to screening OR is picked out by fork shovel during loading is called Steam coal. Slack coal : The fraction that remains after Steam Coal has been removed from the Run of Mine coal is called Slack coal. CRUSHED ROM COAL: When the top size is limited to any maximum limit within the range of 200 250 mm through manual facilities or mechanical facilities is called Crushed ROM Coal.

21

Singareni Coal Grades and Prices :

The revised Grade- wise Basic prices of Run of Mine (ROM) coal of the Singareni Collieries Company Limited as follows.(as on 01-04-2011)

Grade of Coal A B C D E F G

Useful Heat Value per Kcal/Kg Exceeding 6200 Exceeding 5600 exceeding 6200 Exceeding 4940 exceeding 5600 Exceeding 4200 exceeding 4940 Exceeding 3360 exceeding 4200 Exceeding 2400 exceeding 3360 Exceeding 1300 exceeding 2400

ROM Coal(in Rs.) 3393 but but but but but but not not 1840 not 1500 not 1130 not not 690 510 2886

Basic prices of Washery Grade coal: Grade

Washery Grade - D Washery Grade - E Washery Grade - F

Price
Rs.2778 Rs.1690 Rs.1490

Typical coal results:

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In Dr.NTTPS the coal will be received from different companies and mines that could be tested at coal lab for analysis of GCV and other parameters. The coal test results of two types of coals are provided here for reference.

1.INDIAN COAL:( F GRADE )

PARAMETERS UHV Internal moisture Total moisture Ash 2.IMPORTED COAL: PARAMETERS GCV(ADB) Internal moisture Total moisture Ash(ADB) Sulphur (ADB) Volatile matter Size of coal VALUES 6207 Kcal/Kg 6.82% 11.63% 9.18% 0.51% 37.28% <50 MM VALUES 2483 5.83% 10.99% 40.67%

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DR.NTTPS BUNKER LEVELS

BUNKER EMPTY IN MTRS (FROM TOP ) 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 STAGE I 500 440 330 235 175 100 75 30 20 -COAL AVAILABLE (MT) STAGE II & III STAGE IV 500 425 365 309 254 190 139 109 92 67 33 24 15 4.5 2.5 630 593 556 519 482 445 408 371 334 297 260 223 186 149 112 75 38 0 STAGE I 0 60 170 265 325 400 470 480 COAL TO BE FILLED (MT) STAGE II & III 0 75 135 191 246 310 361 391 408 433 467 476 485 495.5 197.5 STAGE IV 0 37 74 111 148 185 222 259 296 333 370 407 444 481 518 555 592 630

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Dr.NTTPS UNITS- BOILER DESIGN VALUES:

UNIT# Capacity (MW) 210 210 210 210 210 210 500 GCV (KCAL/KG) 4500 4500 3686 3686 3686 3686 4400 HEAT RATE(KCAL/KWh) 2351 2351 2301 2301 2251 2251 2188 SPCC (KG/KWHR) 0.522 0.522 0.624 0.624 0.612 0.612 0.496 COAL CONSUMPTION (MT) 2631 2631 3145 3145 3078 3078 5952

1 2 3 4 5 6 7

Note: It was studied that the coal consumption of units may be varying depends upon the type/grade of coal is fed to the bunkers.In practice it is not possible to feed exactly the designed GCV coal. Hence the coal consumption of units may be varied accordingly.

Delegation of powers:
a).Transit Losses Powers of Waiver (as per delegations):
Loss in Percentage
UP TO 2% 2 TO 3% > 3%

Delegation of Powers
Chief Engineer/O&M Chief Engineer/GENERATION-II BOARD OF DIRECTORS

b).Windage & Shrinkage LossesPowers of Waiver (as per delegations):

Loss in Percentage
UP TO 0.6% 0.6 TO 1.2 % > 1.2%

Delegation of Powers
Chief Engineer/O&M Chief Engineer/GENERATION-II BOARD OF DIRECTORS

(Note: As per APERC Norms Transit Loss is 0.8% (Max.))

