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PLANT
By
Ashvani Shukla
C&I
reliance
INTRODUCTION
Thermal power generation plant or thermal power
station is the most conventional source of electric power.
Thermal power plant is also referred as coal thermal
power plant and steam turbine power plant. Before going
into detail of this topic, we will try to understand the line
diagram of electric power generation plant.Athermal
power stationis apower plantin whichheat energyis
converted toelectric power. In most of the world theprime
mover issteamdriven. Water is heated, turns into steam
and spins asteam turbinewhich drives an
electrical generator. After it passes through the turbine, the
steam iscondensedin acondenserand recycled to where it
was heated; this is known as aRankin cycle.
THEORY OF THERMAL
POWER STATION
The theory of thermal power station or
working of thermal power station is
very simple. A power generation plant
mainly consists of alternator runs with
help of steam turbine. The steam is
obtained from high pressure boilers.
Generally in India, bituminous coal, brown
coal and peat are used as fuel of boiler.
The bituminous coal is used as boiler fuel
has volatile matter from 8 to 33 % and ash
content 5 to 16 %. To increase the thermal
6) After rotating the turbine blades, the steam has lost its high pressure, passes out of turbine blades
and enters into a condenser.
7) In the condenser the cold water is circulated with help of pump which condenses the low pressure
wet steam.
8) This condensed water is then further supplied to low pressure water heater where the low pressure
steam increases the temperature of this feed water, it is then again heated in a high pressure heater
where the high pressure of steam is used for heating.
9) The turbine in thermal power station acts as a prime mover of the alternator.
Rankin
cycle
WORKING OF RANKIN
CYCLE
A typical Thermal Power Station Operates on a Cycle which is shown
below.
The working fluid is water and steam. This is called feed water and steam cycle. The ideal
Thermodynamic Cycle to which the operation of a Thermal Power Station closely resembles
is the RANKINE CYCLE. In steam boiler the water is heated up by burning the fuel in air in
the furnace & the function of the boiler is to give dry super heated steam at required
temperature. The steam so produced is used in driving the steam Turbines. This turbine is
coupled to synchronous generator (usually three phase synchronous alternator), which
generates electrical energy. The exhaust steam from the turbine is allowed to condense
into water in steam condenser of turbine, which creates suction at very low pressure and
allows the expansion of the steam in the turbine to a very low pressure. The principle
advantages of condensing operation are the increased amount of energy extracted per kg
of steam and thereby increasing efficiency and the condensate which is fed into the boiler
again reduces the amount of fresh feed water.
The condensate along with some fresh make up feed water is again fed into the boiler by
pump (called the boiler feed pump). In condenser the steam is condensed by cooling
water. Cooling water recycles through cooling tower. This constitutes cooling water circuit.
The ambient air is allowed to enter in the boiler after dust filtration. Also the flue gas
comes out of the boiler and exhausted into atmosphere through stacks. These constitute
air and flue gas circuit. The flow of air and also the static pressure inside the steam boiler
(called draught) is maintained by two fans called Forced Draught (FD) fan and Induced
Draught(ID) fan.
RANKIN CYCLE
CO-GENERATION POWER
PLANT
Cogeneration is also called as combined heat and power or combine heat and
power. As it name indicates cogeneration works on concept of producing two different
form of energy by using one single source of fuel. Out of these two forms one must be
heat or thermal energy and other one is either electrical or mechanical energy.
