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Thermal ( Steam ) Power plants

mainly consists of 4 circuits


Coal and ash Circuit
Coal produced in the mining site is
transported to power plant site
Coal handling equipment for generation of
steam
The combustion of coal produces ash which
is collected and removed to ash storage
yard through ash handling equipments

Air and gas circuit

FD or ID fans are used for supply the air to


combustion chamber of the boiler through airpreheater
The air preheater is placed in the path of flue gases
to preheat the air
The flue gases produced by combustion of fuels in
the boiler furnaces after passing around boiler tubes
and super heater tubes
Pass through a dust collector or precipitator where
most of dust is removed before venting it of to
atmosphere through chimney

Feed water and steam circuit:

Prime mover develops power by utilizing steam


generated in the boiler
Then condenser is used to condense the steam
coming out of prime mover
A pump is used to feed the condensate to the boiler
The condensate leaving the condenser is heated in
feed heaters through extracted steam from lowest
pressure extraction point of the turbine
The feed water may also be supplied from external
source to compensate any loss of steam and water.
In the boiler shell and tubes water circulation is
setup due to density difference of water between
low and high temperature sections
A super heater is used to super heat the wet steam
from boiler drum and is then supplied to prime
movers

Cooling water circuit


In the condenser, quantity of cooling water
required to condense the steam is large and
is taken either from lake, river or sea
The cooling water is taken from upper side
of the river and then passed through the
condenser
The hot water is then discharged to lower
side of the river
The system is known as open system
Where water is not available in abundant
water from condenser is cooled either in
cooling pond or in cooling tower the system
is known as closed system

Main Components of Thermal


Power Plants
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Boiler
Super heater
Economizer
Air preheater
Reheater
Steam turbine
Generator
Condensers
Cooling towers
Pumps

11. Coal mills


12. FD and ID Fans
13. ASH Precipitators
14. Water treatment plant

Essentials of steam power plant

Various equipments

1. A furnace to burn the fuel.


2. Steam generator or boiler containing water. Heat generated in the furnace is utilized to
con- vert water in steam.

3. Main power unit such as an engine or turbine to use the heat energy of steam and
perform work.

4. Piping system to convey steam and water.

In addition to the above equipment the plant requires various auxiliaries and accessories
depending upon the availability of water, fuel and the service for which the plant is
intended. The flow sheet of a thermal power plant consists of the following four main
circuits :
(i) Feed water and steam flow circuit (ii) Coal and ash circuit (iii) Air and gas circuit (iv)
Cooling water circuit. A steam power plant using steam as working substance works
basically on Rankine cycle. Steam is generated in a boiler, expanded in the prime mover
and condensed in the condenser and fed into the boiler again.
(ii) The different types of systems and components used in steam power plant are as follows :
(i) High pressure boiler (ii) Prime mover (iii) Condensers and cooling towers (iv) Coal
handling system (v) Ash and dust handling system (vi) Draught system (vii) Feed water
purification plant (viii) Pumping system (ix) Air preheater, economizer, super heater, feed
heaters.

Fuels used in thermal power plant


Combustion of fuel is accomplished by mixing
with air at elevated temperatures
Oxygen in the air chemically unites with Carbon,
Hydrogen of fuels and produce heat
In thermal power plants normally steam is
produced from water by using combustion heat of
fuels (Except in Gas turbines)
Various fuels were used in thermal power plants
Fossil fuels ( Coal, Oil & Gas)
Industrial waste gases
Synthetic fuels or SYNFUELS

Coal

Coal is the principal energy source for India because of its


large deposits and availability
Coal originated from vegetable matter, which grew millions
of years ago
Trees and plants falling into water decayed and later
produced peat bogs
Huge geological upheavals buried these bogs under layers
of silt
Subterranean heat, soil pressure and movement of earth's
crust distilled off some of the bog's moisture and hardened
it to form coal
Basically classification of coal is based on Physical and
chemical composition
Peat
Lignite and brown coal
Bituminous coal
Anthracite

