Steam Power Plants-1

Steam Power Plants-I
By
Power and Energy are buzz words in todays world.
Electricity is emerged as basic necessity with Food,

Shelter and Clothing for human being.
Life without electricity has become highly unimaginable.
Electric locomotives, Heating, Cooling, Fans, Blowers,

Motors, Illumination are some applications that converts
electrical energy into useful work.
CH KODANDA RAMA RAO Asst.Professor

GITAM UNIVERSITY 2
Progress of any nation is measured in terms of per capita
consumption of electrical energy.(KWH consumed per
person per year)
India- 500 KWH /person per year

UK- 15 times that of India
US- 30 times that of India
Reasons of Popularity of electricity:-

Clean environment for user
Higher efficiency
Better controllability
Quick transfer of power from source to load
Energy conservation is simple

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Power Generation Scenario In India
Thermal Power --- 1,00,000MW

Hydro Power --- 65,000MW
Nuclear Power --- 10,000MW
Other sources --- 20,000MW
Total Installed Capacity--- 1,95,000MW

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Sources Of Electrical Power Generation
A.Conventional Sources
Thermal (Coal)
Nuclear
Gas
Water
B.Non conventional Sources
Wind
Solar- PV
Biomass

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Disadvantages Of Conventional Sources
Fossil fuels shall be depleted, forcing us to

conserve them and find alternative resources.
Toxic, Hazardous gases, Residues pollute
environment.
Overall conversion efficiency is very poor.
Sources are located at remote places with
reference to load, increasing transmission cost.
Maintenance cost is high.

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Block Diagram Of Coal Fired Thermal Plant

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Coal Based Thermal Power Plant
India has rich stock of coal as natural resource.
Chemical energy stored in coal is transformed to

electrical energy.
Coal powder is fired in boiler that converts water into

steam at high temp. and pressure.
This steam is injected over the blades of steam turbine

(prime mover) in controlled way and hence, rotor of 3 PH
a.c. generator rotates.

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Mechanical energy is converted into electrical energy at rated
voltage(10-30KV).
Used steam is cooled down to water using cooling towers and

condensers.
This preheated water is again injected in boiler tubes to

convert back to steam.
Flue gases are passed into atmosphere and fine particles of

ash are collected through ESP.
Ash(40% of coal weight) is collected and transported to AHP.

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Merits of Coal Thermal Plant
Coal is cheap and available in abundance at present.
It is a time tested process, so no experimentation is

required.
Less space required as compared to Hydro based

station and less hazardous than Nuclear power plant.
Less initial cost as compared to other conventional

process of power generation.

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Demerits of Coal Thermal plant
Calorific value (Kcal/Kg) of Indian coal is very low and

large ash content.
Huge volume of ash is produced daily and its disposal is

burning issue today.
Atmospheric pollution is very high.
Transportation of coal to plant and transmission of

generated power to load centre involves large expenses.

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Power plants circuits

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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

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Air and gas circuit
FD or ID fans are used for supply the air to
combustion chamber of the boiler through air-
preheater
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
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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
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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

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Main Components of Thermal Power Plants
1. Boiler
2. Super heater 11. Coal mills
3. Economizer 12. FD and ID Fans
4. Air preheater 13. ASH Precipitators
5. Reheater 14. Water treatment plant
6. Steam turbine
7. Generator
8. Condensers
9. Cooling towers
10. Pumps

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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

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

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Moisture
All coal contains some % of moisture and it is generally varies
from 3 to 30 %
Volatile matter
The volatile matter resent in the coal may me as high as 50%
The volatile matter may be combustible gases
(methane,hydrogen,co) and non-combustible gases(CO2,N2)
These gases decrease heating value of coal and increase the
volume of the furnace required
ASH-
This is resent in two forms
1.)fixed ash- which is formed after burning
2.) free ash- formed from clay and impurities(it can be removed by
washing screening
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Disadvantages of ash
increase cost of transporting, handling ,storing.
Decrease the heating value of coal.
Carbon: gives heating value to coal

sulphar:- adds little heating value
It is responsible to corrosion

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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
Ash softening temperature

