ScottDombrosky

ZackMeyer
MichaelCzajkowski
DominicJosephsSpaulding
RobSwahl(unofficialmember)

PrinciplesofenergyEngineeringEGEE302
Group14FinalProject
Fall2013

A600MWpulverizedcoalfiredpowerplantisoperatinginCarbonCounty,Wyoming.Thisplant
usescoalfromalocalcoalminewiththefollowingcompositionwith18%excessair.
Proximate:
Moisture 12.0%
VM 38.4%
FC 43.6%
Ash 6.0%
HeatingValue(BTU/lb)
Asreceived 11,030
Ultimate(wt.%):
Carbon 62.6
Hydrogen 4.5
Nitrogen 1.2
Sulfur 0.7
Ash 6.0
Oxygen 13.0

Thepowerplantoverallthermalefficiencyis33.0%.Theplantisrequiredtocapture99%ofthe
sulfurdioxideemissions.Theplantalsousesaparticulatecollectiondevice(ESP)withan
efficiencyof99.9%.Theaverageambienttemperatureis80Fand60%RH.TheForcedairdraft
fanandInducedairdraftfanbalancethefurnacedraft.Ashanalysisshowedthattheunburntfuel
lossis0.2%.Assumethatfuelentersatambienttemperature.Thereisaselectivecatalytic
reductionsysteminstalledtoreducetheNO
x
by80%usingNH
3
.Assumethat40%ofthefuel
nitrogenformsNOthatreactswithNH
3
toreducetoN
2
overacatalyst.Theparticulatecollection
deviceisabaghouse.Assumethat5%ofthetotalashflowsasbottomashfromthe
combustionchamberandtherestiscapturedbytheESP.Thecleangasisgoingthroughthe
stack.Thestackneedstobemaintained80Fabovethedewpointofthegas.Thesteamtohigh
pressureturbineflowsat1000Fand2520psig.Theflowrateofhighpressuresteamis4.08
millionlb/h.Ofthissteam3.77millionlbsafterexpansionto653psigwillbegoingbacktothe
heatertoheatitto1000Fand587psig.
Prepareaflowchartforthisplantandlabeltheflowsquantities,pressuresandtemperaturesof
eachflowaroundallthecomponents.Performmaterialandenergybalancesbycalculatingthe
following:

Coalandairfeedratesintons/h
CalculatetheairflowrateinACFHthroughtheFDfan,
Fluegascompositiononwetanddrybasis,
FluegasflowrateinSCFHthroughtheIDfan,
Fluegasproducedperlboffuel,Fluegasmolecularweight,Fluegasmolecularweight(dry)
AshflowratefromtheESPintons/h.
Ammoniarequirementintons/h
Whatpercentoftheheatinputiscapturedbythehighpressureturbineandintermediate
pressureturbinesteam?
Heatlossthroughthestack.
Theadiabatictemperaturethatcanbeachievedbythiscoalinthecombustionchamber.

Recordsofmeetings,howtheresponsibilitiestocarryouttheprojectweredivided,who
performedwhichpartandsincethereareseveralvaluesthathavetobetransmittedfromone
parttoanother,documenttheproblemsencounteredandhowthegrouphasovercomethose
mustbedocumentedandsubmittedwiththeprojectreportsubmission.Thereportmustbe
lookingprofessionalandmustbeinwordandallcalculationsmustbedoneusingexcel.

Ifthereareanyquestionsoraftertheflowchartispreparedyoucanconsultmetomakesure
thatyouontherighttrackifnecessary.Youmustclearlywriteyourassumptionsandreasonsfor
thoseassumptions.

Group14EGEE302

Date:22November10December,2013

Allgroupmemberindividuallylookedovertheprojectinattemptstotrytofigureoutthe
schematicandstateadateforthemeetinglocation.Atthistimeasetupofthegroupexcel
spreadsheetwasmadetoinputquestionsorotherinquiriesthatthegroupasawholehad.