Coal analysis

Two types of coal analysis


Proximate Analysis

Gives: Behavior of coal when heated


FC + VM + M + A = 100% by mass
Ultimate Analysis
Gives: chemical elements along with ash and
moisture
C + H + 0 + N + S + M + A = 100% by mass
based on
(a) as-received basis (useful for combustion calcu)
(b) dry or moisture free basis
(c) dry mineral-matter-free or combustible basis

Coal properties
There are certain properties of coal, which
are important in power plant applications
They are
sulphur content,
heating value
grind ability,
weather ability,

Desirable properties of coal


High calorific value
Small sulphur content ( les than 1%)
Good burning characteristics for complete
combustion
High grind-ability index
High weather-ability

Grading of coal done on the basis


Heating value
Size
Ash content
Sulphur content

Peat

Low grade coal


First stage coal formation
Contains 90% moisture
Small amount of volatile matter
Not suitable for power plants
Used in domestic purposes
Requires 1-2 months for drying in sunlight

Peat (20% water, Dried) has CV of 16 MJ / kg

Lignite (Brown coal)

Intermediate stage of coal development


High amount of moisture 30-40%
Brown in color
High heating value and carbon compared to
peat
Should be stored to avoid spontaneous
combustion
Used in pulverized form
Can be air dried easily
Suitable for local use instead of transporting

Bituminous coal

Containing 46-86% of fixed carbon and 20-40% of VM


Ash content may vary 6-12 %
High percentage of volatile matter CV of 32 MJ / Kg
Available in two forms CAKING and NON Caking
Sub-Bituminous is having less moisture, ash than
lignite and no CAKING power, used in briquette or
pulverized form
Semi-Bituminous coal high carbon and heating value,
contain less moisture, ash, sulphur, &VM, Has
tendency to break into pieces

Anthracite Coals
Contains more than 86% fixed carbon &VM
around 8%
Ignites slowly has high CV of 36 MJ / Kg
Low ash, zero CAKING power
Difficult to pulverize Anthracite coal

Liquid fuels

They are easy to handle, store and to burn


They have nearly constant heating values
They are primarily a mixture of hydrocarbon compounds, which
may also contain nitrogen, oxygen and sulphur
The bulk of the hydrocarbons belong to the paraffin series, like
methane (CH4), ethane (C2H6) propane (C3H8) and butane
(C4H10) which are gaseous, and pentane (C5H12) hexane
(C6H14) and octane (C8H18) which are liquid at STP
In addition, there can be isoparaffins, cycloparaffins and
aromatic compounds

Carbon: 83-87%, Hydrogen: 11-16%,


Oxygen + Nitrogen 0-7%, Sulphur 0-4%
There can also be some moisture and sediment
Crude oil distilled into a number of fractions
gasoline, aviation fuel, kerosene, light diesel oil,
heavy diesel oil, lubrication oil
The heavier fractions are used for boiler fuels
and chemical production
The required physical properties of fuel oil are
specific gravity,
viscosity, pour point,
flash point and heating value

Gaseous fuels
Transportation of natural gas is made through
pipelines
Natural gas is the cleanest of all fossil fuels
It is free from ash and mixes well with air to undergo
complete combustion producing very little smoke
It consists of a mixture of the most volatile paraffinsmethane to pentane
It has high hydrogen content and produces a
considerable amount of water vapour when burned
The heat of combustion varies from 33.5 to 40 MJ/m3
Since the major constituent of all natural gases is
methane
Liquid natural gas (LNG) is transported by special
tankers and stored in spherical pressure vessels to be
used when needed, particularly during peak load.

