THERMAL POWER PLANT

At present 54.09% or 93918.38 MW (Data Source CEA, as on 31/03/2011) of total

electricity production in India is from Coal Based Thermal Power Station. A coal
based thermal power plant converts the chemical energy of the coal into electrical
energy. This is achieved by raising the steam in the boilers, expanding it through the
turbine and coupling the turbines to the generators which converts mechanical
energy into electrical energy.

Coal Based Power Station

Introductory overview
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 Turbine
(IPT) and then to the Low Pressure Turbine (LPT). The outlet of the LPT is sent to
the condenser for condensing back to water by a cooling water system. This
condensed water is collected in the Hotwell and is again sent to the boiler in a closed
cycle. The rotational energy imparted to the turbine by high pressure steam is
converted to electrical energy in the Generator.
Diagram of a typical coal-fired thermal power station

Coal Based Thermal Power Plant

Principal
Coal based thermal power plant works on the principal of Modified Rankine Cycle.

Modified rankine Cycle

Components of Coal Fired Thermal Power Station:

Coal Preparation
i) Fuel preparation system: In coal-fired power stations, the raw feed coal from the
coal storage area is first crushed into small pieces and then conveyed to the coal feed
hoppers at the boilers. The coal is next pulverized into a very fine powder, so that
coal will undergo complete combustion during combustion process
.** pulverizer is a mechanical device for the grinding of many different types of
materials. For example, the are used to pulverize coal for combustion in the steamgenerating furnaces of fossil fuel power plants.Types of Pulverisers: Ball and Tube
mills; Ring and Ball mills; MPS; Ball mill; Demolition
ii) Dryers: they are used in order to remove the excess moisture from coal mainly
wetted during transport. As the presence of moisture will result in fall in efficiency
due to incomplete combustion and also result in CO emission.
iii) Magnetic separators: coal which is brought may contain iron particles. These
iron particles may result in wear and tear. The iron particles may include bolts, nuts
wire fish plates etc. so these are unwanted and so are removed with the help
of magnetic separators.

iv) The coal we finally get after these above process are transferred to the storage
site.
Purpose of fuel storage is two

Fuel storage is insurance from failure of normal operating supplies to arrive.

Storage permits some choice of the date of purchase, allowing the purchaser to
take advantage of seasonal market conditions. Storage of coal is primarily a
matter of protection against the coal strikes, failure of the transportation system
& general coal shortages.
There are two types of storage:
1. Live Storage (boiler room storage): storage from which coal may be
withdrawn to supply combustion equipment with little or no remanding is live
storage. This storage consists of about 24 to 30 hrs. of coal requirements of the
plant and is usually a covered storage in the plant near the boiler furnace. The
live storage can be provided with bunkers & coal bins. Bunkers are enough
capacity to store the requisite of coal. From bunkers coal is transferred to the
boiler grates.
2. Dead storage stored for future use. Mainly it is for longer period of time, and
it is also mandatory to keep a backup of fuel for specified amount of days
depending on the reputation of the company and its connectivity.There are many
forms of storage some of which are
1. Stacking the coal in heaps over available open ground areas.
2. As in (I). But placed under cover or alternatively in bunkers.
3. Allocating special areas & surrounding these with high reinforced concerted
retaking walls.
Boiler and auxiliaries
A Boiler or steam generator essentially is a container into which water can be fed
and steam can be taken out at desired pressure, temperature and flow. This calls for
application of heat on the container. For that the boiler should have a facility to burn
a fuel and release the heat. The functions of a boiler thus can be stated as:1. To convert chemical energy of the fuel into heat energy
2. To transfer this heat energy to water for evaporation as well to steam for
superheating.
The basic components of Boiler are:
1. Furnace and Burners
2. Steam and Superheating

a)
b)
c)

Low temperature superheater

Platen superheater
Final superheater

Economiser
It is located below the LPSH in the boiler and above pre heater. It is there to improve
the efficiency of boiler by extracting heat from flue gases to heat water and send it
to boiler drum.

Advantages of Economiser include

1) Fuel economy: used to save fuel and increase overall efficiency of boiler plant.
2) Reducing size of boiler: as the feed water is preheated in the economiser and
enter boiler tube at elevated temperature. The heat transfer area required for
evaporation reduced considerably.
Air Preheater
The heat carried out with the flue gases coming out of economiser are further utilized
for preheating the air before supplying to the combustion chamber. It is a necessary
equipment for supply of hot air for drying the coal in pulverized fuel systems to
facilitate grinding and satisfactory combustion of fuel in the furnace

Reheater
Power plant furnaces may have a reheater section containing tubes heated by hot
flue gases outside the tubes. Exhaust steam from the high pressure turbine is rerouted
to go inside the reheater tubes to pickup more energy to go drive intermediate or
lower pressure turbines.