Date:11December,2013

GroupMeeting:
Allfourofthegroupmembersmetandworkedontheprojecttogether.Wewerejoined
byoneofourclassmatesRobertSwahlwhohadasimilarprojectasoursandcontributedtoour
project.Whatourmainfocuswastodoeachproblemtogethersoastoeliminateconfusionand
keeptheworkschedulewasontrack.Thefirstproblemwehadwasactuallytryingto
understandthequestionsthattheprojectwasasking,suchasdecidingwhattheschematic
lookedlikeandwhatthecorrectprocesseswere.Weeventuallyagreedontheschematicused
inthespreadsheetaftergoingtoofficehoursandthestudysessionthatwasprovidedon
WednesdayDecember11,2013.
Someotherproblemswehadweredecidingifthechoicetouseambientorstandard
temperaturewereappropriateforcertainsituations,butmostoftheconflictarosefromdifferent
assumptionseachteammemberwasmakingduetothedifficultyoftheproblem.Thequestions
weresolvedwithcollaborativeeffortandbyapplyingcommonsensetojustifythatouranswers
werereasonable.
Theproblemwearecurrentlystuckonisheatlossthroughthestackbutwecant
currentlysolvethequestionbecausethereisnotenoughinformationtounderstandwhatto
actuallysolve.Currentlywemadealistofquestionfortomorrow'sclass(12December,2013)in
ordertofinishoutthelastthreebulletpointsoftheproject.

Date:12December,2013
Classnotes:
Duringclassthegroupaskedquestionstotheunsolvedproblemsofyesterday.The
resultswere.
Heatlossthroughstack:
DeltaH=integral(StandardTemp.toAdiabaticflametemp.)
Heatlosstotheturbines:
(energyintotheturbine/energyfromtheboiler)
Adiabaticflametemperature:
energyfromcoal&inputairenergyofproducts=0

GroupMeeting:
AllfourmemberplusRobertSwahlmetupontheprojectaftertheEGEE302class.As
ofthebeginningofthemeeting,weattemptedtofinishoffthelast3problemsintheproject.The
hardestproblemthatweworkedonwastocalculatetheadiabatictemperatureinthe
combustionchamber.
Asagroup,wewereabletoresolveallthequestionswehadandcreatedthefollowing
solutionsbelow.

AlltheanswerstotheproblemscorrespondtothetabAnswers/BulletedPointsintheexcelspreadsheet.

Forourschematicwecreatedthediagramusingthegeneralinformationgiveninthetemplateofthe
project.ToconfirmthatthediagramwascorrectourgroupconsultedwithDr.Pisupati.

1. Coalandairfeedratesintons/h.

Tosolveforthecoalfeedrateweusedthetotalpowerofthecoalfireplantdividedbythe33%
thermalefficiencysothatwewouldgettherequiredenteringenergy.TogetfromMWtoBtu/hrweuseda
conversionfactorthendividedbythe11030(Btu/lb)coalHHVtofindthelbcoal/hrandthenconvertedto
(toncoal/hr).
Answer:281.22toncoal/h

Solvingfortheairfeedrate.Theactualairsent977.70(lbair/h)dividedbyacoalfeedrate
assumption(100lbcoal/h)togettheairfeedrate9.78(lbair/lbcoal)(withrespecttothefuelfeedrate)and
usedthecoalfeedrate281.22(toncoal/h)tofind(tonair/h).

Answer:2753.402tonair/h

2. CalculatetheairflowrateinACFHthroughtheFDfan.

BecauseourRT/Pvalueisgreaterthan20L/mole,weassumedwewereabletousetheidealgas
lawinordertofindthedensityoftheairflowrate.Thevaluethatwascalculatedwas.0000363(ton/ft^3).We
neededtofindtheairflowratethroughthefanbydividingthe(ton/ft^3)bytherequiredairfeedrate
2753.40(tonair/h)toget75,839,908.68(SCFH),actualtemperature539.67wasfoundstandardconditions
at492Rand1atmwereassumedtocalculatethe(ACFH).

Answer:83,188,055.93ACFH

3. Fluegascompositiononwetanddrybasis.

Usingtheinitialconditionsthatweregivenintheprojectfromtheultimateanalysis,webrokethe
coalintoeachofitscomponentsanddeterminedtheirproductswhencombusted.Fromtheseproductswe
foundthemolefractionsbelow.

