Ministry of Higher Education

Kabul University
Faculty of Engineering
Department of Energy Engineering

Design of Power Plant for Baghlan

Parwan and Panjshir Provinces

Prepared by: Group D

Group members:

1. Mirwais (10676)
2. Najibullah Ebrahimi (11017)
3. Hamid Maliki (10474)
4. Mohammad Fahim Kohistani (10471) Instructor: A. Prof. Hedayatullah Karimi

1-December-2019
Design of Power Plant for Baghlan
Parwan and Panjshir Provinces
 Table of Contents
Titles Page #

Chapter 1
Introduction

1.1 Project Objectives................................................................................................... 1

1.2 Afghanistan Coal Mines ......................................................................................... 1
1.3 Baghlan Province ................................................................................................... 2
1.4 Parwan Province ..................................................................................................... 3
1.5 Panjshir Province .................................................................................................... 3
1.6 Andarab River ........................................................................................................ 3
1.7 Baghlan province Coal mines................................................................................. 4
1.7.1 Coal Mine Karkar ........................................................................................... 4
1.7.2 Coal mine of Ashpeshta .................................................................................. 5
1.7.3 Coal mine of Dudkash .................................................................................... 6

Chapter 2
Cite Description and Data Selection

2.1 Introduction ............................................................................................................ 7

2.2 Electricity Demand ................................................................................................. 7
2.2.1 Parwan Province Electricity Demand ............................................................. 7
2.2.2 Panjshir Province Electricity Demand ............................................................ 7
2.2.3 Baghlan Province Electricity Demand ............................................................ 8
2.3 Site Description of Power Plant ............................................................................. 8

Chapter 3
Thermal Power Plant System

3.1 Thermodynamic Cycle ......................................................................................... 10

3.1.1 Carnot Cycle ................................................................................................. 11
3.1.2 Rankine Cycle ............................................................................................... 11
3.1.3 Otto Cycle ..................................................................................................... 13
3.1.4 Diesel Cycle .................................................................................................. 13

I
 3.2 Steam Generator ................................................................................................... 14
3.2.1 Superheater ................................................................................................... 14
3.2.2 Reheater ........................................................................................................ 15
3.2.3 Economizers .................................................................................................. 16
3.2.4 Air heater ...................................................................................................... 16

3.3 Steam Turbine ...................................................................................................... 17

3.4 Condenser ............................................................................................................. 18
3.5 Feed Water Pump ................................................................................................. 19
3.6 Generator .............................................................................................................. 19
3.7 Clean coal technology .......................................................................................... 20

Chapter 4
Design Calculation and Selection of Equipment

4.1 Generator Selection (Electrical) ........................................................................... 22

4.2 Steam Turbine Selection ...................................................................................... 23
4.3 Steam Generator (Boiler) Selection ..................................................................... 24
4.3.1 Economizer ................................................................................................... 26
4.3.2 Air Heater...................................................................................................... 27
4.4 Condenser Selection ............................................................................................. 27
4.5 Feed Water Pump Selection ................................................................................. 28
4.6 Coal Consumption Calculation ............................................................................ 29
4.7 Coal Handling System Selection .......................................................................... 29
4.8 Clean Carbon Technology Selection .................................................................... 30

Chapter 5
Environmental Impacts of Coal Fired Power Plant

5.1 SO2 Emission Calculation .................................................................................... 32

5.2 NOx Emission Calculation.................................................................................... 33

Chapter 6
Conclusion ............................................................................................................................... 35

References ................................................................................................................................ 36

II
 Table of Figures
Figure Page #

Figure 1-1 Afghanistan Coal Expropriation map (USGS, 2006) ..................................................... 2

