Beruflich Dokumente
Kultur Dokumente
These middling & fines has lower potential and considered as unusable for power generation in general. CFBC
Technology is apt for firing these low GCV coal with high combustion efficiency rate with very low emissions of Nox,
Sox etc.
JSPL initiated a pit-head power plant of 4x135MW Capacity eyeing multiple gains such as best utilization of the
upgraded low GCV coal, negligible fuel handling cost, catering power demand of existing and upcoming plants of
JSPL, Raigarh, evacuating surplus power to power starved Chattisgarh and so on.
General parameters
Coal Property:
_____________________________________________________________________________
Proximate Analysis:
Ultimate Analysis:
Total Moisture
: 10% 14 %
Total Moisture
: 10% 14 %
Ash
: 50% 58%
Ash
: 50% 58%
Volatile matter
: 15% - 21%
Carbon (C)
: 23% 28%
Fixed Carbon
: 13% 20%
Hydrogen (H)
: 2.3% 3.0%
GCV Kcal/Kg
: 2200 2700
Nitrogen (N)
: 0.7% 0.95%
Sulphur
: 0.4% 0.6%
Boiler:
SN
Description
Type
2
3
4
Boiler Capacity
Pressure (at SH O/L Header)
MS Temperature at SH O/L
5
6
7
Unit
C
C
%
249
540+/- 5
245.5
540+/- 5
81.5
Steam Turbine:
SN
Description
1
Type
2
Unit
Value at 100% TMCR
Value at VWO
Tandem compound, single Re-Heat, Re-Generative, Condensing, Multi
Cylinder (HP&IP, LP) Casing
MW
135
141.373 (at 3%
makeup)
TPH
418
447
Bar (g)
132.4
132.4
3
4
5
6
7
C
Ata
0
C
CW O/L Temperature
535
0.1186
33
535
0.1186
33
42
42
Generator:
SN
1
Rated O/P
Description
Unit
MW
MVA Rating
MVA
Power Factor
Terminal Voltage
No. of Phases
RPM
Frequency
Type of excitation
10
Type of AVR
KV
13.8
3
3000
HZ
50
Air
Brushless
Digital
Unit
0
C
Cst
0
C
% Max
% Max
% Max
IS:1593
66
2.0-7.0
12
0.025
0.05%
0.1%
1.8%
% Max
% Wt
Approximate GCV
Ash:
SN
1
2
3
4
5
6
7
8
9
10
169
0.80 Lagging
10
Kcal/ Kg
Sp gravity at 15 C max
Description
Silica
Alumina
Iron Oxide
Titaneum Oxide
Calcium Oxide
Magnesium Oxide
Sulphuric Anhydride
Manganese
Potassium pentoxide
Alkalis & undermined
Abb.
Silica Sio2
Al2o3
Fe2o3
Tio2
CaO
MgO
SO3
Mn
P2O5
IS:1593
58-62
23-26
7-10
0.15-3
3-5
1.5-3
0.15-0.4
0.02-0.04
Traces
Remaining
Main Steam
Temperature
Reheat
Steam
Conditions
Bar
Deg C
Deg C
41.4
62.1
Type
Design Efficiency
of Power Plant
Size of
plant
MW
462
482
27.5
30.5
30
60
103.4
566
33.7
100
103.4
538
538
Reheat + Regeneration
35.7
120
162
566
538
Reheat + Regeneration
37.3
200
158.6
158.6
566
566
566
566
Reheat + Regeneration
Reheat + Regeneration
37.7
38.4
275
550
158.6
566
566
Reheat + Regeneration
38.4
350
241.3
593
566
Supercritical
39.0
375
158.6
566
566
Reheat + Regeneration
39.25
500
The main incentive to keep striving for bigger and better plant is that one expects the thermal efficiency to improve
with size and capital cost per MW decreases with the increase of size.
It can be seen that steam temperatures have increased at quite a slow rate. This is because increasing steam
temperature is intimately bound up with metallurgical advances and such advantages are painfully slow. On the
other hand, by increasing the steam pressure, introducing reheat and rapidly increasing output it has been possible
to reduce the cost per MW of installed plant considerably.