Steam turbines
Steam turbines have been used predominantly as prime mover in all thermal power
stations. The steam turbines are mainly divided into two groups:

1. Impulse turbine
2. Impulse-reaction turbine
The turbine generator consists of a series of steam turbines interconnected to each
other and a generator on a common shaft. There is a high pressure turbine at one end,
followed by an intermediate pressure turbine, two low pressure turbines, and the

generator. The steam at high temperature (536 c to 540 c) and pressure (140 to 170
kg/cm2) is expanded in the turbine.
Condenser
The condenser condenses the steam from the exhaust of the turbine into liquid to
allow it to be pumped. If the condenser can be made cooler, the pressure of the
exhaust steam is reduced and efficiency of the cycle increases. The functions of a
condenser are:

1) To provide lowest economic heat rejection temperature for steam.

2) To convert exhaust steam to water for reserve thus saving on feed water
requirement.
3) To introduce make up water.
We normally use surface condenser although there is one direct contact condenser
as well. In direct contact type exhaust steam is mixed with directly with D.M cooling
water.
Boiler feed pump
Boiler feed pump is a multi stage pump provided for pumping feed water to
economiser. BFP is the biggest auxiliary equipment after Boiler and Turbine. It
consumes about 4 to 5 % of total electricity generation.

Cooling tower
The cooling tower is a semi-enclosed device for evaporative cooling of water by
contact with air. The hot water coming out from the condenser is fed to the tower on
the top and allowed to tickle in form of thin sheets or drops. The air flows from
bottom of the tower or perpendicular to the direction of water flow and then exhausts
to the atmosphere after effective cooling.

The cooling towers are of four types:

1. Natural Draft cooling tower
2. Forced Draft cooling tower
3. Induced Draft cooling tower

4. Balanced Draft cooling tower

Fan or draught system
In a boiler it is essential to supply a controlled amount of air to the furnace for
effective combustion of fuel and to evacuate hot gases formed in the furnace through
the various heat transfer area of the boiler. This can be done by using a chimney or
mechanical device such as fans which acts as pump.

i) Natural draught
When the required flow of air and flue gas through a boiler can be obtained by the
stack (chimney) alone, the system is called natural draught. When the gas within the
stack is hot, its specific weight will be less than the cool air outside; therefore the
unit pressure at the base of stack resulting from weight of the column of hot gas
within the stack will be less than the column of extreme cool air. The difference in
the pressure will cause a flow of gas through opening in base of stack. Also the
chimney is form of nozzle, so the pressure at top is very small and gases flow from
high pressure to low pressure at the top.
ii) Mechanized draught
There are 3 types of mechanized draught systems
1)

Forced draught system

2)

Induced draught system

3)

Balanced draught system

Forced draught: In this system a fan called Forced draught fan is installed at the
inlet of the boiler. This fan forces the atmospheric air through the boiler furnace and
pushes out the hot gases from the furnace through superheater, reheater, economiser
and air heater to stacks.
Induced draught: Here a fan called ID fan is provided at the outlet of boiler, that
is, just before the chimney. This fan sucks hot gases from the furnace through the
superheaters, economiser, reheater and discharges gas into the chimney. This results
in the furnace pressure lower than atmosphere and affects the flow of air from
outside to the furnace.
Balanced draught:-In this system both FD fan and ID fan are provided. The FD fan
is utilized to draw control quantity of air from atmosphere and force the same into

furnace. The ID fan sucks the product of combustion from furnace and discharges
into chimney. The point where draught is zero is called balancing point.
Ash handling system
The disposal of ash from a large capacity power station is of same importance as ash
is produced in large quantities. Ash handling is a major problem.
i) Manual handling: While barrows are used for this. The ash is collected directly
through the ash outlet door from the boiler into the container from manually.
ii) Mechanical handling: Mechanical equipment is used for ash disposal, mainly
bucket elevator, belt conveyer. Ash generated is 20% in the form of bottom ash and
next 80% through flue gases, so called Fly ash and collected in ESP.
iii) Electrostatic precipitator: From air preheater this flue gases (mixed with ash)
goes to ESP. The precipitator has plate banks (A-F) which are insulated from each
other between which the flue gases are made to pass. The dust particles are ionized
and attracted by charged electrodes. The electrodes are maintained at 60KV.
Hammering is done to the plates so that fly ash comes down and collect at the
bottom. The fly ash is dry form is used in cement manufacture.
Generator
Generator or Alternator is the electrical end of a turbo-generator set. It is generally
known as the piece of equipment that converts the mechanical energy of turbine into
electricity. The generation of electricity is based on the principle of electromagnetic
induction.
Advantages of coal based thermal Power Plant
They can respond to rapidly changing loads without difficulty
A portion of the steam generated can be used as a process steam in different
industries
Steam engines and turbines can work under 25 % of overload continuously
Fuel used is cheaper
Cheaper in production cost in comparison with that of diesel power stations
Disadvantages of coal based thermal Power Plant
Maintenance and operating costs are high
Long time required for erection and putting into action
A large quantity of water is required
Great difficulty experienced in coal handling
Presence of troubles due to smoke and heat in the plant
Unavailability of good quality coal

Maximum of heat energy lost

Problem of ash removing