Steam Power Plants-1

Steam Power Plants-I
By
Power and Energy are buzz words in todays world.

Electricity is emerged as basic necessity with Food,
Shelter and Clothing for human being.

Life without electricity has become highly unimaginable. Electric locomotives, Heating, Cooling, Fans, Blowers,
Motors, Illumination are some applications that converts electrical energy into useful work.
CH KODANDA RAMA RAO GITAM UNIVERSITY
Asst.Professor 2
Progress of any nation is measured in terms of per capita
consumption of electrical energy.(KWH consumed per person per year)

India- 500 KWH /person per year
UK- 15 times that of India US- 30 times that of India

Reasons of Popularity of electricity: Clean environment for user
Higher efficiency
Better controllability Quick transfer of power from source to load Energy conservation is simple
Asst.Professor 3
Power Generation Scenario In India

Thermal Power --Hydro Power
1,00,000MW
65,000MW
---
Nuclear Power -- Other sources ---
10,000MW
20,000MW
Total Installed Capacity--- 1,95,000MW
Asst.Professor 4
Sources Of Electrical Power Generation

A.Conventional Sources Thermal (Coal) Nuclear Gas Water B.Non conventional Sources Wind Solar- PV Biomass
Asst.Professor 5
Disadvantages Of Conventional Sources

Fossil fuels shall be depleted, forcing us to conserve them and find alternative resources.
Toxic, Hazardous gases, Residues pollute environment. Overall conversion efficiency is very poor.
Sources are located at remote places with reference to load, increasing transmission cost. Maintenance cost is high.
Asst.Professor 6
Block Diagram Of Coal Fired Thermal Plant
Asst.Professor 7
Coal Based Thermal Power Plant

India has rich stock of coal as natural resource. Chemical energy stored in coal is transformed to
electrical energy.
Coal powder is fired in boiler that converts water into
steam at high temp. and pressure.

This steam is injected over the blades of steam turbine
(prime mover) in controlled way and hence, rotor of 3 PH a.c. generator rotates.
Asst.Professor 8
Mechanical energy is converted into electrical energy at rated
voltage(10-30KV).
Used steam is cooled down to water using cooling towers and
condensers.
This preheated water is again injected in boiler tubes to
convert back to steam.

Flue gases are passed into atmosphere and fine particles of
ash are collected through ESP.

Ash(40% of coal weight) is collected and transported to AHP.
Asst.Professor 9
Merits of Coal Thermal Plant

Coal is cheap and available in abundance at present.
It is a time tested process, so no experimentation is
required.
Less space required as compared to Hydro based
station and less hazardous than Nuclear power plant.

Less initial cost as compared to other conventional
process of power generation.
Asst.Professor 10
Demerits of Coal Thermal plant

Calorific value (Kcal/Kg) of Indian coal is very low and
large ash content.

Huge volume of ash is produced daily and its disposal is
burning issue today.

Atmospheric pollution is very high. Transportation of coal to plant and transmission of
generated power to load centre involves large expenses.
Asst.Professor 11
Power plants circuits
Asst.Professor 12
Thermal ( Steam ) Power plants mainly consists of 4 circuits

Coal and ash Circuit

Coal produced in the mining site is transported to power plant site Coal handling equipment for generation of steam The combustion of coal produces ash which is collected and removed to ash storage yard through ash handling equipments
Asst.Professor 13
Air and gas circuit
FD or ID fans are used for supply the air to combustion chamber of the boiler through airpreheater The air preheater is placed in the path of flue gases to preheat the air The flue gases produced by combustion of fuels in the boiler furnaces after passing around boiler tubes and super heater tubes Pass through a dust collector or precipitator where most of dust is removed before venting it of to atmosphere through chimney
CH KODANDA RAMA RAO GITAM UNIVERSITY Asst.Professor 14
Feed water and steam circuit:

Prime mover develops power by utilizing steam generated in the boiler Then condenser is used to condense the steam coming out of prime mover A pump is used to feed the condensate to the boiler The condensate leaving the condenser is heated in feed heaters through extracted steam from lowest pressure extraction point of the turbine The feed water may also be supplied from external source to compensate any loss of steam and water. In the boiler shell and tubes water circulation is setup due to density difference of water between low and high temperature sections A super heater is used to super heat the wet steam from boiler drum and is then supplied to prime movers
Cooling water circuit

In the condenser, quantity of cooling water required to condense the steam is large and is taken either from lake, river or sea The cooling water is taken from upper side of the river and then passed through the condenser The hot water is then discharged to lower side of the river The system is known as open system Where water is not available in abundant water from condenser is cooled either in cooling pond or in cooling tower the system is known as closed system
Asst.Professor 16
Main Components of Thermal Power Plants

Boiler 2. Super heater 3. Economizer 4. Air preheater 5. Reheater 6. Steam turbine 7. Generator 8. Condensers 9. Cooling towers 10. Pumps
1.
11. Coal mills 12. FD and ID Fans
13. ASH Precipitators

14. Water treatment plant
Asst.Professor 17
Combustion of fuel is accomplished by mixing with air at elevated temperatures
Fuels used in thermal power plant
Oxygen in the air chemically unites with Carbon, Hydrogen of fuels and produce heat
In thermal power plants normally steam is
produced from water by using combustion heat of fuels (Except in Gas turbines) Various fuels were used in thermal power plants
Fossil fuels ( Coal, Oil & Gas) Industrial waste gases Synthetic fuels or SYNFUELS
Asst.Professor 18
Coal is the principal energy source for India because of its

large deposits and availability Coal originated from vegetable matter, which grew millions of years ago Trees and plants falling into water decayed and later produced peat bogs Huge geological upheavals buried these bogs under layers of silt Subterranean heat, soil pressure and movement of earth's crust distilled off some of the bog's moisture and hardened it to form coal Basically classification of coal is based on Physical and chemical composition Peat Lignite and brown coal Bituminous coal Anthracite
Coal
Coal properties
There are certain properties of coal, which are
important in power plant applications They are

sulphur content, heating value ash softening temperature
swelling index
grind ability, weather ability,
Asst.Professor 20
Moisture
All coal contains some % of moisture and it is generally varies from 3 to 30 %
Volatile matter
The volatile matter resent in the coal may me as high as 50% The volatile matter may be combustible gases (methane,hydrogen,co) and non-combustible gases(CO2,N2) These gases decrease heating value of coal and increase the volume of the furnace required ASHThis is resent in two forms 1.)fixed ash- which is formed after burning 2.) free ash- formed from clay and impurities(it can be removed by washing screening
Disadvantages of ash
increase cost of transporting, handling ,storing. Decrease the heating value of coal.
Carbon: gives heating value to coal sulphar:- adds little heating value
It is responsible to corrosion
Asst.Professor 22
Desirable properties of coal

High calorific value
Small sulphur content ( les than 1%) Good burning characteristics for complete combustion
High grind-ability index

High weather-ability
Grading of coal done on the basis

Heating value Size Ash content Sulphur content Ash softening temperature
Asst.Professor 23
Peat Low grade coal

First stage coal formation Contains 90% moisture Small amount of volatile matter
Not suitable for power plants

Used in domestic purposes Requires 1-2 months for drying in sunlight
Peat (20% water, Dried) has CV of 16 MJ / kg
Asst.Professor 24
Lignite (Brown coal)

Intermediate stage of coal development High amount of moisture 30-40% Brown in color High heating value and carbon compared to peat
Should be stored to avoid spontaneous combustion

Used in pulverized form Can be air dried easily
Suitable for local use instead of transporting
Asst.Professor 25
Containing 46-86% of fixed carbon and 20-40% of VM Ash content may vary 6-12 %
Bituminous coal
High percentage of volatile matter CV of 32 MJ / Kg

