Thermal Power Plants And Future Scope

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Contents

Introduction and layout by Vruttiket Kadam Operation and Site selection by Priyadarshani Marwah Thermal power plants in india by Tawqeer Maqbool Coal by Rohit Arora Indian Coal by Shubham Mukharya Liquid and Gaseous Fuels by

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Introduction

A thermal power station is a power plant in which the prime mover is steam driven. Water is heated, turns into steam and spins a steam turbine which drives an electrical generator. After it passes through the turbine, the steam is condensed in a condenser and recycled to where it was heated
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Thermal power plant - coal, nuclear, geothermal, solar thermal electric. In fossil-fueled power plants, steam generator refers to a furnace that burns the fossil fuel to boil water to generate steam.

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Power plant consist of Feed water heating and de-aeration, Boiler, Super heater, Steam condensing, Re-heater, economizer, Bottom ash collection. The energy efficiency of conventional thermal power station is typically 33% to 48%. The required make up water for 500MW plant is approximately 1.25 l/s and at full load its upto 400 l/s. Application Local area such as ship, 4/16/12 industrial plant

Layout

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1. Cooling tower 2. Cooling water pump 3. transmission line 4. Step-up transformer 5. Electrical generator 6. Low pressure steam turbine 7. Condensate pump 8. Surface condenser
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9. Intermediate pressure steam

13. Feed water heater 14. Coal conveyor 15. Coal hopper 16. Coal pulverizer 17. Boiler steam drum 18. Bottom ash hopper 19. Super-heater 20. Forced draught (draft) fan
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21. Re-heater

24. Air pre-heater 25. Precipitator 26. Induced draught (draft) fan 27. Flue gas stack

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OPERATIONS IN A THERMAL POWER PLANT CRITERIA FOR SITE SELECTION

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OPERATIONS IN A THERMAL POWER PLANT

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Principle: Coal based thermal power plant works on the principal of Modified Rankine Cycle.

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Components of Coal Fired Thermal Power Station:

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Coal Preparation
In coal-fired power stations, the raw feed coal from the coal storage area is first crushed into small pieces conveyed to the coal feed hoppers at the boilers The coal is next pulverized into a very fine powder, so that coal will undergo complete combustion during combustion process.

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Boiler and auxiliaries

Functions of a boiler are: To convert chemical energy of the fuel into heat energy To transfer this heat energy to water for evaporation as well to steam for superheating.
T

The basic components of Boiler are: Furnace and Burners Steam and Superheating

Usually, water tube boilers are used in a thermal power plant.

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Economiser
It is located below the LPSH in the boiler and above pre heater. It is there to improve the efficiency of boiler by extracting heat from flue gases to heat water and send it to boiler drum. Advantages of Economiser include 1) Fuel economy: used to save fuel and increase overall efficiency of boiler plant. 2) Reducing size of boiler: as the feed water is preheated in the economiser and enter boiler tube at elevated temperature, The heat transfer area required for evaporation reduces considerably.
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Air Preheater
The heat carried out with the flue gases coming out of economiser are further utilized for preheating the air before supplying to the combustion chamber. It is a necessary equipment for supply of hot air for drying the coal in pulverized fuel systems to facilitate grinding and satisfactory combustion of fuel in the furnace.

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Reheater
Power plant furnaces may have a reheater section containing tubes heated by hot flue gases outside the tubes. Exhaust steam from the high pressure turbine is rerouted to go inside the reheater tubes to pickup more energy to go drive intermediate or lower pressure turbines.

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Steam turbines
Used as prime mover in all thermal power stations. mainly divided into two groups: Impulse turbine Impulse-reaction turbine The turbine generator consists of a series of steam turbines interconnected to each other and a generator on a common shaft.

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Condenser
The condenser condenses the steam from the exhaust of the turbine into liquid to allow it to be pumped. The functions of a condenser are:1) To provide lowest economic heat rejection temperature for steam. 2) To convert exhaust steam to water for reserve thus saving on feed water requirement. 3) To introduce make up water.

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Boiler feed pump

Boiler feed pump is a multi stage pump provided for pumping feed water to economiser. BFP is the biggest auxiliary equipment after Boiler and Turbine. It consumes about 4 to 5 % of total electricity generation.

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Cooling tower

The cooling tower is a semi-enclosed device for evaporative cooling of water by contact with air. The cooling towers are of four types: 1. Natural Draft cooling tower 2. Forced Draft cooling tower 3. Induced Draft cooling tower 4. Balanced Draft cooling tower
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Fan or draught system

In a boiler it is essential to supply a controlled amount of air to the furnace for effective combustion of fuel and to evacuate hot gases formed in the furnace through the various heat transfer area of the boiler. This can be done by using a chimney or mechanical device such as fans which acts as pump.

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Ash handling system

The disposal of ash from a large capacity power station is of same importance as ash is produced in large quantities. Ash handling is a major problem.

Generator
Generator or Alternator is the electrical end of a turbogenerator set that converts the mechanical energy of turbine into electricity. The generation of electricity is based on the principle of electromagnetic induction.
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Criteria for Site Selection

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Transportation network: Easy and enough access to transportation network is required in both power plant construction and operation periods. Gas pipe network: Vicinity to the gas pipes reduces the required expenses. Power transmission network: To transfer the generated electricity to the consumers, the plant should be connected to electrical transmission system

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Geology and soil type: soil and rock layers should be able to withstand the weight and vibrations of the plant. Earthquake and geological faults: Even weak and small earthquakes can damage many parts of a power plant intensively. The site should be away enough from the faults and previous earthquake areas Topography: changing of a sloping area into a flat site for the construction of the power plant needs extra budget. Parameters of elevation and slope should be considered.
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Rivers and floodways: should have a reasonable distance from permanent and seasonal rivers and floodways. Water resources: For the construction and operating of power plant different volumes of water are required which is supplied from either rivers or underground water resources.