Figure 1-2. Andarab River. (Karim Popal, 2016) .......................................................................... 4
Figure 1-3. Coal mine of Karkar (Wikipedia) ............................................................................... 5
Figure 1-4 Coal mine of Ashpeshta (Wikipedia) ........................................................................... 5
Figure 1-5 Coal mine of Dudkash (Wikipedia) ............................................................................. 6
Figure 2-1 Distance from Coal-Fired Power Plant to Andarab River [Google Map] .......................... 9
Figure 2-2 Distance from Coal-Fired Power Plant to Coal Mines (Karkar) Google Map ................... 9
Figure 3-1 Carnot Cycle ............................................................................................................11
Figure 3-2 Rankine cycle...........................................................................................................12
Figure 3-3 Real Rankine cycle ...................................................................................................13
Figure 3-4 Steam Generator (www.coalhandlingplants.com) .........................................................14
Figure 3-5 A superheater unite (Wikipedia) ................................................................................15
Figure 3-6 Moisture Separator reheater (http://www.mac-tpi.com) ................................................15
Figure 3-7 Economizers (Pinterest) ............................................................................................16
Figure 3-8 Air Heater (exportersindia.com) .................................................................................17
Figure 3-9 Steam Turbine (techcenter.com) .................................................................................18
Figure 3-10 Condenser (India MART) ........................................................................................18
Figure 3-11 Feed Water Pump (India MART) .............................................................................19
Figure 3-12 U.S. NRC image of a modern steam turbine generator (STG) ......................................20
Figure 3-13 Rocky Mountain Coal Mining Institute .....................................................................21
Figure 4-1 Selected Electrical Generator GEN-A .........................................................................23
Figure 4-2 Selected Steam Turbine GE STF-D250 .......................................................................24
Figure 4-3 Diagram of Reheat Cycle ..........................................................................................24
Figure 4-4 T-S (Temperature entropy) diagram ...........................................................................24
Figure 4-5 Economizer ..............................................................................................................27
Figure 4-6 Sdwintech Air Heater ................................................................................................27
Figure 4-7 GE Steam Power Condenser ......................................................................................28
Figure 4-8 Coal Handling System by Mill ...................................................................................30
Figure 4-9 Carbon Capture System Diagram ...............................................................................31
Figure 5-1 GE Steam Power SO2 Control System ........................................................................33
Figure 5-2 GE Steam Power NOx Control System ........................................................................34

III
 List of Tables

Table Page #

Table 2-1 Parwan Province Electricity Demand. (Giz, 2016)...............................................7

Table 2-2 Electrical Demand of Parwan, Baghlan and Panjshir ...........................................8
Table 3-1 Thermodynamic Cycles and their constituent Processes ..................................... 11
Table 4-1 Electrical Demand Calculation (MVA) ............................................................ 22
Table 4-2 Electrical Generator ........................................................................................ 22
Table 4-3 Steam Turbine Catalogue ................................................................................ 23
Table 4-4 Calculated Result of Pressures and Temperatures .............................................. 25
Table 4-5 Properties of Steam in Different Point of Cycle................................................. 25
Table 4-6 Isentropic Efficiencies of Turbine and Boiler .................................................... 25
Table 4-7 Calculated Properties of Cycle......................................................................... 26
Table 4-8 Condenser Catalog ......................................................................................... 28
Table 4-9 Feed Water Pump ........................................................................................... 29
Table 4-10 Power Plant Coal Consumption ..................................................................... 29
Table 4-11 Specification by Mill .................................................................................... 29
Table 4-12 Carbon Capture System ................................................................................ 30
Table 5-1 Amount of SO2 emission from coal in an hour from Power Plant........................ 32
Table 5-2 SO2 Control System ....................................................................................... 32
Table 5-3 Amount of NOx Emission in an hour ................................................................ 33
Table 5-4 NOx Control System ....................................................................................... 34

IV
 Chapter 1

Introduction
Afghanistan is a country, which has a lot of natural resources including coal, petroleum and
natural gas. Along with these Afghanistan is a mountainous country with high and large
mountains, because of mountains entity and more rain and snow, the country has long and
water-filled rivers, which extended all along with the country.

Existence of water and natural resources, in a single place, make an opportunity for power plant
making and improvement. Especially coal and water existence and increase in electricity
demand day by day in Afghanistan is a propellant force for coal-fired power plants in the
country.

Baghlan is a central province of Afghanistan, which has both coal and water resource for coal-
fired power plants. The existence of Karkar, Ashpeshta and Dudkash mines in Baghlan
province which are one of the biggest coal mines in the country, and the existence of Andarab
and Surkhab rivers in this province, makes the province more suitable for power plants
implementation. By implementation of the project, along with Baghlan the other two neighbor
provinces Parwan and Panjshir also can use the electricity produced by the power plant.

1.1 Project Objectives

 To find the capability of Baghlan province resources for Coal-Fired Power Plants
 To find the Power Plant Capacity
 Design of a Coal-Fired Power Plant, which capable to supply Electricity at least for two
other neighbors’ Provinces
 To create more job opportunities

1.2 Afghanistan Coal Mines

Coal is a further domestic energy resource of Afghanistan with the potential to contribute as a
fuel source for thermal power production. The coal reserves of Afghanistan are estimated to be
73 million tons. However, the US Geological Survey states: “very little is known about the
character of the Afghan coal resource and much of the existing data is not readily available to
potential users” (USGS, 2006).

