power Plant Engineery Necessity of a Steam Plant epcal power nies fl Vat ae soon he tion oF RAAT 64, crate by hae ty hyde a ri ga powcr generate ond nuclear PON an plant stat uma Pe Pource and fuel resource. The steam power plan <2 Sins yuel ormucear powerplant mal Power Plant 6 = 1.2 Working of Thert ly uses hot products of 0 reneated by burning coal ol hpustion Known ts/lue gus to genet, Js. For this purpose boi furnace is designed fr fring sicam generated in the seam boiler is Heat energy steam is converted into mech ‘ Jectrie power. The low pre passed thro High pressu P ites steam expan inthe nozzles. F hanicalenergy. Mecha Pilized to run the generator and hence to generate aoe tens the condenvet. Here. Steam contenses by tejectng is supplied back to the boiler using condens sonora, a preheat cam ater expanding m the tur het wo the cooling wate, The condensed steam tion pump. The overall efficiency of the plant is increased by wsi Supereater and feed water heaters & Layout of Steam Power Plant Figure 11 shows a general layout of eoal fired thermal power station. The layout consists ant systems. They are, Cov end ash hanaling system 2, Airand flue gas system 3. Cooling wa wea noe a wos mie ee Sem generat in the sit, expan ‘condensate is fed back to the boiler along. PT ee Paths of powerplants given below ith feed water. A brief explanation of differ 1. Coal and Ash handling system i this system coal from the coal m the coal yard is crushed Crushed coal is supplied to the eoal un ee a ae ere tough coal hoppers wheres rn The po ae Hose. T ie Aisposed wo th coat is fed to the fart ae Products of combustion viz. ash and unburit cvsteam Power Plant Coal yard ASS Ho To power transmission dower coal bub @ Tunine| —“owse banker” [gy ; Feed pu Water Weatment plan Y ideo fondenser | Condenser | yoo? bump Hot well extraction pomp it Pump house OOOO Fig 11 : General layout of a steam power plantrae gual an te FECT Hea he nai tas, Adore NN ‘oling water system Ja or pa Whe otc Solin ower is prefer rrr yaavailable, ac me te a al sine conulenscr bes i order clarifier plant is eae ee cunlensct is ischarged is ‘When there is scarcity of water, ° dito the hotell. The Loss of wate eter system sic VE UST Wh “cooling, tower Is instal ara Jensate water is cooled ithe cooling ower. The cok! wate is pup vaporation is compensated BY SUPE 44 Feed water and steam generation system 1: condenser, honwell, Feet ine fed pump. Steam generated SORA ance operates. Superated tea is supped tthe prime ne Such ocd water shouldbe weated ina fed water reatnent plan before sending it othe hotwell 1.3: Types of Fuels used for power generation 4 Fuclisa combustible substance which generates heat when burnt in the presence of 09 Carton and hydrogen are the main constituents of fue. th addition to them, “wel also contains suiphut. oxygen and nitrogen. Depending on the fue, the percentage of Carbo ose, pereentage of Carbon (C) ranges faa 195%, Hydrogen (H,) 2-65, Oxygen (0,) 2-4%. Sulphur ($) 0.534 anal Nitrogen 5% A faci may als contain 2-30% ash, Ina fuel, carbon, hydogen and sulphur ane combustible vents wheteasmingen.and slats incomdustbecloments Since the majercontbctitlec «fuel are carn ad hydrogen fli alo known a hdnocarbon ray ‘When a fut is bumt inthe presence of oxysen it gener ‘inal Power plants an bi ® energy in the form of heat, This * used for electrical power general nd for propelling ships, automobiles paces and locomotives ete Pa Bas primary fuel isa from pr Bi A Se lignite and pu = Nat LYred rto Ts hen ed, ter steam Power Plant ‘Based on the occurrence Based on occurrence Baxed on state Primary Fuel Secondary Fuel SolidFuel Liquid Fuel Gaseous Fuel (Natural) (Aniticial Fig 12: Classification of fuels Based on the occurrence, fuels ate classified as primary fuels and secondary: fuels. A primary fue is avaiable in nature eg: wood, peat, lignite, natural pas, plroleumte.A primary fuel i also called as a natural fuel. A secondary fuel isnot available in nature, but its prepared from primary fuel by artificial means et: gasoline, diesel coke gas, blast furnace gas, Kerosene ete. A secondary fuel is also known as an artifical fue Based om the state, fuels are classified as solid Fuel, liquid fuels and gaseous fuels 1.3.1 Solid Fuels Solid fuels are either natural fuels or artifical fuels. Natural solid fuels sre wood, pest, lignite, bituminous coal and anthracite coal. Antficial solid fuels are charcoal, coke.briquetted coal and pulverized coal. * Natural Solid Fuels 1. Wood Itismainly used as a domestic fel. Ithas low calorific value of about 10500 Lk. Ht consists of about 48.5% C, 6% H,, 1.5% of ash, 43.5% O, and 0.5% N, 2. Peat I is partially carbonized and decomposed material formed mainly due the transformation of buried vegetation. It is considered as the primary stage in the formation of cos, It is a spongy substance with high moisture content (upto 80%). Hence it has to be dried before use. In dry form it has a calorific value of about 14650 ki/kg. It consists of 58% C; 6.3% Hy; 308% 0, 0.9% N, and 49% ash, 3. Lignite [is the secondary stage in the formation of coal. tis brown in colour an hence known as brown coal. tis used as a low grade fuel especially for domestic use and also asa boiler fuel, ItisPower Plant Engingg, scapes ins ey A gu vabout 12500 IKE. lon hey aa ie iharstibles. Piapep §.3.5% ash and other meu T mi sate enh in eng 0 0 cing ig, ASS wt wh wcitomsva snl ate coma Senet 1s a caborific value 07 Se Oran Werte a St Rae, care wale a we ee 0, 15Gb N,, VRS aml 3.5% ash lt Ee im hb AL softens and forms a pasty MS% : Coking tuminos coal er vomannacte ce oe oe oneaig 1 doesn't soften on heating ane mo ‘Nanci oa plants ; 2 Servicii et buried vegetation into coal. Kis mon-eaking andy, Tht af atin A a2 tee cari ve of aout 35.50 KK igen wee araTME CMH, 2540, 05%N, 05S and 2.5% ash. Tn India it is mainly found in Jammu and Kashmir, a boiler fag + Artificial Solid Fuels 1, Wood Charcoal ir, below 280°C. It contains 80 97 ised eating unin cl coninuosy for 151018 horn acted chamic. ‘coal, leaving a dull black colour to coke. It is a hard porous structure and smokeless. It contains 3 ‘produced. Itis used in gas producing plants and blast furnaces i 3. Briquetted Cos B Avis prepar moulding fi roun : bring mist Momma sed tg eg ee ith without he as tis prepared by powdering et iy a a ie "| “ed rade Coal with high ash content. Dry coal is pulverisod® i eaoaee ntly when mixed with air and hence it is used in most ofsie Benga Thi n Power er fue 90% irgical amber mm the ns 85 ke is on of ising ed in the steam Power Plant ‘Advantages and Disadvantages of Solid fuels, ‘Advantages: 1, They can be sored in convenient place without any risk of explosion 2, They can be easily transported, 3, They have low ignition temperature 4, They have low produetion cost, Disadvantages ‘They have lage percentage of ash content Rate of combustion of solid fuels ean not be easily controlled, ‘They produce large amount of smoke. ‘The necessity of various fuel handling equipments (conveyers, crushers, hoppers, bunkers te.) increases the fuel handling costs 5. They have lower ealorific value when compared with liquid fuels. 