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CHAPTER-3
THERMAL POWER PLANTS

Introduction:

The fact that thermal energy is the major source of power generation itself shows the
importance of thermal power generation in India more than 69.8 percent of electric power is
produced by steam plants in India.
A generating station which converts heat energy of coal combustion into electrical energy
is known as a Thermal Power Station or Steam Power Station.
Steam power generation is the generation of electric power by generator which is driven
by a turbine being rotated by steam obtained by heating water, using thermal energy of coal
combustion in the boiler.
PRINCIPLE OF OPERATION:-
A steam power station basically works
on the Rankine cycle principle. Steam is
produced in the boiler by utilizing the heat of
coal combustion. The steam is then expanded
in the prime mover (i.e., steam turbine) and is
condensed in a condenser to be fed in to the
boiler again. The steam turbine drives the
alternator which converts mechanical energy
of the turbine into electrical energy. This type
of power station is suitable where coal and
water are available in abundance and a large
amount of electric power is to be generated.

Figure: Principle of Operation

ADVANTAGES OF THERMAL POWER PLANTS:

1. The fuel (i.e., coal) used is cheaper.

2. Less space is required in comparison with that for hydro-electric plants.
3. Cheaper in initial cost in comparison with other types of power plants of same capacity.
4. Cheaper in production cost in comparison with that of diesel power plants.
5. It can be installed at any place irrespective of the existence of coal. The coal can be
transported to the site of the plant by rail or road ways.
6. Able to respond to rapidly changing loads without difficulty.
7. Such plants can be located near the load centers, hence it requires short transmission lines,
by that we can reduce line losses and transmission cost.
8. Firm capacity of these plants is high compared to other plants.
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DIS-ADVANTAGES OF THERMAL POWER PLANTS:

1. It pollutes the atmosphere due to the production of large amount of smoke and fumes.
2. It is costlier in running cost as compared to hydro electric plant.
3. Handling of coal and disposal of ash is quite difficult.
4. Efficiency of these plants is low compared to hydro electric plant.
5. These plants are less reliable compared to hydro electric plant.

SELECTION OF SITE FOR A THERMAL POWER PLANT

In order to achieve overall economy, the following points should be considered
while selecting site for a steam power station.
(1) Supply of fuel :-
The steam power station should be located near the coal mines so that
transportation cost of fuel is minimum. However, if such a plant is to be installed at a
place where coal is not available, then care should be taken that adequate facilities
exist for the transportation of coal.
(2) Availability of water:-
Availability of water is required for the condenser, boiler... Therefore, such a plant
should be located at the bank of a river or near a canal to ensure the continuous supply
of water.
(3) Transportation facilities:-
A modern steam power station often requires the transportation of material and
machinery. Therefore, adequate transportation facilities must exist to carry material
and as well as for the workers, employees, who are working in the plant. i.e., the plant
should be well connected to other parts of the country by rail, road, etc..,
(4) Cost and type of land:-
The steam power station should be located at a place where land is cheap and
further extension, if necessary, is possible. Moreover, the bearing capacity of the
ground should be adequate so that heavy equipment could be installed.
(5) Nearness to load centers:-
In order to reduce the transmission cost and transmission line losses, the plant
should be located near the center of the load.
(6) Distance from the populated area:-
As huge amount of coal is burnt in a steam power station, therefore, smoke and
fumes pollute the surrounding area. This necessitates that the plant should be located
at a considerable distance from the polluted area.
(7) Labour supplies:-
Skilled and unskilled labourers should be available at reasonable rates near the
site of the plant.
(8) Ash disposal:-
Ash is the main waste product of the steam power plant, which may pollute the
surrounding areas. Hence some suitable means should be provided for the disposal of
ash.
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EFFICIENCY OF A THERMAL PLANT:-

The generation of electrical power in thermal power plants includes basically two states.
Stage-I:- Conversion of heat energy of coal combustion into mechanical energy of turbine.
Stage-II:- Conversion of mechanical energy of turbine into electrical energy by using a
Generator or an Alternator.
By using this concept the efficiency of a thermal power plant can be defined as follows.
1) Thermal efficiency. 2) Electrical efficiency. 3) The overall Plant efficiency.
1) Thermal efficiency:-
The ratio of heat equivalent of mechanical energy transmitted to the turbine shaft to the
heat of combustion of coal is known as Thermal Efficiency of steam power station.

