thermal power plants
TRANSCRIPT
A presentation on
Steam Generator
Coal to Electricity ….. Basics
Coal
Chemical Energy
Super Heated Steam
Pollutants
Thermal Energy
Turbine Torque
Heat Loss In Condenser
Kinetic Energy
Electrical Energy
Alternating current in Stator
Mech. Energy Loss
ASHHeat
Loss
Elet. Energy Loss
Major EnergySources of India
Why Coal?
Coal55%
Gas10%
Diesel1%
Hydel26%
RES5%
Nuclear3%
Share of Coal in Power Generation
Advantages of Coal Fuel
•Abundantly available in India
•Low cost
•Technology for Power Generation well developed.
•Easy to handle, transport, store and use
Shortcomings of Coal
•Low Calorific Value
•Large quantity to be Handled
•Produces pollutants, ash
•Disposal of ash is Problematic
•Reserves depleting fast
•India’s Coal Reserves are estimated to be 206 billion tonnes. Present consumption is about 450 million tonnes.
•Cost of coal for producing 1 unit of electricity (Cost of coal Rs 1000/MT)is Rs 0.75.
•Cost of Gas for producing 1 unit of electricity (Cost of Gas Rs 6/SMC)is Rs 1.20.
Knowing more about Coal
Coal production
•Surface Mining
•Underground Mining
Coal Transportation
•Rail
•Truck
•Conveyor
•Ship
Coal Properties
•Calorific Value
•Grade of Coal (UHV)
•Proximate Analysis
•Ultimate Analysis
•Ash and Minerals
•Grindability
•Rank
•Physical CharacteristicsCoal Beneficiation
•Why?
•Processes
•Effectiveness
Coal production
•Surface Mining
•Underground Mining
Useful Heat Value (UHV) UHV= 8900-138(A+M)
Boiler/ steam generator Steam generating device for a specific purpose.
Capable to meet variation in load demand
Capable of generating steam in a range of operating pressure and temperature
For utility purpose, it should generate steam uninterruptedly at operating pressure and temperature for running steam turbines.
Boiler/ steam generator Raw materials for design
of boilers1. Coal from mines
2. Ambient air
3. Water from natural resources (river, ponds)
o Generating heat energy
o Air for combustion
o Working fluid for steam generation, possessing heat energy
A 500MW steam generator consumes about 8000 tonnes of coal every dayIt will be considered if it requires about 200 cubic meter of DM water in a dayIt will produce about 9500 tonnes of Carbon di Oxide every day
Coal analysis
Typical composition (Proximate analysis)1. Fixed carbon2. Fuel ash3. Volatile material4. Total Moisture5. Sulfur
o High calorific value/ Lower calorific value (Kcal/kg)
o Hardgrove Index (HGI)
Combustion of coal Carbon, hydrogen, sulfur are sources of heat
on combustion
Surface moisture removed on heating during pulverization.
Inherent moisture and volatiles are released at higher temperature, making coal porous and leading to char/ coke formation. (Thermal preparation stage)
Fuel Oil Three liquid fuels used in power plants
• 1. Heavy Fuel Oil (HFO)• 2. LSHS (Low Sulfur Heavy stock)• 3. High speed Diesel (HSD)
Oil firing is preceded by Lowering viscosity and increasing flowability on
heating for better combustion in given turn down ratio.(125oC)
Droplet formation on atomization (by steam/ compressed air/ mechanical pressurization)
Combustion initiation by High energy spark ignition
Combustion of reactants Reaction rate depends on concentration of one of
the reactants
Concentration varies on partial pressure of the reactants.
Partial pressure is a function of gas temperature.
Therefore, reaction rate depends on temperature and substance that enter the reaction.
