CPD 30302: Pilot Plant Operation 2

CHAPTER 1
Steam
Generation

Objectives
At the end of this topic, student should be able to:
Describe how the steam is produced and the processes
involved in the steam generator esp. its application in the
Power Station.
Describe the function of each equipment involved in the
steam generator & relate it with the equipment in the lab.
Apply the principle of thermodynamics in operating the
equipment in the lab.
Run the steam generator in the lab based on the theory
class given.

The Theory of Producing Steam

Water and steam are typically used as heat carriers in

heating systems.

It is well known that water boils & evaporates at 100C at

atmospheric pressure. P , water evaporates at T - e.g. a
pressure of 10 bar equals an evaporation temperature of
184C.

During the evaporation process, a substantial amount of

heat are use for bringing the water from liquid to vapour
phase.

The Theory of Producing Steam

In this condition the steam contains a large

amount of latent heat, corresponding the heat
that was led to the P & T.

The amount of heat is much higher in vapour

compared to the liquid.

Schematic of Conventional Coal Fired Power Station

Schematic of Conventional Coal Fired Power Station

Steam Generating Boiler

To produce steam water must be boiled, requiring the input of

latent heat. Latent heat is the heat or energy required to change
the state of the a fluid ( i.e. change the state of a liquid to gas)

The steam produced in the boiler is called 'wet steam' because it

is contact with the liquid water in the boiler

However, in a power station it is more efficient to re-heat that 'wetsteam' into 'superheated steam'. Superheated steam is a very
efficient medium to transport energy.

The combustion of coal, oil or natural gas is used in conventional

power stations to provide the energy for the boiler. The chemical
energy of these fossil fuels is converted to heat energy, during
combustion. The heat energy is then taken up by the steam.

Steam Generating Boiler

The heated air stream, at T of maybe 800oC, is forced by the pressure

of the forced fan and sucked by the induced daft fan to move through
the boiler.

When the air stream leaves the boiler it would have lost most of its
heat to the superheated steam & may now be only 300 OC.

This air stream however, contains the combustion by-products

(sulphur, carbon dioxide, etc. ) and fly ash, which are small coal
particles that did not burn completely.

These particles are removed by scrubbers - which may operate by

static electrical attraction, or be cyclones, or be bag filters ( like your
vacuum cleaner bags ).

The air stream is then exited to the atmosphere up the chimney stack.

Steam Generating Boiler

Steam Turbine & Generator

Steam Turbine

The superheated steam enters the steam turbine.

The purpose of a steam turbine is to convert heat energy

contained in high P & high T steam into mechanical energy.

The source of the high P / T steam is from boiler.
Generator

The rotating shaft of the steam turbine is coupled to the

electrical generator.
Purpose :to convert mechanical energy into electrical energy.
The source of the mechanical energy : steam turbine or gas
turbine.
The mechanical energy is supplied to the generator in the form
of a rotating shaft, while the generator output is alternating
current electricity transmitted along conductors.

Condenser & Feed Water Pump

Condenser

Steam exhausted from turbines / boiler enters the condenser.

Condenser is a HEX & operated at near vacuum conditions, to
enhance the P drop & improved the efficiency of condensing the
low pressure steam back into liquid water.
Feed Water Pump

The feed water pump must pump the liquid water that was
condensed in the condenser from the low pressure steam, back
into the boiler.

The primary working fluid must be pumped at a slightly greater

pressure than the boiler pressure to ensure that the fluid enters
the boiler.

The Similarities

Thermodynamics
in
Steam Generator

Rankine Cycle

Steam cycles used in electrical power plants is

based on the Rankine cycle.

 1 to 2: Isentropic expansion

(Steam turbine)
2 to 3: Isobaric heat rejection
(Condenser)
3 to 4: Isentropic compression
(Pump)
4 to 1: Isobaric heat supply
(Boiler)
2-3: Condensation process. Provides

saturated liquid at 3.
3-4: H2O is pumped to the boiler P at
point 4 but at this point it is not at the sat
T. (Ideally- isentropic process)
4-5: Heat, Q must be added to change
H2O at 4 to sat water at 5.
5-1:Heat is supplied until the system
reached superheated T at sat P.
1-2: Work, W is delivered to
surroundings (thermal energy-mech
energy).

Calculation Involved In The

Experiment

Calculation of Fuel Heat Rate

Calculation of Heat Transfer Rate to Water &
Steam
Calculation of the Efficiency of the Steam
Generator.

END OF STEAM GENERATION