66, Amount of heat wasted is more dve to unburat and partly burn ful 17. They have the tendency to form eliners at higher temperatures 8. They need excess amount of ar for complete combustion. 1,32 Liquid Fuels Liguid fuels are available in nature inthe form of crude petroleum. Allcommercia iqid fuels sre derived from crude petroleum or crude il. The crude oi, sit comes ou from cil wells contains 53-87% carbon, 10-14% of hydrogen and small percentages of sulphur, nitrogen, oxygen and gases containing mainly ethane and methane ‘The impurities presentin the crue oi areeliminated by the proces of refining i by disilation. Itisbased on the prineipte that boiling points of various hydrocarbons increase with an inerease in molecular weight and when distilled, the crude oils separated into gasoline, kerosene, fuel ol ot reduced erude ol. Following liquid Fuels ae obtained during the process of distillation, 1. Gasoline Itis also known as petro. [tis the lightest liquid petroleum fraction and highly volatile in nature thas specific pravity ranging from 0.70 10 0.78. It is obtained between 65 to 200°C and it isa mixture of a number of hydrocarbons. is light yellow in colour and it is used as a fue in automobiles and aeroplanes 2. Kerosene Ieis heavier than gasoline but less volatile than it. It has specific gravity ranging from 0.78 10 85. nis obtained between 150 0 300°C. It is mainly used in aviation gas turbines as jet fuel and Also in lamps and stoves.ee Z Power Plant Engng io oe ae jeland domesic fuel actor fuel on than kerosene and 'S used as (8 rig avi than 086 10095. : ja from Shae, COm € 4. Diesel a os ri earth eweeogre 310 Kes sed cific gravit sosene. It has SPC indiesel engines. ae js used in furnaces of o I fo OF diesel. Teis use i tae ed above, some artific 1 liquid fuels are also useg . addition to the natural fuels discussed above See (eau poe Alchokol isan ‘ used in many chemical processes ; i id Fuels © Advantages and Disadvantages of Liquid a indw Advantages a 1. Tey have higher calorific value as compared to solid fuels ee 2. They require less excess air for complete combustion due to uniform mixing, ee of fuels ee 3. They can be stored and handled easily as compared to solid fuels. a 44. They posses higher combustion efficiency due to uniform mixing of fuel and air. ‘5. Combustion process and combustion rate can be easily controlled by verying the quantiy: has fuel 6. They require ess storage space as compared to solid fuels. © 7. They bum without forming ash, thus eliminating ash disposal problem, 8. Oil fired combustion systems are much cleaner than coal fired combustion systems. 1 9. They have lower handling cost, lower operation and maintenance cost. 1.3.3 Gaseous Fuels Gaseous fuels are either natural fuels or anifical fuels natural gas near oil bearing areas under earth's surface, coke oven gas, blast furnace gas, producer gas, 1. Natural gas Natural fuels occur in the fom’ Artificial fuels prepared are coal ® =, water gas and mond gas. :ee ee Wingy Frey “Its ation ity of ‘steam Power Plant " as is a by-product obtained during destructive distillation of coal. I mainly contains H,, CO, €0,,CH, and N, It has a calorific value ranging from 21000 kS/m? to 2500) kif’. It is also fen 2 1 3, Coke Oven gas Itisobtaned by the carbonization of bituminous coal. Lis sed for industrial eating 4. Blast Furnace gas itis obtained as a by-product during blast furnace operation, Duc to high percentage of dust comeat it shold be purified before use. It has clon vale ranging between 3800 Ke” 104200 [Unis used 382 fuc in as engines in team generation andi ste! pla’. 5. Producer gas itis obtained by paral combustion of coke or coal in the presence of ar and steam miatre Iunas a calorific value ranging between S000 Kim to 6800 ks used in glass meting in industries and also for power generation. 6, Water gas Itis obtained by passing steam over candescent coke. t burs with abhi flame and hence it isknownas blue wate gas. It has a calorific value ranging between 10500 kn’ to 2300 kim 1 js wed in welding and in furnaces. 7. Mond gas Itis produced by passing air anda large amount of steam over wast coal at about 6S0FC. Tt as. cafoife value of 3800 kin’. tis wed for heating and steam generation, ® Advantages and Disadvantages of Gaseous Fuels Advantages . 1. The rate of combustion and temperature can be easily controlled by regulating the flow rate of gas. Mixing of fuel and air is uniform and hence combustion is complete. 2 3. They are free from solid and liquid impurities and bum completely 4. They burn without leaving traces of smoke and ash 5. They are eco-friendly and do not pollute atmosphere. 6. They can be conveyed easily through pipe lines. 