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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

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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

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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

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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

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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
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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

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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 paraffins-
methane 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.
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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-in-oil and more recently,
coal-oil mixtures (COM)

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Coal handling

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Pulverised coal system
In this system coal is ground to a fine in a pulverised mill and

stored in bunkers from where it is fed into the combustion
chamber by means of steam of hot air .
The air is used to dry the coal an conveying it to the furnace is

called primary air .
The air blow separately to complete the combustion is called

as secondary air

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Advantages of pulverised coal system
Rapid combustion with out use of large
quantity of excess air.
Higher boiler efficiency because of better
combustion.
Low grade coal can be used.
Ash removal is easy.
Fluctuation of loads can be easily used.
Disadvantages
installation cost is high.
Risk of explosions are more
Special equipment is required for starting the system
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1.Ring Type Coal Crusher
2.Hammer Mill Coal Crusher
3.Brad Ford Breaker
Ring Type Coal Crusher

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Hammer Mill Coal Crusher

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

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Brad Ford Breaker

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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

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Belt conveyors
Best suitable for transporting large quantity over large
distance
It consists of end less belt running over a pair of end pulleys

and supported by series of rollers.
The inclination at which coal can be successfully elevated by

belt conveyor is about 200
Average speed of belt conveyer is 60-100 m/min
Load carrying capacity of the belt is 50-100 tones/hr

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Advantages
It is most economical method of coal transporting in
medium and large capacity plants
Min repair and maintenance cost
power consumption is minimum
Disadvantages
not suitable for greater heights and small distance

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Screw conveyors
It consists of end less helicoids screw rotating inside a
housing .the movement of screw drives the coal from
end of the conveyor to other end where it is discharged
This is used for small capacities

Its length is limited to 30 m
Seed 70 to 120 RPM
Max capacity-125 ton/hr
Low initial cost
Simple and compact
Adaptable to space available
Dust roof CH KODANDA RAMA RAO Asst.Professor
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Disadvantages
High power consumption
Excessive wear and tear
Short life compared to belt conveyor

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Bucket elevators
Used for moderate lift ,the coal can be conveyed at a speed of
16-40m/min
Less power is required
Coal can be discharged at elevated laces
Less floor area is required
Disadvantages
Its capacity is limited

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Pulverized coal handling system

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Bowl Mill

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Bowl Mill

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Ball and Race mill

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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.

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Disadvantages
1. Added investment in coal preparation unit
2. Added power needed for pulverizing coal
3. Investment needed to remove fly ash before ill fan
4. Large volume of furnaces needed to permit desired heat
release and to withstand high gas temperature

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1. Grate-fired furnaces
2. Chamber-type or flame furnaces
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)

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Grate

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Chamber type

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Fuel bed furnaces (coarse particles)
There are two ways of feeding coal on to the grate
1. Overfeeding
2. Underfeeding

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Overfeeding

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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

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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 water gas
reaction also takes
The stream while passing through distillation zone VM
is added
In distillation zone moisture is added
Know stream contains N,CO2,CO,H2,VM&moisture
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For combustion of this stream
A hot ignition point ( In the range of 1000-1300oC
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

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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

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Underfeeding

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Underfeeding
In underfeeding coal is fed from below
Primary air passing through holes in tuyeres
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
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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

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Traveling grate stoker

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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

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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

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Spreader stoker

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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
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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
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Underfeed stokers

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Multiple retort

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ASH HANDLING SYSTEM
Mechanical Handling System
Hydraulic Ash Handling System
Low pressure System
High pressure System
Pneumatic Ash Handling System
Steam Jet System

