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St.

Peter’s College

Iligan City

College of Engineering

Mechanical Engineering Department

POWER PLANT DESIGN

In Partial Fulfillment of the Requirements in

Industrial Plant

Submitted to:

Bernabe Q. Sanchez, Ph.D

Submitted by:

Kim S. Deygabi
Peak Demand: 38 MW

Design Load: 36 MW

Base Load: 18 MW

Location

The peak demand for the Lanao del Norte is about 63 MW. Fitting this peak load onto the given
load curve.

M
e
g
w
a
t
t

hours
Base Load Selection Argument
Using Fig. 2-9 from Morse PPE, for a condensing steam turbine @ 27.78% operating range, the
thermal efficiency is 19% or at 59 MW. Assuming a coal calorific value of 18 MJ/kg.

The needed amount of coal to maintain 1 MWh is

3600 𝑀𝐽
1MWh → 𝑀𝐽 = 1052.63 kg of coal / MWh
(18 𝑥 0.19)
𝑘𝑔

For a 24hour operation at 10 MW

(10MW) (24hr) (1052.63) = 252,631.2 kg of coal

The area above the curve and below the base load line represents a loss for the operating
range:

Loss= (24 box units) (10MWh) =240 MWh

Thus, (240 MWh) (1052.63 kg of coal/ MWh) =252631.2 kg of coal considered as waste

Assuming price of electricity 8500php/ MWh; coal price of 7 php/kg. This means that the profit
energy is:

Value of total coal burned= (252631.2 k of coal) (7php/kg)

= 1,768,418.4 php

And hence, a profit of:

PROFIT= (10MWh) (24) (8500php/MWh)- 1,768,418.4 php

= 3,225,000- 1,768,418.4

= 2,079,555

AVERAGE LOAD COMPUTATION

10MWh+14MWh
A1= (2hours)= 24 MWh
2

14MWh+17MWh
A2= (2hours)= 31 MWh
2

17MWh+25MWh
A3= (2hours)= 42 MWh
2
25MWh+27MWh
A4= (2hours)= 52 MWh
2

27MWh+33MWh
A5= (2hours)= 60 MWh
2

33MWh+40MWh
A6= (2hours)= 73 MWh
2

40MWh+35MWh
A7= (2hours)= 75 MWh
2

35MWh+31MWh
A8= (2hours)= 66 MWh
2

31MWh+24MWh
A9= (2hours)= 55 MWh
2

24MWh+21MWh
A10= (2hours)= 45 MWh
2

21MWh+17MWh
A11= (2hours)=38 MWh
2

17MWh+15MWh
A12= (2hours)= 32 MWh
2

ATOTAL= 593 MW

593,000 𝑀𝑊ℎ
Average Load= = 24.708 MW
24ℎ𝑟

24.708
Load Factor = = 0.65
38

Annual MWh produced


Use Factor= capacity hours of operation

593,000 (365 days)


=24 hours (36)(365)

Use factor= 686.34

(24.708) (365)
Capacity Factor= (32)(365)
=0.77
Given: Coal-Fired Power Plant

Rated Power: 36 MW

5 Heater: 4 CLOSE, 1 OPEN

Throttle Condition: 478°C, 6.5 MPa

Back Pressure: 10 Kpa, 45.8075°C

Power Required: 36 MW

Generator efficiency: Assumption- FULL-LOAD

0.055
Ŋgen= 0.98- 3 rating
(equation 8-10, Morse , PPE)

1000

0.055
Ŋgen= 0.98- 3 36,000

1000

Ŋgen=96.33%

FRICTION LOSS

5
Friction Loss= x normal rating (equation, Morse, PPE)
𝑟𝑎𝑡𝑖𝑛𝑔

1000

5
= x 36,000
36,000

1000

= 30,000 KW

TURBINE EFFICIENCY

ŊT= 0.94 x Blade efficiency -2% to 5% rotation and leakage allowance (equation 11-13,
Morse)