7. Combustion efficiency is more due to necessity of minimum amount of excess air. 8, They canbe directly used as fuel in internal combustion engines. Disadvantages 1. They are highly inflammable, 2. They require larger storage volume capacity.a Power Plant Eng 2 ering ‘neering 1.3.4 Nuclear Fuels oon : J yeneration of enormous, ‘Nuclear reactions, namely fission and fasion, result in the ge sHOEMOUS Moun wD energy. In fision reactions, a heavy atom is spit by neutrons into two lighter 'e4EMEN' fgg 1 reactions. two lightes atomic lel ae fused together to forma single, EAN NUCLEUS Inordee yy yets ‘cary out nuclear reactions fissionable materials ate used 3s fuels ee will! © Natural fuels isle ‘Uranium ithe only fssonabe puclear fel aeutrng nature, gonsissof 93% of 0.75 .,U' and small traces of ,.U* Out ofthese isotopes only U8 wed in Fission reaction, amo 1. © Artificial fuels Plutonium, Pu and Uranium, ,U°" are the fssionable materials produced artificially fom cal . U™ and Thorium, Th’ respectively. Uranium - 238 and Thorium » 232 are available in pater They are known as fertile materials, These fertile materials when placed close (0 U"" ina reactor, absorb the emitted neutrons to produce fissionable materials as follows 1 QU" + pa! ,,U" + y-radiation .U™ —,.Np™"(Neptunium) +_e°(Blectron) E oN” Pu + : 2 oTh™ + gn! ,,Th™ + y-radiation Th’? —,,Pa""(Protactinium) + ¢° (Electron) Pa? QU + et Advantages over solid fuels 1. Under favourable conditions, the cost of generation of nuclear power iscompetitive wit coal based power generation. 2. Isotopes produced as by products can be used in agriculture, medicine, scientific research and industrial processing. 3. Used in transportation systems especially in nuclear powered submarines 4 Complete fission of one kg of fissile uranium produces about 23 x 10" kWh of energy which is equivalent to the energy generated by burning 3300 tonnes of bituminous coal Disadvantages 1. The radiation emitted during the re 2. Nuclear waste disposal is a maj living things on the earth, ons highly hazardous. jor problem and if not disposed propery itis dangerous to allsteam Power Plant = 1.4 Combustion of Fuels Due to the presence of combustible ele fuels bar in the presence of oxygen (O,) 3 {sence necessary to supply sufficient amount of will be incomplete. This meat instead of carbon dioxide (CO, Following combustion equati amount of gases produced, 1. C+0, + C0, Based on molecular weight, 12k carbon dioxide the carbon in sd th reducing the amous ie, 2kg of C + 32 kg of O. + 44 kg of CO, u s Tkg of C+ Fhe of 0, + Phe of CO, 2. 2C +0, 4 20 Based on molecular weight, 24 kg of carbon combines carbon monoxide. ie, 24 kg of C+ 32 ke of O, + $6 kg of CO 4 z kg of C + Fhe of 0, + Fkg of CO 3. 2C0 + 0, + 2€0, Based on molecular weight, $6kgof carbon monoxide combines with 32 kg of ox 8 kg of CO, i.e, $6 kg of CO + 32 kg of O, 88 kg of CO, 4 u 1kg of CO + Fhe of O, > ke of CO, 4. 2H, + 0, + 2H,0 Based on molecular weight, 4 kg of H, combines with water. ie, d kg of H, + 32 kg of O, 36 kg of HO 1 kg of H, + 8 kg of O, + 9 kg of HO 5. $+0, +80, Based on molecular weight, of SO, ie. 32 kg of S +32 kg of O, ~ 64 kg of S 1g of S + 1 kg of 0, > 2kg of SO, 32 kg of oxygen formi 12 kg of sulphur combines with 32 kg of oxyger forming 64 kei | “ uels steam F = 15 Calorific values of Fi mount of heat liberated by pause fuel is defined as the 3! combention of wait quantity of Fuel Tre calor vane of Sold Laid oS crouch i Hi compe combustion of wt ast fe ay the amt of het Uber ated by cng, fc defied 0 he sant ux defined as the amon Of heat bere, Si Uni lume of fuel In SL units i ‘ower calorific value (LCV) of 151 Higher calorific value (HCV) and Fue, 1 Migr Cari Ya CS) sgn, When ae Se ee prota cond back o initial (00m) empeTae, then xy. ser em condeme un evolve nen beat. This adds up to the heat liberated by burning, Te Siuting sasimum amount of beat per kg of fuel. This heat is known as higher clos clue of fuel, and itis denoted by HCV. : Higher calorific value of the given fuel can be determined by using Dulong’s formula. Le:C. H.O and § represent the percentage by weight of Carbon, Hydrogen, Oxyges wx Sulpo respectively Then. OC 144000 H + 9295S P00 ery) ear 2. Lower Calorific Value (LCV) 4s mont of the combustion processes, the products of combustion (e.g.: gas coming cu: Douler chimney) can not be cooled wo its initial temperature. Thus water vapours doesn’t condest sonnei ater heat of water vapours is ost tothe atmosphere, The resultant heat ier the ful which excludes the intent heat of evaporation of water vapours is know, A ae of fuel. 1s denoted by LOW eee ‘sturation temperature is 2466 kg Thus lower calor LCV = HCV — mx 2466 ; Ree Saks see mist ma of nat apa As one part of hydrogen by mass cpa Pd ha Lev = He see Ht pee ruc ormed Per kg of fuel burnt, Produces 9 pans of water ‘Vapour by mass, the mass“ Of Hydrogen by we * NSIEh' The Caloritic values of soli, liquidPhete ted by mplere oducts ‘water ng the lorific Nand st of ense dby of that this of Table 1.1 Calorifie values of Solid Fuels SNe] Fuel HCY in Kh 1. | Wood (a) 046s 2. | Peat dry) 14650 3. | Lignite 21500) 4. | Bituminous Coat 31400 5. | Ambracite Coal 35600 6_| Coke 31600 Table 1.2 Caloric values of Liquid Fuels SNe Fuel Spar | HCV in Kika 1 | Gasoline 070-078 | 47.000 2 | Kerosene 078-085 - 3. | Diesel 086-095 | 45500 4_| Heavy fuetoit 095 44500 Table 1.3 Calorfic values of Gaseous Fuels SNo[__ Fuel HCV in Ki | LCV in Ki T. | Natural gas 37000 = 2. | Coal gas 32,000 29.00 3. | Town gas 19,500 17,500 4. | Coke oven gas 21.400 19,200 5. | Blast furnace gas | 4000 400 6, | Producer gas 5.000 4.800Le = power Plant Engineering 7 juelfor Complete Combustion St" iquid ft - 1 1.Sinimum air required pr Ma tO cami Hin at Oven) A ta for complete cmson ~ suffevsn-0] ~ 10013. ilgeodert) rage by mn fee combustion of fuel is given By> o A 23¢h of oxygen by mass, minimut required for burning one kg of liquid fuel m'« completely isziven by vimum air requi 100 i eet Ttere(u-2) | (kg /kg of fuel) 3) ” of: 18 °) | = +a(H-O)as = ale (He = 1.7 Minimum air required per m° of Gaseous fuel for complete combustion For determining the minimum ar required for completely burning one m’ of a gaseous fuel, the volumetric analysis ofthe gaseous fuel is done. A gaseous fuel has a mixture of combustible and incombustible gases. Volumetric analysis ofthe fuel gives percentage by volume of following gases 1. Hydrogen (H,) 2H, + 0,420 . ie, 2 Volume of H, + 1 Volume of O, -» 2 volume of HO IH, + 40,4 0 | volume of H, +% Volume of O,-> 1 volume of HO. irbon monoxide (CO) 2€0 +0, 4 2.