Increased output is normally associated with increasing pressure and temperature conditions. This is because:-
1. The higher cost of high temperature components is partly affected by a reduction in the number of
components per MW.
2. Losses become proportionately smaller in the large machine.
3. High density steam must be associated with large flows to give reasonably sized H.P. blades.
Rankine Cycle
The Rankine cycle is the simplest theoretical cycle using vapour as the working medium. The basic arrangement of
this, the simplest of all vapour cycles is shown in fig 1 (Scheme) and Fig 2 (TS Diagram).
Fig 3 Sensible, Latent and Superheat, 100 bar, 566 oC Cycle on T-S Diagram
Steam then expands isentropically i.e. enters the turbine and rotates it, as shown by the line DEF. At point
E there is no superheat left in the steam and so from E to F there is increasing wetness. At F and steam is at a
pressure of 30 m bar abs. Steam is then passed out of turbine to the condenser and condensation of steam takes
place as represented by the line FA. At point A the steam has all been condensed and condensate is at boiling
temperature ready to begin another cycle.
50
100
150
200
221.2
263.9
311.0
342.1
365.7
374.15
1154.5
1408.0
1611.0
1826.5
2107.4
Latent heat(Kj/Kg)
50
100
150
200
221.2
1639.7
1319.7
1004.0
591.9
0
263.9
311.0
342.1
365.7
374.15
Superheat addition: The curve CD shows the process of steam being superheated at a constant pressure of 100 bars from the state of
dry saturated steam at 311 deg C to the designed stop valve temp. of 566 deg C.The area plCD represents the
amount of superheat. The amount of heat required by deducting the total heat at C from total heat at D and is
equal to 811.6 Kj/Kg. Quantity of heat required to superheat steam to a given temperature varies with pressure.
Table3 Variation of superheat for different pressure (final temp 570 deg C)
Pressure Bar absolute
50
100
150
200
Thermal Efficiency of the cycle:Useful heat
Thermal efficiency
=
Total heat
Useful heat means that part of total heat which is used in rotating the turbine i.e. when the steam expand
adiabatically(adiabatic expansion means no heat accepted or rejected during the process; all work done by steam
at the expense of its internal energy) in the turbine represented by line DEF fig - 6. Expansion of steam takes place
up to a pressure of 30 m bar (24.1 deg C). The condensation takes place at a constant temp. as indicated by line
FA, until all latent heat is removed.
Heat removed from steam or useless heat is shown or useless heat is shown by rectangular pmAF. Amount of this
rejected can be calculated as follows:
= 3438.3kJ/kg
=1-
Rejected Heat
1 -
Total heat
1917.2
3438.2
= 0.4423 or 44.23%
This is the highest possible efficiency for a basic Rankine Cycle with steam at 100 bar absolute, 566oC and
backpressure is 30m bar. Ofcourse, in practice a turbine operating under this cycle will be less efficient. It can also
be noted that how superheating of steam adds to efficiency. If steam is not superheated the total amount of heat
in this cycle will be addition of sensible heat and latent heat only i.e.1307 + 1319.7 = 2626.7kJ/kg
So, Thermal efficiency= 1 Rejected heat
Total heat
= 1 - 1917.2
2626.7
= 0.2701 or 27.1%
Hence, efficiency of basic Rankine Cycle can be improved by increasing the superheat. But this scope
becomes limited due to limitations of materials, which can withstand very high temperature and the cost associated
with it.
REHEATING
To increase the heat available compared to the heat rejected is to increase the superheated steam
temperature. Unfortunately this is only possible to a very small degree because of metallurgical limitations. Thus
there is very little scope in this direction. Therefore the alternative is to probably expand the steam in the turbine to
some suitable intermediate condition and then pass it back to the boiler to be reheated to some high temperature.
It is then piped back to the turbine to continue expansion.