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ASH HANDLING FLOW DIAGRAM

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Mechanical Handling System

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In this type belt conveyor is used
Used for low capacity power plants
Ash is quenched (cooled)by allowing it to fall through

water seal over the belt conveyor
Quenched ash is then carried to a dumping site over the

belt
This is continuous handling system in which power

consumption is low
It handles 3.5 tons of ash per hour with a speed of

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Low pressure System

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in this system trough provided below the boiler
furnace and water is made to flow through it
The ash directly falls into trough and is carried by

the water to the sump
The water and ash are separated with the help of

screen in the sump.
The water is pumped back to the trough and used

again while the ash is carried to the dumping site

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Low pressure System

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High pressure System

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In this the the hoppers below the boiler is fitted with
water nozzles at the top and at the sides.
Ash is quenched by the top nozzle and side nozzles

provide the drive force for the ash.
The water and ash are separated with the help of

screen in the sump.
The water is pumped back to the trough and used

again while the ash is carried to the dumping site

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Advantages of hydraulic system
clean, dustless and totally enclosed
Carrying capacity is large.
Discharge ash at a considerable distance of over

600m.
Can also handles a stream of molten ash

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Pneumatic Ash Handling System

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In this system ash from boiler is pulverised in the
crushers
fine ash is then passed into stream of high velocity

air
Cyclone separators are used to remove ash from air

stream
Clean air is send to atmosphere

Ash is send to dumping site
System can handle 5-30 tons of ash /hr

CH KODANDA RAMA RAO
GITAM UNIVERSITY
Asst.Professor
85
Advantages
Dust can be eliminated as the material are handled in
a closed circuit
Flexible and can fit varying conditions.
It can carry ash through long distance
Disadvantages
Maintenance charges are high due to wear out of pipe

line.
More noisy than other system.
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Dust collection
the exhaust gas leaving the boiler contain
particles of solid matter in suspension
smoke, dust(fly-ash),un -burnt coal(cinder)
The quantity of dust is more in pulverised
firing .
Less in stroker

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Types of dust collectors
Mechanical dust collectors

1. Wet type collectors
2. Dry type collectors
Electrical precipitators(dust collectors

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Wet type dust collector
Water is sprayed to separate dust from flue
gas
Induced fan is used to carry gas through
chimney
Water is carried to a sludge pond

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Dry type dust collector
Inertia separators
Cyclone separator is one of the common forms of inertia

separators
Gravitational separators
It works slowing down gas flow so that dust particles remain

in a chamber for a long duration so as to settle at the bottom
It requires a large chamber and not suitable in power plants

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Types of Boilers
What Type of Boilers Are There?
1. Fire Tube Boiler

2. Water Tube Boiler
3. Packaged Boiler
4. Fluidized Bed (FBC) Boiler
5. Stoker Fired Boiler
6. Pulverized Fuel Boiler
7. Waste Heat Boiler
8. Thermic Fluid Heater (not a boiler!)
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Type of Boilers
1. Fire Tube Boiler
Relatively small steam

capacities (12,000
kg/hour)
Low to medium steam
pressures (18 kg/cm2)
Operates with oil, gas
or solid fuels
(Light Rail Transit Association)

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UNEP 2006
Type of Boilers
2. Water Tube Boiler

Used for high steam
demand and pressure
requirements
Capacity range of 4,500
120,000 kg/hour
Combustion efficiency
enhanced by induced
draft provisions
Lower tolerance for
water quality and needs
(Your Dictionary.com)
CH KODANDA RAMA RAO Asst.Professor water treatment plant93
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Type of Boilers
3. Packaged Boiler Comes in complete

package
To Features
Chimney
High heat transfer
Faster evaporation
Good convective
heat transfer
Good combustion
Oil
efficiency
Burner
High thermal
efficiency
(BIB Cochran, 2003) Classified based on
number of passes
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Type of Boilers
4. Fluidized Bed Combustion

(FBC) Boiler
Particles (e.g. sand) are suspended in high
velocity air stream: bubbling fluidized bed
Combustion at 840 950 C
Capacity range 0,5 T/hr to 100 T/hr
Fuels: coal, washery rejects, rice husk, bagasse
and agricultural wastes
Benefits: compactness, fuel flexibility, higher
combustion efficiency, reduced SOx & NOx
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Type of Boilers
4a. Atmospheric Fluidized Bed

Combustion (AFBC) Boiler
Most common FBC boiler that uses preheated
atmospheric air as fluidization and combustion air
4b. Pressurized Fluidized Bed