€0, 0 +40, C0, 1 olume of CO + %4 3. Methane (CH) CH, + 20,500,420 cao sal led ae —@ Volume of ©, 1 volume of CO, | volume of CH, +2 2 Nolume of 0, 1 volume of CO, +2 volume of H,O.7 Fahane (CH) CH, + 30, 2.0, +21,.0 } volume of C.H, +3 Volume of 0,» 2 volume of CO, + 2 volume of HO 5. Carbon dioxide (CO,) Iris not combustible al hence it doesn't require oxy gen 6, Nitrogen (N,) 1s not combustible and hence it doesnt require oxygen. ) From te above four equations, we can determine the amount of oxygen requie to burn one cous fue a Follows (Oxygen requited/m’ of fuel for complete combustion, L[H, co 1 = tyre, 436th |m imal iad el Acattiospherie air conta fof gaseous fuel is given by, 21% of oxygen by volume, minimum air required to burn one m Minimum volume of st requied fmol) 1 fm, ,co 100 ip iageh eee ee ‘Minimum air required i 3 4 2CH, + ICH, | of M5 ren, sean]! el Where H,, CO, CH, and C,H, are percentage by volume of respective fuels = 18 Principle of automatic contro! of combustion tn order to ensure sufficient amount of team generation at the requisite pressure and to ‘maintain corect proportion of fuel and air in a furnace for complete combustion, contol of combustion in the furnace is very much essential. Control of combustion may ke by manual oF by auwmatic means. Automatic control of combustion is used to distribute the load evenly on the boiler as per the changing demand, Combustion can be effectively contolleé by regulating the antes of air and fuel ofboth. In order to ensure products of combustion flow into the chimney at proper speed tis essential to regulate differential gas pressure inthe furnace In ease of automatic ont, the conteolling devices operate based on the change in pressure of team,1 Engineering Mand Masict | 2 1.9 Fuel Bur al that coribustion can issibation 8° ‘ = ilar to pulvet completed with mii onsiderably low §. ts operation cost is considera eave varying sizes of acon and wit rng isu 1. Ie is difficult to operate the system with varying oe entrainment of ash i the produts 2, bus snpetson bring fine ol partes i eae eeu ences Wa HS MEE 2, Many ine rb carbon pals touecombestonystem. 1.102 Under feed principle nthe ype of ker the fel andar ve i on. hs ker ae i mes in contact with the raw psig through te hols he gate on pray ca Aa iis Merah te volatile mae 6 the Bf calm masons ue Be existing ave he re slain com et ater ad pases hugh he igniion zore and then een ino the segion of incandescent coke naust gases resulting in alos, also carried wi the same direction. In this stoker air after lind CO, +0,+N,+H,0 IK Secondery st fe Beebe vin.cO-+C0, +N, +H, Re Incandescent ‘coke Green coal Primary air pot Primary ai Under feed principle care is at a hi! earacteris The burnings pushes the wrone, AS Ino before re “D which hs through centering In ‘gases a form sn In ‘The pr ‘matter fresha gives! fusing stoker ‘ The reactions which take place in the i ne en wi in the incandescent zone of under-feee stoker are exacll ‘one of over-feed stoker exce ofthe volatile matter ins volaile mater Par of the broken volatile mate ‘coming out of raw finally discharged to the Pt some breaking ofthe molecular structs bed pas through a reg * reacts with the oxygen of air. The gasamoas Peng ducts Da log, i afte cat fi enter, ily ie * nt ie steam Power Plant 2» feat mohor An acral staker ts the WH eaNe aa wl sheave fet pros gto AK 1 te Ae Wea fy yada fm the cases el Ilsa ase thay removal By aT f# The tae of alt ups has a mans e tte oa he ape tauning 45 the rising ait ex pushesae ignition plane sow fei thet suitace aadetoates a mananuitae ht amabese t nore As the aie flow tate wpe, ea wo he fel Bes AL AAPA 4a A He ove fis are the tel fet tac nn he sh ance Ui overt mth tsa the at hs 4 9 tho he eae HH efor reaching the pon pan, the ne stn an et De eape 4 The unner-feed metheal of fie! supply 1s best fo su Dias al BN co which have high votatile matter. he wale ater gots Heated a high Hypa through incandescent region of coal The solute matter being a a higher temperate before ng the furnace burns quickly when mivea wih seconnlry ai Incase of over t gases andthe form smoke st burning, the volatile matter willbe considerably cower tha the face fone requires longer time for complete tuts his nay cieale a KM 4 Inunderfeed stokers, the fet is fed fro underneath the fire and The primary airs supplied faa below where combustion takes place. The ft ‘matter as ic passes through the initial fuel be onto. The te attr mixes wit fresh ir and enters into the combustion zone. The cate combustion proves isighly efictent atl _ives high rates of heat release, Bituminous aaa sii bitursius coals With sal ash content anal fusing temperature above 1300°C (caking or non-caking) can be bunt very eftevtively sing these stokes, ‘The underfeed stokery ean be divide! into two main types 1 The single retort stoker 2. Multiple revort stokerPower Plant Engineering Hopper eg% Steam ‘See, Tove oseee ee 308 eyliner wagere es setks on, EK Pihers (a) Single retort stoker (©) Single retort type stoker Fig. 1.9 : Single retort stoker Figure shows the arrangement of single retort stoker. The fuel is placed large hopper on the front of the furnace. Then iti further fed by reciprocating ram or serew conveyor into the bottom of the horizontal through, The air is supplied through the tuyeres provided along the upper edge of the grate. The ash and clinkers are collected onthe ash plate provided with dumping arrangement ‘The coal feeding capacity of a single retort stoker varies from 100 to 2000 kg per hour. Due to inability of obtaining even ar distribution from the sides of retorts multi-retortstokers are generally used for increasing the burning capacity of the stoker. 