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POWER SYSTEMS- INTRODUCTION STEAM POWER PLANT

By

Mr.V.MADHU, B.E.,M.Tech.,MISTE.,MIAENG,
Assistant Professor in EEE Dept., Swarnandhra Institute of Engineering & Technology, Seetharampuram, WG Dt, AP

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UNIT III POWER SYSTEM ENGINEERING


INTRODUCTION

Sources of energy: Secondary energy sources


Electricity Heat Light

Primary energy sources


Coal, Oil, Nuclear fuels, Water Wood Candles, Oil lamps

Conventional sources of energy Non-renewable sources of energy Non-conventional sources of energy Renewable sources of energy

Fossil fuels Coal, Oil, Natural gas


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INTRODUCTION

1 kg of Uranium U235 releases as much energy as the burning of 4,500 tonnes of coal or 2000 tonnes of oil. Power generated in India : 1947 2007 2012 1360 MW 1,38,251 MW 2,09,276 MW

Total energy consumption in the world : Coal accounts for 32.5 % Oil accounts for 38.3 % Coal fed steam power plants : Neyveli 1000 MW North Chennai 630 MW

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INTRODUCTION

Gas based plants : Narimanam 10 MW Basin bridge 120 MW Hydro-electric power plants : Mettur 360 MW Kundah Basin development project 130 MW Periyar hydro-electric project 145 MW Kodayar hydro-electric project 100 MW Nuclear power plants : Kalpakkam 470 MW Kundankulam 2000 MW (Tirunelveli, TN)

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CLASSIFICATION OF POWER PLANTS

Power plants using conventional (nonrenewable) sources of energy


Steam power plant Nuclear(Atomic) power plant Diesel power plant Gas power plant

Power plants using Nonconventional(renewable) sources of energy


Hydro electric(Hydel) power plant Solar thermal power plant Wind powered generation(aerogeneration) Wave power plant Tidal power plant Geothermal power plant Bio-mass power plant Oceanthermal power plant
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STEAM (THERMAL) POWER PLANT


Fuel : Coal or Oil Main parts : Boiler, Turbine, Generator

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Schematic diagram of coal based steam power plant


To chimney Coal storage Flue gases

Coal handling plant

Air preheater Feed water Economizer

Air Super heated Steam

Main valve

To power grid

Ash storage

Ash handling plant

Boiler

Super heater Flue gases Steam

Turbine

Generator

HP heater

Condensate extraction pump

LEGEND
Coal Ash Air Water Flue gases Steam

Boiler feed pump LP heater Circulating water pump

Condenser

Cooling tower

Cooling water

River or Canal

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General layout of steam power plant

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Steam Turbine Power Generation


Power generating concept Steam (heat energy) mechanical energy (rotational energy) electrical energy Steam (superheated) is produced in boiler (steam generator). Undergoing several processes Rotate turbine Generator Produce electrical load.

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Fuels used for steam generation


The primary fuels which are burned to release heat and generate steam in boilers are the fossil fuels coal, fuel oil and natural gas. Besides these, industrial wastes like blast furnace gas, coke oven gas, refinery gas, bagasse, saw mill wood dust, rice husk etc. are also used to boost primary fossil fuels in the form of combination firing.

Coal
In India, coal is the main source of energy because of its large deposits and availability. Coal originates from millions of years old vegetable matter transformed by subterranean heat and soil pressure. The vegetable decay first produces peat bogs, which after distillation of its moisture by subterranean forces hardens to brown coal or lignite. Continuing metamorphosis produces higher grade coals.

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Fuels used for steam generation


Coal (contd..)
According to geological order of formation, coal may be of the following types with increasing carbon content: Peat Lignite Sub-bituminous

Bituminous
Sub-anthracite Anthracite Graphite Each type of coal has a certain set of physical parameters which are mostly controlled by moisture, volatile content (in terms of aliphatic or aromatic hydrocarbons) and carbon content. Peat contains up to 90% moisture and is not attractive as a utility fuel. Coal Ranking is a measure of carbon content in the coal. Lignite is considered to be low rank and anthracite to be high rank.

