THERMAL POWER PLANT

Coal to Electricity

BOILER
BOILE R DRUM TO HP TURBINE
FROM HP TURBINE TO IP TURBINE

WATER WALLS

SUPER HEATER

REHEATE R LOW TEMP SH

COMBUSTION ZONE

ECONOMISER WIND BOX

FROM BOILER AIR PRE HEATERFEED PUMP

TO CHIMNEY

TYPICAL SCHEME OF COAL / OIL FIRED POWER PLANT

SUPERHEATER TUBES

REHEATER PANEL

VIEW OF ESP

CONDENSER

HP TURBINE MS

IP TURBINE

LP TURBINE

TG SET

CRH NRV

HPSV

IPSV IPCV

GENERATOR

HPCV

HPCV CRH NRV

IPCV HPSV
IPSV

MS

HRH

Condenser
BOILER

VIEW OF CONTROL ROOM

EFFICIENCY OF THERMAL POWER PLANT

EFFICIENCY OF THERMAL POWER PLANT

TYPE
BOILER (1) TURBINE (2)

EFFICIENCY
88-90 % 45-50 %

GENERATOR (3)
OVERALL CYCLE (4) = 1x2x3

96-98 %
34-42 %

Specific coal consumption

How much coal was consumed to produce one unit of

electricity
Specific Coal

= Heat Rate / Calorific Value of Coal

Consumption (Unit :- Kg/KWHr) For Example, If Heat rate is 2000 Kcal / KWhr & Coal
Calorific Value is 4000 Kcal / Kg Then, Specific Coal Consumption will be = 2000/4000 =

0.5 Kg/KWHr

Some thumb rules w.r.t thermal plant

Specific Steam Consumption :- 3 Ton of Steam flow required for 1 MW of power Specific Coal Consumption :- 0.5 Kg coal is required for generation of 1 unit of electricity Auxiliary Power :- Around 8-10% power is consumed by

power plant auxiliaries

Some thumb rules w.r.t thermal plant

Efficiency of Thermal power ranges from 33 to 40 %

One 500 MW thermal power plant generates 12 million

units of electricity daily

Around 22000 TO 69000 m3/hr of water is required for

condensing steam in Condenser for a 210 TO 660 MW Each power station has to maintain stock of minimum 7 days (Critical Stock)

MAJOR COMPONENT OF BOILER SIDE

COMPONENT
COAL BUNKER COAL MILL PA FAN FD FAN ID FAN WATER WALLS, SUPERHEATER, REHEATER, LOW TEMPERATURE SUPERHEATER, ECONOMISER BOILER DRUM

PURPOSE
TO STORE PULVERISED COAL FOR PULVERISING COAL FOR PRIMARY AIR FOR SECONDARY AIR TO MAINTAIN VACUUM INSIDE FURNANCE SO THAT FLUE GASES CAN BE EVACUATED VARIOUS WATER / STEAM CARRYING TUBES INSIDE THE BOILER. IN ALL THESE TUBES WATER / STEAM TAKES HEAT FROM FURNACE WHERE COMBUSTION OF COAL / OIL TAKES PLACE. TO SEPARATE WATER FROM STEAM

COAL AND COMBUSTION

RES 5%

Nuclear 3%

Why Coal?
Advantages of Coal Fuel Shortcomings of Coal Abundantly available in India Low cost Technology for Power Generation well developed. Easy to handle, transport, store and use Low Calorific Value Large quantity to be Handled Produces pollutants, ash Disposal of ash is Problematic Reserves depleting fast

Hydel 26%

Coal 55% Diesel 1%

Gas 10%

Share of Coal in Power Generation

Indias Coal Reserves are estimated to be 206 billion tonnes. Present consumption is about 450 million tonnes.
Cost of coal for producing 1 unit of electricity (Cost of coal Rs 1000/MT)is Rs 0.75.

Cost of Gas for producing 1 unit of electricity (Cost of Gas Rs 6/SMC)is Rs 1.20.

Coal what is it?

