I.

Introduction

Coal is an important source of energy for the world, particularly for power

generation. Demand for coal has grown rapidly over the last decade,

outstripping that for gas, oil, nuclear and renewable energy sources. This

comes at a cost. Coal contributes to over 40% of global anthropomorphic

CO2 emissions and more than 70% of CO2 emissions that arise from power

generation are attributed to coal.

The deployment of coal power plants largely depends on their

competitiveness compared to gas-fired power, nuclear power, etc. There are

roughly four types of coal-fired power plants. Probably, most coalfired power

plants to be built within the next decades will be either pulverised coal power

plants based on the simple Rankine cycle (steam cycle), or Integrated

Gasification Combined Cycle (IGCC) power plants.

2
Peak Demand: 63 MW

Design Load: 59 MW

Base Load: 25 MW

II. COAL POWER PLANT SITE LOCATION

The peak demand for the Lanao Del Norte is about 63 MW. Fitting this peak load onto
the given load curve.

3
M
E
G
A
W
A
T
T
S

HOURS

Base Load Selection Argument

Using Fig. 2-9 from Morse PPE, for a condensing steam turbine @ 90% operating range, the
thermal efficiency is 22% or at 59 MW. Assuming a coal calorific value of 25MJ/kg.

The needed amount of coal to maintain 1 MWh is

3600 𝑀𝐽
1MWh → 𝑀𝐽 = 654.54 kg of coal / MWh
(25 𝑥 0.22)
𝑘𝑔

For a 24 hour operation at 85 MW

(25MW)(24hr)(654.54)= 392, 724 kg of coal

4
The area above the curve and below the base load line represents a loss for the operating
range:

Loss= (35 box units) (10MWh) =350 MWh

Thus, (350 MWh) (654.54 kg of coal/ MWh) =229, 089 kg of coal considered as waste

Assuming price of electricity 7500php/ MWh; coal price of 5 php/kg. This means that the profit
energy is:

Value of total coal burned= (229,089 k of coal)(5php/kg)

= 1,145,445 php

And hence, a profit of:

PROFIT= (10MWh)(43)(7500php/MWh)- 1,145,445 php

= 3,225,000- 1,145,445

= 2,079,555

III. CALCULATION

A. AVERAGE LOAD COMPUTATION

25MWh+27MWh
A1= (2hours)= 52 MWh
2

27MWh+29MWh
A2= (2hours)= 56 MWh
2

29MWh+33MWh
A3= (2hours)= 62 MWh
2

33MWh+40MWh
A4= (2hours)= 73 MWh
2

5
 40MWh+45MWh
A5= (2hours)= 85 MWh
2

45MWh+52MWh
A6= (2hours)= 97 MWh
2

52MWh+51MWh
A7= (2hours)= 103 MWh
2

51MWh+54MWh
A8= (2hours)= 105 MWh
2

54MWh+63MWh
A9= (2hours)= 117 MWh
2

63MWh+58MWh
A10= (2hours)= 121 MWh
2

58MWh+47MWh
A11= (2hours)=105 MWh
2

47MWh+25MWh
A12= (2hours)= 72 MWh
2

ATOTAL= 1048 MW

1048 𝑀𝑊ℎ
Average Load= = 43.67
24ℎ𝑟

43.67
Load Factor = = 0.74
63

Annual MWh produced

Use Factor= capacity hours of operation

911,600 (365 days)

=24 hours (59)(365)

Use factor= 643.78

43.67(365)
Capacity Factor= =0.74
59(365)

Given: Coal-Fired Power Plant

Rated Power: 59 MW

5 Heaters: 4 CLOSE, 1 OPEN

6
 Throttle Condition: 700°C, 7.5 MPa

Back Pressure: 10 Kpa

Power Required: 59 MW

B. GENERATOR EFFICIENCY

Generator efficiency: Assumption- FULL-LOAD

0.055
Ŋgen= 0.98- 3 rating
(equation 8-10, Morse, PPE)
√
1000

0.055
Ŋgen= 0.98- 3 59,000
√
1000

Ŋgen=96.58%

C. FRICTION LOSS

5
Friction Loss= x normal rating (equation, Morse, PPE)
𝑟𝑎𝑡𝑖𝑛𝑔
√
1000

5
= x 59,000
59,000
√
1000

= 38,405.72 KW

D. TURBINE EFFICIENCY

ŊT= 0.94 x Blade efficiency -2% to 5% rotation and leakage allowance (equation 11-13,
Morse)