Let us consider the same 100bar cycle, now with reheat. Fig - 7 below shows the cycle. Steam as usually
starts expanding after being superheated. At the point G when the pressure had dropped to 20 bar the steam is
taken out of turbine and reheated to 566oC as shown by the line GH. It is then fed to the LP turbine where it
expands to the condenser pressure.
The efficiency of the cycle is determined in a similar manner to the previous cases and works out to be
46.09%.
So, reheating had improved efficiency from 44.23% to 46.23% to 46.09%. A further advantage of
reheating is that the wetness of the exhaust steam is reduced considerably.
Let us see the previous 100 bar cycle, this time with regenerative feed heating (Fig 7). The steam
expands isentropically in the turbine until the temperature is 250oC after which the steam is bled to an infinite
number of feed heaters. The result is quantity of heat represented by area under the curve KL is transferred to the
water side shown by the area LFpr has been given to feed water whereas before it would have been rejected in the
condenser. The heat represented by the area LKF has also been transferred to feed water, where as formerly it
would have done some useful work in turbine, so there is some loss of work too. Yes, but on the balance its is
better to loss the power from the triangle LKF to save the heat represented by large rectangle LFpr that would have
been wasted.
Regenerative feed heating elevates the condensate temperature represented along the boiling water line to
M and the remaining sensible heat is supplied in the economizer and boiler to point B.
Let us find the efficiency with reheat;
Total heat supplied = sensible heat from M to B + Latent heat + superheat
Amount of latent heat and superheat in this cycle are same on the previous cycle with superheat and eual; to
1319.7kJ/kg and 811.6kJ/kg respectively.
Now, sensible heat
= 322.2 kJ/kg
= 243.5 kJ/kg
Heat rejected
= 1192.2kJ/kg
So, efficiency
1 - Rejected Heat
Total Heat
- 1192.2
2453.5
= 0 .514 or 51.4%
Hence you find how efficiency of Rankine cycle changes with reheating and feed heating.
= 44.23%
= 46.09%
= 51.4%
A combination of reheating and feed heating will give higher ideal cycle efficiency.
The improvement in thermal efficiency permits a reduction in the size of boiler as it has less heat input to do
for a given load.
2)
The increased amount of steam tapped for feed heating increases the cost of the feed heaters and the steam
piping between turbine and heaters.
3)
The increase in the total steam consumption increases the cost of the steam piping between the boiler and
the turbine, the cost of high pressure end of the turbine and that of feed piping and feed pumps.
4)
The decrease in the amount of steam flowing through the low-pressure end of the turbine and the amount of
steam to be condensed. It decreases the cost of low-pressure end of the turbine and the cost of condensing
plant, C.W. culverts, etc.
5)
The higher feed temperature consequent upon the use of extensive regenerative feed heating would cause
the flue gases to leave the boiler economizer at a higher temperature, thus inevitably reducing the boiler
efficiency to an extent which could largely counter balance the increase in turbine thermal efficiency. For this
reason it is necessary to employ a further regenerator in the form of an air heater in which the heat of the
flue gases is transferred to the combustion air supplied to the furnace.
Another consideration with respect to boiler design is that the feed temperature at the economizer inlet must be
higher than the due point of the boiler flue gases, but not high enough to cause steaming in the economizer also,
the temperature of feed water in the economizer outlet must be less than the saturation temperature of water at
that particular pressure, normally difference shall be 20oC.
Familiarization of Boiler and Turbine system at DCPP
Boiler:
Shanghai Boiler Works Ltd. (SEC/SBWL) has supplied JINDAL STEEL & POWER LIMITED four sets of 460TPH CFB
boiler. The boiler mainly consists of drum, membrane water wall furnace, thermal insulation cyclone separator, U type seal pot and back-pass convective heating surface.
1. Steam and water system: The steam and water system consists of economizer, drum, evaporative
heating surface (furnace water wall and evaporate panels), superheater panels, back-pass superheater, final
superheater and re-heater.
