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INTRODUCTION:
A thermal power plant converts heat energy of coal into electrical energy. coal is burnt in a
boiler which converts water into steam. The expansion of the steam turbine produces
mechanical power which drives the Excitation Generator(Alternator) coupled to the turbine.
Thermal power plant contribute maximum to the generation of power for any country.
Thermal power plant s constitutes 75.43% of the total installed captive and non-captive
power generation in India. In thermal generating stations coal, oil, natural gas etc. are sources
of energy.

CAPTIVE THERMAL POWER PLANT OF HINDALCO

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GENERAL OVERVIEW AND PLANT LAYOUT OF HINDALCO POWER PLANT:

Thermal power generation plant or thermal power station is the most conventional source of
electric power. It is working of thermal power plant. It is also called “Steam Turbine Power
Plant.”

The theory of thermal power station or working of thermal

power station is very simple.

The thermal power plant mainly consists of a Steam turbine that is hydraulically coupled
with Excitation Generator OR Alternator.

 The steam is obtained from the High Pressure Boilers.

 Coal and Air are used as fuel of boiler.
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HINDALCO FULL PLANT LAYOUT

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EQUIPMENTS OF A THERMAL POWER PLANT

1) coal handling plant

2) pulverizing plant

3) Ash handling plant

4) Draft fans( i-Induced draft fans, ii-Forced draft fans)

5) Boiler

6) Turbine

7) Alternator

8) condenser

9) Superheater,Air preheater,reheater

10) Economiser

11) Deaerator

12) Feed water pump

13) Cooling tower

14) Electrostatic precipitator

15) Fuel gas Stack

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 COAL HANDLING PLANT

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 PULVERISING PLANT
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 ASH HANDLING PLANT

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 HIGH PRESSURE STEAM BOILER(CFBC)

PARAMETERS:- UNITS:- DESIGN DATA:-

Boiler capacity Tph 155

Superheater pressure kg/cm^2g 89.2

Superheater Temp deg’c 515

Feed water Temp deg’c 210

 A boiler or a steam generator is a closed vessel in which water under pressure

converted into steam.
 It is designed in such a manner that it will absorb maximum amount of heat
released in the process of combustion
 They are 2 types (FIRE TUBE & WATER TUBE BOILERS)
 LAYOUT OF CFBC BOILER AT HINDALCO POWER PLANT
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WORKING

 In a Thermal power plant the steam is produced in high pressure in the steam boiler
due to burning of fuel (pulverised coal) in boiler furnaces.
 Generally we use cold cyclone type boiler for the production of steam.
 The steam is then superheated in the high pressure superheater.
 The superheated steam then enters into the turbine and rotates the turbine blades with
the help of rotor.
 The high pressure energy converted into kinetic energy due to rotating blades.
 After impacting energy to the turbine rotor the steam passes out of the turbine to the
condenser.
 The turbine is hydraulically coupled with the excitation generator that its rotor will
rotate with the rotation of turbine blades.
 The kinetic energy changed into electrical energy in the excitation generator and with
the help of step up transformer high amount of electricity is generated in mega watts.
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 DRAFT SYSTEM

 The circulation of air is caused by a difference in pressure known as draft.

 It is a differential pressure b/w atmosphere and inside the boiler.
 It is necessary to cause the flow of gases through boiler setting.

They are two types (Induced draft &Forced draft)

 Induced draft (ID fans) are used for the extraction of Ash from the furnace.
 The ash is collected through the ESP(Electrostatic precipitator) and other gases like
Carbon dioxide, NOX ,Particulate matter, Sulphur dioxide, Stack emissions .
 Those other gases are removed through the Chimney.
 The use of Forced draft (FD fans) only for proper mixing and complete combustion
of coal in the furnace.
 Generally 4 FD fans & 2 ID fans are used in the steam boiler(furnace).
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 SUPERHEATER & REHEATER

 Most of modern boilers are having superheater and reheater arrangement.

 Superheater is a component of a steam-generating unit in which steam ,after it
has left the boiler drum,is heated above its saturation temp.
 The superheater may consist of one or more stages of tube banks arrangement
for effective transfer heat from the products of combustion.
 Reheater is a steam boiler component in which heat is added to this
intermediate-pressure steam,which has given up some of its energy in
expansion through the high-pressure turbine.
 The steam after reheating is used to rotate the second steam turbine where the
heat is converted to mechanical energy is used to run the alternator ,which is
coupled to turbine ,there by generating electrical energy.
 A superheater is generally 2 types (High pressure heater & Low pressure
heater)

FLOW CHART
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 CONDENSER

 It is the device which is used in the thermal power plant for phase change.
 It condenses the low pressure wet steam. That means the high pressure wet steam
is changed into low pressure wet steam.
 Steam after rotating steam turbine comes to the condenser. Here it refers to the
shell and tube type heat exchanger (or surface condenser) installed at the outlet
of every steam turbine in thermal power stations of utility companies generally.
 These condenses are heat exchanges which convert steam from its gaseous to its
liquid state ,also known as phase transition.
 In so doing, the latent heat of steam is given out inside the condenser ,where water
is in short supply an air cooled condenser is often used.
 An air cooled condenser is however significantly more expensive and can’t
achieve as a low steam turbine backspace(and therefore less efficient) as a surface
condenser.
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 The purpose is to condense the outer (or exhaust) steam turbine to obtain
maximum efficiency and also to get the condensed steam in the from of pure
water, otherwise known as condensate back to steam generator or (boiler)
As boiler feed water.