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Coal Penalty Calculations (APGENCO)

a).On Excess Wetness: If 1% excess moisture found in coal then the penalty is calculated as follows: Formulae=Rake wt * Extra Moisture% * 2 * Cost/MT Eg: Rake wt: 3600 MT Extra Moisture: 1% Cost /MT: Rs.5555 (AS PER PO price/MT) Penalty =3600 *0.01*2*5555 = Rs.3,99,960/Rake. b).On Excess Ash : If 1% excess ASH found in coal then the penalty is calculated as follows: Formulae=Rake wt * Extra Ash% * 1 * Cost/MT Eg: Rake wt: 3600 MT Extra Ash: 1% Cost /MT: Rs.5555 (AS PER PO PRICE/Mt) Penalty =3600 *0.01*1*5555 = Rs.1, 99,980/Rake.

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ENVIRONMENTAL STANDARDS Thermal Power Plants:

The emission standards for thermal power plants in India are being enforced based on Environment (Protection) Act, 1986 of Government of India and its amendments from time to time. A summary of emission norms for coal based thermal power plants is given in Tables

Emission Standards:
Pollutant Emission limit Particulate Below 210 MW matter(PM) 350 mg/Nm3 Particulate 210 MW & above matter(PM) 150 mg/Nm3 Particulate 500 MW & above matter(PM) 50 mg/Nm3 Height/Limits: (Stack height requirement for SO2 control) Capacity Less than 200/210 MWe 200/210 MWe (or) less than 500 MWe 500 MWe and Above Capacity

Stack

Stack Height (Meter) H = 14 (Q)0.3 where Q is emission rate of SO 2 in kg/hr, H = Stack height in meters 200 275 (+ Space provision for FGD systems in future)

The norm for 500 MW and above coal based power plant being practiced is 40 to 50 mg/Nm and space is provided in the plant layout for super thermal power stations for installation of flue gas desulphurisation (FGD) system. But FGD is not installed, as it is not required for low sulphur Indian coals while considering SO X emission from individual chimney.

27

FREE TIME FOR LOADING/UNLOADING OF WAGONS AT GOODS SHEDS & SIDINGS: (As per Indian railways)
Type of wagons
OPEN WAGONS
like BOXN, BOX, BOY, BOI, BOST, BOXNHA, BOXNHS, NBOY etc

Loading (Hrs:Mts) 5:00

Unloading (Hrs:Mts) 7:00

HOPPER WAGONS like BOBS, NBOBS, BOBR,NBOBR, BOBY, NBOBY etc. FLAT WAGONS like BFR, BRH, BRN, BFK, BFKI, BFNS, CONCORD rakes etc. TANK WAGONS (black oil)

5:00

2:30

6:00

N.A 7:00 (up to 29 wagons) 9:00 (30 wagons & above)

7:00

RATES OF DEMMURRAGE CHARGES :(As per Indian railways)

Rates of demurrage charges per 8-wheeled wagon per hour or part of an hour for detention of wagon in excess of the permissible free time notified for the wagon for loading or unloading shall be as under.

Detention in excess of permissible free time First 24 hrs Next 24 Hrs Beyond 48 hrs

Broad Gauge Rs.100/Rs.200/Rs.300/-

Meter Gauge Rs.70/Rs.140/Rs.210/-

Narrow Gauge Rs.50/Rs.100/Rs.150/-

Delegation of Powers to waive Demurrage Charges:

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Designation of S.No. officer at corporate and Regional level 1 2 3 4 5 6 7 MD Director (O&C) CCM RRM Sr.RTM STM ACM/ATM/Area Officer in Jr.Scale

Maximum amount of demurrage per wagon which can be considered by an officer Full Powers Rs.2,00,000/Rs.1,00,000/Rs.25,000/Rs.6,000/Rs.600/Rs.300/-

APPENDIX
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Performance Calculations -Thermal Plants

1. Plant Load Factor (PLF) = Generation Achieved In Month x 100 Possible Generation in Month 2. Availability factor (AF) = Actual running hours x 100
Possible running hours 3. Loading factor 4. Specific Coal Consumption = PLF Availability = Coal consumption (fed to bunkers as per coal plant) Generation = Oil Consumption Generation