Other fuels
Industrial Wastes & Byproducts
blast furnace gas, coke oven gas, and refinery
gas sugar factory refuse (bagasse); saw mill
wood dust, rice husk
Synthetic fuels
Gaseous and liquid fuels from coal
economically and environment friendly manner
Liquid fuels using mixtures of fine coal in oil
have been known as colloidal fuel, coal-inoil and more recently, coal-oil mixtures
(COM)

Coal handling

Coal handling system

In Case of Rail Delivery


Most Commonly Used are :
Wagon Tippler Hopper
Hydraulic Gates Opening

Hydraulic Gates Opening

Operation
The gates bellow the wagons are hydraulic controlled
By opening the gates the coal flows downwards due to gravitational force
and is moved to the bellow pit
Demerits
Due to the dust the Hydraulic will not work smoothly
Require a lot of maintenance

Wagon Tippler Hopper

Preparation

Crushers and breakers used to crus the big size coal into small size
coal
Driers used to dry the coal if it contains lot of moisture it is also further
done in the pulverizes
Magnetic sprayers used to separate the iron parts that come along with
the coal from the mines these may damage the parts of pulverizes or
may have a bad effect on the boiler

Coal Crushers
Why?
Reduce size from 200mm to 20mm
Types of crushers
1.Ring Type Coal Crusher
2.Hammer Mill Coal Crusher
3.Brad Ford Breaker

Ring Type Coal Crusher

Operation
The coal is fed at the top left corner
Is crushed in between the plane loose
rings and the adjustable plates.
The loose rings with the jaws used to take
the crushed coal down words
Adjustable plate and the screen determine
the maximum size of the discharged coal

Hammer Mill Coal Crusher

OPERATION
The coal is fed at the top
Is crushed by the action of rings that pivot
off center on a rotor or by swinging
hammers attached to it
Adjustable screen bars determine the
maximum size of the discharged coal

Brad Ford Breaker

Brad Ford Breaker


Bradford breaker which is used for large
capacity work
It consists of a large cylinder made up of
perforated steel plates to which lifting
shelves are attached on the inside
The cylinder rotating slowly at about 20
rpm receives coal at one end
The shelves lift the coal up and then the
coal drops down by gravity

Transfer

Belt Conveyor

Belt conveyor

Belt conveyor

Screw conveyor

Bucket & Grab bucket elevator

Skip Hoist and flight conveyor

Stoker and Re-claimer


Stoker terms for storing the coal into
the stock yard
Re-claimer means to take the coal
back from the stock yard
It moves on the rail track along with
adjustable length of belt conveyor

Combustion Equipments
for Lumped coal burning
1. Grate-fired furnaces

Grate

Chamber type

Combustion Equipment For


Burning Coal

Fuel bed furnaces (coarse particles)


Pulverized coal furnaces (fine particles)
Cyclone furnaces (crushed particles)
Fluidized bed furnaces (crushed small
particles)

Fluidized bed
Air passed through the coal particles
As the air velocity increase it create the
pressure drop equal to the weight of coal
particles.
Particles are buoyed up.
High degree of particle mixing.

Fuel bed furnaces (coarse particles)


There are two ways of feeding coal on to the
grate
1. Overfeeding
2. Underfeeding

Overfeed stoker

Underfeed stoker

Overfeeding

Overfeeding
Receives fresh coal from top surface has
following distinct zones
Fresh or green coal
Coal losing moisture (Drying zone)
Coking layer (loosing of VM) Distillation zone
Incandescent coke ( Fixed carbon is
consumed) Combustion zone
Ash layer progressively cooled

Operations
Primary air gets warmed up as it flows through the ash
layer
As it passes through the incandescent coke
layer(1200 C) Carbon converted to Carbon dioxide
releasing heat continues till oxygen is consumed, if
layer is thick CO2 is converted to CO reducing layer
temperature
The stream while passing through distillation zone VM
is added
In distillation zone moisture is added
now stream contains N,CO2,CO,H2,VM&moisture

For combustion of this stream


A hot ignition point ( In the range of 1000-1300 oC
Done by providing a fire brick lined arch which stores
up the heat and remains at high temperature

Sufficient fresh air


Secondary air or over-fire air

Turbulence
Providing secondary air at right angles to up-flowing
gas stream emerging out of fuel bed