The feed water enters low temperature economizer from one side of the pack-pass and then high temperature
economizer. The heated water then enters the drum through 2 connecting pipes. The water in the drum flows
to the furnace water wall through 4 large diameter downcomers, and 02 to the evaporate panels through
downcomers. Then the saturated steam is lead to the drum through link tubes.
The saturated steam is lead to back-pass superheater from drum through 2 connecting pipes. The superheat
steam flows through back-pass superheater, low temperature superheater panels, first-stage de-superheater,
high temperature superheater panels, secondary-stage de-superheater and final superheater.
2. Gas and air system: The boiler is of balanced draft. Zero pressure point is set at the inlet duct of cyclone
separator. The air is send into the air pre-heater by fans (include primary air fan and secondary air fan). The
hot primary air enters wind box arranged under the furnace and flows through the nozzles on the grate and
fluidizes the materials inside the furnace. The hot secondary air is send into the furnace through secondary
nozzles. The high pressure fluidizing air is used as greasing air of seal pot and fluidizing air of ash cooler.
3. Coal & Ash circulation system: Fuel, sorbent and bed materials are fluidized in the furnace by the primary
air. Fuel particles, high temperature materials and sorbent particles are mixed sufficiently. Combustion process
is completed in the dense-phase area, however small particles are carried out by the gas, which are separated
in the cyclone as the heavy particles drop down and the light fly ash are carried by the gas to the back-pass.
Two thermal insulation cyclone separators are arranged between furnace and back-pass. A U type seal pot is
arranged under each separator. Fluidizing nozzles are arranged at the bottom of the seal pot, which fluidizes
the material and send it back to the furnace.
4. Ash drain system: Ash generation will be tune of 50% of the coal firing rate, in which, Fly ash and bed ash
ration is 55:45. Bottom ash is drained from the furnace bottom. The temperature of bed ash is about 800 Deg
C. The bottom ash will drag to ash coolers that will be cooled to as low as 120 Deg. Fly ash is drained from the
back-pass and ESP.
Item
Unit
Value
Set
m3
1150
Effective volume
977.5
3
0.85
Bulk Density
T/ m
Tons
830
Hrs
12 (6 Hrs x 2 Bunkers)
Unit
Value
Gravimetric
Item
Type
Max O/P
TPH
60
Set
Unit
Value
Centrifugal
Item
Type
27
Capacity
m3/ Hr
165486
mmwc
2345
IGV
KW
1200
Voltage
6600
Set
Unit
Value
Centrifugal
Item
Type
Inlet air capacity
27
Capacity
m / Hr
135505
mmwc
1567
IGV
KW
800
Voltage
6600
Set
Item
Unit
Value
Type
Centrifugal
Inlet air capacity
139.5
Capacity
m / Hr
604337
mmwc
854
Hyd Coupling
KW
1700
Voltage
6600
Set
Unit
Value
Constant volume
Item
Type
(displacement type)
2
27
Capacity
m3/ Hr
19118
mmwc
7608
KW
400
Voltage
6600
Set
Unit
Value
Electrostatic Precipitator
No
1
Item
Type
eight fields
2
Flow of gas
Flow area
Pressure drop
154.6
m3/ Hr
962280
m2
333
mmwc
<30
>99.97
Mg/ m3
<40
Set
Power station output or capacity mentioned in terms of MW in general. Kilo-Watt-Hour or KWh is the basic unit of
electricity.
Heat rate:
Heat rate is a significant indicator of power station performance. Heat rate defined as Heat Input (Kcal or KJ) per
Unit electricity generation (KWh). Lower the heat rate, higher the plant efficiency.
1. Turbine Heat Rate: Turbine heat rate is defined as heat input to turbine (in Kcal) per unit generation. At
DCPP, guaranteed turbine heat rate is 2042 Kcal/ KWh.
2. Unit heat rate: Turbine heat rate divided by boiler efficiency leads unit heat rate. For DCPP, guaranteed
boiler efficiency is 82.7% and their by unit heat rate will be 2469 Kcal/ KWhr. (NB: 2042/.827= 2469)
3. Station / Plant heat rate: Auxiliary power consumption of Thermal power plant is considered at 10% of
the plant total capacity. So, the power output can be calculated as 90% of total generation and the station
heat rate will be 2743 Kcal/ KWhr.(NB:2469/.90=2743)
Boiler efficiency:
Efficiency of boiler can be calculated in two ways viz; direct method and indirect method.