Assumption: Reaction turbine blading with velocity ratio, R= 0.75

Then blade efficiency = 95% with 3% allowance, (figure 11-19, Morse)

ŊT= 0.94 x 0.95 -0.03 = 0.863 = 86.3 %

7
 59,000
WT= 0.9658+ 38,405.72

= 99,494.97 KW

E. Pressure at extraction:

Pb=Pressure at boiler= 7.5 MPa

Pc= Pressure at condenser / Back-pressure= 10 KPa

Tsat Pb + Tsat Pc
n+1

Tsat Pb= at 7.5 MPa, temperature is 290.53°C

Tsat Pc= at 10 KPa, temperature is 45.81°C

n= 5 heaters

290.53+45.8
= 40.79°C
5+1

EXTRACTION E:

Tsat= 290.53-40.79

= 249.74°C @ 3.958 MPa

EXTRACTION D:

Tsat= 208.9°C @ 1.867 MPa

EXTRACTION C:

Tsat= 16816°C @ 757 KPa

8
EXTRACTION B:

Tsat= 127.37°C @ 249.67 KPa

EXTRACTION A:

Tsat= 86.58°C @ 61.54 KPa

Extraction at condenser:

Tsat= 45.79°C @ 9.9 KPa

State 1: BOILER:

T1= 700°C

P1= 7.5 MPa

S1= 7.3145 KJ/kg-K

H1= 3885.44 kj/kg

State E:

S1=Se’= 7.3145 kj/kg-k at 3.958 MPa

Thus Te’= 577.05°C ; he’= 3622.53 kj/kg

Solving for he:

3885.44−ℎ𝑒
Ŋ= 0.863=
3885.44−3622.53

he = 3658.55 kj/kg

9
Actual State E:

Pe= 3.958 MPa Te= 592 °C

he =3658.55 kj/kg Se= 7.3565 kj/kg-k

State D:

S1=Sd’= 7.3145 kj/kg-k at 1.867 MPa

Thus Td’= 448.21°C ; hd’= 3355.89 kj/kg

Solving for hd:

3885.44−ℎ𝑑
Ŋ= 0.863=
3885.44−3355.89

hd = 3428.44 kj/kg

Actual State D:

Pd= 1.867 MPa Td= 481.30°C

hd =3428.44 kj/kg Sd= 7.4128 kj/kg-k

State C:

S1=Sc’= 7.3145 kj/kg-k at 757 KPa

Thus Tc’= 314.64°C ; hc’=3088.80 kj/kg

Solving for hc:

3885.44−ℎ𝑐
Ŋ= 0.863=
3885.44−3088.80

hc = 3197.93 kj/kg

Actual State C:

Pc= 757 KPa Tc= 366.62°C

10
hc =3197.93 kj/kg Sc= 7.49 kj/kg-k

State B:

S1=Sb’= 7.3145 kj/kg-k at 249.67 KPa

Thus Tb’= 2205.1°C ; hb’= 2881.78 kj/kg

Solving for hb:

3885.44−ℎ𝑏
Ŋ= 0.863=
3885.44−2881.78

hb = 3019.28 kj/kg

Actual State B:

Pb= 249.67 KPa Tb= 274.54°C

hb = 3019.28 kj/kg Sb= 7.69 kj/kg-k

State A:

S1=Sa’= 7.3145 kj/kg-k at 61.54 KPa

Thus Ta’= 86.57°C ; ha’= 2579.09 kj/kg

Solving for ha:

3885.44−ℎ𝑎
Ŋ= 0.863=
3885.44−2579.09

Ha = 2758.05 kj/kg

Actual State A:

Pa= 61.54 KPa Ta= 139.10°C

Ha = 2758.05 kj/kg Sa= 7.79 kj/kg-k

11
State 2:

S1=Sa2’= 7.3145 kj/kg-k at 9.99 KPa

Thus T2’= 45.78°C ; ha’= 2317.62 kj/kg

Solving for h2:

3885.44−ℎ2
Ŋ= 0.863=
3885.44−2317.62

H2 = 2532.45 kj/kg

Actual State2:

Pa= 9.99 KPa Ta= 45.78°C

Ha = 2532.45 kj/kg Sa= 7.988 kj/kg-k

STATE 3: Assumption- Condenser exit state of saturated liquid at 10 KPa, then:

P3= 10 KPa

h3= hf at p3= 191.81 kj/kg

t3= 45.80°C

s3= sf= 6.49 x 10-1 kj/kg-k

v3= 0.00101 m3/kg

STATE 4: Pump 1 (assumption: incompressible flow, typical pump efficiency of 80%)