1
Today coal is produced by artisanal miners and delivered by road to the consumer. It is used
by kilns for brick production, a cement factory, and domestic consumers. The coal production
of Afghanistan is estimated to be 35,000 metric tons per year as per 2008. The pre-war coal
production of Afghanistan peaked in 1987 at 167,000 metric tons per year (USGS, 2006).

Most of the coal currently being mined in Afghanistan occurs in Jurassic rocks of the central
Afghan platform (Figure 1).

Figure 1-1 Afghanistan Coal Expropriation map (USGS, 2006)

1.3 Baghlan Province

Baghlan is one of the thirty-four provinces of Afghanistan. It is in the north of the country. As
of 2013, the province has a population of about 741,690 (Wekipedia, 2019).

Its capital is Puli Khumri, but its name comes from the other major town in the
province, Baghlan. The ruins of a Zoroastrian fire temple, the Surkh Kotal, are located in
Baghlan.

2
Baghlan has three major coal reserves in different area which are Karkar, Ashpeshta, and
Dudkash.

Baghlan electrical demand is about 78.41 MW which Da Afghanistan Breshna Shirkat (DABS)
just can provide 2 MW (Development, 2017).

1.4 Parwan Province

Parwan is one of the central provinces of Afghanistan, which has ten districts and its capital is
Charikar. Parwan population is 491,870. Which is mostly a rural society (Wekipedia, 2019).

The Parwan province is located north of Kabul province and south of Baghlan province. Its
area is about 5974 Km2.

Parwan has 15 different kinds of mines which four of them are Coal mine, Lead, Zinc and
Barrels mine which are located in Sia Gerd district, the four other mines are in Sorkh Parsa
which are Copper, Iron, Chromite and Trawartine, the other three mines are in Salang district
which are Marble, Poly Methyl Iron and the four mines are in others area.

Parwan electrical demand is 52 MW which DABS just can provide 2.3 MW from the Pushta
Sorkh substation.

1.5 Panjshir Province

Panjshir is located in the northeastern part of the country. The province is divided into seven
districts and contain 512 villages. As of 2018, the population of Panjshir province is about
50,000. Bazarak serves as the provincial capital. A report says that 70,000 people of Panjshir
province living outside of this province, particularly located in Kabul city of Afghanistan
(Wekipedia, 2019).

Panjshir electrical demand is about 5.29 MW which DABS plan to electrified this province.

1.6 Andarab River

Andarab River starts from 2102m height of north-west Bazarak Knot. After flowing through
Khanjan and other villages it combines with Surkhab River and flows through middle Baghlan,
which then named Kunduz River. Total the Kunduz River contain about 5.7 km3 in a year.
(Wekipedia, 2019)

3
 Figure 1-2. Andarab River. (Karim Popal, 2016)

The Afghanistan Coal Reserves are Dara-e-Suff in Balkh province, Karkar in Baghlan
province, Sabzak-e-Herat in Herat province, Ashpeshta in Baghlan province and Dudkash in
Baghlan province.

1.7 Baghlan province Coal mines

1.7.1 Coal Mine Karkar

Karkar Mine is one of the largest coal mines in Afghanistan, with 120 tons of coal
extracted annually. The mine was discovered in 1939 in a mountain in the Baghlan
area. The mine extends within a range of four kilometers inside the mountain, with a
depth of 750 meters and 12 streams of coal. Previously, a company from the Czech
Republic working in these mines was the old, worn-out item (Wekipedia, 2019).

4
 Figure 1-3. Coal mine of Karkar (Wikipedia)

1.7.2 Coal mine of Ashpeshta

This mine is located at (Du Aab-e-Mikh-e-Zarin Kuhmard). It has 158 pit and around
1000 staff working in it. The mine can produce around 160000 tons of coal per year.

Figure 1-4 Coal mine of Ashpeshta (Wikipedia)

5
1.7.3 Coal mine of Dudkash
The mine is located fifteen kilometers northeast of Pul-e-Khumri, the capital of
Baghlan province, and was discovered by a shepherd in 1317, one of Afghanistan's
largest coal mines.

In the year 1350, the mine became an enterprise and its highest production were in the
year 1366, at 165,000 tons, and its lowest production in the year 1370, reaching 10,000
tons (Wekipedia, 2019).