Indirect method: Indirect method counts various losses and their by considered as more accurate than
direct method of finding efficiency. However, blow down loss is omitted in indirect method. There are
reference standards for Boiler testing at site using indirect method namely British Standard BS 845: 1987
and US standard ASME PTC-4-1 Power test code steam generating units. Indirect method is also called
heat loss method, covers various losses such as
Estimated project Cost of 4 x 135 MW Captive Power Plant is Rs.2259.00 Crores. The CPP will cater to ever
increasing power demand of not only the existing but also the upcoming Steel complex at Raigarh.
Sl.
1
Project cost
Description
Total Project Cost
Phase I
Rs.1179.00 Crores
Phase II
Rs.1080.00
Generation
Item
Unit
Quantity
Remark
MW
135.00
MU
3.24
MU
2.92
at 90% PLF
MU
0.29
at 10% of generation
MU
2.62
Rs in Cr
1.14
MU
78.73
Monthly revenue
Rs in Cr
34.25
Yearly generation
MU
944.78
Considering 12 months
MU
866.05
Rs in Cr
376.73
Rs in Cr
1506.93
From 04 Units
Coal
Item
Unit
Quantity
Remark
Tones
162
Tones
145
Tones
130
Tones
3120
T/MW
1.075
0.28
Rs in Cr
Rs in Cr
8.42
Rs in Cr
92.66
Rs in Cr
370.66
at Rs 900/ T of Middling
Considered 01 month S/D
Fuel Oil
Item
Unit
Quantity
32.00
Cold startup
12.00
Hot Startup
06 cold startup & 12 hot startup
336.00
Rs/T
30000.00
Rs in Cr
1.01
Rs in Cr
4.03
Fuel cost
Remark
One unit
Miscellaneous costs
Item
Unit
Quantity
Unit
Quantity
Rs in Cr
1506.93
Expenditure
Rs in Cr
487.69
Net Savings
Rs in Cr
1019.24
Remark
5% of capital cost of 2259 Crores
Remark
From 04 units
Simple payback period:This is the simplest technique that can be used to appraise a project proposal. The Simple Payback Period can be
defined as the length of the time required for the running total of net saving before depreciation to equal the
capital cost of the project. Shorter the payback period, more attractive the project becomes.
Simple payback period (SPP)
: Capital cost of the projects / Net annual saving.
SPP (of DCPP) : 2259 / 1019
: 2.21, to say 2 years 03 months
Discounted cash flow methods:Even though, SPP is a simplest technique for a quick evaluation, it has a number of major weaknesses as below:
SPP does not consider savings that are accrues after the payback period is finished.
SPP does not consider either interest, inflation etc. Other way, time value for money is not been considered
in SPP Method.
Net present value: NPV method calculates the present value of the all yearly cash flows (i.e. capital costs and
net savings) incurred or accrued throughout the life of a project, and summates them. Costs are represented as
negative value and savings as positive. The sum of all the present value termed as NPV. The higher the NPV, the
more attractive the proposed project.
PV = S x DF; DF = (1+IR/100)-n
PV is the Present Value of S in n years time, S is the value of cash flow in n years time, DF is the discount
factor or simply interest on capital.
Profitability Index: Profitability index termed as sum of the discounted net savings per capital cost.