Available in two forms CAKING and NON Caking
Sub-Bituminous is having less moisture, ash than lignite and no CAKING power, used in briquette or pulverized form Semi-Bituminous coal high carbon and heating value, contain less moisture, ash, sulphur, &VM, Has tendency to break into pieces
Asst.Professor 26
Contains more than 86% fixed carbon &VM around 8% Ignites slowly has high CV of 36 MJ / Kg
Anthracite Coals
Low ash, zero CAKING power

Difficult to pulverize Anthracite coal
Asst.Professor 27
Liquid fuels
They are easy to handle, store and to burn They have nearly constant heating values They are primarily a mixture of hydrocarbon compounds, which
may also contain nitrogen, oxygen and sulphur The bulk of the hydrocarbons belong to the paraffin series, like methane (CH4), ethane (C2H6) propane (C3H8) and butane (C4H10) which are gaseous, and pentane (C5H12) hexane (C6H14) and octane (C8H18) which are liquid at STP In addition, there can be isoparaffins, cycloparaffins and aromatic compounds
Carbon: 83-87%, Hydrogen: 11-16%,
Oxygen + Nitrogen 0-7%, Sulphur 0-4%

There can also be some moisture and sediment Crude oil distilled into a number of fractions gasoline,
aviation fuel, kerosene, light diesel oil, heavy diesel oil, lubrication oil The heavier fractions are used for boiler fuels and chemical production The required physical properties of fuel oil are
specific gravity, viscosity, pour point, flash point and heating value
Asst.Professor 29
Gaseous fuels Transportation of natural gas is made through pipelines

Natural gas is the cleanest of all fossil fuels It is free from ash and mixes well with air to undergo complete combustion producing very little smoke It consists of a mixture of the most volatile paraffins-
methane to pentane It has high hydrogen content and produces a considerable amount of water vapour when burned The heat of combustion varies from 33.5 to 40 MJ/m3 Since the major constituent of all natural gases is methane Liquid natural gas (LNG) is transported by special tankers and stored in spherical pressure vessels to be used when needed, particularly during peak load.
Industrial Wastes & Byproducts
Other fuels
blast furnace gas, coke oven gas, and refinery gas sugar factory refuse (bagasse); saw mill wood dust, rice husk Synthetic fuels Gaseous and liquid fuels from coal economically and environment friendly manner Liquid fuels using mixtures of fine coal in oil have been known as colloidal fuel, coal-in-oil and more recently, coal-oil mixtures (COM)
Asst.Professor 31
Coal handling
Asst.Professor 32
Pulverised coal system
In this system coal is ground to a fine in a pulverised mill and stored in bunkers from where it is fed into the combustion chamber by means of steam of hot air .
The air is used to dry the coal an conveying it to the furnace is called primary air . The air blow separately to complete the combustion is called as secondary air
Asst.Professor 33
Advantages of pulverised coal system
Rapid combustion with out use of large quantity of excess air. Higher boiler efficiency because of better combustion. Low grade coal can be used. Ash removal is easy. Fluctuation of loads can be easily used. Disadvantages
installation cost is high. Risk of explosions are more Special equipment is required for starting the system
1.Ring Type Coal Crusher 2.Hammer Mill Coal Crusher 3.Brad Ford Breaker
Ring Type Coal Crusher
Asst.Professor 36
Hammer Mill Coal Crusher
Asst.Professor 37
OPERATION
The coal is fed at the top Is crushed by the action of rings that pivot off centre
on a rotor or by swinging hammers attached to it Adjustable screen bars determine the maximum size of the discharged coal
Asst.Professor 38
Brad Ford Breaker
Asst.Professor 39
Brad Ford Breaker