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Environmental resources: Operation of a power plant has important impacts on environment. Locations that are far enough from national parks, wildlife, protected areas are selected. Population centers: site should have enough distance from population centers.

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Need for power: should be near the areas where there is more need for generation capacity, to decrease the amount of power loss and transmission expenses. Climate: temperature, humidity, wind direction and speed affect the productivity of a power plant. Land cover: Some land cover types such as forests, orchard, agricultural land, pasture are sensitive to the pollutions caused by a power plant.

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Area size: the minimum area size required for the construction of power plant should be defined. Distance from airports: Usually, a power plant has high towers and chimneys and large volumes of gas. Consequently for security reasons, they should be away from airports. Archeological and historical sites: Usually historical building are fragile and at same time very valuable. Vibration caused by power plant can damage them,

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THANK YOU!

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Materials required
1.

Feed water

- water circulated through closed circuit of power plant - a plant of 100 MW may require 500 tons of water per hour - 2% loss may occur
2.

Coal - quantity sufficient to generate steam in the

boiler

- calorific value of Indian coals containing 30 % ash taken as 20000 KJ/Kg

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4.

Ash - 30- 40% ash mixed with Indian coal - harmful contents in ash, thus to be disposed off properly

4.

Sulphur dioxide - highly poisonous hence its formation in combustion chamber must be avoided. - low Sulphur content coal 4/16/12 preferred.

Requirements for 100 mw power plant

COAL FEED AIR FOR COOLING ASH WATER COMBUSTIO WATER N SULPHUR AIR IN DIOXIDE COOLING WATER

60 tons

10 tons 1200 tons

2500 tons

20 tons 2 tons

25000 tons

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S no. 1 2 3

Thermal Power Stations In India

State Power station Capacity(MW) units Kothagndam Gauhati Barauni Bokaro Patratu 500 120 150 210 400 200 2x105 Andhra Pradesh Assam Bihar 2x250 4x15, 3x20

Delhi

Rajghat

Indraprashtha 350 Badarpur 5 4/16/12 Gujarat Dhuvaran Ukai 300 440 240 2x220 2x120

Thermal power stations in india

6 Haryana Faridabad Panipat 7 Madhya Pradesh Kobra Satpura 8 200 440 420 300 2x240 4x110

Maharashtra Nagpur(kora 480 di) Nashik Paras 280 90 460 600 450

9 10

Orissa Tamil Nadu

Talcher Neyvelli Eunose

4x60,2x110

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Thermal power stations in india

11 Uttar Pradesh Harduagan Obra 12 West Bengal Samtaldih Chandrapur Durgapur 220 1322 480 1250 690 3 x 130, 3 x 120, 2 x 250 2 x 30, 1 x 70, 2 x 75, 1 x 110 1x55, 1x60, 1x105 1x40, 3x94, 5x200

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Future scope of thermal power plants

In India, current installed capacity 135401.63MW Peak power shortage of 10 % and overall power shortage of 7.5% Proposed target to build up 100000MW by 2012 out of which 4/16/12

Future scope of thermal power plants

Indias location favors solar energy concentration. annual global variation , 1600-2200 Kw/m2 India has a flourishing and largely indigenous nuclear power program 4/16/12 and expects to have 20,000 MWe

Coal

Coalis acombustibleblack or brownish-blacksedimentary rockusually occurring inrock stratainlayers or veinscalledcoal bedsorcoal seams. It is used as fuel for thermal power plant.
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Basic composition

The main constituents are carbon, hydrogen, oxygen, nitrogen, sulphur, moisture and ash. Their percentages varies from different types of coal.

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Classification of coal

Peat Lignites Sub Bituminous Bituminous Anthracite Graphite Coke

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Peat

It is 1st stage of formation from wood In its dehydrated form, peat is a highly effective absorbent for fuel and oil spills on land and water. Uses

Domestic fuel in Europe Power generation in Russia

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Lignites or brown coal

Intermediate stage between peat and coal. Have high moisture, high ash and low heat contents. Burns with smoky flame. The lowest rank of coal and used almost exclusively as fuel for electric power generation.
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Sub Bituminous coal

Properties range from those of lignite to those of bituminous coal. Contains 15 to 20 % volatile matter and has a tendency to break into small sizes Uses

as fuel for steam-electric power generation

as an important source of 4/16/12 lightaromatic hydrocarbonsfor

Bituminous Coal

It is dense sedimentary rock, black but sometimes dark brown often with well-defined bands of bright and dull material. Average calorific valve of 31350 kJ/kg. Uses

primarily as fuel in steam-electric power generation. for heat and power applications in

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Anthracite Coal

The highest rank of coal is a harder, glossy, black coal. It is noncaking and has high % of fixed carbon. Burns with very short blue flames or without flames. High calorific valve of 35500 KJ/Kg.
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Graphite

The highest rank is difficult to ignite and is not commonly used as fuel. Uses

mostly used in pencils when powdered used as alubricant.