Combustion (PFBC) Boiler
Compressor supplies the forced draft and
combustor is a pressure vessel
Used for cogeneration or combined cycle power
generation
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Type of Boilers
4c. Atmospheric Circulating Fluidized

Bed Combustion (CFBC) Boiler
Solids lifted from bed,
rise, return to bed
Steam generation in
convection section
Benefits: more
economical, better space
utilization and efficient
combustion

(Thermax Babcock
GITAM & Wilcox Ltd, 2001)
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Type of Boilers
5. Stoke Fired Boilers

a) Spreader stokers
Coal is first burnt in suspension then in coal bed
Flexibility to meet load fluctuations
Favored in many industrial applications

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Type of Boilers
5. Stoke Fired Boilers

b) Chain-grate or traveling-grate stoker
Coal is burnt on moving
steel grate
Coal gate controls coal
feeding rate
Uniform coal size for
complete combustion
(University of Missouri,
CH KODANDA RAMA 2004)
RAO Asst.Professor
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Type of Boilers
6. Pulverized Fuel Boiler

Pulverized coal powder blown with combustion
air into boiler through burner nozzles
Combustion
temperature at 1300 -
1700 C
Benefits: varying coal
quality coal, quick
response to load
changes and high pre-
heat air temperatures Tangential firing
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UNEP 2006
Type of Boilers
7. Waste Heat Boiler

Used when waste heat
available at medium/high
temp
Auxiliary fuel burners
used if steam demand is
more than the waste heat
can generate
Used in heat recovery
from exhaust gases from
gas turbines and diesel
Agriculture and Agri-Food
engines
Canada, 2001
UNEP 2006
Type of Boilers
8. Thermic Fluid Heater

Wide application for indirect process heating
Thermic fluid (petroleum-based) is heat transfer
medium
Benefits:
Closed cycle = minimal losses
Non-pressurized system operation at 250 C
Automatic controls = operational flexibility
Good thermal efficiencies
Type of Boilers 3. Heat transfer
through heat
8. Thermic Fluid Heater exchanged
User equipment
2. Circulated
to user 4. Fluid
equipment returned to
heater
Control
panel
Insulated
outer wall
1. Thermic
fluid heated Blower Exhaust
motor
in the heater unit
(Energy
Fuel oil
filter Machine India)
Industrial Boilers
Steam generators
Closed vessels
made of steel and
used for generation of steam
vaporizing water
combustion of fuels
eg. coal,coke,oil,wood,saw dust and begesse etc.
Steam used for producing power,for industrial process
work or for heating proposes.

Requirements of a Perfect
Steam Boilers
Should be absolutely reliable,capable of producing
maximum steam at required pressure for minimum of fuel
consumption,with minimum attention and minimum initial
cost and operating cost.
Simple constructions
Quick starting from cold
Strong enough against temp. stress & strains
Well design combustion chamber
Less floor area, space & light weight
Best gauges,safety valves and other mountings
Easily accessible for inspection,cleaning and repairs

Classification of Steam
Boilers
Vertical or Horizontal
Stationary(Power plant,industrial,central heating and combined
power and heating boilers.),Portable,Locomotive or Marine
Internally Fired or Externally Fired (Lancashire and Locomotive
Boilers)
Solid,Liquid or Gas Fired
Fire(Smoke)Tube:Water is outside the tubes while the hot
gases are inside the tubes
eg.Vertical,Cochran,Lancashire,Cornish,Locomotives,etc) or
Water Tube: Contain a large number of small tubes through
which water circulates,the fire and hot gases being outside of
the tubes.eg.Babcock and Wilcox, Stirling and High pressure
Boilers etc.)

Vertical Boilers
Used in small factories,small water supply
plants,cranes,excavators,winch engines in mines
and on sites of temporary nature such as
construction work etc.
Required minimum floor space,not required
elaborate foundations,and is portable.
Cheap,easy to start but inefficient due to large
wastage of fuel and less heating surface.
Vertical Boilers are:Simple(having one to three
cross tubes), fire tubes and water tubes types.