 COOLING TOWERS

 A cooling tower is a device which is one type of heat exchanger is

used to exchange heat to atmosphere by extracting heat in from of
latent heat.

 It is an open device and is used to condense the steam that means to

cool the steam .

 Typically a 2000mw plant needs about 1500mGallon of water.

 Most plants use a closed cooling system where warm water coming
from condenser is cooled and reused.

 Small plants use spray ponds and medium and large plants use cooling
towers.

 Cooling tower is a steel or concrete hyperbolic structure having a

reservoir at the base for storage of cooled water.
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 Height of the cooling tower may be 150m or so and diameter at the

base is 150m.

 BOILER FEED WATER PUMP

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 ECONOMISER
 Flue gases coming out of the boiler carry lot of heat.
 It extracts a part of this heat from flue gases and uses it for heating
feed water.
 This use of economiser results in saving coal consumption and higher
boiler efficiency.

 STEAM TURBINE

 A steam turbine is used to convert the heat energy or pressure energy of

steam into mechanical energy .

 It drives the excitation generator or Synchronous generator.

 It uses the principle that steam when issuing from a small opening attains a
high velocity.
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 This velocity attained during expansion depends on the initial and final
heat content represents the heat energy converted into kinetic energy.

 They are two types

 Impulse turbine
 Reaction turbine
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 FULL WORKING THEORY

 In a thermal plant the primary process is coal feeding process.In this process
the coal feeded to the coal feeder from the coal bunker.The coal feeder is
feeded with the coal by the help of chain drives or belt drives.
 After the coal feeder is feeded with coal the coal burning process starts inside
boiler furnace.
 If the coal contains so much moisture then ti is removed by air blaster process.
 Then high temp is given to the coal feeder.The bed temp of the furnace rises
upto 850 ºc inside it and then it goes up .Here after it comes to the economiser
-2 first and ecomiser-1.
 In the economiser the temp only increases and with the help of primary and
secondary mechanical or induced draft fans the complete burning and proper
combustion takes place.
 But the hot gas is not free from stack and other harmful gases.so to remove the
effect of harmful gases it is further sent to the ESP(electro static precipitator).
 Then with the help of induced draft fans the ash after burning is extracted from
the furnace.
 All other gases like Stack emissions,flue gas emissions,NOX
emissions,hydrocarbons,sulphur content,carbo dioxide,particulate matter are
being extracted through the Chimney.
 Then the hot steam free from harmful gases will gather at economiser-1 and
they will be collected in the drum.so the drum temp increases.
 The temp of drum is not enough to provide it to the boiler for steam generator.
 So from the outlet of the drum the hot gases come to the superheater-1 and due
to the superheater -1 the temp increases more and again collected in drum.
 Similarly from the drum outlet the hot gases again enters into superheater -2
and superheater-3 and simultaneously temp increases to a very high level.
 Thus it is supplied to the boiler.sometimes the boiler doesn’t srart-up.so for
such problem HGG(hot gas generator) is used for primary strat up by oil
supply.
 In the steam boiler the water is heated up by burning the fuel in air in the fuel
in air in the furnace and the function of the boiler is to give dry super heated
steam at required temp.
 The steam so produced is used in driving the steam turbines.
 The turbine is coupled to synchronous generator (usually 3 phase ) which
generates electricity 10.5kvolt.
 The amount of electricity generated from the alternator is further stepped up to
50-100 mwatt.
 The exhaust steam from the turbine is allowed to condense into the water in
steam condenser of turbine with the help of condensate extraction pump
which creates suction at very low pressure and allows the expansion of the
steam or throttling.
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 The principal advantages of condensing operation are the increasing amount of

energy extracted per kg of steam and there by increasing efficiency and the
condensate which is fed into the boiler again reduces the amount of fresh feed
water.
 The condensate along with some fresh make up feed is again fed into the
boiler by pump(called the boiler feed pump)
 In condenser the lp steam is condensed by cooling water.
 Cooling water provided by cooling tower and recycles through it.This
constitutes cooling water circuit.
 The ambient air is allowed to enter in the boiler after dust filtration.
 Also the flue gas comes out of the boiler and exhausted into the atmosphere
through stacks.
 The flue gas in form of stacks constitute air and flue gas circuit
 The flow of air and also the static pressure inside the steam boiler (called
draught) is maintained by ID and FD fans.
 Inside the boiler there are various heat exchangers.(Economiser ,evaporator).It
is basically water tubes. 1-Downcomer riser circuit
2-superheater
3-Reheater or Air-preheater
 In economiser the feed water is heated to considerable amount by the
remaining heat of flue gas.
 The boiler drum actually maintains a head for natural circulation of two phase
mixture (steam-water)through the water tubes.
 This is also super-heater which also takes heat from flue gas and raises the
temp of steam as per requirement.
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 ESTIMATION OF TOTAL POWER GENERATION

NO. OF UNITS POWER GENERATION NO OF BOILERS

UNIT 1 67.5 MGWATT 2

UNIT 2 100 MGWATT 3

UNIT 3 100 MGWATT 3

UNIT 4 100 MGWATT 3

UNIT 5 100 MGWATT 2

NET GENERATION OF ELECTRICITY FROM HINDALCO POWER PLANT IS 467.5

MEGA WATT
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TURBINE AND BOILER CONTROL SOFTWARE FLOW DIAGRAM

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SOME PICTORIAL VIEW OF HINDALCO CAPTIVE POWER PLANT

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