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German English C H O S Volatiles Classific Designat Carbon Hydroge Oxygen Sulfur % ation ion % n% % % Braunko Lignite 45-65 60-75 6.0-5.8 34-17 0.5-3 hle Flammk Flame 40-45 75-82 6.0-5.8 >9.8 ~1 ohle coal Gas Gasflam flame 35-40 82-85 5.8-5.6 9.8-7.3 ~1 mkohle coal Gaskohl Gas coal 28-35 85-87.5 5.6-5.0 7.3-4.5 ~1 e Fettkohl 87.5Fat coal 19-28 5.0-4.5 4.5-3.2 ~1 e 89.5 Forge 89.5Esskohle 14-19 4.5-4.0 3.2-2.8 ~1 coal 90.5 Non Magerko 90.5baking 10-14 4.0-3.75 2.8-3.5 ~1 hle 91.5 coal Anthrazi Anthraci 7-12 >91.5 <3.75 <2.5 ~1 4/16/12 t te

Heat content kJ/kg <28470 <32870 <33910 <34960 <35380 <35380 35380 <35300

Properties Of Coal

Each type of coal has a certain set of physical parameters which are mostly controlled by moisture volatile content ash carbon content
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Coal Analysis

Basically they are of 2 types Proximate Analysis Ultimate Analysis

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Proximate Analysis

The objective of coal proximate analysis is to determine the amount of fixed carbon (FC), volatile matters (VM), moisture, and ash within the coal sample. This is done following basis

AR (as-received) basis AD (air-dried) basis DAF (dry, ash free) basis

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For Example
Proximat Unit e Analysis (AR) (AD) (DB) (DAF)

Moisture Ash Volatile Matter Fixed Carbon Gross Calorific Value 4/16/12

(wt. %) (wt. %) (wt. %) (wt. %) (MJ/kg)

3.3 22.1 27.3 47.3 24.73

2.7 22.2 27.5 47.6 24.88

22.8 28.3 48.9 25.57

36.6 63.4 33.13

Ultimate Analysis

The objective of coal ultimate analysis is to determine the constituent of coal, but rather in a form of its basic chemical elements.

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For Example
Proximate Analysis Unit (AR) (AD) (DB) (DAF)

Carbon(C) Hydrogen(H) Nitrogen(N) Total Sulphur(S) Oxygen(O)

(wt. %) 61.1 (wt. %) 3.00 (wt. %) 1.35 (wt. %) 0.4 (wt. %) 8.8

61.5 3.02 1.36 0.39 8.8

63.2 3.10 1.40 0.39 9.1

81.9 4.02 1.81 -

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Coal Blending

Coal blending in power station is mainly adopted to reduce the cost of generation and increase availability of coal. The low-grade coals can be mixed with better grade coal without deterioration in thermal performance of the boiler thus reducing the cost of generation.
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Methods Of Blending

Blending underground Blending on ground level Precision Coal Blending

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Blending underground

A tunnel equipped with a conveyor belt and specially designed scraper is employed for the coal blending operation. When different types of coal are placed in the tunnel, the scraper puts coal on the 4/16/12 conveyor belt by moving through the

Disadvantages

Large underground structure Long construction time High investment and maintenance costs Difficult to ensure homogeneity of blending process Will result in uneven burning in the boiler
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Blending on ground level

Different types of coal will be built up to a coal stock pile in horizontal layers. By vertical excavation of the coal stock the different coal types 4/16/12

Disadvantages

Incomplete mixing process Low quality of blending Lacks homogeneity Will result in uneven burning in the boiler

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Precision Coal Blending

Different types of coal are placed in each silo (of which there are usually six). Computer controls discharge from each silo using Extromats, and ensures the correct percentage of each type of coal falls onto a conveyor belt from each silo 4/16/12 mixing the coal in precisely the right

Advantages

Reliable and consistent quality blending guaranteed within 1% of required specification Homogeneous blend Controlled process Relatively small site due to vertical nature Ability to blend numerous types of coal with consistent output 4/16/12

MAJOR COAL FIELDS AND MINING CENTERS IN INDIA

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COAL SITES IN INDIA

Large deposits of coal: Bengal Bihar Madhya Pradesh Main coal fields are in: Ranigang Jharia Bokaro

1. 2. 3. .

1. 2.

3. 4/16/12

INTRODUCTION

It includes 163 open cast mines, 273 underground mines and 35 mixed mines Coal is used by many industries such as thermal power generation, steel , cement, fertilizers, textile , chemicals and brick manufacturing The power generation sector in India consumed 77.0% of the total coal 4/16/12 produced in fiscal 2009.

Proved Recoverable Coal Reserves Of India

Bituminous and Anthracite: 56100 Sub Bituminous: 0 Lignite: 4500 Total: 60600 Percentage of World: 7% Reserved life: 106 years India is the worlds forth largest importer of coal. 4/16/12

DIFFICULTIES OF INDIAN COAL

Ash content in Indian coal lies between 20%-30% due to which there is reduced thermal efficiency of the plant. This occurs due to following reasons: Unburnt carbon Excessive clinker formation Heat lost in ashes Further there is difficulty in disposal

1. 2. 3. .

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Such high ash content coal can be used more economically I pulverized form, because it increase the thermal efficiency as high as 90% and controls can be simplified just by adjusting the position of the burners in pulverized fuel boilers. The recent Indian power plant are generally designed to use pulverized coal. 4/16/12

SELECTION OF COAL FOR THERMAL POWER PLANT

Slow burning coal: generates high fuel-bed temperature and therefore require forced draught. Fast burning coal: is highly volatile and requires combustion chambers for the combustion of volatiles.