Elemental Composition

C
H

65-95%
2-7%

Inhomogeneous organic fuel formed mainly from decomposed plant matter. Over 1200 coals have been classified. Coalification forms different coal types: (Peat) Lignite Temperature Bituminous coal Time, Coal Rank Anthracite (Graphite)

O
S

<25%
<10%

N
Ash

1-2%
5-15%

Proximate Analysis

Char 20-70% H2 O
VM

2-20%
20-45%

Knowing more about Coal

Coal Properties Calorific Value Grade of Coal (UHV) Proximate Analysis Ultimate Analysis Ash and Minerals Grindability Rank Coal production Surface Mining Underground Mining Physical Characteristics Coal Beneficiation Why? Processes Effectiveness Coal Transportation Rail Truck Conveyor Ship Coal production Surface Mining Underground Mining Useful Heat Value (UHV) UHV= 8900-138(A+M)

Coal Applications
Homes heat and cooking Transportation steam engines Industry metal works Electricity power plants

Coal classification
Anthracite: hard and geologically the oldest Bituminous

Lignite: soft coal and the youngest

Further classification: semi- anthracite, semi-bituminous, and sub-bituminous

Coal Properties

Physical properties
Heating or calorific value (GCV) Moisture content Volatile matter Ash

Chemical properties
Chemical constituents: carbon, hydrogen, oxygen, sulphur

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Physical properties
Heating or calorific value
The typical GVCs for various coals are:

Parameter

Lignite (Dry Basis)

4,500

Indian Coal
4,000

Indonesian Coal
5,500

South African Coal

6,000

GCV (kCal/kg)

25

Physical properties
Moisture content
% of moisture in fuel (0.5 10%) Reduces heating value of fuel Weight loss from heated and then cooled powdered raw coal

Volatile matter
Methane, hydrocarbons, hydrogen, CO, other Typically 25-35% Easy ignition with high volatile matter Weight loss from heated then cooled crushed coal
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Physical properties
Ash
Impurity that will not burn (5-40%) Important for design of furnace Ash = residue after combustion

Fixed carbon
Fixed carbon = 100 (moisture + volatile matter + ash) Carbon + hydrogen, oxygen, sulphur, nitrogen residues Heat generator during combustion
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Analysis of Coal
Proximate analysis of coal
Determines only fixed carbon, volatile matter, moisture and ash Useful to find out heating value (GCV) Simple analysis equipment

Ultimate analysis of coal

Determines all coal component elements: carbon, hydrogen, oxygen, sulphr, other
Useful for furnace design (e.g. flame temperature, flue duct design) Laboratory analysis
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Analysis of Coal
Proximate analysis(Physical properties)
Typical proximate analysis of various coals (%)

Indian Coal
Moisture Ash Volatile matter Fixed Carbon 5.98 38.63 20.70 34.69

Indonesian Coal
9.43 13.99 29.79 46.79

South African Coal

8.5 17 23.28 51.22

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Analysis of Coal
Ultimate analysis (Chemical Properties)
Typical ultimate analysis of coal (%)

Parameter Moisture Mineral Matter (1.1 x Ash) Carbon Hydrogen Nitrogen Sulphur Oxygen

Indian Coal, % 5.98 38.63 41.11 2.76 1.22 0.41 9.89

Indonesian Coal, % 9.43 13.99 58.96 4.16 1.02 0.56 11.88

GCV (kCal/kg)

4000

5500
30

Performance Evaluation Principles of Combustion

Combustion: rapid oxidation of a fuel Complete combustion: total oxidation of fuel (adequate supply of oxygen needed) Air: 23.2% oxygen, 76% nitrogen and other Nitrogen: (a) reduces the combustion efficiency (b) forms NOx at high temperatures Carbon forms (a) CO2 (b) CO resulting in less heat production

31

Performance Evaluation

Principles of Combustion
Control the 3 Ts to optimize combustion: 1T) Temperature 2T) Turbulence 3T) Time

32

Performance Evaluation

Principle of Combustion
Oxygen is the key to combustion

Bureau of Energy Efficiency, India, 2004

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Performance Evaluation Stoichiometric calculation of air required

Stoichiometric air needed for combustion of furnace oil Theoretical CO2 content in the flue gases Actual CO2 content and % excess air Constituents of flue gas with excess air Theoretical CO2 and O2 in dry flue gas by volume

34

Performance Evaluation

Concept of Excess Air

Measure CO2 in flue gases to estimate excess air level and stack losses

Excess air (%)

Carbon dioxide (%)

Source: Bureau of Energy Efficiency, India, 2004

35

Performance Evaluation

Concept of Excess Air

Measure O2 in flue gases to estimate excess air level and stack losses

Excess air (%)

Residual oxygen (%)

Bureau of Energy Efficiency, India, 2004
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Flame Inside Furnace

Fuel Burning furnaces

Furnace provide controlled, efficient conversion of chemical energy of fuel into heat energy which is transferred to the heat absorbing surfaces of the steam generator.