1.10.2.2. Multi-retort stoker ‘The multi-retortstoker is shown in fig, It consists of a series of altemate retorts and tuyere ‘boxes for supply of air. Each retort is fitted with a reciprocating ram for feeding and pusher plates for he uniform distribution of coal. The coal falling trom the hopper is pushed forward during the §nward stroke ram, Then the distributing rams (pushers) push the entre coal down the length ofthe stoker. The ash formed is collected atthe other end as shown in figure, The number of retorts may vary from 2 to 20 with local burning capacity ranging from 300 kg to 2000 kg per hour per retort.Extension, grate rate gauge) = \ uel ae Fig. 1.10 : Muti-retort stoker Underfeed stokers use forced drat for maintaining sufficient air flow through the fuel bed. ‘The primary air is supplied from main wind box tothe fuel bed situated below the stoker. The partly pum coal imoes on to the extension grate, The low pressure air entering into the extension grate, wind from main wind box is supplied to the thinner fuel bed on the extension grate. The quantity supplied can be regulated by an air damper. The air pressure in the main wind boc under the stoker is also varied to meet variable load. Provision is also made for varying the air pressure under the different sections of the stoker in order to correct for irregular fuel-bed conditions. Forced draft ‘causes rapid combustion. It is also necessary to introduce ‘overfire ai’ when high volatile coals are Used to prevent the smoke formation, Combustion contro is introduced into the stoker drive either by varying the ram stoke or by changing the rate of reciprocation. On-off contre! is used on motor driven stokers. ‘The advantages and disadvantages of the underfeed stokers are as follows : Advantages 1. Itgives higher thermal efficiency compared with chain grate stokers. The combustion rate is considerably higher. Sufficient amount of coal always remains on the grate so thatthe combustion is continued in the event of temporary breakdown of the coal supply system. 4. The part load efficiency is high with multiple retort stoker. 5. Useof forced draft and relatively arge quantity of fuel on the stoker make them responsive to rapid changes in load. 6. Tuyeres, grate bars and retorts are not subjected to high temperature as they remain always in contact with fresh coalou Disadvantages atoms Iehas igh initia The of insllation cooking 2 requites large space for intl Chae ehiee bio 1 1 Vane Stak an . ss content ike antaite coal = 4 Irs not suitable for burning fow grade ed system of firs ard 0 x over pulverised syste ing, up 140.3 Advantages and Disadvantages of toker firing over pul ee dsiven pi Advantages 1 Thereisn used. Some SETA ATA wmnmetemaceconitnn he divided 2, Thiscan be used for medium capacity plant more economical cee 3. Its tre from danger of explosion, Atomiza 44 ‘The building space requirement compared with pulverised system i less Ge 5. The capital investment as compared to pulversed system isles. Ste 6. The maintenance and operating costs ae ess. heating 7. Theauniliary plant roquitedis considerably reduced ii) Me 8 Italso works for few hours in the event of coal handling plant failure as large amount of coal ani is stored on the grate rating 9. The dust collection problem are less severe compared with pulverised system as most ofthe ash is removed from the gate 10, The stoker firing systems are more reliable Disadvantages The loss of coal is mo ‘rough ridding, There is heavy we 1 3. The troubles. : slinkering of combustion chan + Sudden variations of load can be met pulverised fuel firing, ; mber walls are very common, of efficiency as in the case of 5 The furnaces need ite arches which increase th Tekies tease the Construction cost and cre ‘troubles during Stan loses are considerably mnsteam Pow 20 2 1.11 Oil Burners Ol burners ean be classified imo two different types, namely, (2) vapowising type and iyatomising type. The wapourising burners are used for domestic purpose especially in portable air heaters, cooking Noves ete, The atomizing burners are commonly used in industrial heating. 1, Vapourising Petromac stove which burns kerosene i. classical example of a vapourising burner. Here an ‘upward moving high velocity fuel jets allowed to strike against hot moving plate. The vapours burm with a short intense flame. The fuel fs stored in a fuel tank below the fuel line and a hand «riven piston is used to inerease the oil pressure by compressing the ai into the reservoir. 2. Atomizing burner These burners are very commonly used in ol-ired furnaces of steam generators. The ol is divided into fine particles to inerease the surface area of contact with the combustion ait. Due to atomization a homogencous mixture of oil and air is produced which is fired in the furnace Atomization is achieved by two methods. {i Steam or air jet atomization Steam jet atomization is used in power appliances whereas, ait heating work. Komization is used for li) Mechanical atomization [In mechanical atomization oil is pressurised by using a pos rotating wheel which displ fumaces. ive displacement pump or a laces the oil centifugally, Its used in high capacity team generating Alcor steam inlet Oil inet Fig. 111 : Atomizing burner nn eT aePower Plant Engineer, tein rear cap samira iiples ant cance er tube. Near the tip of the oe a Woas tha Tissot sere Newt os oe ri See cers are simplerin constriction. Differey ee tai gas flow can be control ‘using SE en Seat tacos Men cn wi eo Fe mene gamete ina roe Gas = Fumace ® ) Fig. 1.12 : Gas burners = 1.13 Pulverised Fuel Burning 1. By breaking, a given mass of. ‘combustion. The increase of su ‘of coal particle is shown in Fi rig No smaller pieces exposes more coal surface area for iL 13, Pet Per Umit volume with he decreasing diame ‘steam Powe ssubstant 9 10, nL.sing ere the tiny a Hi he ‘steam Power Plant 8 000 é 3 2000 3 £2000, = 1000 0002 004 006 O08 1 Diameter in inches Fig: 1.13 Variation of surface area with particle size This increase varies rapidly after 0.01 inch diameter of the coal particle and there is no substantial increase after 0.001 inch diameter. 2. Greater surface area of coal per unit mass of coal allows faster combustion as more coal surface is expoved to heat and oxygen. This educes the excess ar requirec to ensure complete ‘combustion and the fan power also. 3. The system is perfectly free from clinker and slagging troubles, 4. Thivsystem works successfully with or in combination with gas and oi, $. Large amount of heat release is possible and with such rate of heat generation, each boiler of pulverised fuel fired system can generate as large as 200 tons of steam. per hour le coal can be burnt more easily. 