Cogeneration is the most optimum, reliable, clean and efficient way of utilizing fuel. The
fuel used may be natural gas, oil, diesel , propane, wood, bagasse, coal etc. It works on
very simple principle i.e. the fuel is used to generate electricity and this electricity
produces heat and this heat is used to boil water to produce steam , for space heating
and even in cooling buildings. In conventional power plant , the fuel is burnt in a boiler ,
which in turn produces high pressure steam. This high pressure steam is used to drive a
tribune, which is in turn is connected to an alternator and hence drive an alternator to
produce electric energy. The exhaust steam is then sent to the condenser, where it gets
cool down and gets converted to water and hence return back to boiler for producing
more electrical energy. The efficiency of this conventional power plant is 35% only. In
cogeneration plant the low pressure steam coming from turbine is not condense to
form water, instead of it its used for heating or cooling in building and factories, as this
low pressure steam from turbine has high thermal energy. The cogeneration plant has
high efficiency of around 80 - 90 %. In India, the potential of power generation from
cogeneration plant is more than 20,000 MW.
b) Steam-turbine topping CHP Plant- In this the fuel is burned to produce steam,
which generates power. The exhaust steam is then used as low-pressure process
steam to heat water for various purposes.
c) Water- turbine topping CHP Plant- In this type of CHP plant a jacket of cooling
water is run through a heat recovery system to generate steam or hot water for
space heating. d) Gas turbine topping CHP plant- In This topping plant a natural
gas fired turbine is used to drives a synchronous generator to produce electricity.
The exhaust gas is sent to a heat recovery boiler where it is used to convert water
into steam, or to make usable heat for heating purposes.
Bottoming cycle power plant - As its name indicate bottoming cycle is exactly
opposite of topping cycle. In this type of CHP plant the excess heat from a
manufacturing process is used to generate steam, and this steam is used for
generating electrical energy. In this type of cycle no extra fuel is required to
produce electricity, as fuel is already burnt in production process.
Configuration of Cogeneration Plant
Gas turbine Combine heat power plants which uses the waste heat in the flue
gas emerging out of gas turbines. Steam turbine Combine heat power plants
that use the heating system as the jet steam condenser for the steam turbine.
Molten-carbonate fuel cells have a hot exhaust, very suitable for heating.
Combined cycle power plants adapted for Combine Heat and Power.
In a coal based power plant coal is transported from coal mines to the power
plant by railway in wagons or in a merry-go-round system. Coal is unloaded
from the wagons to a moving underground conveyor belt. This coal from the
mines is of no uniform size. So it is taken to the Crusher house and crushed to
a size of 20mm. From the crusher house the coal is either stored in dead
storage( generally 40 days coal supply) which serves as coal supply in case of
coal supply bottleneck or to the live storage(8 hours coal supply) in the raw
coal bunker in the boiler house. Raw coal from the raw coal bunker is supplied
to the Coal Mills by a Raw Coal Feeder. The Coal Mills or pulverizer pulverizes
the coal to 200 mesh size. The powdered coal from the coal mills is carried to
the boiler in coal pipes by high pressure hot air. The pulverized coal air
mixture is burnt in the boiler in the combustion zone.
Generally in modern boilers tangential firing system is used i.e. the coal
nozzles/ guns form tangent to a circle. The temperature in fire ball is of the
order of 1300 deg.C. The boiler is a water tube boiler hanging from the top.
Water is converted to steam in the boiler and steam is separated from water
in the boiler Drum. The saturated steam from the boiler drum is taken to the
Low Temperature Superheater, Platen Superheater and Final Superheater
respectively for superheating. The superheated steam from the final
superheater is taken to the High Pressure Steam Turbine (HPT). In the HPT the
steam pressure is utilized to rotate the turbine and the resultant is rotational
energy. From the HPT the out coming steam is taken to the Reheater in the
boiler to increase its temperature as the steam becomes wet at the HPT
outlet. After reheating this steam is taken to the Intermediate Pressure
Once-through boilers have been favored in many countries, for more than 30
years.
They can be used up to a pressure of more than 300 Kg Bar without any change
in the process engineering. Wall thicknesses of the tubes and headers however
need to be designed to match the planned pressure level.
Once-through boilers have been designed in both two-pass and tower type
design, depending on the fuel requirements and the manufacturers general
practice.
For the past 30 years, large once-through boilers have been built with a spiral
shaped arrangement of the tubes in the evaporator zone.
The latest designs of once-through boilers use a vertical tube arrangement
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