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IMPORTANT FACTORS FOR SELECTION OF COAL

Sizing, Caking, Swelling properties, Ash fusion temperature, Sulphur content also carries considerable importance in most cases.
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Electro-static precipitator(ESP): works better with high sulphur coal because of improved resistivity of the flue gases. Large size coal should be used when draught is low and some moisture percentage must be maintained if the percentage of fineness in coal is high. Anthracite coal as fuel requires

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Sizes of coal

SELECTION OF COAL ACCORDING TO COMBUSTION EQUIPMENT

Ultimate and proximate analysis Resistance to degradation Grindability Deterioration during storage Caking characteristics Slagging characteristics Corrosive characteristics.

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Liquid Fuels

Usage
Used extensively in industrial applications

Examples
Furnace oil Light diesel oil Petrol Kerosine Ethanol LSHS (low sulphur heavy stock)

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Properties

Density
Ratio of the fuels mass to its volume at 15 oC, kg/m3 Useful for determining fuel quantity and quality

Specific gravity
Ratio of weight of oil volume to weight of same water volume at a given temperature Specific gravity of water is 1 Hydrometer used to measure

Viscosity
Measure of fuels internal resistance to flow Most important characteristic for storage and use Decreases as temperature increases

Flash point
Lowest temperature at which a fuel can be when an open flame is passes over it heated so that the vapour gives off flashes

4/16/12 point of furnace oil: 66oC Flash

Pour point

Lowest temperature at which fuel will flow Indication of temperature at which fuel can be pumped

Specific heat

kCal needed to raise temperature of 1 kg oil by 1oC (kcal/kgoC) Indicates how much steam/electricity it takes to heat oil to a desired temperature Heat or energy produced Gross calorific value (GCV): vapour is fully condensed Net calorific value (NCV): water is not fully condensed

Calorific value

Sulphur content
Depends on source of crude oil and less on the refining process Furnace oil: 2-4 % sulphur

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Carbon residue
Tendency of oil to deposit a carbonaceous solid residue on a hot surface Residual oil: >1% carbon residue

Water content
Normally low in furnace oil supplied (<1% at Free or emulsified form Can damage furnace surface and impact flame refinery)

Storage of fuels Store in cylindrical tanks above or below the ground Recommended storage: >10 days of normal consumption Cleaning at regular intervals

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Furnace Oil

Furnace oil is a dark colored fuel, either distilled or residual fraction of crude oil that is extracted while petroleum distillation and is used for the purpose of generation heat and power. This fuel is sticky, thick and glutinous in nature. Furnace oil is known by the name of 4/16/12 oil internationally and also as fuel

Uses of Furnace Oil:

As fuel for Power Generation in DG Sets As fuel for Boilers/ Furnaces/ Air preheater/ Any other HeatersAs fuel for BunkeringAs fuel/ Feedstock in Fertilizer Plants Low sulphur fuels will emit lesser quantity of sulphur dioxide and thus cause minimal environmental pollution. sulphur fuels will not cause

Advantages:

Low 4/16/12

Light Diesel Oil (LDO)

Light Diesel Oil falls under class C category fuel having flash point above 66OC. It is a blend of distillate components and a small amount of residual components. Uses of Light Diesel Oil (LDO) :
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As fuel for lower RPM engines

Superior Kerosene Oil (SKO)

Kerosenes are distillate fractions of crude oil in the boiling range of 150250C. They are treated mainly for reducing aromatic content to increase their smoke point (height of a smokeless flame) and hydrofining to reduce sulphur content and to improve odour, colour & burning qualities (char value).

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Low Sulphur Heavy Stock (LSHS)

Low Sulphur Heavy Stock (LSHS) is a residual fuel processed from indigenous crude. This fuel is in lieu of FO in the same applications where furnace oil is suitable. The main difference with LSHS and FO is in the form of higher pour point, higher calorific value and lower sulphur content in LSHS. As this fuel has higher pour point 4/16/12

Uses of Low Sulphur Heavy Stock (LSHS):

As fuel for Power Generation in DG Sets As fuel for Boilers/ Furnaces/ Air preheater/ Any other Heaters As fuel for BunkeringAs fuel/ Feedstock in Fertilizer Plants

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Typical specifications of fuel oils

Properties Furnace Oil
Density (Approx. g/cc at 150C) Flash Point (0C) Pour Point (0C) G.C.V. (Kcal/kg) Sediment, % Wt. Max. Sulphur Total, % Wt. Max. Water Content, % Vol. Max. Ash % Wt. Max. 0.89-0.95 66 20 10500 0.25 < 4.0 1.0 0.1

Fuel Oils L.S.H.S

0.88-0.98 93 72 10600 0.25 < 0.5 1.0 0.1

L.D.O
0.85-0.87 66 18 10700 0.1 < 1.8 0.25 0.02

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Gaseous Fuels

Classification of gaseous fuels

A) Fuels naturally found in nature

-

Natural gas Methane from coal mines Gases derived from coal Gases derived from waste and biomass From other industrial processes Liquefied Petroleum gas (LPG) Refinery gases

(B) Fuel gases made from solid fuel

-

(C) Gases made from petroleum

-

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Natural gas

Methane: 95% Remaining: 5%: ethane, propane, butane, carbon dioxide, other gases High calorific value fuel Does not require storage facilities No sulphur Mixes readily with air without producing smoke or soot pentane, nitrogen,

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Methane

Methane is a colourless, odourless gas with a wide distribution in nature. It is the principal component of natural gas, a mixture containing about 75% CH4, 15% ethane (C2H6), and 5% other hydrocarbons, such as propane (C3H8) and butane (C4H10). The "firedamp" of coal mines is 4/16/12 chiefly methane.