6 Wie variety and low ge 7. I gives fast response to load changes as rate of combustion can be eontrlled easly and immediately. Automatic control applied to pulverised fuel fired boilers is elfective in ‘maintaining an almost constant steam pressure under wide load variatiens "ling surfaces are free from corrosion and fouling as smokeless combustion is possible % The banking losses are low compared with stoker firing system, 10, The boilers canbe state from col very rapidly and efficiently 1. Practically no ash handling problems exist ————————— = |Ta FURNACE FUEL FILE SCREW FEEDER Caderfeed stoker sy prope 14 The pu is ca 14. Theta 15, Rate« 16, Thes temp 17 The 18, Ail 19. Ther thes Sjsadv 1 Ad 2. Pul 3 Th 4m 5. Sp 1.13.1 4 Yo i direct3 Power stew? Tres posible ose Righly eh rcpepstion ua Thepulerisingy prcated oui ps for rapid flame 1 secondary air (350° C) which be ‘can be repaired without cooling the unit as the pu'verising equipment 4, The fumace volume required is considerably less. as the use of burners which produce turbulence inthe furnace makes it possible to complete combustion with minimum travel of flame length 15. Rate of feed of the fuel can be regulated ‘The smaller quantity of excess air and thorough mi temperature with little smoke. ing of air and fuel produce a high furnace 17, The system is free from slagging and clinkering troubles. 18. Ability touse high combustion air temperature, There are no moving parts in the furnace, subjected to high temperature therefore the life of the system is more and the operation is troubleless, fisadvantages 1. Additional equipment required to pulverise the coal increases the initial cost 2 Pulverised coal fring produces fly ash which requires separate fly ask removal equipment 5, The furnace has to be designed to high temperature 4. There will be chance of explosion 5 Special equipment is required for starting the system, 1.13.1 Pulverised fuel handling systems _,. There are two methods used to feed pulverised fuel to the furnace. 4. Unit or direct system In unit system, a separate pulverising unit is provided for each furnace and the fuel is fired directly into the furnance without being stored. The raw coal from overhead coal bunker falls into, feeder and there itis dried by supplying hot air. The coal is then transferred to the pulverising mill ‘where itis pulverised. Primary air is supplied to the mill by the fan, The mixture of pulverised coal ‘and pnimary air then flows to burner where secondary air is added.secondary ait caver] awa Feodor Fan puiverising rl Hot air Fig 1.14 : Unit system Advantages 1, Systemis simple and cheaper 2. Direct contol of combustion from pulverising mills possible. 5, Coal transportation system is simple Disadvantages 1. Mill operates at variable load. 2. System is less flexible 3. No reserve in case of emergency. 4, Fan handles air and coal mixture. 2. Bin or central system load demands. ie euough seperate feeders in accordant? ‘The separ and t Ady‘steam Power Plant Raw coal Return aie en 7 oe Sh reeder Pars | Fon Ge hae é Hot ai a aie Fig LIS : Bin system Coal from the raw coal bunker is fed by gravity toa dryer where it is dried by the hot aur mill. “The pulverised coal from the mills transferred to pulversed coal bunker. The ait from the coal is separated in the cyclone separator and returned to the mill. The primary ait is mixed atthe Feeder and the mixture is supplied to the burner, Advantages 1 vein il grins he val at ey res inept of ond 3 Ths atays seme oan resere. Ts ule fe mil wil at tte coat 9 theta FE 5: Ess fan handles clean i The pulveriser can be shutdown when sufficient capacity has been achiev. The same can ] ‘be used during peak load periods “The fan handles only air therefore there is no problem of excessive wear of fan blades. 6 7. Itoffers good control over the fineness of coal 8, More latitude is provided in the arrangement ofthe burners 9. ‘The boiler aisles are unobstructed. 10, The labour required is less. “The mill capacity is low as it always works at rated load, But additional equipment needed for fore storing in the bin, and the conveying system itself, separating air from pulverised coal bet discarded in offset the economy of lower mill capacity, Presently, the central system has been. favour of unit system owing to building requirements, high initial coal and complications in most of the parts.ee ee Disadvantages 1 Ceniral system 2. The power consumption of auxiliaries is high Ther (foal hand is higher than unit syste 3, There is possibility of fire hazard due to the stored pl space. js highor in first cost and occupies is vefore, overall power COnSUMLN ery ised coal 44. The coal transportation system becomes more comple: 5, Driers are essential. 6. The operation ani! maintenance charges are higher than ee a ee ‘The bin system is not favoured in modem power stations, on account of 7 area pulverised fuel to cake. In addition to thi, mtu a the endef the sre PP ea sen installations. of 60 ‘maintenance costs, losses through vents, capital costs and opera ‘Consequently the unit systems adopted universally forall high capacity 1.13.2 Pulverised mills, There ate various types of mills used for pulversing the coal, These are 1. Ball 2. Balland Race mill 3. Impact or Hammer mill and 4. Bowl mil Allthe four types of mills are discussed here unde in deta. 1. Ball mitt ‘The bll mill shown in ig consists fa large cylinder part filled wit various size steel balls (2.510 Semindiameter)-Coal (6 mis fed ino the cylinder that mixes with these balls. Pulverization takes place asa result of action between the balls and the coal, as the cylinder is rotated (130 mi ‘nin peripheral velocity). ‘The mill ons of ul sds, peri, laser nd exhauser to the casifier which sfrter passed tothe pulverser withthe hep of ssrew conveyor. A aixture of tempering air and hot ar fom air-preheatr is introduced in the pulveriser. These streams of i cary the plverisd coal and passthrough the clasiir. The oversized pticles ave thrown ream inthe classifier and fine material is passed ial is passed t é ‘The output of the mill can be contolle Eira ee ones ‘The feeders supply coal coal per hour containing 4 tons % moisture requites 'S KW hr energy per ton of coal, ie The pr the coe + There fire ke the unit system oF IME capacity. —4otorsteam Power Pl tures of this pulveriser te + The grinding clements are not seriowly affected by metal scrap and other Foreign material in the cal unlike the grinders in most other pulverisrs. There is considerable qua ity of col which aets asa reservoir. This plveriser prevents the {siamese oon LEcwnmns geSGes oper ena 5 [ 2 : Gene SEMetr asi canter FAL - ' awshes LJ) Bee 1 [Sf Abert os gry Sree en ‘Screw conveynor for coal LW {Hot air from air pre Fig. 1.16 : Double