Bradford breaker which is used for large capacity work It consists of a large cylinder made up of perforated
steel plates to which lifting shelves are attached on the inside The cylinder rotating slowly at about 20 rpm receives coal at one end The shelves lift the coal up and then the coal drops down by gravity
Asst.Professor 40
Belt conveyors
Best suitable for transporting large quantity over large distance It consists of end less belt running over a pair of end pulleys and supported by series of rollers. The inclination at which coal can be successfully elevated by belt conveyor is about 200 Average speed of belt conveyer is 60-100 m/min Load carrying capacity of the belt is 50-100 tones/hr
Advantages
It is most economical method of coal transporting in medium and large capacity plants Min repair and maintenance cost power consumption is minimum
Disadvantages
not suitable for greater heights and small distance
Asst.Professor 42
Screw conveyors
It consists of end less helicoids screw rotating inside a housing .the movement of screw drives the coal from end of the conveyor to other end where it is discharged This is used for small capacities Its length is limited to 30 m Seed 70 to 120 RPM Max capacity-125 ton/hr Low initial cost Simple and compact Adaptable to space available Dust roof
Asst.Professor 43
Disadvantages
High power consumption Excessive wear and tear
Short life compared to belt conveyor
Asst.Professor 44
Asst.Professor 45
Bucket elevators
Used for moderate lift ,the coal can be conveyed at a speed of 16-40m/min Less power is required
Coal can be discharged at elevated laces

Less floor area is required Disadvantages Its capacity is limited
Pulverized coal handling system
Asst.Professor 47
Bowl Mill
Asst.Professor 48
Bowl Mill
Asst.Professor 49
Ball and Race mill
Asst.Professor 50
Pulverization
Advantages

Low excess air requirement Less fan power Ability to use highly preheated air reducing exhaust losses Higher boiler efficiency Ability to bum a wide variety of coals Fast response to load changes Ease of burning alternately with, or in combination with gas and oil Ability to release large amounts of heat enabling it to generate about 2000 t/h of steam or more in one boiler Ability to use fly ash for making bricks etc. Less pressure losses and draught need.
Disadvantages
1.
2.
3. 4.
Added investment in coal preparation unit Added power needed for pulverizing coal Investment needed to remove fly ash before ill fan Large volume of furnaces needed to permit desired heat release and to withstand high gas temperature
Asst.Professor 52
1.
2.
Grate-fired furnaces Chamber-type or flame furnaces
Combustion Equipment For Burning Coal

Fuel bed furnaces (coarse particles) Pulverized coal furnaces (fine particles) Cyclone furnaces (crushed particles) Fluidized bed furnaces (crushed small particles)
Asst.Professor 54
Grate
Asst.Professor 55
Chamber type
Asst.Professor 56
Fuel bed furnaces (coarse particles)
There are two ways of feeding coal on to the grate

1. 2.
Overfeeding Underfeeding
Asst.Professor 57
Overfeeding
Asst.Professor 58
Overfeeding
Receives fresh coal from top surface has following
distinct zones
Fresh or green coal Coal losing moisture (Drying zone) Coking layer (loosing of VM) Distillation zone Incandescent coke ( Fixed carbon is consumed)
Combustion zone Ash layer progressively cooled
Asst.Professor 59
Operations
Primary air gets warmed up as it flows through the ash
layer As it passes through the incandescent coke layer(1200 C) Carbon converted to Carbon dioxide releasing heat continues till oxygen is consumed, if layer is thick CO2 is converted to CO reducing layer temperature water gas reaction also takes The stream while passing through distillation zone VM is added In distillation zone moisture is added Know stream contains N,CO2,CO,H2,VM&moisture
For combustion of this stream

A hot ignition point ( In the range of 1000-1300oC
Done by providing a fire brick lined arch which stores up
the heat and remains at high temperature
Sufficient fresh air