Net Present Value and Profitability Index for a 10 Year span
Discount factor is nothing but accrues figure of interest, depreciation and inflation. Here, we have considered 10%
interest, 10% depreciation and 4% inflation
Net Present Value and Profitability Index for a 10 Year span
Year
Net Savings
Present Value
-2259
-2259
1
2
3
4
5
6
7
8
9
0.862
0.743
0.641
0.552
0.476
0.41
0.354
0.305
0.263
0
0
0
0
0
0
0
0
0
1019
1019
1019
1019
1019
1019
1019
1019
1019
878
757
653
562
485
418
361
311
268
10
0.227
1019
231
NPV
2666
Profitability index
1.18
PACKAGE NAME
Owner
BTG PACKAGE
Shanghai Electric
Company (SEC), China
Shanghai Electric
Company (SEC), China
Boiler: Mr Aravindaran
Turbine: Mr U K Ghosh
MAKE-UP WATER
SYSTEM
"RAUNAQ International
Ltd
Mr Balamurugan / Mr T V
Gopi
PTDM Plant
TRIVENI
TRIVENI
Mr Sunil Porwal
COOLING TOWER (2
Nos.)
"PAHARPUR COOLING
TOWERS LTD."
"PAHARPUR COOLING
TOWERS LTD."
Mr Sunil Porwal
EOT CRANE
"CSD,RAIGARH"
"CSD,RAIGARH"
Mr U K Ghosh
CHIMNEY
GDC
Mr A Kar/ Mr U K Ghosh
SIMPLEX Infrastructure
Ltd
SIMPLEX Infrastructure
Ltd
GDC
Mr A Kar/ Mr U K Ghosh
"WPIL LTD."
"WPIL LTD."
Mr Sunil Porwal
"Siemens"
"Siemens"
Mr S K Garai
10
POWER/GENERATOR
TRANSFORMER
Mr S K Garai
11
ST & UAT
Mr S K Garai
12
Service Transformer
13
CHP
"Crompton Greaves
Ltd."
Enviro abrasion
Resistant Ltd.
14
AHP
"Crompton Greaves
Ltd."
Enviro abrasion
Resistant Ltd.
"Mecawber Beekay
Ltd."
15
16
HT Switchgear
Siemens
17
MISCELLANEOUS PUMPS
"WPIL LTD."
18
COMPRESSED AIR
SYSTEM
19
HT POWER CABLE
Mr S K Garai
Mr R Verma
Mr Vinay Krishan
Boiler: Mr Aravindaran
Sunil Hi-Tech
Turbine: Mr U K Ghosh
Mr S K Garai
"WPIL LTD."
Mr Vipin Chaudhary
Mr S K Garai
Mr Balamurugan / Mr T V
Gopi
Mr Balamurugan / Mr T V
Gopi
Mr Sunil Porwal
"LLOYD LTD."
FUEL OIL SYSTEM
21
"HBL LTD."
"HBL LTD."
Mr S K Garai
22
RE JOINT
"CORI ENGINEERING
LTD."
"CORI ENGINEERING
LTD."
Mr U K Ghosh
23
BF VALVE
Mr Balamurugan / Mr T V
Gopi
24
BUSDUCT
"CONTROL &
SWITCHGEAR LTD."
"CONTROL &
SWITCHGEAR LTD."
Mr S K Garai
25
C&I
Mr J Kole
Tyko fire
Tyko fire
Mr Sarkar
Mr Balamurugan / Mr T V
Gopi
26
27
28
LP PIPING
29
BOP ELELCTRICAL
30
DG SETS
31
LT switch gear
32
Air conditioning
Mr Vipin Chaudhary
33
Ventilation
M/S SK SYSTEM
Mr Vipin Chaudhary
34
35
Elevator
36
LT Power Cable
37
220 KV Transmission
Line
38
Logistics
39
40
Mr S K Garai
Mr Sarkar
M/S KEI
Mr Vipin Chaudhary
Mr S K Garai
Mr Sunil Porwal
Mr Aravindaran
Mr S K Garai
Mr S K Garai
Mr Balamurugan
41
O&M Contract
M/s SEC
42
Supervision of
Refractory Application &
Furnace drying
M/s SEC
Mr Ravindrakumar
43
33 kV Switchyard
M/s Siemens
Mr S K Garai
44
33 kV Transformers
Mr S K Garai
45
SCADA
Mr S K Garai
46
Effluent Treatment
Mr Sunil Porwal
47
Mr J Kole