Simple Cross tube vertical
boiler
consists of a cylindrical shell surrounding a cylindrical fire box.
heating surface is about 8-10 times the grate area.
50% efficiency

Cochran Boiler
It is well design of a Vertical multitubular fire tube boiler
Improvement over the simple vertical boiler as it provides
greater heating surface.
Total heating surface area is about 10-25 times the grate
area
Efficiency 70-75%
Ranges from 1m dia.X2m high,evaporation 20kg/hr to 3m
dia X6m high,evaporation 3000kg/hr.

Cochran Boiler contd.

Lancashire Boiler
Is horizontal smoke tube boiler size range from a
shell 2m diaX6m long to 3m diaX10m long
Working pressure range are up to 20kgf/cm2
Ratio of heating surface to grate area is 24-30
Efficiency is about 56% without economizer and
75% with economizer.
Similar to Cornish boiler,in Lancashire Boiler two
flue tubes but in Cornish boiler only one flue
tubes are there.

Lancashire Boiler contd

Lancashire Boiler contd

Locomotive Boiler
Is an internally fired multitubular fire tube boiler

Babcock and Wilcox water
tube Boiler
Water tube boiler having lager pressure ranges and larger
sizes.
Three main parts, steam and water drum,water tubes and
furnace.

Stirling Boiler
Example of water tube boiler where bent tube are used instead of
straight tube which are used in Babcock and Wilcox boiler

High Pressure Boilers
Two types- Natural circulation & Forced circulation Boilers

High Pressure Boilers
contd
La-Mont Boiler( Forced circulation Boiler)

Once-Through Forced
Circulation Boiler
Does not required a steam and water drum,saving in weight
Supercritical Pressure Boiler
Two types- Benson and Ramzin

Ramzin Boiler

Loeffler Boiler
Indirect heating is combined with forced circulation

Velox boiler
Fire tube forced circulation Boiler

Fire tubes Vs water tubes
Boilers
Fire tubes boilers has a large volume of water,therefore
more flexible and can meet the sudden demand of steam
without much drop of pressure.
Fire tubes boiler is rigid and of simple mechanical
construction,so greater reliability and low in first cost.
Fire tube boilers can be made in smallest sizes therefore
simple to fabricate and transport, occupies less floor space
but more height.
Due to mostly externally fired water tubes boiler so furnace
can be altered considerably to meet the fuel requirements.
Water tubes boilers are more readily accessible for
cleaning,inspection and repairs,compared to the fire tube
boilers.
Modern trend is in the favors of water tube boiler due to
continuous increase in capacities and steam pressures.

Mountings and Accessories
Fitting and devices which are necessary for
the safety and control are knows as boiler
mountings
Fitting or devices which are provided to
increase the efficiency of the boiler and
help in the smooth working of the plant
are knows as boiler accessories
Fittings - Safety
Water level indicators
Safety valves
Combined high steam and low water safety
valve
Fusible plug

Fittings - Control
Pressure gauge
Junction or stop valve
Feed check valve
Blow-off cock
Man hole and Mud Box

Boiler Mountings and
Accessories
Fitting and devices which are necessary for the safety and
control are knows as boiler mountings
Fitting or devices which are provided to increase the
efficiency of the boiler and help in the smooth working of
the plant are knows as boiler accessories.
Fittings which are essential from the safety
point of view are as follows,
Water level indicators
Safety valves
Combined high steam and low water safety valve
Fusible plug

Boiler Mountings and
Accessories contd.
Fittings which are essential from the control
point of view are as follows,
Pressure gauge
Junction or stop valve
Feed check valve
Blow-off cock
Man hole and Mud Box
The important accessories are
Superheater
Economiser
Air-preheater
Feed pump or injector
Performance of a boiler
1. Boiler
2. Boiler blow down
3. Boiler feed water treatment

Performance of a Boiler
1. Boiler performance
Causes of poor boiler performance
-Poor combustion
-Heat transfer surface fouling
-Poor operation and maintenance
-Deteriorating fuel and water quality
Heat balance: identify heat losses