The firing system introduce the fuel and air for combustion, mix these reactants, ignite the mixture and distribute the flame and combustion. Furnace can be divided into two types:

a. Grate-fired furnaces b. Chamber-type or flame furnace

Combustion Equipment's
Coal may be fed into furnace for combustion in lump pieces or in powder form.
a. Fuel bed furnaces (for coarse particles) b. Pulverized coal furnaces (fine particles) c. Cyclone furnaces (crushed particles) d. Fluidized bed furnaces (crushed small particles)

Fuel bed combustion

A grate is used at furnace bottom to hold a bed of fuel. There are two ways of feeding coal on to the grate:

a. Overfeeding b. Underfeeding

In overfeeding, the coal is fed into the grate above the point of air admission and in case of underfeeding, the coal is admitted into the furnace below the point of air admission.

Primitive Method of solid Combustion

O2+CO2+N2+H2O Flame Secondary Air
VM+CO+CO2+N2+H2

Green Coal Incandescent coke

ASH Grate Primary Air

CO+CO2+N2+H2

Top-feed updraft combustor

Physics of Fixed Bed Combustion

A bed of stoker-sized coal particles is supported by a grate. Air flows upwards through the grate and the fuel bed. Upon heating, coal particles first undergo a stage of Thermal preparation. Evaporation of Moisture drying. Distillation of VM (Pyrolosis) Production of enough VM to start ignition. Combustion of char. The coal flows slowly downward at a velocity Vs, as the coal burns out in the lower layer of the bed.

Overfeed and underfeed fuel bed section

Difference

Automation in Fuel Bed Combustion

Also called Mechanical grate or Stokers. Uniform operating condition Higher burning rate Greater efficiency TYPES: Travelling Grate Stoker Conveyor type Chain Grate Stoker Spreader Stoker Vibrating Stoker Underfeed Stoker

Conveyor Type

Stokers are used for burning non-coking free burning high volatile high ash coals. Although initial cost of this stoker is high but operation and maintenance cost is low.

Spreader Stoker

Spreader Stoker
Advantages
Its operation cost is low. A wide variety of coal can be burnt easily by this stoker. A thin fuel bed on the grate is helpful in meeting the fluctuating loads. Ash under the fire is cooled by the incoming air and this minimizes clinkering. The fuel burns rapidly and there is little coking with coking fuels.

Disadvantages
The spreader does not work satisfactorily with varying size of coal. In this stoker the coal burns in suspension and due to this fly ash is discharged with flue gases which requires an efficient dust collecting equipment.

Underfeed stoker

Closing Remarks on Mechanical stokers

In all MS forced draft fans are used both for PA and over fire SA. A practical engineering limit seems to be reached when the length and width of the grate are about 9 m with grate area 80 m2. In practice stokers have rarely exceeded a capacity of 135 tons/hour. Heat release rate-1340 kW/m2 Stoker firing is limited to relatively low capacity up to 50 kg/s of steam due to low efficiency. However, in their size range (19 to 32 mm) stokers remains important in steam generator system. Beyond a certain size of boiler, stokers become impracticable and uneconomical (increase floor area).

Pulverized Fuel Combustion

Invented in 1920. Fine particles of coal ~ 75 microns. Huge heat release per unit area : 2 5 MW/m2. Steam generation : 2000 tons/hour.

Schematic of typical coal pulverized system

A Inlet Duct; B Bowl Orifice; C Grinding Mill; D Transfer Duct to Exhauster; E Fan Exit Duct.