Heat equivalent of mechanical energy

transmitted to turbine shaft
Thermal efficiency (Thermal) =
Heat of coal combustion

2) Electrical Efficiency (or) Efficiency of generation:-

The ratio of heat equivalent of electrical output to the heat equivalent of mechanical
energy transmitted to turbine shaft is known as Electrical Efficiency of steam power plant.

Heat equivalent of electrical output

Electrical efficiency (Electrical) = Heat equivalent of mechanical
energy transmitted to turbine shaft

3) Overall Power plant efficiency:-

The ratio of heat equivalent of electrical output to the heat of combustion of coal is
known as Overall Efficiency of steam power station.

Heat equivalent of electrical output

Overall efficiency (Overall) =
Heat of combustion of coal

Hence, Overall Plant efficiency = .

SCHEMATIC ARRANGEMENT OF A THERMAL POWER PLANT

PRINCIPLE OF OPERATION:-
A generating station which converts heat energy of coal combustion into electrical energy
is known as a Thermal Power Station or Steam Power Station. A steam power station
basically works on the Rankine cycle principle. Steam is produced in the boiler by utilizing the
heat of coal combustion. The steam is then expanded in the prime mover (i.e., steam turbine) and
is condensed in a condenser to be fed in to the boiler again. The steam turbine drives the
alternator which converts mechanical energy of the turbine into electrical energy. This type of
power station is suitable where coal and water are available in abundance and a large amount of
electric power is to be generated.
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ELEMENTS IN A THERMAL POWER PLANT:-

Although steam power station simply involves the conversion of heat of coal combustion
in to electrical energy, yet it includes many arrangements for proper working and efficiency. The
schematic arrangement of a modern steam power station is shown in the above figure. The whole
arrangement can be divided into the following four stages for the sake of simplicity.
1) Fuel and Ash circuit.
2) Air and Flue gas circuit.
3) Steam, Power generating and Feed water circuit.
4) Cooling water circuit.
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FUEL AND ASH CIRCUIT:-