Boiler efficiency: determine
deviation from best efficiency
Heat Balance
An energy flow diagram describes geographically
how energy is transformed from fuel into useful
energy, heat and losses
Stochiometric
Excess Air
Un burnt
Stack Gas
FUEL INPUT STEAM

OUTPUT
Convection & Blow Ash and Un-burnt parts

Radiation Down of Fuel in Ash
Heat Balance
Balancing total energy entering a boiler against
the energy that leaves the boiler in different forms
%
Heat loss due to dry flue gas
% Heat loss due to steam in fuel gas

%
100.0 % Heat loss due to moisture in fuel
BOILER %
Fuel Heat loss due to moisture in air
2% Heat loss due to unburnts in residue
%
Heat loss due to radiation & other
unaccounted loss
%
Heat in Steam

Heat Balance
Goal: improve energy efficiency by reducing avoidable losses
Avoidable losses include:
- Stack gas losses (excess air, stack gas

temperature)
- Losses by unburnt fuel
- Blow down losses
- Condensate losses
- Convection and radiation
Boiler Efficiency
Thermal efficiency: % of (heat) energy input that is
effectively useful in the generated steam
BOILER EFFICENCY
CALCULATION
1) DIRECT METHOD: 2) INDIRECT METHOD:

The energy gain of the The efficiency is the
working fluid (water and steam) different between losses
is compared with the energy and energy input
content
CHof the boiler
KODANDA RAMAfuel.
RAO Asst.Professor
Boiler Efficiency: Direct Method

Heat Outputx 100 Q x (hg hf) x 100
Boiler efficiency () = =
Heat Input qx GCV
hg -the enthalpy of saturated steam in kcal/kg of steam

hf -the enthalpy of feed water in kcal/kg of water
Parameters to be monitored:
- Quantity of steam generated per hour (Q) in kg/hr
- Quantity of fuel used per hour (q) in kg/hr
- The working pressure (in kg/cm2(g)) and superheat temperature
(oC), if any
- The temperature of feed water (oC)
- Type of fuel and gross calorific value of the fuel (GCV) in kcal/kg of
fuel CH KODANDA RAMA RAO Asst.Professor
The two main functions of any draught system
are:
1. To supply sufficient quantity of air to the
furnace for the complete combustion of fuel.
2. To remove the flue gases (products of com-
bustion) from the furnace for their exit to the
atmosphere through chimney (stack).

Draught at any point in the air / gas passage is
the difference between absolute air / gas
pressure at that point and the ambient
atmospheric pressure.
It is +ve, if Pgas > Patm and -ve, if P gas < Patm

NATURAL DRAUGHT

The natural draught is produced by the action of
chimney or stack.
Its amount is dependent upon the average
temperature difference between the flue gases
within the chimney and the outside air and also
on the height of the chimney above the level of the
furnace grate.
Weather conditions, boiler operating conditions
and the height of the chimney have a considerable
effect on the amount of natural draught.

MECHANICAL DRAUGHT

This type of draught is needed when the natu-
ral draught produced by a chimney is not suf-
ficient or where a certain draught must be
maintained irrespective of weather conditions.
Boilers with mechanical draught do not need so
high a chimney as is necessary with natural
draught.
Mechanical draught is of two types: forced
draught and induced draught.

Position of I.D. Fan

Position of F.D. and I.D fans
The F.D. fans are placed at the air entrance to
the air preheater. The total system up to the
stack entrance is under positive gauge pressure.
They handle cold air. So, they have many
advantages as compared to I.D. fans:
1. Lower maintenance costs.
2. Consume less power
3. Their load is reduced by the absence of
additional gas equivalent of the fuel used.
4. So, capital and operating costs are lower.