The total amount of Dudkash coal, which is two to three meters thick, reaches 15
million tons and its gender is good and usable.

Coal is also important due to its geographical location in the vicinity of the industrial
centers and its proximity to the Kabul-Kunduz highway.

The tunnels in these mines are not standardized and more coal is extracted in a non-
standard manner.

The tunnel is 200 meters deep and 600 meters long and is arched by iron and ladder,
becoming a safe and standard mine. More than a million Afghans have been consumed
and need more to rebuild this tunnel.

Figure 1-5 Coal mine of Dudkash (Wikipedia)

6
 Chapter 2

Cite Description and Data Selection

2.1 Introduction
As of 2018, coal was the largest source of electricity 38%. The same share as 20 years
previously. Because Afghanistan also has enough coal mines, we can build coal-fired plants to
help the making of the Afghanistan energy system toward energy sustainability. Coal-fires
power station or coal power plant is a thermal power station, which burns coal to generate
electricity. Coal-fired power stations generate over a third of the world’s electricity but cause
hundreds of thousands of early deaths each year, mainly form air pollution. This study will be
describing the build of a coal-fired plant which locate in Dasht-e- Kilagai and the source of this
plant is Karkar, Ashpeshta and Dudkash Coal Mines.

2.2 Electricity Demand

As we say before this plant will be supply the electricity demand of Baghlan, Parwan and
Panjshir provinces and the electricity demand of each province describe as below:

2.2.1 Parwan Province Electricity Demand

Parwan Province Electrical Demand is about 52 MW in 2025.

Electrical Demand 2021 2022 2023 2024 2025

Parwan – Net Demand
GWh 41 70 104 143 189
Residential GWh 22 38 56 74 94
Governmental GWh 10 11 13 15 16
Others GWh 9 21 35 54 79
Table 2-1 Parwan Province Electricity Demand. (Giz, 2016)

2.2.2 Panjshir Province Electricity Demand

There is not any survey to finding energy demand in Panjshir province. That is why we use and
approach, Consider the Parwan province energy demand, and due to the population of Parwan
and Panjshir provinces, we estimate the electricity demand of Panjshir province.

Therefore, the Panjshir province electricity demand in 2025 is equal to:

7
Electrical demand
Panjshir Province Population
= (Electrical Demand of Parwan Province)
Parwan Province Population

50000
𝐏𝐚𝐧𝐣𝐬𝐡𝐢𝐫 Electrical Demand = (52 MW) = 5.29 MW
491870

2.2.3 Baghlan Province Electricity Demand

By the base of Parwan energy consumption, we achieve the Baghlan province energy
consumption.

Electrical demand
Baghlan province population
= (Electrical Demand of Parwan Province)
Parwan province population

741690
𝐁𝐚𝐠𝐡𝐥𝐚𝐧 Electrical Demand = (52 MW) = 78.41 MW
491870
Total Electrical Demand of Baghlan, Panjshir and Parwan Provinces

Total Electrical Demand = 52 MW +5.29 MW + 78.41 MW = 135.7 MW

With 25% future load = 135.7 * 125% = 169.625 MW
And 5% Transmission Loss = 169.625 * 1.05 = 178.11 MW

Electrical Demand Calculation (MW)

Current Demand 25% Future Load 5% Transmission Loss Total
Provinces
(MW) (MW) (MW) (MW)
Panjshir 5.29 1.32 0.33 6.94
Baghlan 78.41 19.60 4.90 102.91
Parwan 52.00 13 3.25 68.25
Total 135.70 33.93 8.48 178.11

Table 2-2 Electrical Demand of Parwan, Baghlan, and Panjshir

2.3 Site Description of Power Plant

The studied shows that the proper location to build a Coal-Fired Power Plant is Dasht-e-
Kilagai. This plant located at the nearest distance of Andarab River 2.2-mile (3.54 Km) and

8
nearest distance with Karkar, Ashpeshta and Dudkash coal mines, which has a 13-mile (20.917
Km) distance from Karkar coal mine.
The following figures show the location of the plant and its distance from the Andarab River,
coal mines (Karkar, Ashpeshta, and Dudkash).