This circuit includes two units, namely
a) Fuel unit Coal storage plant, Coal handling plant.
b) Ash unit Ash storage plant, Ash handling plant.
The coal is transported to the power station by road or rail or ship according to the location of
the plant from coal mines. This coal is primarily stored in the coal storage plant. Storage of coal
is primarily a matter of protection against;
i) Failure of transportation systems and ii) General coal shortages.
i.e., to maintain continuous availability of the coal at the plant for continuous operation of
the plant.
From the coal storage plant, coal is delivered to the coal handling plant where it is
pulverized (i.e., crushing the coal into small pieces or powder), for rapid combustion without
using large quantity of excess air. The pulverized coal is fed to the boiler by belt conveyors. The
coal is burnt in the boiler and the ash produced after the complete combustion of coal is removed
to the ash handling plant and then delivered to the ash storage plant for disposal into the
environment.
AIR AND FLUE GAS CIRCUIT:-
In a boiler the combustion of the fuel requires supply of sufficient quantity of air and
removal of exhaust gases (flue gases) and this is achieved by draught system. So, this circuit
includes two units, namely
a) Air unit Forced draught fan, Air-Pre heater
b) Passage of Flue gases.
Air is drawn from the atmosphere by a forced draught fan through the air pre-heater, in
which it is heated by using the heat energy of flue gases, on the way passing to chimney. i.e., the
air pre-heater increases the temperature of the air supplied for coal burning by deriving heat from
flue gases. This air is now fed to boiler for the combustion of coal, which releases exhaust gases
called flue gasses. The principal benefits of preheating the air are,
i) Increased thermal efficiency and
ii) Increased steam capacity per square metre of boiler surface.
The flue gasses after passing around the boiler tubes and super heater tubes are drawn by
the induced draught fan through dust collector (or precipitator), economizer and air pre-heater
and finally exhausted to the atmosphere through chimney.
STEAM, POWER GENERATING AND FEED WATER CIRCUIT:-
This circuit consists of boiler for the production of steam and other auxiliary equipment
for utilization of flue gases and re-using of steam after utilized by the turbine, by using
condenser and etc.., i.e., feeding the condensate to the boiler and as well as power generating
equipment.
This circuit includes three units, namely
a) Steam unit Boiler, Super heater.
b) Power generation unit Steam turbine, Alternator.
c) Feed water unit Feed water heater, De-aerator, Economizer.
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Boiler:-
The heat of combustion of coal in the boiler is utilized to convert water into steam at high
temperature and pressure. The flue gasses from the boiler make their journey through super
heater, economizer, and air pre-heater and are finally exhausted to atmosphere through the
chimney.
Super Heater:-
The steam produced in the boiler is wet and is passed through a super heater where it is
dried and super heated by the flue gases on their way to chimney. By using this super heating
process, we can improve the overall efficiency of the plant by keeping the steam at high pressure
and temperature before expanded in the turbine. The super heated steam from the super heater is
fed to the steam turbine through the main valve as shown in the figure.
Steam Turbine:-
The dry and super heated steam from the super heater is fed to the steam turbine through
main valve. The heat energy of steam when passing over the blades of the turbine is converted in
to mechanical energy.
Alternator:-
The steam turbine is coupled to an alternator. The alternator converts mechanical energy
of turbine in to electrical energy. The electrical output from the alternator is delivered to the bus
bars through transformer, circuit breaker, and isolators.
Feed Water:-
The steam after utilized by turbine is exhausted to the condenser which condenses the
exhausted steam by means of cold water circulation. The condensate from the condenser is used
to feed water to the boiler. This feed water on its way to the boiler is heated by feed water
heaters and economizer. After heated by feed water heater, the feed water is passed to
economizer through de-aerator. The function of de-aerator is to reduce dissolved oxygen content
in the feed water. This helps in raising the overall efficiency of the plant.
Economizer:-
An economizer is essentially a feed water heater and drives heat from the flue gases for
this purpose. The feed water is fed to the economizer before supplying to the boiler. The
economizer extracts a part of heat of flue gasses to increase the feed water temperature.
COOLING WATER CIRCUIT:-
Cooling water unit Condenser, Cooling tower.
In order to improve the efficiency of the plant, the steam exhausted from the turbine is
condensed by means of a condenser. Condensation is the process of converting steam in to water.
Water is drawn from a natural source of supply such as a river, canal, or a lake and is circulated
through the condenser. The circulating water takes up the heat of the exhausted steam and itself
becomes hot. This hot water coming out from the condenser is discharged to the river.
In case the availability of water from the source of supply is not assured throughout the
year, or if the plants are not nearer to the natural sources of water like river, lake, etc.., cooling
towers are used. Hot water from the condenser is passed on to the cooling towers where it is
cooled. The cold water from the cooling tower is reused in the condenser.
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FUELS FOR THERMAL POWER PLANT:-

