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Boiler
Super heater
Economizer
Air preheater
Reheater
Steam turbine
Generator
Condensers
Cooling towers
Pumps
Various equipments
3. Main power unit such as an engine or turbine to use the heat energy of steam and
perform work.
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.
Coal
Coal analysis
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,
Peat
Bituminous coal
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
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
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
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
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
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
Transfer
Belt Conveyor
Belt conveyor
Belt conveyor
Screw conveyor
Combustion Equipments
for Lumped coal burning
1. Grate-fired furnaces
Grate
Chamber type
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.
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
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
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
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
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
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.
Pulverization
Advantages
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
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