Liquefied Petroleum Gas (LPG)

Propane, butane and unsaturates, lighter C2 and heavier C5 fractions Hydrocarbons are gaseous at atmospheric pressure but can be condensed to liquid state LPG vapour is denser than air: leaking gases can flow long distances from the source

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Slurry Fuel

Coal-water slurry fuel(CWSF or CWS or CWF) is afuelwhich consists of finecoalparticles suspended in water. CWS consists of 55-70% of fine dispersed coal particles and 30-45% of water. Coal particles suitable for diesel fuel replacement typically need to be less than 20 micrometres in diameter.
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History

Toward the end of 1950s, the Soviet Union started the development of new ways to utilize coal sludge for power generation. Two major problems of sludge transportation and sludge combustion were solved during the series of experiments and research. Ball mills pulverize and mix the coal sludge with water producing coal-water slurry (mix of liquids and hard particles). CWS produced by milling the sludge and/or regular coal near the coal mine near Belovo (Siberia, Russia) was transported through the pipeline to Novosibirsk (Siberia, Russia), a distance of 262km.

The unique difference of projectBelovo-Novosibirskuses CWS directly for combustion in steam boilers at a rate of 1340 tons/hr. In other world projects CWS was used only for transportation which was followed then with drying of CWS before 4/16/12 the combustion of the pulverized coal.

Preparing CWS

Coal of almost any types could be used as a raw for WCF: lignite, flame and gas flame coals, anthracites. CWS preparation consists of three major stages: Prior crushing till 10 to 25 micrometers or 60 to 65 micrometers Wet milling and homogenization Intermediate storage Standard crushers could be used for prior crushing of raw coal. On the wet milling and homogenization stage coal is milling and mixing with water and (if required) some additives. Countries like Russia have developed high efficient and low consumption method of wet milling and homogenization what reduces energy expenses for 4/16/12

1.

2. 3.

Combustion of CWS

CWF can be used in several different applications, in the largest particle form it is a viable substitute for heavy grade fuel oils used to produce steam in boilers. Low speed marine or modular powerplant diesels can operate on pure CWF. For gas turbine testing CWF particles five to ten micrometres in size have been used to demonstrate useful substitution for petroleum or natural gas in combined cycle gas turbine powerplant applications. The smaller the particle size the more versatile the CWF is for application, however the finer the particle size the more difficult it is to manufacture.

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Benefits

The presence of water in CWS reduces harmful emissions into the atmosphere and makes the coal explosion-proof. Presence of water in CWS reduces harmfulemissionsinto the atmosphere, makes the coal explosion-proof, makes use of coal equivalent to use of liquid fuel (heating oil) and gives other benefits.

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Emulsion Fuel

Emulsified Fuelsareemulsionscomposed of water and a combustible liquid, either oil or a fuel. Emulsions are a particular example of adispersioncomprising a continuous and a dispersed phase. In the case of emulsions both phases are theimmiscibleliquids, oil and water.
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Types of Emulsions

Microemulsion

Macroemulsion
StabillityMacroemulsions are kinetically stabilized. Particle SizeMacroemulsions are formed by a shearing process and have dimensions of 100nm to over 1 micrometer. Macroemulsions are prone tosettling(orcreaming) and changes in particle size over time.

StabilityMicroemulsions are thermodynamically stable systems. Particle SizeMicroemulsions are formed spontaneously and have dimensions of 10 to 200 nm.

Microemulsions are isotropic.

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Different types of Emulsions

Water-in-oil (invert emulsions). Oil-in-water (regular emulsions).

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Water-in-oil Emulsion Fuel Surfactant based emulsion is a

water-in-oil emulsion fuel consisting of from 5 percent to 10 percent water dispersed as droplets in a continuous oil phase.

The key to achieving maximum combustion with this fuel is producing water droplets in the range of 5 microns to 20 microns in diameter within the oil.

This is accomplished by introducing a small amount of surfactant (PEP99) to control water droplet size and prevent coalescence. Proper mixing and proportioning of the water, oil and surfactant creates a 4/16/12 very stable emulsion that is ready

A typical burner atomizer produces a spray of fuel oil droplets around 100 microns to 200 microns in diameter, depending on fuel quality and atomizer design.

Large fuel droplets do not completely burn, leaving unburned carbon to collect on heat transfer surfaces and escape as particulate matter in the exhaust gases. This reduces overall thermal efficiency.

In the combustion of a water-in-oil emulsion, the primary spray fuel droplets are further divided as a result of the explosive vaporization caused by rapid heating of the water dispersed within the individual fuel droplets. The internal water droplets undergo spontaneous nucleation of steam bubbles at a temperature well above 100oC, causing a violent conversion of the water droplet to steam. The vaporization, in turn, produces a rapid expansion of the surrounding oil droplets, fragmenting the oil into a vast number of smaller fuel droplets. The name for this process is secondary atomization.

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Oil-in-water Emulsion fuel

Most oils are less dense in water, and if oil and water are mixed then the oil will simply float to the surface. In emulsions, the oil is dispersed as liquid droplets through the continuous phase, usually but not necessarily water.

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Contd.

This means that an emulsion is thermodynamically unstable. Those droplets want to combine together again to form a single blob of oil. To prevent them from doing this, emulsions contain a surfactant which coats the surface of each drop and prevents the droplets from coalescing.

However the oil is still less dense than the water. So each drop is prone to floating upwards. This process is called creaming - the oil droplets will gradually form a dense layer at the top of the sample.