Results
Carbon is in CO, CO2 both are color less
Carbon with hydrogen in VM which will be
cracked to form free carbon at high
temperature suspended in gas stream
If Burner is not designed properly or
operated properly leads to unburnt carbon
particles this appears as black smoke on
chimney top

Underfeeding

Underfeeding
In underfeeding coal is fed from below
Primary air passing through holes diffuses
through spaces in the raw green coal picking up
moisture
In distillation zone to stream VM is added
In incandescent zone VM breaks readily burns
with secondary air present above it where it is
fed from top
VM burning is somewhat cooler need longer
time to ignite and burn

Mechanical Stokers
Overfeeding
1. Traveling grate stoker
2. Chain grate stoker
3. Spreader stoker
4. Vibrating grate stoker
Underfeed stoker
1. Single retort
2. Multiretort

Traveling grate stoker

Traveling grate stoker


Grate surface is made up of Cast Iron
bars joined together by links to form
endless belt
Belt wound around two sprockets
A coal gate regulates the depth of fuel bed
Simultaneous adjustment of Fuel bed
thickness, primary air flow controls the
burning rate so that at the end of its rear
ash only remains

Advantages & Disadvantages


Simple and Initial cost is low
Reliable in service and maintenance is low
Gives high rate of heat release per volume of
the furnace
Limited coal can be carried on grate
Clinker problems are common
Ignition arches are required
There is always some loss in the form of
particles

Spreader stoker

Spreader stoker
Coal from hopper is fed by rotating feeder
Feeder normally will have Blades fitted on the
drum
Fine particles burn in suspension
Speed of the feeder varies with the steam output
of boiler
Grate is made up of CI bars, Links underneath
the grate are connected to a lever
Fuels used may be Bituminous, lignite, wood
waste, baggase
Coal size used in 6-36 cm

Advantages and Disadvantages

A wide variety of fuels can be used


Clinker formation is reduced
High temperature preheated air can be used
Quick response to load variation
Gives equal pressure drop and proper air
distribution
Operation cost is low
Difficult to operate variable sized coal particles
Fly ash and entrapped carbon particles

Underfeed stokers

Multiple retort

Pulverised coal

Why pulverisers?
Size reduction
(mm to micron)
Other things:
Drying (primary
airapprox 300
degree)
Feeding

Types of Pulverisers
Ball and tube mill (low speed < 75 rpm)
Ball and tube race mill (medium speed 75225 rpm)
Bowl mill (medium speed 75-225 rpm)
Impact or hammer mill (> 225 rpm)
.depending upon the nature of coal

Pulverised coal firing


Pulverised coal firing is done by two system :
(i) Unit System or Direct System. (ii) Bin or Central System.
Unit System.
In this system the raw coal from
the coal bunker drops on to the
feeder.
Hot air is passed through coal in
the feeder to dry the coal.
The coal is then transferred to
the pulverising mill where it is
pulverised.
Primary air is supplied to the
mill, by the fan.
The mixture of pulverised coal
and primary air then flows to
burner where secondary air is
added.
The unit system is so called from
the fact that each burner or a
burner group and pulveriser
constitute a unit.

Unit system
Advantages
(i)The system is simple and cheaper than the central system.
(ii) There is direct control of combustion from the pulverising mill.
(iii) Coal transportation system is simple

Bin or Central System.


Crushed coal from the raw coal bunker is fed by gravity to a dryer where hot air is
passed through the coal to dry it.
The dryer may use waste flue gases, preheated air or bleeder steam as drying agent.
The dry coal is then transferred to the pulverising mill.
The pulverised coal obtained is transferred to the pulverised coal bunker (bin)
The transporting air is separated from the coal in the cyclone separator.
The primary air is mixed with the coal at the feeder and the mixture is supplied to the
burner.
Advantages
l. The pulverising mill grinds the coal at a steady rate irrespective of boiler feed.
2. There is always some coal in reserve. Thus any occasional breakdown in the coal supply will
not effect the coal feed to the burner.
3. For a given boiler capacity pulverising mill of small capacity will be required as compared to
unit system.
Disadvantages
1. The initial cost of the system is high.
2. Coal transportation system is quite complicated.
3. The system requires more space.