classifier ball mill «A wide range of fuels including anthracite and bituminous coat which ae dificult to pulverise, canbe used in this mill. ‘© The system is simple to operate, low in it 2. Ball and race mill This is also known as contact mill. I consists of two elements which have a rolling action With respect to each other. The coal passes between the rotating elements time and again until it tas been pulverised to the desired degree of fineness. The pulverization is completed by & combination of crushing impact and atrition between grinding surfaces. The cod is crushed between two moving surfaces: balls and races. The upper staionary race and lower rotating race driven by jal cost but has high operating zost.TT 4 worm and gear, hold heal emer them The coals upped hog erating ae dm, bby a worm and gear, hold the balls between them. The coal is supplied through the otaung tai {Seder tthe upper righ he ers he acs. The mong balls a 5 ap Setween them to ci ito poder. Spring hold down the upper Maton re force needed for cng ‘forced draft fan spies, tir tthe ml rough he ala space sto The air peks up the oat dst ths fetwcen the alsa aces ad then ees clasfier above" The ied wae make te ering ai © form a eyelnic Now towing ‘oversized particles to the wall of the classifier The oversized particles slide down for furthe; xing inthe mil The coal pale of equredsze arc aken ode burners with om bet tthe casi Fine discharge ! : An ze = g|serna is is oc \ 24 2afl : Grinding z 3 semen pe : A : c lk. 5 se ; Qua ¥ = ‘LL, 4 FE tower race SBat ra Hot primary avr supply Fain Fig, 117 : Balt and race mill The mill provided with a means of separating heavy impurities from the coal and thus reducing wear and possible damage 1 the grinding element, These heavy particles resist the upwar thrust caused by the primary air stream and collect in a compartment in the base of mill, and the? they are removed periodically The automatic combustion control regulates the flow of primary a {through the pulveriser and feeder and maintains the coal supply. When more coal is required, the Primary ait flow is increased automatically and its higher velocity in the mill varies addition Coal contain ‘of coal pulver Advantage space occ Tower capital 3. Impact Th primary air throw srinding% ‘he farmace This actin sive the aman of coal An the pubverser and dere top. thas causing the eee see ov spy HO a he fa ss wh ths il Naas ya Ahowetone he Maes etasew by cea patil wats) As de caning of the pects is une presse the Kaka of fine coal themph the ‘ sg tases the palverised fel 4 he Mn at the beer tor, Ths il ca Haale as 209 sostre Ml fer and fan nee early YSKW ha ener pert Advantages and disadvantages cl xeupie, lower power comuimptions i AW er plese The adentage if owe oi verted, lower weight and: ~ -courweighatthe wear pen and these pulversers un 8. Impact or Ha Stationary pegs Pomay a & coal P—————— Promary ae tan ejector arms —_| F ' ft Motor Bearing ky 4 4 t HIE Final grinding Rotating Pamary grinding stage peas stage Fig. 118 : Impact mill s ivalso known ay impact mill as pulverization takes place by impact. The coal in pulveriser Hi = oan in suspension during the entire pulverising process. AH the grinding elements and the sr) air fan are mounted on a single shaft as shown in fig. The primary ait fan induces flow of through the pulvenser carrying the coal to the primary slage of grinding, In the primary stage of sanuilar state by impact with a sentes of hammers and then into pee air VE eePowar Plant Engine, tinely palverised cr) tating SCOOP sn, the nal pees cared ona ota the fina stage of pr ejector ars whic throw th ipeys The al the How of primary le pact hack sn the rit ie nye co fee The ouput of the pulveriver scone by Va) ie contr why at Advantages © Pulveriser is dieetly connected to th 1 The power required to dive the pulver a wide range of rating, nd therefore operates at high speed, roportiona 0 the co puIVerised er is nearly pr to high speed ofthe pulveriser andthe fan bey 4. How mt oe “The boul mil shown in Figure 1.19 consist of stationary rollers and a power driven bow: which pulverzation takes place asthe oa passes between the sides of the bow and the roles, primary ar inuced dah fan draws stream of heated ar through the mil, carrying the pulvere oa info a stationary classifier located in the top of palveriser. The classifier returns the co articles f coal to the bow for Further grinding through the centre cone ofthe classifier. The ci Pulverised to the desired finenes is catid to the burner through the fan, The impurities in cia Containing heavy particles are thrown over the side by centrifugal force as these enter the roar bow. The heavy particles thrown ot all nt the space below the bowl, These are discharge fv hemi hough spot The automat como charges the supply af oa othe bow! tot snl by adjusting the Feeder speed andthe flow of primary ai by regulating the damper in the Som from the puleriser tothe fan er ey ken © Leal eg: Sel * Tot © Sul + Gri * vo! oH 60-70% size, grin A oa pal ng cd steam Power Plant ‘Spring Stationary spring Toaded rollers motor Hot air stream from air preheater Fig. 1.19: Bow! mill Some features of this pulveriser are * Classifier may be adjusted to change the coal fineness while the pulveriseris operating, * Leakage of coal from the mill casing is completely eliminated as the mill operates under negative, pressure. Selection of the bow mill is based on the following of parameters. * Total moisture content, used to determine the mill drying capacity ‘* Sulphur and mineral content, used to determine pyrite removal sizing requirements. © Gnindability, used to select the mill size. * Volatile matter, used to determine the required coal fineness. © Higher heating value of the coal, which affects the ability of « pulveriser to meet the boiler requirement for maximum continuous rating A typical moder pulveriser can grind most of the fuel to atleast 98-99% passing 50 mesh and 60-70% passing 200 mesh. The capacity of the pulveriser is also dependent on the raw coal feed. Size, grindability, moisture content and fineness required of the final coal eerBall mill ‘steam Pow ‘MIM Fires « = Pyrite Hows = Accu © Local ‘The c that exceet very lean could rede ‘can preve used are v mill fires 1.43.31 Bur