To prevent creaming, many emulsion products contain additives called stabilizers that inhibit creaming. Stabilizers work by increasing the viscosity of the continuous phase in which the oil droplets are immersed, or by inducing some kind of interaction between droplets. 4/16/12

Benefits
improved atomization improved carbon burnout lower S03formation Lower V2O5formation reduced back-end fouling reduced back-end corrosion elimination of fireside additives lower particulate lower NOxlower 02 shorter flame length reduced flame impingement improved heat transfer reduced soot blowing reduced acid mist reduced boiler maintenance including downtime 4/16/12

1. 2. 3. 4.

Coal Handling Coal Storage Coal Preparation Coal Feeding

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107107

Schematic representation

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108108

Coal Handling

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109109

Coal handling via Conveyor

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110110

COAL HANDLING (cont)

Coal needs to be stored at various stages of the preparation process, and conveyed around the CPP facilities. Coal handling is part of the larger field of bulk material handling, and is a complex and vital part of the CPP. Types of handling system Conveyor Shipment Trucks
111111

1.

2.

3.

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Coal Storage

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112112

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113113

Types of coal storage

Stockpiles
Stockpiles provide surge capacity to various parts of the CPP. ROM coal is delivered with large variations in production rate of tonnes per hour (tph). A ROM stockpile is used to allow the wash plant to be fed coal at lower, constant rate.

Stacking
Travelling, lugging boom stackers that straddle a feed conveyor are commonly used to create coal stockpiles.

Reclaiming
Travelling, lugging boom stackers that straddle a feed conveyor are commonly used to create coal stockpiles. 4/16/12 114114

Coal Preparation

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115115

Hammer Rings for Coal Crushing

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116116

Methods of coal preparation Crushing

Crushing reduces the overall top size of the ROM coal so that it can be more easily handled and processed within the CPP. Crushing requirements are an important part of CPP design and there are a number of different types.

Screening
117117 Screens are used to group process

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Coal Feeding by paddle feeder

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118118

Coal feeding gravimetric feeder

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119119

Methods of coal feeding

Gravimetric coal feeder

Here the coal separation takes place in the rolling mill. After the coal passes the mill, it falls in stroking area where it is fed to the FBC boilers due to gravitational force

Paddle Feeder.

To scoop the raw coal from the table below the Track hopper to the respective conveyor; generally two feeders are provided on each side with in a Track hopper; when not in use they are parked on either side;
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Ash Handling Introduction

A huge quantity of ash is produced in Power Plants, sometimes being as much as 10 to 20% of the total quantity of coal burnt in a day. Handling of ash includes:

Its removal from the furnace. Loading on the conveyors and delivery to the fill or dump from where it can be disposed off.

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Handling of ash is a problem because:

Ash coming out of the furnace is too hot It is dusty It is irritating to handle It is accompanied by some poisonous gases.

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Quenching of ash
Ash needs to be quenched before handling due to following reasons:

Quenching reduces corrosion action of ash. It reduces the dust accompanying the ash. It reduces the temperature of the ash.
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Ash forms clinkers by fusing in large

Principal Requirements of Ash Handling Plant

The plant should be able to handle large clinkers, boiler refuse, soot and dust with minimum attention of operators. It should have enough capacity to cope with the volume of ash that may be produced in the station. The plant should not cost much and the operating and maintenance 4/16/12 charges should also be minimum.

The operation of the plant should be noiseless as much possible. The plant should be able to operate efficiently under all variable load conditions. It should be able to handle hot and wet ash effectively. In case of addition of units, it should need minimum changes in original layout of plant.
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Ash Handling Systems

The modern ash handling systems are mainly classified into four groups:

Mechanical Handling System Hydraulic System Pneumatic System Steam Jet System

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Mechanical Handling System

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Used for low capacity power plants using coal as a fuel. The hot ash coming out of boiler furnace is made to fall over the belt conveyor through a water seal. The cooled ash falls on the belt conveyor and it is carried continuously to the overhead bunker. Ash is carried to the dumping site from the ash bunker with the help of trucks.

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The control valve is opened and closed manually to load the truck. Life of this system is 5 to 10 years. Maximum capacity is limited to 5 tons per hour. Major advantage of this system is low power consumption.

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Hydraulic Ash Handling System

In this system ash is carried with the flow of water with high velocity through a channel and finally dumped in the sump. The system is subdivided as follows:

Low Pressure System High Pressure System

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Low Pressure System

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In this system a trough or drain is provided below the boilers and the water is made to flow through the trough. The ash directly falls into the troughs and is carried by water to sumps. In the sump the water is separated from ash by making the mixture pass through a screen. This water is pumped back to the trough for reuse and ash is removed 4/16/12 to the dumping yard.

High Pressure System

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The hoppers below the boilers are fitted with water nozzles at the top and on sides. The top nozzles quench the ash while the side ones provide the driving force for the ash. The cooled ash is carried to the sump through the trough. The water is separated from ash and recirculated.
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Capacity is 120 tonnes/hour and

Advantages

The system is clean, dustless and totally enclosed. It can be used to handle stream of molten ash. Working parts do not come in contact with the ash. The unhealthy aspects of ordinary ash basement work is eliminated.
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Its ash carrying capacity is

Pneumatic System

These systems can handle abrasive ash as well as fine dusty materials such as fly-ash and soot. It is preferable for the boiler plants from which ash and soot must be transported some far off distance for final disposal.