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Boilers

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Boiler is an apparatus to produce steam. Thermal energy released by combustion of fuel is transferred to water, which vapourises and gets converted to steam at the desired temperature and pressure.

The performance of a boiler is measured in terms of its evaporative capacity which is also called as Boiler Power. It is defined as the amount of steam produced in kg/hour. It may also be expressed in kg of steam per kg of fuel burnt or kg/hr/m2 of heating surface. Boilers are classified according to the following criteria:
According to flow of water and hot gases.
Water tube Fire tube

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Boilers
According to flow of water and hot gases.
Water tube Fire tube

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According to position of furnace


Internally fired Externally fired

According to the position of the principle axis


Vertical Horizontal Inclined

According to application
Stationary Mobile (Marine, Locomotive)

According to circulating water


Natural circulation Forced circulation

According to steam pressure


Low pressure Medium pressure High pressure

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Water Tube Boilers

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In water tube boilers, water is circulated through tubes and hot products of combustion flow over these tubes

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Water Tube Boilers


Water tube boilers can further be classified as follows:
Horizontal straight tube boilers

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Bent tube boilers


Cyclone fired boilers Water tube boilers have the following advantages: High pressures (about 140 kg/cm2) can be obtained Large heating surfaces can be obtained by use of large number of tubes therefore steam can be generated easily. Efficiency is higher because of high velocity of in tubes which improves heat transfer. water

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Fire Tube Boilers

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In fire tube boilers, the hot combustion gases pass through the tubes, which are surrounded by water.

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Fire Tube Boilers

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Fire Tube Boilers


External furnace

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Fire tube boilers can further be classified as follows:

Internal furnace
Fire tube boilers have the following advantages: Low cost Fluctuations of steam demand can be easily met Compact in size Disadvantage of fire tube boilers is that they contain more water in the drum and if the flue gas circulation is poor, they can not quickly meet the steam demand. For the same output, the outer shell of fire tube boiler is much larger than the shell of a water tube boiler.
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Pulverized coal firing system


In the pulverized coal firing system, the coal is reduced to a fine powder with the help of grinding mill and then admitted into the combustion chamber with the help of primary hot air. The primary air also helps to dry the coal before entering the combustion chamber.

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Secondary air required to complete the combustion process is supplied separately to the combustion chamber.
The resulting turbulence in the combustion chamber helps in uniform mixing of fuel and air and good combustion.

Elements of a pulverized coal firing system

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Pulverized coal

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Coal is pulverized (powdered) to increase its surface area (and therefore exposure) thus permitting rapid combustion. The pulverized coal is obtained by grinding the raw coal in pulverizing mills. Various types of pulverizing mills are: Ball mill Ball and race mill Hammer mill Bowl mill

Essential functions of pulverizing mills are:


Drying of the coal Grinding Separation of particles of a desired size.
Coal pulverizing mills reduce coal to powder by any (or all) action such as Impact, Abrasion and Crushing
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Ball and race mill for pulverizing coal

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Advantages of Pulverized coal firing system

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Any grade of coal can be used because coal is powdered before use. Rate of feed of fuel can be easily regulated better fuel economy.

Since there is almost complete combustion of fuel, there is increased rate of evaporation and hence better boiler efficiency.
Greater capacity to meet peak load. System is free from sagging and clinkering troubles associated with lump coal. Practically no ash handling problems. No moving parts within the furnace that is subjected to high temperatures.

This system works successfully in combination with gas and oil.


Requires much less air compared to stoker firing Furnace volume is considerably small.

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Disadvantages of Pulverized coal firing system


High capital cost. Lot of fly-ash in the exhaust removal of fine dust is expensive.

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Possibility of explosion is high because pulverized coal burns like gas. Maintenance of furnace brickwork is costly because of high temperatures. Special equipments required to start the system.

Skilled operators are required.


Separate coal preparation plant is necessary. Periodic maintenance of pulverized coal dispensing system is needed.