5. Specific Oil Consumption

6. Deemed Generation = Generation + Back down 7. Deemed PLF = Generation + Back down Possible Generation 8. Heat rate = (Weighted average CV of coal*Coal consumption+ Weighted average CV of oil*Oil consumption) Generation x 1000

BOILER Efficiency Calculations

1. Ash collected /Kg. of fuel in Fly Ash = % Ash in Coal X % Ash appearing at ESP 100- % Combustibles in Fly Ash 2. Ash collected / Kg. of fuel in Bottom Ash = % Ash in Coal X % Ash appearing in furnace bottom
100 - % Combustibles in Bottom Ash

3. Combustibles in Fly Ash / Kg. = Ash collected per Kg. of fuel in Fly Ash X % Combustibles in Fly Ash
100

4. Combustibles in Bottom Ash/ Kg. = Ash collected /Kg. of fuel in Bottom Ash X % Combustibles in Bottom
Ash

100

5. % Total Combustibles in Fly Ash and Bottom Ash per Kg. of fuel fired = (Combustibles in Fly Ash per Kg. + Combustibles in Bottom Ash per Kg.)X100

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6. Dry Gas Quantity after APH =

__________1______________( % C + % S - % M ) 12 X % CO2 in FG after AH 2.67

7. Sensible Heat in FG leaving APH = Dry Gas Quantity X Specific Heat ( tg - ta ) 8. % Dry Gas Loss = Sensible Heat in Flue Gas X 100 4.186X CV of Coal 9. % Loss due to Combustibles in Ash = Total Combustibles in Ash X CV of Carbon X
100 CV of Coal

10. Total Moisture = % Moisture in Coal + ( 9 X % Hydrogen in Coal )

100

11. Heat loss per Kg. of Moisture = Specific Heat of Moisture ( FG Temp. at AH O/L - Min. Gas Temp) + Enthalpy of vapor in the process of Combustion(Latent Heat of water) + 4.2 ( MGT - Dry Bulb Temp)

12. % Loss due to Moisture &Hydrogen in Fuel = Total Moisture X Heat/Kg. of Moisture X100
4.186 X CV of Coal

13. % Loss due to Fly Ash = 0.9 X Ash in Coal X ( FG Temp. at AH O/L - Dry bulb temp.)
CV of Coal

14. % Loss due to Bottom Ash =0.1 X Ash in Coal X Specific Heat of Ash ( Bottom ash Temp. - Dry Bulb Temp.)
CV of Coal 15. Total % Loss due to Sensible Heat in Ash = % Loss due to Fly Ash + % Loss due to Bottom Ash

16. O2 required for % Carbon in Coal Kg. = O2 required per Kg. of Carbon X % Carbon in Coal
100

17. O2 required for % Sulphur in Coal Kg. = O2 required per Kg. of Sulphur X % Sulphur in Coal 18.
100 100 Total O2 required = O2 required for (Carbon + Hydrogen + Sulphur) - O2 in Coal

19. O2 required for % Hydrogen in Coal Kg. = O2 required per Kg. of Hydrogen X % Hydrogen in
Coal

100

100

20. Stiochiometric Dry Air = Total O2 required X 100

% O2 in Atmosphere by weight 21. % Excess Air = 21 . 21- % O2 from Orsat Analysis after AH

22. Total Combustion Air = % Excess Air X Stoichiometric Dry Air 23. % Loss due to Air Moisture = Moisture in Air X Total Combustion Air X 1.88 (tg ta ) X 100 4.186 X CV of Coal 24. % Total Loss = % Loss due to (Dry gas+Combustibles+Moisture & Hydrogen in fuel+Sensible Heat+Radiation+Air Moisture)

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25. Boiler efficiency = 100 - % Total Loss

Performance Calculations -AIR PREHEATER

1. 2. Temperature Head = (FG Temp before AH) (Sec' Air Temp before AH)
% Leakage of CO2 = (% CO2 in FG before AH - % CO2 in FG after AH) x 90 % CO2 in FG after AH Corrected exit gas temperature without leakage =(% Leakage of CO2 / 100) x 0.95 ( FG Temp after AH - Sec' Air Temp before AH) + FG Temp after AH Corrected gas temp drop without leakage= (FG Temp before AH - Corrected exit gas temp Without leakage)

3. 4.