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The exhauster provided at the discharge end creates a high velocity stream which picks up ash and dust from all discharge points and then these are carried in the conveyor pipe to the point of delivery. Large ash particles are generally crushed to small sizes through mobile crushing units which are fed from the furnace or hopper and discharge into the conveyor pipe which terminated into a separator at 4/16/12

The separator working on the cyclone principle removes dust and ash which pass out into the ash hopper at the bottom while clean air is discharged from the top. The ash carrying capacity varied from 25 to 15 tons per hour.

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Advantages

No spillage and re-handling. High flexibility. There is no chance of ash freezing or sticking in the storage bin and material can be discharged freely by gravity. The ductless operation is possible as the materials are handled totally in an enclosed conduit.

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Disadvantages

There is a large amount of wear in the pipe work necessitating high maintenance charges. More noisy than other systems

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Steam Jet System

In this system steam is passed through a pipe at sufficiently high velocity which is capable of carrying dry solid materials of considerable size along with it. In a high pressure steam jet system, a jet of high pressure steam is passed in the direction of ash travel through a conveying pipe in which the ash from the boiler ash hopper is 4/16/12

Advantages

Less space requirements. Less capital cost in comparison to other systems. Auxiliary drive is not required. The equipment can be installed in awkward position too. Ash can be removed economically through a horizontal distance 200 meters and through a vertical 4/16/12

Disadvantages

Noisy Operation. The system necessitates continuous operation since its capacity is limited to about 7 tonnes per hour. Due to abrasive action of ash the pipes undergo greater wear.

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Ash Disposal

Vacuum Extraction Plant: This system is disposal is used on both stoker and pulverised fuel installations and give good service. Water Ejector System: This system can also be used with stoker as well as with pulverised fuel-fired boilers with equal efficiency. Its adaption is more economical if the high pressure water is used for the system. 4/16/12

Steam Ejector System: This system is also used to carry the dust to the disposal site. Mechanical Conveyors: The dust is also carried by mechanical conveyors like screw and belt provided it is wetted before carrying.

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The ash and dust is transported using one of the two systems:

Wet System Dry System

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Wet System

In the wet system, ash is transported to ash ponds in form of a slurry. As ash settles in the pond, the part of the water evaporates and the remainder is either recycled or impounded. This system requires installation of pipelines and construction of embarkments.
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Advantages

Transportation of ash by pipelines eliminates noise, dust and traffic problem. Use of manned equipment is eliminated. The system is unaffected by transportation strikes.

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Disadvantages

Large quantities of leachate under a positive pressure head in pond pose a constant threat to ground water quality. This is prevented by surface preparation and artificial lining which are very costly. Larger area is required. Area of wet system may be twice of the dry area. Scaling and cementation within 4/16/12 pipeline.

Dry System

In the dry system, ash is transported to the disposal site in a relatively dry state (in the form of a paste). Water is added only to compact the ash. It does not require embankments to hold ash. Compacted ash surfaces are covered with top soil and seeded.

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Advantages

Leachate quantities are significantly reduced. Water and power consumptions are very less. Compacted ash is a structural material which can be sold. This system offers greater flexibility in operation as ash is transported by vehicles to different sites.

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Disadvantages

Use of trucks make this system totally dependent. It presents increased visual impact along transportation route. Wetting of ash containing calcium or magnesium forms lumps which may stick to the conveying belt.

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The presence of excess ash seriously reduces the boiler capacity, because sufficient coal cannot be burnt on the grates to do the necessary work. The ash produced is abrasive and will wear out the conveying parts on contact with it. When ash forms clinkers, it is very difficult to remove from the grate.
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Ash and its effects on Boiler operation and performance

The molten ash may also accumulate

Dust Handling Contents

Dust collection Classification Mechanical dust collector Wet dust collector Performance of dust collector Installation of dust collector
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Dust collection & its disposal

Dust collection is done because

Most of the Indian coal contains 30% to 45% of ash It contains only 1% to 1.5% of sulpher. Contains large percentage of silica.

It is necessary to clean the gas streams contaminated with particle. Dust or these contaminated gas affect the atmosphere leading to 4/16/12

Classification

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Mechanical dust collector

Cyclonic collectors, fabric filters, electronic precipitators, wet scrubbers and combination of all may help to reduce the emissions from coal fired boilers

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Gravitational Seperators

Separating the dust particles with help of gravity. Different methods are:
1. 2. 3.

in the cross sectional area Changing the direction of the gas flow Impingement of gas stream on baffels

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Bag house duct collector

Are designed to collect 99.9% of dust particle (particle size above 1) Are more sensitive to consideration of objectionable gases. the temperature of the hot gas passing through bag house can be controlled by cold air bypass. Presently used bag fabric filters are impregnated with teflon.

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Advantages

Not sensitive to flashy resistivity. High collection efficiency. Less costlier

Disadvantages

Sensitive to fluctuating temperature

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Pulse- jet dust collector

Can be used for high temperature applications in coal fired boiler. Fabric filters contains of large box with suspended filter bag

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Cyclon seperator

A high velocity gas stream carrying dust particle enter tangentially to the conical shell. This produce a whirling motion of the gas within chamber and throws heavier particle to side, falls out to collector at bottom.

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Advantage

More rugged so maintenance cost is low Efficiency is higher. Efficiency increases with Disadvantages increases of load Incapable of removing dust and ash particles which remains in suspension Requires more power than other collector. 4/16/12 Is not flexible.