Ash disposal
A large quantity of ash is, produced in steam power plants using coal. Ash produced in about 10 to 20% of the total coal burnt in the furnace. Handling of ash is a problem because ash coming out of the furnace is too hot, it is dusty and irritating to handle and is accompanied by some poisonous gases. It is desirable to quench the ash before handling due to following reasons:

1. Quenching reduces the temperature of ash. 2. It reduces the corrosive action of ash. 3. Ash forms clinkers by fusing in large lumps and by quenching clinkers will disintegrate. 4. Quenching reduces the dust accompanying the ash.

Types of Ash
Burning of Coal leads to generation of Ash Can be the non- combustible part of fuel, or generated after the burning of the coal Two Types are : Bottom Ash Fly Ash

Bottom Ash
Non- Combustible Part of Combustion Comprises traces of combustibles embedded in forming clinkers and sticking to hot side walls of a coal-burning furnace The clinkers fall by themselves into the water or sometimes by poking manually, and get cooled May be used as an aggregate in road construction and concrete

Fly Ash
Residual of Coal Combustion Comprises of fine particles that rises with Flue Gases All types of fly ash includes substantial amounts of silicon dioxide and Calcium Oxide Size range from 0.5 m to 100 m

Challenges of Ash handling

Indian coal presents high ash content generally which tends to be inconsistent. Design of the system has to adequately cover anticipated variations and be capable of handling the worst scenario. System has to be environmentally friendly. System has to be reliable with least maintenance problems. System has to be energy efficient

Ash and dust collecting Equipment's

Hydraulic system

Pneumatic system

Mechanical system.

Dust collection system

The size of dust particles is designated in microns (1 = 0.001 mm). Dust particles are mainly ash particles called fly ash intermixed with some quantity of carbon ash material called cinders. Gas borne particles larger than 1 in diameter are called dust and when such particles become greater in size than 100 they are called cinders. Smoke is produced due to the incomplete combustion of fuels, smoke particles are less than 10 in size.

The disposal smoke to the atmosphere is not desirable due to the following reasons : 1. A smoky atmosphere is less healthful than smoke free air. 2. Smoke is produced due to incomplete combustion of coal. This will create a big economic loss due to loss of heating value of coal. 3. In a smoky atmosphere lower standards of cleanliness are prevalent. Buildings, clothing's, furniture etc. becomes dirty due to smoke. Smoke corrodes the metals and darkens the paints. To avoid smoke nuisance the coal should be completely burnt in the furnace.

Types of dust collectors

The various types of dust collectors are as follows : 1. Mechanical dust collectors. 2. Electrical dust collectors. Mechanical dust collectors. Mechanical dust collectors are sub-divided into wet and dry types. In wet type collectors also known as scrubbers water sprays are used to wash dust from the air. The basic principles of mechanical dust collectors are shown in Fig. As shown in Fig. by increasing the cross-sectional area of duct through which dust laden gases are passing, the velocity of gases is reduced and causes heavier dust particles to fall down. Changing the direction of flow of flue gases causes the heavier particles of settle out. Sometime baffles are provided as to separate the heavier particles. Mechanical dust collectors may be wet type or dry type. Wet type dust collectors called scrub scrubbers make use of water sprays to wash the dust from flue gases. Dry type dust collectors include gravitational, cyclone, and baffle dust collectors.

Electrostatic Precipitators. It has two sets of electrodes, insulated from each other that maintain an electrostatic field between them at high voltage. The flue gases are made to pass between these two sets of electrodes. The electric field ionises the dust particle; that pass through it attracting them to the electrode of opposite charge. The other electrode is maintained at a negative potential of 30,000 to 60,000 volts. The dust particles are removed from the collecting electrode by rapping the electrode periodically. The electrostatic precipitator is costly but has low maintenance cost and is frequently employed with pulverised coal fired power stations for its effectiveness on very fine ash particles and is superior to that of any other type.

4.13.1 FLY ASH SCRUBBER It is similar to a mechanical ash collector but has a flowing water film on its inner walls. Due to this film, the collected ash is removed more rapidly from the apparatus to the bin. The degree of ash collection in scrubbers varies from 0.82 to 0.90. The dust laden gas enters through the inlet pipe. Cinder Catcher. Cinder catcher is used to remove dust and cinders from the gas. In this catcher the dust laden gas is made to strike a series of vertical baffles that change its direction and reduce its velocity. The separated dust and cinders fall to the Hopper for removal. Cinder catchers are ordinarily used with stoker firing.