Fuels may be classified as Solid, Liquid, Gaseous and as natural or prepared. The various
fuels commonly used for combustion in the thermal power plant are coal, oil, and gas. Gaseous
fuel is rarely economical except when the power plant is located near natural gas field or gas
manufacturing industries. Oil is used only where it is plentiful and cheap. Coal is the most
commonly used fuel in thermal plants.
1) LIQUID FUELS:-
Oil can be used in a boiler furnace to generate steam. Practically all the commercially
used liquid fuels are furnished by petroleum and its by-products.
Advantages:
1. Fuel handling costs are less.
2. Load fluctuations can be met easily.
3. There is no problem of ash disposal.
4. Very clean compare to coal.
Disadvantages:
1. Heat produced is costly in comparison to coal or gas.
2. Natural resources of oil are in short supply in our country and therefore, use of oils
is limited for generation of electrical power.
3. Oil has a much higher percentage of hydrogen as compared to coal and therefore
much higher moisture loss, Hence lower overall combustion efficiency.
2) GASEOUS FUELS:-
These fuels can be broadly classified in to natural or manufactured. Natural gas comes
out of gas wells and petroleum wells. It contains 60-95% of Methane with small amounts of
other hydrocarbons. It is piped in large volumes to distances of hundreds of kilometers in steel
pipes having large diameters. So, the cost of fuel transmission is high.
Advantages:
1. Load fluctuations can be met easily.
2. There is no problem of ash disposal.
3. Very clean compare to coal.
Disadvantages:
1. Storage is not easier compared to liquid, solid fuels.
2. Major limitation of using natural gas as fuel is that the power plant must be located
near the natural gas field otherwise cost of transportation will be high.
3) SOLID FUELS:-
Coal is the solid fuel used in thermal power plants. Coal contains moisture, carbon,
hydrogen, sulphur, nitrogen, oxygen and ash etc..,
Classification of coals:-
The coals can be classified in the order of heat or calorific value namely Peat, Lignite,
Bituminous, Semi-Bituminous, Sub-Bituminous (black lignite), Anthracite, Semi- Anthracite.
Among all these types, semi-bituminous coals are best suited for power generation due to
its advantages like,
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i) High Enthalpy of combustion value between 27,000 and 35,000 KJ/Kg.

ii) Low ash content compared to other types of coals.
iii) Low percentage of moisture.
Analysis of coals:-
In order to find out the commercial value of coal, two tests are performed. These are
Proximate and Ultimate analysis.
Proximate analysis of coal gives good indication about heating and burning properties of
coal. The test gives the composition of coal in respect of moisture, ash and fixed carbon.
Ultimate analysis is a test that enables us to know the chemical composition of coal with
respect to elements like carbon, hydrogen, oxygen, sulphur, nitrogen, and ash ..,
Selection of coal for power plant:-
The selection of coal for a power plant depends on various factors like as follows.
i) Calorific Value:-
It represents the amount of heat energy for a given mass of coal in kcal/kg. Coal with
a higher calorific value is preferred.
ii) Sulphur content:-
Sulphur content should be low (preferably below 1%) for the coal, because of the
chance of the formation of sulphur dioxide in the combustion process of coal, which is a health
hazard.
iii) Ash content:-
Presence of huge ash content reduces the utility of coal and creates problems of ash
handling. So, ash content should be low in coal for greater efficiency.
iv) Weatherability:-
It is a measure of the ability of coal to withstand exposure to environment without
excessive crumbling and damaging to quality. So, the coal should be strong about this parameter.
FUEL HANDLING SYSTEM
In general, majority of the thermal plants are all over the world uses coal as fuel. In a
thermal power station half of the total stations operating cost is on account of coal, and therefore
problems of coal handling for a thermal station requires careful considerations.
Function:-
The function of coal handling system is, to move coal from a receiving point (coal
available areas) to the firing equipment.
Requirements:-
Requirements of a good coal handling plants are,
i) It should be reliable, simple, and requiring a minimum of operatives and minimum of
maintenance.
ii) The plant should be able to deliver the required quantity of coal at destination during
peak periods.
The coal handling plant consists of various stages are shown follows. All of these steps
may or may not followed in all the plants. It depends on the type of plant, load factor and the
plant capacity.