The total system is put under pressure (pressure
furnace). So, the drawbacks are:
1. Gas tight furnace construction to avoid leakage
of various gases from the furnace walls.
2. Special attention must be given to the design of
inspection doors, soot, blower boxes and fuel
igniter openings

I.D. fans are located in the gas stream between
the air-preheater and the stack, either before or
after the dust collector.
They discharge essentially at atmospheric
pressure and place the entire system under
negative pressure.
Their power consumption is greater as compared
to F.D. fans and they must also handle corrosive
combustion gases and ash

I.D. fans are seldom used alone. When both F.D.
and I.D. fans are used, the F.D. fans push
atmospheric air through the air-preheater,
dampers; various airducts and burners into the
furnace.
The I.D. fans suck the combustion gases from the
furnace through the heat transfer surface
(Superheaters, reheaters, economisers and gas
side air preheater) and into the stack.

The chimney, because of its height, adds a
natural draught of its own. Such a system is
called "Balanced Draught". It means that the
pressure in the furnace is approximately
atmospheric. Actually, it is kept at a slightly
negative pressure to ensure that any leakage
would be inward.


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Steam Power Plants-I

Electricity is emerged as basic necessity with Food,

Life without electricity has become highly unimaginable.

Electric locomotives, Heating, Cooling, Fans, Blowers,

CH KODANDA RAMA RAO Asst.Professor

India- 500 KWH /person per year

Reasons of Popularity of electricity:-

CH KODANDA RAMA RAO Asst.Professor

Thermal Power --- 1,00,000MW

Total Installed Capacity--- 1,95,000MW

CH KODANDA RAMA RAO Asst.Professor

CH KODANDA RAMA RAO Asst.Professor

Fossil fuels shall be depleted, forcing us to

CH KODANDA RAMA RAO Asst.Professor

CH KODANDA RAMA RAO Asst.Professor

India has rich stock of coal as natural resource.

Chemical energy stored in coal is transformed to

Coal powder is fired in boiler that converts water into

This steam is injected over the blades of steam turbine

CH KODANDA RAMA RAO Asst.Professor

Used steam is cooled down to water using cooling towers and

This preheated water is again injected in boiler tubes to

Flue gases are passed into atmosphere and fine particles of

Ash(40% of coal weight) is collected and transported to AHP.

CH KODANDA RAMA RAO Asst.Professor

Coal is cheap and available in abundance at present.

It is a time tested process, so no experimentation is

Less space required as compared to Hydro based

Less initial cost as compared to other conventional

CH KODANDA RAMA RAO Asst.Professor

Calorific value (Kcal/Kg) of Indian coal is very low and

Huge volume of ash is produced daily and its disposal is

Atmospheric pollution is very high.

Transportation of coal to plant and transmission of

CH KODANDA RAMA RAO Asst.Professor

CH KODANDA RAMA RAO Asst.Professor

CH KODANDA RAMA RAO Asst.Professor

CH KODANDA RAMA RAO Asst.Professor

CH KODANDA RAMA RAO Asst.Professor

CH KODANDA RAMA RAO Asst.Professor

CH KODANDA RAMA RAO Asst.Professor

Carbon: gives heating value to coal

CH KODANDA RAMA RAO Asst.Professor

CH KODANDA RAMA RAO Asst.Professor

CH KODANDA RAMA RAO Asst.Professor

CH KODANDA RAMA RAO Asst.Professor

CH KODANDA RAMA RAO Asst.Professor

CH KODANDA RAMA RAO Asst.Professor

They are easy to handle, store and to burn

CH KODANDA RAMA RAO Asst.Professor

CH KODANDA RAMA RAO Asst.Professor

CH KODANDA RAMA RAO Asst.Professor

In this system coal is ground to a fine in a pulverised mill and

The air is used to dry the coal an conveying it to the furnace is

The air blow separately to complete the combustion is called

CH KODANDA RAMA RAO Asst.Professor

CH KODANDA RAMA RAO Asst.Professor

CH KODANDA RAMA RAO Asst.Professor

CH KODANDA RAMA RAO Asst.Professor

CH KODANDA RAMA RAO Asst.Professor

CH KODANDA RAMA RAO Asst.Professor

It consists of end less belt running over a pair of end pulleys

The inclination at which coal can be successfully elevated by

Average speed of belt conveyer is 60-100 m/min