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PPE

Power Plant Engineeing


Mechanical
Engineering
Dr. M Varaprasada Rao

WELCOME

MY DEAR STUDENTS AT GIET

POWER PLANT ENGINEERING

An Introduction by
Dr. Varaprasada Rao
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Prof. Varaprasada Rao Ex.NTPC

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Prof. Varaprasada Rao Ex.NTPC

THE PRINCIPAL INVOLVED IN THE CLASSICAL


POWER PLANT

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Prof. Varaprasada Rao Ex.NTPC

Sources of electricity
generated
Gas power plants 10%
Coal fuel plants 53.3%
Oil 0.9%
Hydro electric 24.7%
Nuclear 2.9%
Renewable energy

sources 7.7%

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Prof. Varaprasada Rao Ex.NTPC

Gas power plants


Gas-based plants, are environmentally friendly

unlike coal or petroleum-based feedstock like


naphtha
Acid rain content lower than those generated by
coal-based plants
Deterrent
Not too popular in India almost 70% of natural gas

requirements for power plants (about 114 million tonnes)


are imported
Requirement met through imports are through hostile
territories
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Prof. Varaprasada Rao Ex.NTPC

Thermal Power Status in


India
India is one of the worlds largest consumer of

energy
Conventional sources: Thermal, Hydro and
Nuclear.
Non- conventional: Wind, solar, Geothermal,
tidal.
Installed capacity 1,61,352MW
Thermal = 95151.74MW
Nuclear = 4,120MW
Hydro = 36877.76MW
RES = 13242.41MW

Annual power production 680 billion KWH

Break up of Power
Thermal Power Plants 75%
Hydro Electric Power Plants - 21%
Nuclear Power Plants - 4%
Installed wind power Generation 9655MW
30% to 40% of electrical power is lost in

transmission and distribution

STRUCTURE OF POWER
SYSTEM

STRUCTURE OF POWER
SYSTEM

Power system owned by state

electricity boards.
Private sector utilities operate in
Mumbai, Kolkata, Ahmedabad
Regional electricity boards
Northern, Southern, Eastern, Western,
North-eastern.
Power Grid corporation- Central.

Thermal Power Plants


Installed Capacity 93,392.64MW
1. Coal based 77,458.88MW
2. Gas Based 14,734.01MW
3. Oil Based 1199.75MW

General Layout of Thermal Power


Station

Main Components
Fuel Handling Unit
Ash Handling Unit
Boiler Unit
Feed Water Unit
Cooling Water Unit
Generator Unit
Turbine Unit

Main Circuit
Fuel And Ash Circuit
Air And Gas Circuit
Feed Water And Steam Circuit
Cooling Water Circuit

Fuel And Ash Circuit


Fuel stored and fed to the boiler through

conveyor belts. Broken down into proper


shape for complete burning.
Ash thus generated after burning is removed
from the boiler through ash handling
equipment

Air And Gas Circuit


Air is required for combustion of fuel and is

supplied through fans


Air is passed through air preheater to extract
energy from flue gases for proper burning of
the fuel
Flue gases have ash and several gases which
are passed through the precipitator(dust
collector) and go to atmosphere through
chimney.

Feed Water And Steam


Circuit
Steam Converted to water by condenser.
Water is demineralized & hence not wasted to

have better economic operation of the plant.


Some part of steam and water is lost while
passing through different parts.
Boiler feed pump feeds water into the boiler
drum where it is heated to form steam.
Wet steam is again heated in super heater
before passing through the turbine
Steam is expanded in the turbine to run it.
After which again it goes to boiler for reheating

Cooling Water Circuit


To condensate the steam, large quantity of

cooling water is required which is taken from


river or pondage
After passing through the condenser, it is fed
back to the river or Pondage

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Boiler

Turbine

Turbine Full View

Economizer

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The McGraw-Hill Companies, Inc.,1998


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Coal Fired Steam Generator System

Primitive Method of solid Combustion


O2+CO2+N2+H2O
Flame

Secondary Air

VM+CO+CO2+N2+H2
Green Coal
Incandescent coke
CO+CO2+N2+H2

ASH
Grate
Primary Air

Top-feed updraft combustor

Physics of Fixed Bed Combustion


A bed of stoker-sized coal particles is supported by a

grate.
Air flows upwards through the grate and the fuel bed.
Upon heating, coal particles first undergo a stage of
Thermal preparation.
Evaporation of Moisture drying.
Distillation of VM (Pyrolosis)
Production of enough VM to start ignition.
Combustion of char.
The coal flows slowly downward at a velocity Vs, as the
coal burns out in the lower layer of the bed.