𝑊𝑝1
=h4’-h3= v3(p4-p3) 3
𝑚4

h4’-h3= v3(p4-p3) 4

h4’= (0.00101)(757-10) + 191.81

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h4’= 192.564 kj/kg wp1

ℎ4′ −ℎ3 192.564−191.81

Ŋ= 0.863= =
ℎ4−ℎ3 ℎ4−191.81

H4= 192.68 kj/kg

Thus;

H4= 192.68 kj/kg t4= 45.859°C

P4= 757 kpa s4= 0.649 kj/kg-k

STATE 5: Closed Feed water Heater 1 A

Required hs= TTD = 2.25°C

H5 at p4 and tsat A- TTD 5 4

H5 at 757 kpa and 86.57°C- 2.25°C

H5 at 757 kpa and 84.32°C A’

H5= 353.64 kj/kg

Thus;

H5= 353.63 kj/kg t5= 84.32°C

P5= 757 kpa s5= 1.12 kj/kg-k

STATE 6: Closed Feed water Heater 2 B

H6 at p5 at tsat b- TTD 6 5

H6 at 757 kpa and 127.37°C- 2.25°C

H6 at 757 kpa and 125.12°C b’

’

13
 H6= 525.93 kj/kg

Thus;

H6= 525.93 kj/kg t6= 125.12°C

P6= 757 kpa s6= 1.58 kj/kg-k

STATE 7: Open Feed water Heater

H7 at pc at tsat c- 7 C 6

H7 at 757 kpa and 168.16°

H7= 711.15 kj/kg D” B”

t7= 168.16°C

s7= 2.02 kj/kg-k

V7= 1.11 x 10-3 m3/kg

STATE 8: PUMP 2
𝑤𝑝2
𝑚𝑏
=h8’-h7= v7(p8-p7)

H8’= v7(p8-p7) + h7 8 7

H8’= (1.11 x 10 -3)(7500-757) +711.15

H8’= 718.63kj/kg Wp2

ℎ8′ −ℎ7 718.63−711.15

Ŋ= 0.863= =
ℎ8−ℎ7 ℎ8−711.15

H8= 719.20 kj/kg

Thus;

H8= 719.20 kj/kg t8= 169.16°C

P8= 7500 kpa s8= 2.025 kj/kg-k

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STATE 9: Closed Feed water Heater 3

H9 at p8 and tsat d + TTD

H9 at 7500 KPa and 208.95°C + TTD

H9 at 7500 KPa and 208.95°C + 2.25° 9 8

H9 at 7500 KPa and 211.2 °C E” D’

H9= 905.12 kj/kg

Thus;

H9= 905.12 kj/kg t9= 211.2°C

P9= 7500 kpa s9= 2.42 kj/kg-k

STATE 10 : Closed Feed water Heater 4

H10 at p9 and tsate + TTD

H10 at7500 KPa and 249.74°C + 2.25°C

H10 at 7500 KPa and 252 °C

H10= 1095.31 kj/kg 10 9

Thus;

H10= 1095.31 kj/kg t10= 252°C

P10= 7500 kpa s10= 2.803 kj/kg-k E”

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 IV. SOLVING FOR THE MASS FLOW RATES:

HEATER E:

Me(E) + 1(9) = Me(E’) + 1(10)

Me(3658.55 kj/kg) + 1(905.13 kj/hg) = Me(1084.47 kj/kg) + 1(1095.31 kj/hg)

Me = 0.0739 kg/s

HEATER D:

Md(3428.44) + 0.0739(1084.37) +(71981) =(905.12)+ md(892.85)

Md= 0.0415 kg/s

HEATER C :

Md(3197.93 kj/kg)+(0.0415+0.0739)(892.85)+(1-0.0739-0.0415+mc+mb)(525.93)+
mb(535.16)= 1(711.15)+ mc(3197.93) + (0.1154)(892.85)+(0.8846-mc-mb)(525.93)+
mb(535.16) = 711.15

Mc(3197.93)+106.16 + (465.24-525.93mc-525.95mb)+mb(535.16)= 711.15

3197.93 mc + 571.4- 525.93 mc – 525.93mb+ 535.16 mb= 711.15

2672mc +9.23 mb= 139.75 equation 1

HEATER B:

Mb(3019.28 kj/kg)+(1-0.0739-0.0415-mc-mb)(353.64= (1-me –md- mc –mb)(525.93) +

mb(525.16)