Combustion Reactions (Carbon)
Main reactions 2C + O2 = 2CO + 3950 BTU/lb (Deficit air)
C + O2 = CO2 +14093 BTU/lb
Secondary reactions2CO + O2 = 2CO2 + 4347BTU/lb
C + CO2 = 2CO -7.25MJ/kg
Combustion Reactions (Carbon)
Carbon reaction 2C + O2 =2CO [Eco =60kJ/mol]
C + O2 =CO2 [Eco2 =140kJ/mol]
reaction at 1200oC
4C + 3O2 =2CO + 2CO2 (Ratio 1:1)
Reaction at 1700oC
3C + 2O2 = 2CO +CO2 (Ratio 2:1)
It is desirable to supply combustion air at lower temperature regime in furnace
Combustion Reaction (H2, S)
Hydrogen reaction
2H2 + O2 = 2H2O +61095 BTU/lb
Sulfur reaction
S + O2 = SO2 + 3980 BTU/lb (undesirable)
Coal for combustion
Anthracite Semi-anthracite Bituminous Semi-Bituminous Lignite Peat
High CV, low VM High CV, low VM Medium CV, medium VM Medium CV, medium VM Low CV, high VM, high TM Very low CV, high VM & TM
Heat Generation in furnace Heat input in the furnace
Efficiency of thermal power plants is 37%-45% for different types of cycle
For typical conventional P.F. boilers, coal flow rate is
290-350 T/hr For 500 MW units120-145 T/hr For 200 MW units
Cycle
ElectFurnace
MWQ
Tangential Firing System
MAIN EQUIPMENTS OF FUEL & FIRING SYSTEM
• MILLS OR PULVERISERS
• FEDDERS
• BURNERS
TYPES OF FEEDERS
• VOLUMETRIC FEEDRES
• GRAVIMETRIC FEEDERS
PULVERIZERS
OBJECTIVES
• TO CRUSHED THE COAL
• REDCED TO A FINENESS SUCH THAT 70-80% PASSES THROUGH A 200MESH SIEVE
ADVANTAGES OF PULVERISED COAL FIRING
• EFFICIENT UTILISATION OF CHEAPER GRADE OF COALS
• FLEXIBILITY IN FIRING WITH ABILITY TO MEET FLUCTUATING LOADS
• BETTER COAL COMBUSTION INCREASING THE BOILER EFFICIENCY
• HIGH AVAILIBILITY
XR P(B H EL)
E M ILLS(B AB C O C K )
M PS
B O W L/B ALL & R ACE
VER TIC AL SPIN D LE
PR ESSU R IZED
TU B E
C LASSIFIC ATIO N O F M ILLS
BOWL MILL
Model no. Base capacity(T/Hr)
623XRP 18.4703XRP 26.4763XRP 33.8803XRP 36.5883XRP 51.1903XRP 54.11003XRP 68.11043XRP 72.0
BASE CAPACITY(T/HR)AT HGI -55Total Moisture-10%Fineness-70% THRU 200 MESH
BALL& RACE MILL(E MILL)
Model no. Base capacity(T/Hr)
7E9 258.5E10 358.5E9 4010E10 5510.9E11 6110.9E10 7010.9E8 80
TUBE MILL
Model no. Base capacity(T/Hr)
BBD4760 83BBD4772 90
AIR AND DRAFT SYSTEM
OBJECTIVES
• THE AIR WE NEED FOR COMBUSTION IN THE FURNACE AND FLUE GAS THAT WE MUST EVACUATE• TRANSPORT AND DRY THE PULVERISED COAL• SEALING OF BEARINGS FROM COAL/DUST
DRAFT SYSTEM
DRAFT MEANS THE DIFFRENCE BETWEEN THE ATMOSPHERIC PRESSRE AND PRESSURE EXISTING IN THE FURNACE
•NATURAL DRAFT- OBTAINED BY TALL CHIMNEY
• INDUCED DRAFT- BY ID FANS
• FORCED DRAFT- BY FD FANS
• BALANCE DRAFT - BY ID AND FD FANS•GENERALLY IN POWER PLANT BALANCE DRAFT SYSTEM IS USED.
FANS IN POWER PLANT
• FORCED DRAFT FAN
• INDUCED DRAFT FAN
• PRIMARY AIR FAN
• SEAL AIR FAN
• SCANNER AIR FAN
THE BASIC INFORMATION NEEDED TO SELECT A FAN ARE
• AIR OR GAS FLOW-KG/HR
• DENSITY(FUNCTION OF TEMPERATURE AND PRESSURE)
• SYSTEM RESISTANCE(LOSSES)
AIR PRE HEATERS
OBJECTIVES
• TO RAISE THE TEMPERATURES OF PRIMARY AND SECONDARY AIR BY UTILISING HEAT FROM FLUE GAS AT LOW TEMPERATURE
ADVANTAGES OF AIR PREHEATERS
• INCREASE THE BOILER EFFICIENCY
• STABILITY OF COMBUSTION IMPROVED BY USE OF HOT AIR
• PERMITTING TO BURN POOR QUALITY COAL
Ljungstrom type Bisector
TWO PASS BOILER ARRANGEMENT
Electro Static Precipitator
To remove fly ash from the flue gases electrostatic precipitators are used.