Assumption: Reaction turbine blading with velocity ratio, R= 0.75

then blade efficiency = 95% with 3% allowance, (figure 11-19, Morse)

ŊT= 0.94 x 0.95 -0.03 = 0.8 = 86.3 %


36,000
W T= 0.9653+ 38,405.72

= 75,699.825 KW

Pressure at extraction:

Pb=Pressure at boiler= 6.5 MPa

Pc= Pressure at condenser / Back-pressure= 10 KPa

Tsat Pb + Tsat Pc
n+1

Tsat Pb= at 6.5 MPa, temperature is 280.86°C

Tsat Pc= at 10 KPa, temperature is 45.8075°C

n= 5 heaters

280.86+45.8
= 39.18°C
5+1

EXTRACTION Boiler:

Tsat= 280.86-39.18

= 241.68°C at 6.50 MPa

EXTRACTION E:

Tsat= 241.63°C at 3.45 MPa

EXTRACTION D:

Tsat= 202.51°C at 1.64 Mpa

EXTRACTION C:

Tsat= 163.33°C at 0.67 Mpa

EXTRACTION B:
Tsat = 124.16°C at 0.23 Mpa

Extraction A:

Tsat = 84.98°C at 0.07 Mpa

Extraction Condesnser:

Tsat = 45.81°C at 0.01 Mpa

State 1: BOILER:

T1= 478°C

P1= 6.5 MPa

S1= 6.77 KJ/kg-K

H1= 3364.02 kj/kg

State E:

S1=Se’= 6.77 kj/kg-k @ 3.45 MPa (steam table)

Thus Te’= 377.25°C ; he’= 3170.88 kj/kg

Solving for he:

3364.02−ℎ𝑒
Ŋ= 0.722=
3364.02−3170.88

he = 3224.56 kj/kg

Actual State E:

Pe= 3.45 MPa Te= 400.28°C

he =3224.56 kj/kg Se= 6.8511 kj/kg-k

State D:

S1=Sd’= 6.77 kj/kg-k @ 1.867 MPa

Thus Td’= 274.55°C ; hd’= 2976.36 kj/kg


Solving for hd:

3364.0234−ℎ𝑑
Ŋ= 0.722=
3364.0234−2976.36

hd = 3087.13 kj/kg

Actual State D:

Pd= 1.64 MPa Td= 322.28°C

hd = 3084.13 kj/kg Sd= 6.96 kj/kg-k

State C:

S1=Sc’= 6.77 kj/kg-k @ 0.67 Mpa

Thus Tc’= 158°C ; hc’=2761.32 kj/kg

Solving for hc:

3364.0234−ℎ𝑐
Ŋ= 0.722=
3364.0234−2761.32

hc = 2928.87 kj/kg

Actual State C:

Pc= 0.67 Mpa Tc= 237.64°C

hc =2928.87 kj/kg Sc= 7.08 kj/kg-k

State B:

S1=Sb’= 6.77 kj/kg-k @ 0.23 Mpa

Tb’=124.64°C; hb’=2584.24 kj/kg

Solving for hb:

3364.02−ℎ𝑏
Ŋ= 0.722=
3364.02−2589.24

hb = 2804.63 kj/kg
Actual State B:

Pb= 0.23 Mpa Tb= 2804.63°C

hb = 2804.63 kj/kg Sb= 7.3 kj/kg-k

State A:

S1=Sa’= 6.77 kj/kg-k @ 0.07 Mpa

Ta’= 89.93°C; ha’= 2669.45 kj/kg

Solving for ha:

3364.02−ℎ𝑎
Ŋ= 0.722=
3364.02−2402.01

Ha = 2669.45 kj/kg

Actual State A:

Pa= 0.07 Mpa Ta= 94.87°C

ha = 2669.45 kj/kg Sa= 7.5 kj/kg-k

State 2:

S1=Sa2’= 6.77 kj/kg-k @ 0.01 Mpa

Thus T2’= 45.81°C ; ha’= 2144.08 kj/kg

Solving for h2:

3364.02−ℎ2
Ŋ= 0.722=
3364.02−2144.08

h2 = 2483.22 kj/kg

Actual State2:

Pa= 0.01 Mpa Ta= 45.81°C

ha = 2483.22 kj/kg Sa= 7.8 kj/kg-k


STATE 3:

h3= hf at p3= 191.81 kj/kg

t3= 45.81°C

v3= 0.0010103 m3/kg

STATE 4: Pump 1 (assumption: incompressible flow, typical pump efficiency of 81%)

𝑊𝑝1
=h4’-h3= v3(p4-p3) 3
𝑚4

h4’-h3= v3(p4-p3) 4

h4’= (0.0010103) (670.10-10) + 191.81

h4’= 192.50 kj/kg wp1

ℎ4′ −ℎ3 192.50−191.81


Ŋ= 0.722= =
ℎ4−ℎ3 ℎ4−191.81

h4= 192.766 kj/kg

Actual State 4:

h4= 192.766 kj/kg t4= 45.83°C

P4= 670 Kpa s4= 7.8 kj/kg-k

STATE 5: Closed Feed water Heater 1 A

Required hs= TTD = 2.25°C

H5 at p4 and tsat A- TTD 5 4

H5 @ 670 kpa and 84.98°C- 2.25°C

H5 @ 670 kpa and 882.73°C A’

H5= 346.89 kj/kg

@ 84.98°C; @ State A 0.07 Mpa


Then; SA’ = 1.1342 Kj/kg.K

HA’ = 355.89 Kj/kg

@ HA” = HA’ =355.89 @ State 2 PA = 0.01 Mpa

Then;

H5= 346.91 kj/kg t5= 82.73°C

P5= 670 kpa s5= 1.16 kj/kg-k

STATE 6: Closed Feedwater Heater 2 B

H6 at p5 at tsat b- TTD 6 5

H6 at 670 kpa and 124.16°C- 2.25°C

H6 at 670 kpa and 121.91°C b’


H6= 512.23 kj/kg

Thus;

H6= 512.23 kj/kg t6= 121.91°C

P6= 670 kpa s6= 1.55 kj/kg-k

@ 124.16°C; @ State B 0.23 Mpa

STATE 7: Open Feedwater Heater 1

H7 at pc at tsat c- 7 C 6

H7 at 670 kpa @ 163.33°

H7= 689.48 kj/kg D” B”

s7= 1.97 kj/kg-k

HB” = HB’ =521.48 Kj/kg @ State C = 0.67 Mpa


Tb” =121.16°C

Sb” = 1.57 Kj/ Kg. K

Hd”=Hd’=863.72 kj/kg

Sd” = 2.37 Kj/Kg.K

Td” = 163.19°C1

STATE 8: PUMP 2
𝑤𝑝2
𝑚𝑏
=h8’-h7= v7(p8-p7)

Where:

V7=Vp @ P2 = 670 Kpa

V2 = 1.11X10^-3

H8’= v7(p8-p7) + h7 8 7

H8’= (1.11 x 10 -3) (6500-670) +689.48

H8’= 695.93kj/kg Wp2

ℎ8′ −ℎ7 695.93−689.48


Ŋ= 0.81= =
ℎ8−ℎ7 ℎ8−689.48

H8= 697.44 kj/kg

Thus;

H8= 697.44 kj/kg t8= 164.26°C

P8= 6500 kpa s8= 1.98 kj/kg-k


STATE 9: Closed Feedwater Heater 3

H9 @ p8 and tsat d + TTD

H9 at 6500 KPa and 202.51°C + TTD

H9 at 6500 KPa and 202.51°C + 2.25° 9 8

H9 at 6500 KPa and 201.76 °C E” D’