Electrostatic precipitators

Used in removal of fly-ash from electric utility boiler emissions. Designed to operate at any desired efficiency

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Working principle

Dust laden is passed between oppositely charged conductors and become ionized. Once the dust is charged it is passed through dust collecting plates. There the plates are charged as electrode, where dust particles get separated and clean air goes out.
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Advantages

Effective to remove very small particle Effective to remove high dust loaded gas The draught loss of this separator is the least of all Low maintenance charge. Ease to operate. Dust is collected in dry form.

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Disadvantages

Direct current is not available with modern power plant. Running charge are also high Space required is larger than wet system.

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Wet type

Used for control of emission of SO2 by using scrubbers. The gases and fumes are dissolved in the liquid(water + lime) which is spread in the dust collector. Mixture in the form of thick fluid from bottom of the collector. Cleaned flue gases go out from top.
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While mixing , the fine slow moving droplets collide with the wet dust particles. Wetted particles agglomerate until heavy enough to drop out of the gas stream.

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Performance of dust collectors

Effect of particle size Velocity on the collection efficiency Power requirement with an increase in load Efficiency size. Efficiency with an with an in dust particle in gas velocity. in gas velocity

MECHANICAL COLLECTOR(DRY):

Draught loss with an 4/16/12 and power required

WET COLLECTORS

Efficiency with an in relative velocity between water and gas and quantity of water. Efficiency with an particles Power requirement velocity. in size of the dust with an in relative

ELECTROSTATIC PRECIPITATOR

Efficiency is least affected by particle size

Efficiency highly affect due to in gas 4/16/12 velocity.

Installation of collector

Installed either before air-heater or after air-heater. installed between boiler outlet and the chimney but on the chimney side of air-heater Advantage of the above is that it reduces the cleaning charges. Installed after air heater, the heat utilized for heating the air will be 4/16/12 more

Installation of electric collector to hot side is more preferable and economical But in the western power plant the electrostatic precipitators do not function because of use of low sulpher contain coal. According to placement of the electrostatic precipitator :

Hot side arrangement Cold side arrangement

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COMPARISION BETWEEN POWER PLANTS.

BY:UTKARSH GARG Click to edit Master subtitle style PRN:08070121431

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CONTENTS

INTRODUCTION CHART REPRESENTATION CLASSIFICATION ADVANTAGES

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INTRODUCTION

Apowerplant is an industrial facility for thegenerationof electric power. Nearly all power stations consist of agenerator, a rotating machine that converts mechanical power intoelectrical powerby creating relative motion between amagnetic 4/16/12 fieldand aconductor.

POWER PLANT

CHART REPRESENTATION RAW SITE CAPACITY EFFICIENCY COST DRAWBACKS

MATERIAL SELECTION STABLE LAND (APPRO X) 5003500MW 4002000MW 33-48% US$ 1- COSTLY AND 1.5 POLLUTION billion US$ 2 billion WASTE DISPOSAL

THERMAL FOSSIL FUELS

NUCLEAR URANIUM- ISOLATED 235 AREA SOLAR SUNS HEAT MAX. SUN RAYS

20-35%

50-350MW VERY LESS US$ LESS 1billion EFFICIENT AND HIGH COST US$ 1 billion MASSIVE AREA REQUIRED FOR SET UP

HYDRO- WATER ELECTRIC

CLOSE TO A 200080-90% WATER 22000MW BODY CAN BE SET 8-2000KW 46-52% UP ANYWHERE

DIESEL

DIESEL

US$ .25 ONLY USED billion FOR SMALL APPLICATIONS

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THERMAL POWER PLANT

These power plants generate electrical energy from thermal energy (HEAT). Since heat is generated by burning fossil fuels like coal, petroleum, or natural gas, these power plants are also collectively referred to as the fossil fueled power plants.
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SITE SELECTION

Geology and soil type Gas pipe network Water resources Climate
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ADVANTAGES

The fuel used is quiet cheap Less initial cost Less space required as compared to hydroelectricpower plant Cost of generation is less 4/16/12

NUCLEAR POWER PLANT

Nuclear power plantswork on the chemical process of fission. Nuclear power plants have ways to control or stop these reactions when they seem to go out of control and become threatening. The nuclear fuel used in the nuclear

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SITE SELECTION

Disposal of Waste Distance from populated areas Availabilty of Water

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ADVANTAGES

Almost negligible emissions A small amount of matter creates a large amount of energy Nuclear power is reliable. This technology is readily available; it does not have to be developed first. Nuclear power is also not so expensive as compare to power from coal

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The difference between thermal and nuclear power generation

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HYDRO POWER PLANTS

These plants use the kinetic energy of flowing water to produce electrical energy. Hydro power plants store water in large reservoirs. Despite their utility, the major drawback of hydro power plants is 4/16/12

ADVANTAGES

Less pollution Renewable source of energy Cheap electricity produced Automated plants
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SOLAR POWER PLANT

Solar energy is one of the most abundant natural resources that is capable of providing more power than the current demand requires. Most of thesolar powerplants are concentrating solar power plants in which the rays of the sun are concentrated into a single beam using lenses and mirrors.
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WHY LESS EFFICIENT ?

The main reason because of which solar power plant is less efficient is because of its low conversion rate of the suns rays to electricity using photovoltaic cells. These cell convert less than 7% of the suns energy into electricity. The major disadvantage being that these cells are very expensive and 4/16/12 increase the cost.

DIESEL POWER PLANT

Adiesel generatoris the combination of adiesel enginewith anelectrical generator,often called analternator to generate electrical energy. Diesel generators, sometimes as small as 200kW are widely used not only for emergency power, but also many have a secondary function of feeding power to utility grids either 4/16/12

THANK YOU

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Thank you

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