Secondary air or over-fire air
Turbulence
Providing secondary air at right angles to up-flowing gas
stream emerging out of fuel bed
Asst.Professor 61
Results
Carbon is in CO, CO2 both are color less Carbon with hydrogen in VM which will be cracked to
form free carbon at high temperature suspended in gas stream If Burner is not designed properly or operated properly leads to unburnt carbon particles this appears as black smoke on chimney top
Asst.Professor 62
Underfeeding
Asst.Professor 63
Underfeeding
In underfeeding coal is fed from below Primary air passing through holes in tuyeres
diffuses through spaces in the raw green coal picking up moisture In distillation zone to stream VM is added In incandescent zone VM breaks readily burns with secondary air present above it where it is fed from top VM burning is somewhat cooler need longer time to ignite and burn
Mechanical Stokers
Overfeeding 1. Traveling grate stoker 2. Chain grate stoker 3. Spreader stoker 4. Vibrating grate stoker Underfeed stoker 1. Single retort 2. Multiretort
Asst.Professor 65
Traveling grate stoker
Asst.Professor 66
Traveling grate stoker

Grate surface is made up of Cast Iron bars joined
together by links to form endless belt Belt wound around two sprockets A coal gate regulates the depth of fuel bed Simultaneous adjustment of Fuel bed thickness, primary air flow controls the burning rate so that at the end of its rear ash only remains
Asst.Professor 67
Advantages & Disadvantages

Simple and Initial cost is low Reliable in service and maintenance is low
Gives high rate of heat release per volume of the furnace

Limited coal can be carried on grate Clinker problems are common Ignition arches are required
There is always some loss in the form of particles

Spreader stoker
Asst.Professor 69
Spreader stoker
Coal from hopper is fed by rotating feeder Feeder normally will have Blades fitted on the drum Fine particles burn in suspension Speed of the feeder varies with the steam output of boiler Grate is made up of CI bars, Links underneath the grate are connected to a lever Fuels used may be Bituminous, lignite, wood
waste, baggase Coal size used in 6-36 cm

Asst.Professor 70
Advantages and Disadvantages

A wide variety of fuels can be used Clinker formation is reduced High temperature preheated air can be used Quick response to load variation Gives equal pressure drop and proper air
distribution Operation cost is low Difficult to operate variable sized coal particles Fly ash and entrapped carbon particles
Underfeed stokers
Asst.Professor 72
Multiple retort
Asst.Professor 73
ASH HANDLING SYSTEM

Mechanical Handling System Hydraulic Ash Handling System
Low pressure System High pressure System Pneumatic Ash Handling System Steam Jet System
Asst.Professor 74
ASH HANDLING FLOW DIAGRAM
Asst.Professor 75
Mechanical Handling System
Asst.Professor 76
In this type belt conveyor is used Used for low capacity power plants Ash is quenched (cooled)by allowing it to fall through water seal over the belt conveyor Quenched ash is then carried to a dumping site over the belt This is continuous handling system in which power consumption is low It handles 3.5 tons of ash per hour with a speed of 0.3m/min
CH KODANDA RAMA RAO GITAM UNIVERSITY Asst.Professor
77
Hydraulic Ash Handling System Low pressure System
Asst.Professor 78
in this system trough provided below the boiler furnace and water is made to flow through it The ash directly falls into trough and is carried by the water to the sump
The water and ash are separated with the help of screen in the sump. The water is pumped back to the trough and used again while the ash is carried to the dumping site
Hydraulic Ash Handling System Low pressure System
Asst.Professor 80
Hydraulic Ash Handling System High pressure System
Asst.Professor 81
In this the the hoppers below the boiler is fitted with water nozzles at the top and at the sides.
Ash is quenched by the top nozzle and side nozzles provide the drive force for the ash. The water and ash are separated with the help of screen in the sump.
The water is pumped back to the trough and used again while the ash is carried to the dumping site
Advantages of hydraulic system clean, dustless and totally enclosed Carrying capacity is large. Discharge ash at a considerable distance of over 600m. Can also handles a stream of molten ash
Asst.Professor 83
Pneumatic Ash Handling System
Asst.Professor 84
In this system ash from boiler is pulverised in the crushers fine ash is then passed into stream of high velocity air
Cyclone separators are used to remove ash from air stream Clean air is send to atmosphere Ash is send to dumping site System can handle 5-30 tons of ash /hr
Advantages Dust can be eliminated as the material are handled in a closed circuit Flexible and can fit varying conditions.
It can carry ash through long distance Disadvantages