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Pulverized coal firing


Basically, pulverized fuel plants may be divided into two systems based on the method used for firing the coal:

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Unit System or Direct System


RAW COAL BUNKER

SECONDARY AIR

FURNACE

Bin System or Central System Unit or Direct System: This system works as follows:
Coal from bunker drops on to the feeder.
Coal is dried in the feeder by passage of hot air. The coal then moves to a mill for pulverizing. A fan supplies primary air to the pulverizing mill.
HOT AIR PRIMARY AIR + COAL BURNER FEEDER

PRIMARY AIR PULVERIZING FAN MILL

Pulverized coal and primary air are mixed and sent to a burner where secondary air is added.

It is called Unit System because each burner or a group of burners and pulverizer constitute a unit.
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Pulverized coal firing


Bin or Central System:

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Coal from bunker is fed by gravity to a dryer where hot air is admitted to dry the coal. Dry coal is then transferred to the pulverizing mill. Pulverized coal then moves to a cyclone separator where transporting air is separated from coal.

Primary air is mixed with coal at the feeder and supplied to the burner.
Secondary air is supplied separately to complete the combustion.
CYCLONE SEPARATOR

RAW COAL BUNKER

RETURN AIR

EXHAUST FAN VENT Dryer

CONVEYO R

SECONDARY AIR

FURNACE

FAN PULVERIZING MILL HOT AIR PRIMARY AIR FAN FEEDER

PRIMARY AIR + COAL BURNER

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Ash Handling

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Large power plants produce a huge quantity of ash, sometimes as much as 10 to 20% of the coal burnt per day. Therefore, mechanical devices are used for effective collection and disposal of ash.

Ash handling includes:


Removal of ash from furnace Loading to conveyors and delivery to fill or dump from where can be disposed off. it

Handling of ash is a problem because it is too hot when it comes out of furnace, dusty and sometimes poisonous and corrosive. Ash needs to be quenched before handling due to following reasons: Quenching reduces corrosive action of ash It reduces the dust accompanying the ash It reduces the temperature of ash Fused clinkers will disintegrate making it easier to handle

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Ash Handling Equipment

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A good ash handling equipment should have the following characteristics: It should have enough capacity to cope with the volume of ash that may be produced in a station. It should be able to handle large clinkers, boiler refuse, soot etc., with little attention from workers. It should be able to handle hot and wet ash effectively and with good speed. It should be possible to minimise the corrosive or abrasive action of ash. Operation of the plant should be easy, economical, simple and noiseless. It should be able to operate effectively under all variable load conditions. It should also remove fly ash and smoke to control air pollution.

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Ash Collection and Transportation

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Coal Handling System

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Screw Conveyor

Belt Conveyor 41

Coal Handling System

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Bucket Elevator 42

Typical input and output for a 500 MW boiler

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225 tons/hr coal 5400 tons/day coal (54 rail cars) Bottom Ash 108 tons/hr Fly Ash 432 tons/hr SOx 228 tons/day NOx 20 tons/day Steam 2000 tons/hr
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High Pressure Boilers

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In all modern power plants, high pressure boilers (> 100 bar) are invariably used due to their inherent advantages.

If high pressure steam is used, plant efficiency is increased because lesser quantity of steam is required for generating a given power; i.e., work done per unit mass of steam is higher.
Forced circulation of water can be used which helps arrangement of furnace and water surfaces and reduction of heat exchange area. Tendency for scale formation is reduced due to high velocity of water. Danger of overheating id reduced as all parts are more uniformly heated. Differential expansion is less due to more uniform temperature distribution thus reducing possibility of gas and air leakages. Following types of high pressure boilers are generally used: La Mont Boiler Benson Boiler

Loeffler Boiler
Schmidt-Hartmann Boiler
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CROSS COMPOUND TURBINE

Mitsubishis 1,000MW -class steam turbines define high-temperature, highpressure, high-output performance.
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TANDEM COMPOUND TURBINE