Answer:

molefraction(wet) molefraction(dry)
CO2 0.15075 0.16452
H2O 0.08369
NO 4.95E05 5.41E05
SO2 6.32E05 6.90E05
O2 3.02E05 3.30E05
N2 0.76541 0.83532

4. FluegasflowrateinSCFHthroughtheIDfan.

Solvingforthewetfluegasmolarflowratetotal34.609(lbmole/h)wemultiplythemolecularweight
ofthegas29.582(lb/lbmole)wewouldgettheamountofwetfluegasenteringthestacks1,023.60(lbwet
fluegas/h)andusingthefactor359SCF/lbmole,theSCFHcanbecalculated.

Answer:367,483.017SCFH

5. Fluegasproducedperlboffuel,Fluegasmolecularweight,Fluegasmolecularweight(dry).

Thefluegasmolecularweightwascalculatedusingthesumofallthemolecularweightsofits
componentsmultipliedbytheirmolefractions.Thesameprocedureforcalculatingthedrymolecularweight
byremovingthemoisture.Usingthe1,023.630(lbwetfluegas/hr)anddividingbythe100lb/hrcoalfeedrate
basistogetthe(lbfluegas/lbfuel).

Answer(molecularweight):29.577
Answer(molecularweightdry):30.632651745658
Answer(lbfluegas/lbfuel):10.2362957406556

6. AshflowratefromtheESPintons/h.

TheanalysissaidthattheESPhadanefficiencyof99.9%.Fromthis,weareabletotakethe
amountofashfromtheultimateanalysisandmultiplyitby0.1%inordertofindouthowmuchashis
allowedthroughtheESP.

Answer:0.00000285ton/h

7. Ammoniarequirementintons/h(NO=NitrogenOxide)

Wenotedthat80%oftheproducedNOwasreducedwithNH3tocreateN2andH2O.Usingthis
wecreatedabalancedchemicalequation.Fromtheultimateanalysis,wefoundthemolesofNOgoingto
theaminescrubber.Fromthis,andathechemicalequationwewereabletocalculatetherequiredmass
flowrateofammoniarequiredtothisamountofNO.

Answer:0.00007(tonNH3/h)

8. Whatpercentoftheheatinputiscapturedbythehighpressureturbineandintermediatepressure
turbinesteam?

WefoundtheenthalpiesofthecoalandtheairgoingtoeachturbinefromthesteamtablesB8(fromthe
book).Weadjustedtheenthalpiestoourcalculatedfeedrate,theenthalpiesforthehighpressureturbine
andlowpressureturbinewerefoundtobe1457.370(btu/lb)and1,517.590(btu/lb).Whenthenfiguredout
thetotalwetaircomingintotheboiler0.736151797813036(btu/hr).Tofindthetotalboilerenthalpywefirst
foundtheenthalpyofcoalbyusingthe11,030(BTU/lb)HHVmultipliedbythecoalfeedrate562,433.034(lb
coal/hr).Theenthalpyofairiscalculatedbythecoalfeed562,433.034(lbcoal/hr)multipliedbytheamount
ofwetair0.736151797813036(btu/hr).Thetotalboilerenthaplyis6,603,731,861.921.Togetthehighand
lowpressureturbinesenthalpywemultipliedtheamountofmolesgoingthroughthesystemwitheach
4,080,000.000lb/hourand3,770,000.000pounds/hwecangetourpercentages.

AnswerHighPressure:90.041%
AnswerLowpressure:86.638%

9. Heatlossthroughthestack.

WetableB.9(fromthebook)andtheheatcapacitiestofindthechangeinenthalpyfromstack
temperaturetoambienttemperatureofallthegasesinthestack.Usingthetotalenthalpy805.59
(btu/lbmol)ofthegasandthetotalwetflowrateofthegas34.605lbmole/htofindtheheatlossin
btu/hr.web

Answer:27,877.05btu/hr

10. Theadiabatictemperaturethatcanbeachievedbythiscoalinthecombustionchamber.

Wesetthesumoftheenthalpiesequaltozerousingthegivenheatofformationoftheproductsin
theflueandtheairconstantsrelatedtothesensibleenthalpy.WefoundtheheatofformationfromB.1and
B.2(fromthebook).Tofindtheadiabatictemperaturewecanusetheintegraloftheourreference
temperature(25C)toouradiabatictemperature.ThenusetheCpvaluestofindthesensibleenthalpy
calculatepluggingthatintoexcelandusingtheGoalSeekfunctionweobtainedtheadiabatictemperature.

Answer:2039.7K