5. 6.

Temperature without leakage =(% Leakage of CO2 / 100) x 0.95 ( FG Temp

after AH - Sec' Air Temp before AH) + FG Temp after AH

Gas side Efficiency = (Corrected gas temperature drop x 100 ) Temperature Head % Excess Air before APH =[21/(21- % O2 before AH)]-1 % Excess Air after APH = [21/(21- % O2 after AH)]-2 Stoichimetric Air (Actual air required for Combustion) = Total Air Flow (1+ % Excess air before AH) Air Flow at AH Outlet = Stoichimetric Air (1+ % Excess air after AH) Leakage across APH= Air flow at AH Outlet - Total Air Flow % Leakage across APH = Leakage across AH Total Air Flow

7. 8.

9.

10. 11.

12.

CONVERSIONS
ENERGY CONVERSIONS:

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British Thermal Unit 1 British Thermal Unit 1 Footpound 1 joule 1 calorie 1 kcal 1 kwhr
1 0.001285 9.481x10-4 0.003969 3.969 3413

Footpounds
777.9 1 0.7376 3.088 3088 2.655x106

Joules
1055 1.356 1 4.187 4187 3.6x106

calories
252.0 0.3238 0.2388 1 1000 8.598x105

Kcal
0.252 3.238x10-4 2.388x10-4 0.001 1 859.8

Kwhr
2.93x10-4 3.766x10-7 2.778x10-7 1.163x10-6 0.001163 1

Power Conversions:
Foot-Pounds per second 1 ft-pound per second 1 hp 1 Cal per sec 1 kw 1 watt
1 550 3.088 737.6 0.7376

Horsepower
0.001818 1 0.005615 1.341 0.001341

calories per second

0.3238 178.1 1 238.8 0.2388

Kilowatts
0.001356 0.746 0.004187 1 0.001

Watts
1.356 746 4.187 1000 1

Measurement Conversions
1 short ton (ton) = 2,000 lb = 907.19 Kg 1 metric ton (tonn) = 2,204.6 lb = 1000 Kg 1 thousand Btu (kBtu) = 1,000 Btu 1 million Btu (MMBtu) = 1,000,000 Btu 1 quad = 1 quadrillion Btu = 1015 Btu = 1,000,000,000 MMBtu 1 kilowatt-hour (kWh) = 1,000 watt-hours 1 megawatt-hour (MWh) = 1,000 kWh 1 gigawatt-hour (GWh) = 1,000 MWh

Conversions Units:
From Kcal/Kg to Mj/Kg multiply Kcal/Kg by 0.004187 From Kcal/Kg to Btu/lb multiply Kcal/Kg by 1.8

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From MJ/Kg to Kcal/Kg multiply MJ/Kg by 238.80 From MJ/Kg to Btu/lb multiply MJ/Kg by 429.90 From Btu/lb to Kcal/Kg multiply Btu/lb by 0.5556 From Btu/lb to Mj/Kg multiply Btu/lb by 0.002326

Conversions Gross/Net (as per ISO, for As received figures )

Net CV = Gross CV -50.6 H -5.85 M-0.191O Net CV = Gross CV -91.2 H -10.5 M-0.34 O Kcal/Kg Btu/lb

Net CV = Gross CV -0.212 H -0.0245 M-0.0008O MJ/Kg (Where M- % Moisture, H-% Hydrogen, O- is % Oxygen from Ultimate analysis as received basis)

Power Generation:
1 MWh = 3600 MJ 1 MW = 1 MJ/s 1 MW (Thermal power ) [MW th ] = approx 1000 Kg steam/hr 1 MW (Electrical power ) [MWe ] = approx MW(thermal power) 3

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