followin, 1 tts 2. Its 3. Its combi of airs at low] | steam Power Plant Mill fires are most often caused due to the following reasons. '¢ Pyrite building from pyrite plow failure. «Hot startup with loaded mil ‘+ Accumulation of coal dust in mill devices. ‘Localized bot spots from poor primary air flow. ‘The causes of fires are also dependent upon coal properties (volatile matter and moisture) a inputand produces sat exceed pulverising rating. Wet coal always blocks feeders, reduces system it ‘xy lea fucl-air mixture inthe mill. Better coal handling method and effective trash separation ould reduce feeder problems and the likelihood of mill fire, Closing of the multipart outlet valve Gan prevent the spread of fire from mill to burner lines. Three major types of quenching methods ned are water, steam and CO, injection. Use of water has proved inadequate in some deep seated ml fires. Steam injection is effective but explasive CO-H, mixture may result from steam coke reaction 4.13.3 Pulverised fuel burnersiturnaces ‘Burners are used to bur the pulverised coal. The pulverised coal burners should satisfy the following requirements. 1. It should mix the coal and primary air thoroughly and project the same in the furnace with secondary ai. Ie should create proper ci 3. It should control the flame shape and its travel in the furnace 4 The mixture of coal and air should move away from the burner ata rate equal to flame travel lation and maintain stable combustion of coal to avoid the flash back with the burner. 5. The burner should avoid over heating, internal fires and excessive abrasive wear. Different types of fuel bumers are used to burn solid, liquid and gaseous fuels. Solid fuel mainly used is pulverised coal. Liquid fuels are burt in oil burners whereas, gaseous fuels are burnt in gas burners. Function of the coal burners is to bum pulverized coal in the presence of primary and secondary air in a boiler furnace. Coal burners are classified according to their design and ‘rangement in the furnace. Following types of coal bumers are used in practice. 1. Streamline burner Itis also known as long-flame or U-flame burner. It is designed to fire downwards in the furnace without any turbulence. Thin flat streams of air and fuel mixture is discharged in the furnace which travels considerably long distance producing a long flame and ensuring complete combustion. Heated secondary air which is fed at right angles to the flame enstres proper mixing far and fuel. This type of burner is suitable for burning fuels with low volatile matter as fuel flows atlow velocity (15 00 45 mvs) and hence takes more time to travel inthe furnaceWater wall tube Toash po Fig 120. U~ flame burner 2. Turbulent Burner tus made upof cla dachageonfices or with aight narrow outlets Its placed i © wall of water cooled fumaces. The fuel and ai musture pass through the burner such that they !! property atthe furnace entrance Fue! but ms in the fumace proxtucing a short turbulent f1a% ‘These borer are very wel to bum high vate mane naeTTT ‘Seconda air ig 121 : Turbulent burner 3. Tangential Burner 16 In tangential burners, fuel and air streams are ejected in horizontal direction tangent to an ix imaginary circle at the centre ofthe furnace. The burners are placed atthe corners of the furnace ec. toensure intense turbulence and thorough mixing of fuel and ar All the fuel and air nozzles can be fited at an angle of 20 to 25"above and below the horizontal plane,Power Plant Engineer, Fuel = Fumace SS ri Fuel tee Fig 1.22 Tangential burner Cyclone burners ar used to bum crushed coal instead of pulverized coal. This is to elimina fly ash handling problems. It consists ofa cyclone furnace as shown in figure. Crushed coal about 8 mm size i fed from the feeder tothe centre of the cyclone along with primary air. Ths creates a vortex flow in the furnace. The secondary air is supplied separately to increase tke 3 ‘vortex flow. The ash formed due to rapid buming of coal drains down the inner wall of the fureasSccondary air Fuel Ait Fig 1.23: Cyclone burner ‘as molten slag. Hot flue gases along with 10 0 20% of fly ash enter the furnace, Due to centrifugal faction most of the fly ash is thrown against the furnace wall and is drained cut along with molten slag, Thus flue gases leaving the furnace is clean.See power Plant Engineer, a eae aa ‘over liquid fuels merits an dements 0 ih D {disadvantages of 1 > Discuss the advantages a Deine caorifie value of fuel us foe 1 paseo wich is used in practical cal : v uel ant See gc tween HCV and LCV tata ee value of fuel and cexph ‘one met, |g Sora the etd ne ring the cali ihe eat ketch 6. Write a short note on the follos es (eas ue gen (2) Coal burners, (b) Oil but ac 7. The percentage composition by weigh ae =e erequired to burn one kg of coat completely. a) Calculate the minimum quantity of air required ic pharma (b) 150% excess aris supplied determine the percentage compo by volume, 8, Drawa neat diagram of thermal power pl 9, Briefly explain witha neat sketch the working of (Chain grate stoker. ee iy Spreader stoke. raw a general layout ofa steam power plant showing the diferent circuits and systems 10, Draw a general lay coe (VTU Feb 206, cexplain them, 11. What are the merits and demerits of pulverised coal? (VTU Feb 2004 12. Explain with aneat sketch the working principle of double classifier ball mill (VTU Feb 2004 13, What is meant by ‘over feed” and ‘under feed” principles of firing coal? (VTU Mar 2001 1 of a coal used in powe nbrefly its workin; 1 using coal as fuel and expl 14, List the advantages and disadvantages of using pulverised con, (VTU Mar 2061 15. Explain the unit system and bin system of pulverised coal firing, (VU Mar 2001)e« 16, Describe citferent types of averfeed stkers and discuss the merits and demerits of each ove a lemerits of each 17, What are the advantages of burning the fuels in pulverised term? earn a oe = +s. Why such burners are useful for Indian coals, ‘are the different methods used for supplying puilvetised fuel Mra praet “pplying pulverived fuel to the combustion chambers 20, A iel has the following analysis by mass C = $7: satya for complete combustion of 1 ky 21, The chemical anal a alysis by mass of fuel is C *. H, =4%, Ash = 9%, Find the amount ol of this fuel,