Automation in Fuel Bed Combustion


Also called Mechanical Stokers.
Travelling Grate Stoker
Chain Grate Stoker
Spreader Stoker
Vibrating Stoker
Underfeed Stoker

Travelling Grate Stoker


Boiler type: natural circulation
Firing method: stoker fired
Max. continuous rating:9,7 kg/s
Steam
450C

temperature

outlet:

Steam pressure outlet: 4,0 Mpa


Gross efficiency: 87%
Fuel type: Bituminous coal
Net calorific value: 23 MJ/kg

SPREADER-STOKER FIRED BOILER

Solid fuel- fired boiler system

Typical Size Distribution Coal for Stoker


Furnace

Closing Remarks on Grate Firing


The first limit on grate firing is that of scale.
A practical engineering limit seems to be reached when

the length and width of the grate are about 9 m with


grate area 80 m2.
At 2 MW/m2, the steam capacity at 85% efficiency would
be 150 MW or 270 tons per hour.
In practice stokers have rarely exceeded a capacity of
135 tons/hour.
The limitation is partly grate area and partly firing
density.
The limitation on firing density exist due to:
The rate of movement of the reaction plane could not
match the opposed rate of fuel flow leading to blow-off.
The experience with grate combustion led to
development of many requirements for further
development.

Parameters for Combustion Requirements


Heat Release Rate
Volumetric Combustion Intensity
Area Combustion Intensity
Effective Reactor Height
Coal Firing Density
Area Firing Density
Products of combustion Velocity
Air Velocity
Combustion time
Particle Heating Rate
Heat Transfer Fluxes
Heat exchange surface area per unit cross sectional area

of combustion chamber,

Heat Release Rate : A Capacity Limit


Most common Grate fired furnace ~ 30 MW.
Maximum obtained ~ 150 MW.
Maximum Power Generation Capacity ~ 50 MW
Future Projected Requirement ~ 3000 MW

Firing Densities Limits : An Optimal Choice


Firing densities are expressed in two ways:
A volumetric combustion intensity, Iv.
High value of Iv :
Compact furnace
Low Capital cost
Less time for combustion
Low Values of Iv
Bulky furnace
More time for combustion
Low Running Cost
Area Firing Intensity, IA
High value of IA
Sleek furnace
Higher combustion Temperatures
Better Ignition
Low Value of IA
Poor Ignition
Fat furnace
Low Nox
Solid Ash

Pulverized Fuel Combustion


Invented in 1920.
An universal choice for power plants till 1990.
Fine particles of coal ~ 75 microns.
Surface area : 150 m2/kg.
Huge heat release per unit area : 2 5 MW/m2.
Steam generation : 2000 tons/hour.

Fluid Mechanics of Solid Beds

Floating Bed
Static Bed

Velocity

Dynamic Bed

Interactive Combustion of PC Particles


For an isolated particle, a spherical
envelope flame is formed around the
particle.
The flame acts as a sink for fuel and oxygen
and as a source for thermal energy.
If another burning particle is brought near
the particle, the CO released by the
particles competes for oxygen molecules.
Further the interstitial temperature and
species profiles are also affected.
At some point the flames surrounding each
particle will merge and a common flame is
formed around the particles.
If more particles are brought near, then a
common flame may be formed around an
array or cloud of particles.

ABOUT ELECTROSTATIC
PRECIPITATOR

Nowadays, the environment protection has


become a crucial problem and the
authorities are requested to set increasingly
more stringent limits , one of which is the
emissions from the industrial plants of solid
particulate and other gaseous pollutants.

ABOUT ELECTROSTATIC PRECIPITATOR

What is ESP

Electrostatic precipitator (ESP) is a widely


used device in so many different domains
to remove the pollutant particulates,
especially in industrial plants.

HOW ESP WORKS

Main process of ESP

Generally, the processes of


electrostatic precipitator are known as
three main stages: particle charging,
transport and collection.

Schematic of wire-plate ESP

Schematic of wire-plate electrostatic


precipitator

Mechanism of ESP

Mechanism of electrostatic precipitator

PROCESS OF Particle charging


Particle charging is the first and
foremost beginning in processes.
As the voltage applied on precipitator
reach threshold value, the space inside
divided into ionization region and drift
region.

The electric field magnitude around the


negative electrode is so strong that the
electrons escape from molecule.
Under the influence of electric field, the positive
ions move towards the corona, while the
negative ions and electrons towards the
collecting plates.

Particle transport
In the moving way, under the influence of
electric field, negative ions cohere and charge the
particles, make the particles be forced towards
collecting-plate.

Particle collection
As soon as the particles reach the plate,
they will be neutralized and packed by
the succeeded ones subsequently. The
continuous process happens, as a result,
particles are collected on the collecting
plate.

Coal Mining
Surface Mining

Strip Mining

Underground Mining

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Coal Power Plant

Feedwater

Feedwater used in a steam boiler to transfer heat energy from the fuel burning area
to mech. Energy of spinning steam turbine

Boiler

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Operation

Rectangular furnace, pulverized coal is blown in from fuel nozzles at 4 corners. The
coal then burns quickly and forms a fireball at the center (seriously, a fireball!!!).