H9= 875.74 kj/kg

Hd” = @ Heater D 202.51°C @ 1.64 Mpa @ Sat. Liquid

Hd” = 863.72 kj/kg

Sd” = 2.35 Kj/kg

Thus;

H9= 875.74 kj/kg t9= 204.76°C

P9= 6500 kpa s9= 2.36 kj/kg-k

STATE 10 : Closed Feedwater Heater 4

H10 at p9 and tsate + TTD

H10 @ 6500 KPa and 241.68°C - 2.25°C

H10 at 6500 KPa and 239.43 °C

H10= 1035.15 kj/kg 10 9

Thus;

H10= 1035.15 kj/kg t10= 234.43°C

P10= 6500 kpa s10= 2.69 kj/kg-k E”

@ Pressure Heater E 3.45 Mpa

Te” = 241.24°C
He” = 1045.82 Kj/kg

Se” = 2.72 Kj/kg.K


SOLVING FOR THE MASS FLOW RATES

HEATER E:

Me(E) + 1(9) = Me(E’) + 1(10)

Me(3224.56 kj/kg) + (1)(875.74 kj/hg) = Me(1045.82 kj/kg) + (1)(1033.15 kj/hg)

Me = 0.0731661419 kg/s

HEATER D:

Md(3084.13) + (0.0739)(1045.82) +(697.44) =(875.74)+ md(863.72)

Md= 0.0802978391 kg/s


HEATER C :

Mc(2761.32)=(Md=Mc)(803.72)=(1)(1-ME-MD-MC-
MB)(512.23)=MB(521.48)+(1)(689.48)

2761.32MC=863.72MC+863.72ME+512.23-512ME-512.23MD-512.23MC-
512MB+521.48MB=689.48-512.23

MC(2249.09)+MD(35.49)ME(351.49)-
MB(9.25)+177.25MC(2249.04)+(0.0807978391)(351.49)+(0.0731661417)(351.49)-
MB(9.25)=177.25

MC(2249.09)+28.2239+25.7172-MB(9.25)=177.25

MC(2249.09)+53.9411-MB(93.5)=177.25

MC(2249.09)-1413(9.25)+177.25-53.9411

MC(2249.09)-MB(9.25)=123.3084

123.3084+𝑀𝐵(9.25)
2249.09mc= equation 1:
2249.09

HEATER B:

MB(2804.63) + (1-ME-MD-MC-MB)(346.9141)= (1.ME-MD-MC-


MB)(512.23+(MB)(521.48)

MB(2804.63)+346.9141-346.9141ME-346.911MD-346.9141MC-346.9141MB=512.23-
512.23ME-512.23MD-512.23MC-512.23MB+521.48MB

MB(2804.63-346.9141-521.48)+ME(-346.9141+512.23)+MD(-346.9141+512.23)MC(-
346.9141+512.23)MB(-346.9141+512.23-521.48)=512.23-346.9141

MB(1936.2349)+ME(165.3159)+MD(165.3159)+MC(165.3159)+MB(-
356.1641)=165.3159

MB(1936.2359)+(0.0731661414)(165.3159)+(0.0802978391)(165.3159)+MC(163.3159)
+MB(-356.1641)=165.3159
MB(1936.2359)+12.0955+13.2745+MC(165.3159)+MB(-356.1641)=165.3159

MB(1936.2359)+MC(165.3159)+MB(-356.1614)=165.3154-25.37

MB(1936.2349)+MC165.3159)+MB(-356.1641)=139.9454

MB(1936.2354-3256.1641)+MC(165.3159)=139.9459

MB(1580.0718)+MC(165.3159)=139.9459

123.3089+𝑀𝐵(9.25)
MB(1580.0718)+ [ ](165.3159)= 139.9459
2249.09

20384.9218 𝑀𝐵(1529.1721)
MB(1580.0718)+ + = 139.9459
2249.09 2249.09

MB(1580.7517)=139.9459-9.0636

139.9459−9.0636
MB=
1580.7517

MB= 0.08279750703

For Mc:

123.3084+(0.08279750703)(9.25)
MC=
2249.09

Mc= 0.05281823044 kg/s

HEATER A:

Ma (2669.45) + (1-0.0731661419-0.0802978341-0.05281823044-
0.08279750703)(192.5)= ma(355.89)+(0.731661419-0.0802978391-0.05281823044-
0.08279750703)(346.9141) ma(2669.45) +(0.05242500443)(192.5) = (355.89) ma
+(0.05242500443)( 275.24)

Ma(2669.45)+10.0918=MA(355.89)+18.1864
MA(2664.45)-MA(355.89)=18.69-10.0918

MA(2313.56)=8.5982

8.5982
MA=
2313.56

MA=0.003687745544 kg/s

The mechanical work done per kg of steam floww to the throttle is calculated:

W= 1(3364.0234- 3224.56) +(1-0.073166)(3224.56-3084.13)+(1-0.073166-


0.0802978)(3364.0234-3224.56) +(1-0.073166-0.0802978-0.052818-
0.0827975)(2761.32-2804.63)+(1-0.073166-0.0802978-0.0528182-
0.0827975)(2804.63-2669.45)+(1-0.073166-0.0802978-0.05281823-0.0827975-
0.0036774)(2669.45-2483.22)

W= 581.3459896 kj/kg throttle

5%
FRICTION LOSS= x 581.3459896 = 8.803131411 kj/kg
36,000

1000

0.05%
Genearator Efficiency= 0.98-
36,000

1000

=0.9633 or 96.33%

Input to generator per kg stea flow of throttle

= 581.3459896-8.803131411

= 572.5428582 kj/kg

Energy in Electrical output per gram flow = Input Gen. * Gen. Eff.

= 572.5428582*0.9633
= 551.5305353 J/g

1000 𝑠 3600𝑠
Sice 36 MW (3600 Kj/s) * ∗
1 𝑘𝑗 1𝐻𝑅

= 1.296*10^11

The Full Throttle flow is:

1.29 ∗ 10^11
1000𝑔
𝑒𝑛𝑒𝑟𝑔𝑦 𝑖𝑛 𝑒𝑙𝑒𝑐𝑡𝑟𝑖𝑐𝑖𝑡𝑦( )
1𝑘𝑔

= 234,982.46 kg/hr

BOILER: 1

Qin=m (h1 –h10)

Qin= 96.62 (3885.94- 1095.31) Qin

Qin = 269,582.36 KW

THERMAL EFFICIENCY: 10

𝑤𝑡 99,494.97 𝑘𝑔/𝑠
Ŋ= = x 100
Qin 269,582.36 𝐾𝑊

Ŋ= 36.4%
STATE PRESSURE TEMPERATURE ENTHALPY ENTROPY QUALITY
(KPa) (°C) (kj/kg) (kj/kg-k)

1 6500 280.86 3885.44 7.3145


E 3450 241.63 3658.55 7.3565
D 1640 202.51 3428.44 7.4123
C 670 163.33 3197.93 7.49
B 230 124.16 3019.28 7.69
A 70 84.98 2758.05 7.79
2 9.99 45.81 2532.45 7.98
3 10 45.85 191.81 0.649 0.94
4 757 84.32 192.68 0.649
A’ 61.54 86.57 353.64 1.12
A” 10 45.80 362.54 1.15
6 757 125.12 525.93 1.18 0.071
B’ 249.47 127.37 535.16 1.606
B” 757 127.25 535.16 1.60
7 757 168.16 711.15 2.02
8 7500 169.16 719.81 2.025
D’ 1867 20.93 892.85 2.41
D” 7557 168.13 892.5 2.43 0.088
9 7500 211.20 904.12 2.42
10 7500 252 1095.31 2.803
E’ 3958 249.73 1084.37 2.79
E” 1867 208.93 1084.37 2.81 0.100

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