They have collection efficiency over 99.5%
The efficiency depends on various parameters such as velocity of flow, quantity of gas, resistivity of ash, voltage of fields, temperature etc
Principle of Operation
The fluegas laden with flyash is sent through ducts having negatively charged plates which give the particles a negative charge. The particles are then routed past positively charged plates, or grounded plates, which attract the now negatively-charged ash particles. The particles stick to the positive plates until they are collected by periodically rapping.
SELECTION OF BOILER
TYPE OF BOILER
Based on steam parameter- Subcritical/ Supercritacal
Based on steam/ water circuit-Once throuh/ drum type
Based on air/ flue gas path- Tower/Two path/ T-type
Type of fuel- Coal fired/ oil fired
Type of draft system-
Type of burner arrangement- Tangential/Front/ opposed
Selection of Firing system- Type of mills
Single reheat/ double reheat
Type of water wall tube- Plain, rifled
Type of tubing arrangement- Spiral/ straight
• Tube leakages from boiler pressure parts.
• Erosion of tubes due to high ash content and velocities
• Over heating of tubes
• Passing from valves causing difficulty in maintaining the parameters
• Failure or incorrectness of measured parameters
• Overloading of boiler due to very poor quality of coal
• Deposition of ash (clinkers) on furnace walls.
• Difficulties in removal of ash from the boiler
• Reduced effectiveness of heat transfer leading to loss of efficiency.
• Improper combustion of coal in the boiler.
Typical Boiler Problems
• Air ingress from the nose arch, penthouse and boiler second pass and quantification thereof
• Difference between on line reading and the actual oxygen in the flue gas duct
• Difference between actual and 'on line' temperature
• measurement of air heater air / gas outlet temperatures
• Fouling and Slagging
• High unburnt Carbon in flyash or bottomash
• High air heater leakage
• Boiler operation at high excess air
Typical Boiler Problems contd..
A Few words on Super Critical Boiler
Definition “CRITICAL” is a thermodynamic expression
describing the state of a substance beyond which there is no clear distinction between the liquid and gaseous phase.
The critical pressure & temperature for water are
Pressure = 225.56 Kg / cm2 Temperature = 374.15 C
SUPERCRITICALTHERMAL CYCLE
ADVANTAGES (1)
Improvements in plant efficiency by more than 2 %
Decrease in Coal Consumption Reduction in Green House gases. Overall reduction in Auxiliary Power
consumption. Reduction in requirement of Ash dyke
Land & Consumptive water.
SUPERCRITICAL – ADVANTAGES (2)
Sliding pressure operation because of Once
through system .
Even distribution of heat due to spiral wall
arrangement leading to less Boiler tube failure,
thereby improving system continuity and
availability of the station.
Low thermal stress in Turbine .
The startup time is less for boiler.
SUPERCRITICAL – DISADVANTAGES
Higher power consumption of BFPHigher feed water quality required.
More complex supporting and framing in Boiler due to Spiral Wall tubes.
Slight higher capital cost.
Description unit 660 500
S/H STEAM FLOW T/HR 2225 1625
SH STEAM PR KG/CM2 256 179
SH STEAM TEMP 0C 540 540
RH STEAM FLOW T/HR 1742 1397.4
RH STEAM TEMP INLET 0C 303.7 338.5
RH STEAM TEMP OUTLET 0C 568 540
RH STEAM PRESS INLET KG/CM2 51.17 46.1
FEED WATER TEMP 0C 291.4 255.2
COMPARISION OF 660 MW Vs 500 MW BOILER
COST COMPARISON FOR 660 MW vs. 500 MW
DESCRIPTION 660 MW 500 MW
1. 1Cost of Boiler alone 1970.73 Cr 1020.54 Cr
2 Cost of ESP 153.00 Cr Included above
3 Total cost of Boiler + ESP 2124.00 Cr 1020.54 Cr
4 Boiler cost Per MW 1.07 Cr 1.02 Cr
5 Cost of TG for entire stage 1204.72 Cr 634.31 Cr
6 Cost of TG Per MW 0.6Cr 0.63 Cr