Bin or central system

Pulverised fuel firing system

Pulverized coal handling system

Ball and tube mill

Ball and tube mill

Ball and tube mill

Ball and tube mill

Ball and tube mill


Mills can be designed and manufactured for very large
capacity. Also each mill can supply coal to two sets of
burner. Boiler can be designed with lesser number of
mills.
Higher power consumption per tons of coal and high
starting torque makes drive motor large.
Suitable for base load stations only where load variation is
less.
Response to load change is very fast. During operation
presence of relatively large quantity of pulverized coal in
grinding zone acts as a storage reservoir. In case of
sudden increase in fuel demand fuel flow can be
increased almost instantaneously.
Start up and shutdown time is longer.
Product fineness is very good.

Bowl Mill

Bowl Mill

Bowl mill

Bowl mill
Replacement of grinding elements takes lesser time.
Capacity and product fineness deteriorate with wearing
out of grinding elements. Rate of erosion of bowl and
rings are very high.
Frequent shutdown of mills are required for adjustment of
loading springs which becomes loose for wearing out of
roller and bowl.
Ingress of non crushable material may damage mill
internals.
Reject rate is very high. Elaborate mill reject system
becomes essential for larger units. Disposal of mill reject
is another problem to be tackled by power station.

Impact/Hammer Mill

Impact/Hammer Mill

Impact/Hammer Mill
A simple, compact and low cost mill.
Mill can be designed for very high temperature. This
facility makes this mill suitable for use with high moisture
lignite fuel.
Wear of grinding elements reduces mill capacity.
Product fineness is low.

Ball and Race mill

Ball and race mill


Capacity and product fineness does not deteriorate
appreciably with wearing out of grinding elements
because of self compensating mechanism.
Hydro -pneumatic loading system maintains constant
loading pressure. But it is costly and needs maintenance.
Response to load change is slow compared to tube mills.
Start up and shut down time is less.
Ingress of non crushable material may damage mill
internals.
Chances of grinding zone fire are almost nil.

Ball and race mill

Ball and race mill

Pulverization
Advantages

Low excess air requirement


Less fan power
Ability to use highly preheated air reducing exhaust losses
Higher boiler efficiency
Ability to bum a wide variety of coals
Fast response to load changes
Ease of burning alternately with, or in combination with gas and
oil
Ability to release large amounts of heat enabling it to generate
about 2000 t/h of steam or more in one boiler
Ability to use fly ash for making bricks etc.
Less pressure losses and draught need.

Disadvantages
1. Added investment in coal preparation unit
2. Added power needed for pulverizing coal
3. Large volume of furnaces needed to permit desired heat
release and to withstand high gas temperature

Ash handling system


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.
Handling of ash includes its removal from the furnace, loading on the conveyors and delivered
to the fill from where it can be disposed off.

ASH HANDLING EQUIPMENT


Mechanical means are required for the disposal of ash. The handling equipment should
perform the following functions:
(1) Capital investment, operating and maintenance charges of the equipment should be low.
(2) It should be able to handle large quantities of ash.
(3) Clinkers, soot, dust etc. create troubles, the equipment should be able to handle them
smoothly.
(4) The equipment used should remove the ash from the furnace, load it to the conveying
system
to deliver the ash to a dumping site or storage and finally it should have means to dispose of
the stored ash.
(5) The equipment should be corrosion and wear resistant.

ASH HANDLING FLOW DIAGRAM

Ash handling

Hydraulic Ash Handling System


Low Velocity System

Hydraulic Ash Handling System


High Velocity
System

Pneumatic Ash Handling 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, clothings,
furniture etc. becomes dirty due to smoke. Smoke corrodes the metals and darkens the paints.
To avoid smoke, 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
Dry type dust collectors include gravitational, cyclone, and baffle dust collectors.
from flue gases.

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.

ESP

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.

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