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Coal Power Plant

Steam Turbine Generator

Steam enters from the turbine generator and is pumped into


the bottom of the condenser, where pumps recycle the
condensed steam from the feedwater

Stack

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Is a series of steam turbines interconnected to each other and


then a generator

Steam Condenser

Operation

Releases process emissions.

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Coal Power Plant Operation

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Coal Power

Cheap
Cheaper per unit energy than oil or natural gas
Will continue to be an important global resource

Abundance
Coal is the worlds most abundant fossil fuel
Sufficient reserves for the next 250 years

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Coal
Power
Efficiency
Larger power plants are more efficient
38% of the chemical energy is converted to energy

Safe
safest fossil fuel to transport, store and use
scrubbers

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Coal Power -difficulties


Coal-Fired Power Plants are the largest

contributor of hazardous air pollutants.

o Sulfurdioxide(SO2)
o NitrogenOxide(NOx)
o CarbonDioxide(CO2)
o Mercury

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Effects on the
environment and Human health
CO2 ~ carbon dioxide pollution, making energy use the single largest
source of greenhouse gases in the U.S. and the world

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Effects on the

environment and

Human health
SO2

Sulfur dioxide combined with nitrogen


oxide react with water and oxygen in the
atmosphere to form acidic compounds,
which can mix with natural precipitation
and fall to the earth as acid rain.

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Sulfur dioxide can also combine


with nitrogen oxide and other
particles to form particulate matter.
o trigger heart attacks and strokes
o lead to cardiac arrhythmia
(irregular heartbeat)
o respiratory irritation, and worsen
asthma.
o premature death (Both shortterm and long-term exposure)
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Effects on the

environment and

Human health

NOx

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When nitrogen oxide (chemically) reacts with volatile organic


compounds (VOCs) and sunlight ground-level ozone or smog is
formed.

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Effects on the

environment and

Human health

Mercury

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One of the most dangerous pollutants released into the


air through the exhaust system when coal is burned.

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Future of Coal
Economy
Our economy relies on coal importation and
exportation
The demand for coal usage to provide electricity will
continue to grow

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Future of Coal

Clean coal technology

A new generation of coal-burning power plants with energy processes that


reduce air emissions and other pollutants.
Clean Air Acts

Coal power plants technology


must adapt to the changing
political climate towards
environmental issues.

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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:

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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
Varaprasadais
Rao used
Ex.NTPC to super heat the wet
88
A superProf.
heater

Cooling
water
circuit

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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.
2.
3.
4.
5.
6.
7.
8.
9.
10.
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Boiler
Super heater
Economizer
Air preheater
Reheater
Steam turbine
Generator
Condensers
Cooling towers
Pumps

11. Coal mills


12. FD and ID Fans
13. ASH Precipitators
14. Water treatment plant

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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 Prof. Varaprasada Rao Ex.NTPC
1/19/15
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Coal analysis
Two types of coal analysis
Proximate Analysis
Gives: Behavior of coal when heated
FC + VM + M + A = 100% by mass
Ultimate Analysis
Gives: chemical elements along with ash and moisture
C + H + 0 + N + S + M + A = 100% by mass
based on
(a) as-received basis (useful for combustion calcu)
(b) dry or moisture free basis
(c) dry mineral-matter-free or combustible basis

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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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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
cycloparaffins
and
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Rao isoparaffins,
Ex.NTPC
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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
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Liquid
natural gas (LNG) is transported by

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

Go to
C H. P

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Coal Crushers
1.Ring Type Coal Crusher
2.Hammer Mill Coal Crusher
3.Brad Ford Breaker

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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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Combustion Equipments
for Lumped coal burning
1. Grate-fired furnaces
2. Chamber-type or flame furnaces

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Grate

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Chamber type

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Combustion Equipment For


Burning Coal

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Fuel bed furnaces (coarse particles)


Pulverized coal furnaces (fine particles)
Cyclone furnaces (crushed particles)
Fluidized bed furnaces (crushed small
particles)

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Fuel bed furnaces (coarse particles)


There are two ways of feeding coal on to the
grate

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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
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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
5. Single retort
6. 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
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Underfeed stokers

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Multiple retort

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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

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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.
2.
3.

4.

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Added investment in coal preparation unit


Added power needed for pulverizing coal
Investment needed to remove fly ash before ill
fan
Large volume of furnaces needed to permit
desired heat release and to withstand high gas
temperature

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ASH HANDLING
SYSTEM
Mechanical Handling System
Hydraulic Ash Handling System

Low Velocity System


High Velocity 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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Hydraulic Ash Handling System


Low Velocity System

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Hydraulic Ash Handling System


Low Velocity System

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Hydraulic Ash Handling System


High Velocity System

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Pneumatic Ash Handling


System

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Thank you

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