3019.28mb + (312.83-353.64 mc - 353.64 mb)= 465.24 -525.93 mb + 535.16 mb

2665.64 mb – 353.mc +312.83 = 465.24 -525.93 mc + 9.23 mb

2656.41 mb + 172.29 mc = 152.41 equation 2

16
2656.41 mb + 172.29 mc = 152.41

152.41−172.29 mc
mb = equation 3
2656.41

substitute equation 3 to 1 to get mc

2672mc +9.23 mb= 139.75

152.41−172.29mc
2672mc +9.23 ( )= 139.75
2656.41

Mc= 0.0523 kg/s

Substitute value of mc to 2

2656.41 mb + 172.29 mc = 152.41

2656.41 mb + 172.29 (0.0523) = 152.41

Mb= 00.054 kg/s

HEATER A:

Ma (2758.05) + (1-0.0739-0.0415-0.0523-0.054)(192.68)= ma(362.54)+(0.7783)(353.64)

ma(2758.05) +(149.96) = (362.54) ma + 275.24

Ma= 0.052 kg/s

The mechanical work done per kg of steam floww to the throttle is calculated:

W= 1(3885.44- 3688.55) +(1-0.0739)(3658.55-3428.44) +(0.8846)(230.57)+

(0.8323)(178.65) + (0.7783)(261.23)+(0.726)(225.6)

17
W= 1029.75 kj/kg throttle

5%
FRICTION LOSS= x 1029.75 = 6.70 kj/kg
59,000
√
1000

Input to generator per kg stea flow of throttle

= 1029.75 -6.70

= 1023. 05 kj/kg

𝑤𝑡
= 1029.75 kj/kg
𝑚1

𝑤𝑡 99,494.97 𝑘𝑔/𝑠
M1 = =
𝑚1 1029.75 𝑘𝑗/𝑘𝑔

M1= 96.62 kg/s

V. BOILER: 1

Qin=m (h1 –h10)

Qin= 96.62 (3885.94- 1095.31) Qin

Qin = 269,582.36 KW

VI. THERMAL EFFICIENCY: 10

𝑤𝑡 99,494.97 𝑘𝑔/𝑠
Ŋ= = x 100
Qin 269,582.36 𝐾𝑊

18
Ŋ= 36.4%

VII. PROPERTIES TABLE

STATE PRESSURE TEMPERATURE ENTHALPY ENTROPY QUALITY

(KPa) (°C) (kj/kg) (kj/kg-k)

1 7500 700 3885.44 7.3145

E 3958 592.75 3658.55 7.3565
D 1867 481.30 3428.44 7.4123
C 757 366.62 3197.93 7.49
B 249.67 274.54 3019.28 7.69
A 61.54 139.10 2758.05 7.79
2 9.99 45.78 2532.45 7.98
3 10 45.85 191.81 0.649 0.94
4 757 84.32 192.68 0.649
A’ 61.54 86.57 353.64 1.12
A” 10 45.80 362.54 1.15
6 757 125.12 525.93 1.18 0.071
B’ 249.47 127.37 535.16 1.606
B” 757 127.25 535.16 1.60
7 757 168.16 711.15 2.02
8 7500 169.16 719.81 2.025
D’ 1867 20.93 892.85 2.41
D” 7557 168.13 892.5 2.43 0.088
9 7500 211.20 904.12 2.42
10 7500 252 1095.31 2.803
E’ 3958 249.73 1084.37 2.79
E” 1867 208.93 1084.37 2.81 0.100

19
VIII. SCHEMATIC DIAGRAM

20
IX. TS DIAGRAM

X. Chimney

21
Average coal assumption = 1800 kg/hour

mass of flue gases formed per kg of coal, (m+1) = 14kg

mass of air supplied per kg of coal, m = 13kg

Total pressure losses through the system, hf = 20 mm of water

Pressure head equivalent to velocity of flue gases = 1.3 mm

Actual Draught required (pd)ac = 20+1.3 = 21.3 mm

Now Draught required theoretically in N/m2

= 261.2 N/m2

22
 = 261.2 N/ m2

= 261.2

4.846 H = 261.2
261.2
H= = 53.9 m
4.846

Diameter of Chimney

mf = mass flow rate of flue gas in kg/sec

=0.65kg/m3

Now velocity head of flue gases, h = 1.3 mm of water

= 2 m of flue gases

23
=6.26 m/sec

d =1.479 m

24