Maintenance charges are high due to wear out of pipe line. More noisy than other system.
Dust collection the exhaust gas leaving the boiler contain particles of solid matter in suspension smoke, dust(fly-ash),un -burnt coal(cinder) The quantity of dust is more in pulverised firing . Less in stroker
Asst.Professor 87
Types of dust collectors

Mechanical dust collectors 1. Wet type collectors
2. Dry type collectors

Electrical precipitators(dust collectors
Asst.Professor 88
Wet type dust collector Water is sprayed to separate dust from flue gas Induced fan is used to carry gas through chimney
Water is carried to a sludge pond
Asst.Professor 89
Dry type dust collector

Inertia separators
Cyclone separator is one of the common forms of inertia separators Gravitational separators It works slowing down gas flow so that dust particles remain in a chamber for a long duration so as to settle at the bottom It requires a large chamber and not suitable in power plants

Steam Power Plants-1

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Steam Power Plants-I

Power and Energy are buzz words in todays world.

Shelter and Clothing for human being.

CH KODANDA RAMA RAO GITAM UNIVERSITY

Progress of any nation is measured in terms of per capita

consumption of electrical energy.(KWH consumed per person per year)

UK- 15 times that of India US- 30 times that of India

CH KODANDA RAMA RAO GITAM UNIVERSITY

Power Generation Scenario In India

Nuclear Power -- Other sources ---

Total Installed Capacity--- 1,95,000MW

CH KODANDA RAMA RAO GITAM UNIVERSITY

Sources Of Electrical Power Generation

CH KODANDA RAMA RAO GITAM UNIVERSITY

Disadvantages Of Conventional Sources

CH KODANDA RAMA RAO GITAM UNIVERSITY

Block Diagram Of Coal Fired Thermal Plant

CH KODANDA RAMA RAO GITAM UNIVERSITY

Coal Based Thermal Power Plant

steam at high temp. and pressure.

CH KODANDA RAMA RAO GITAM UNIVERSITY

Mechanical energy is converted into electrical energy at rated

convert back to steam.

ash are collected through ESP.

CH KODANDA RAMA RAO GITAM UNIVERSITY

Merits of Coal Thermal Plant

station and less hazardous than Nuclear power plant.

process of power generation.

CH KODANDA RAMA RAO GITAM UNIVERSITY

Demerits of Coal Thermal plant

large ash content.

burning issue today.

generated power to load centre involves large expenses.

CH KODANDA RAMA RAO GITAM UNIVERSITY

Power plants circuits

CH KODANDA RAMA RAO GITAM UNIVERSITY

Thermal ( Steam ) Power plants mainly consists of 4 circuits

CH KODANDA RAMA RAO GITAM UNIVERSITY

Air and gas circuit

Feed water and steam circuit:

Cooling water circuit

CH KODANDA RAMA RAO GITAM UNIVERSITY

Main Components of Thermal Power Plants

11. Coal mills 12. FD and ID Fans

13. ASH Precipitators

Combustion of fuel is accomplished by mixing with air at elevated temperatures

Fuels used in thermal power plant

CH KODANDA RAMA RAO GITAM UNIVERSITY

Coal is the principal energy source for India because of its

important in power plant applications They are

CH KODANDA RAMA RAO GITAM UNIVERSITY

CH KODANDA RAMA RAO GITAM UNIVERSITY

Desirable properties of coal

High grind-ability index

Grading of coal done on the basis

CH KODANDA RAMA RAO GITAM UNIVERSITY

Peat Low grade coal

Not suitable for power plants

Peat (20% water, Dried) has CV of 16 MJ / kg

CH KODANDA RAMA RAO GITAM UNIVERSITY

Lignite (Brown coal)

Should be stored to avoid spontaneous combustion

Suitable for local use instead of transporting