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SINGLE SHAFT TURBINE

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SINGLE SHAFT TURBINE


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Tandem Compound Turbine

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Power Generating Plant

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STEAM (THERMAL) POWER PLANT

Coal and Ash circuit


Pulverized coal from the storage area (called stack) is taken to the boiler by means of coal handling equipment such as belt conveyors, bucket elevators etc. Note : A thermal power plant of 400 MW capacity requires 5000 to 6000 tonnes of coal per day. After the pulverised coal is burnt at 15000C to 20000C by combustion it gets collected in the ash pit. It is removed from the ash pit by ash handling systems like belt conveyors, screw conveyors etc. Note : A thermal power plant of 400 MW capacity requires 10 hectares area per year if ash is damped to a height of 6.5 metres.

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STEAM (THERMAL) POWER PLANT

Air and flue gas circuit


The air from the atmosphere gets heated in the air preheater. The air receives its heat from the hot flue gases passing to the chimney. The hot air enters the boiler and helps in combustion of fuel in the boiler. The flue gases, after combustion in the boiler furnace, pass around the boiler tubes, heating the water present in the tubes. The flue gases then pass through a dust collector which removes any dust or solid particles. The filtered flue gas passes through the economiser and preheater and is forced out through the chimney by a draught fan.

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STEAM (THERMAL) POWER PLANT

Feed water and steam circuit


The superheated steam from the boiler enters the steam turbine. The superheated steam temperature is about 6000C at a pressure of 30 Mpa(300 kg/cm2) The steam expands in the turbine causing the turbine blades to rotate. After doing mechanical work on the blades and loosing its energy, the steam becomes wet and the pressure of steam becomes less. The wet steam passes through a condenser where it completely becomes water. The condensed water that has a temperature of 300C to 400C is collected in a tank called hot well. The water from the hot well is fed into the boiler through the economiser. The economiser preheats the water before entering the boiler. The economiser receives its heat from the flue gases leaving the boiler . Preheating the feed water in the economiser increases the boiler efficiency and helps quicker production of steam.

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STEAM (THERMAL) POWER PLANT

Cooling water circuit Water is circulated around the condenser to condense the steam coming out of the turbine. Cooling water enters the condenser at 100C to 150C and leaves at 200C to 250C. Plenty of water is required for condensing the steam in the condenser. The water may be taken from sources such as river or lake.

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STEAM (THERMAL) POWER PLANT

Advantages of thermal power plant :


Low initial cost Since located near the load centre, the cost of transmission and the losses due to transmission are considerably reduced. The construction and commissioning of thermal power plant takes lesser period.

Disadvantages of thermal power plant:


Fuel is a non-renewable source of energy. Efficiency decreases with decreasing load. Cost of power generation is high. Smoke produced by burning the fuel causes air pollution. Life of thermal power plant is 25 years. The efficiency decreases to less than 10% after its life period. Turbines has a high running speed of 3000 to 4000 rpm.

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ELECTROSTATIC PRECIPITATOR

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Why is the efficiency low for thermal plant?


The heating value or the energy available in the coal, is in the range of 10,500 kJ/kg to 27,000 kJ/kg. A heating value of 20,000 kJ/kg is equivalent to 5.56 kwh of electrical energy. In practice the effective conversion is only around 43% to 47% of the theoretically possible value. Reasons for low thermal efficiency: Due to practical limitations in heat transfer, all the heat produced by combustion is not transferred to the water; some is lost to the atmosphere as hot gases. Moisture in coal vapourises taking latent heat from the combustion heat and exits the boiler along with the hot gases. This is a loss. The steam is condensed for re-use. During this process the latent heat of condensation is lost to the cooling water. This is the major loss and is almost 40 % of the energy input. Losses in the turbine blades and exit losses at turbine end are some of the other losses. The Rankine cycle efficiency is dictated by the maximum temperature of steam that can be admitted into the turbine. Due to metallurgical constraints steam temperatures are at present limited to slightly more than 600 C. Various auxiliary equipment like pulverizers, fans, pumps and precipitators in large power plants consume around 6 % of the generator output for internal consumption.
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THANK YOU

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