Figure 2-1 Distance from Coal-Fired Power Plant to Andarab River [Google Map]

Figure 2-2 Distance from Coal-Fired Power Plant to Coal Mines (Karkar) Google Map

9
 Chapter 3

Thermal Power Plant System

A thermal power station is a power station in which heat energy is converted to electric power.
In most places the turbine is steam-driven. Water is heated, turns into steam and spins a steam
turbine which drives an electrical generator. After it passes through the turbine the steam
is condensed in a condenser and recycled to where it was heated. This is known as a Rankine
cycle. The greatest variation in the design of thermal power stations is due to the different heat
sources; fossil fuel power generation, though nuclear heat energy, solar heat energy, biofuels,
and waste incineration are also used. Some prefer to use the term energy center because such
facilities convert forms of heat energy into electrical energy. Certain thermal power stations
are also designed to produce heat for industrial purposes, for district heating, or desalination of
water, in addition to generating electrical power.

3.1 Thermodynamic Cycle

A thermodynamic cycle consists of a linked sequence of thermodynamic processes that involve
the transfer of heat and work into and out of the system, while varying pressure, temperature,
and other state variables within the system, and that eventually returns the system to its initial
state. In the process of passing through a cycle, the working fluid (system) may convert heat
from a warm source into useful work, and dispose of the remaining heat to a cold sink, thereby
acting as a heat engine. Conversely, the cycle may be reversed and use work to move heat from
a cold source and transfer it to a warm sink thereby acting as a heat pump. At every point in
the cycle, the system is in thermodynamic equilibrium, so the cycle is reversible (its entropy
change is zero, as entropy is a state function).

During a closed cycle, the system returns to its original thermodynamic state of temperature
and pressure. Process quantities (or path quantities), such as heat and work are process
dependent.

We have different categories of thermodynamics cycles according to the combustion divided

into two parts which are internal combustion and external combustion the major type of this
classification is described in the table.

10
 Process 1-2 Process 2-3 Process 3-4 Process 4-1
Cycle Notes
(Compression) (Heat Addition) (Expansion) (Heat Rejection)
Power Cycle normally with external combustion – or heat pump cycles
Bell Coleman Adiabatic Isobaric Adiabatic Isobaric A reversed Brayton Cycle
Brayton Adiabatic Isobaric Adiabatic Isobaric Jet Engine aka first Ericsson cycle from 1833
Carnot Isentropic Isothermal Isentropic Isothermal
Ericsson Isothermal Isobaric Isothermal Isobaric The second Ericsson Cycle from 1853
Scuderi Adiabatic Variable Pressure and Volume Adiabatic Isochoric
Stirling Isothermal Isochoric Isothermal Isobaric
Stoddard Adiabatic Isobaric Adiabatic Isobaric
Power Cycle normally with internal combustion:
Diesel Adiabatic Isobaric Adiabatic Isochoric
Lenoir Isobaric Isochoric Adiabatic Isobaric Pulse jets (Note: 3 of the 4 processes are different)

Otto Adiabatic Isochoric Adiabatic Isochoric Gasoline/Petrol Engines

Rankine Adiabatic Isobaric Adiabatic Isobaric Steam Engine

Table 3-1 Thermodynamic Cycles and their constituent Processes

3.1.1 Carnot Cycle

Carnot Cycle operates in a reversible process which first proposed in 1824 by French
engineer Sadi Carnot. The Carnot cycle is composed of four reversible processes—two
isothermal and two adiabatic—and it can be executed either in a closed or a steady flow
system. The four reversible processes that make up the Carnot cycle are as follows:

 1-2: Reversible adiabatic expansion

 2-3: Reversible isothermal heat rejection
 3-4: Reversible adiabatic compression
 4-1: Reversible isothermal heat addition

Figure 3-1 Carnot Cycle

3.1.2 Rankine Cycle

In a steam power plant, supply and rejection of heat are more easily realized at constant
pressure than at constant temperature. It was William John Macquorn Rankine, after whom
the Rankine cycle is named, who first calculated the maximum possible work that could be

11
developed by an engine using dry saturated steam between the pressure limits of the boiler
and condenser. The Rankine cycle is an ideal thermodynamic cycle involving the following
processes:
 Steam generation in the boiler at constant pressure
 Isentropic expansion in steam turbine
 Condensation in condenser at constant pressure
 Pressurizing condensate to boiler pressure by isentropic compression

Figure 3-2 Rankine cycle

3.1.2.1 Real Rankine cycle

In an ideal Rankine cycle both the compression in the boiler feed pump (process 3-4) and
expansion in the turbine (process 1-2) take place isentropically (reversibly and
adiabatically). Hence, the efficiency of the ideal Rankine cycle may be regarded as the
highest efficiency achievable in practice with a straight condensing machine. However, in
a real Rankine cycle the efficiency that could be achieved is less than the efficiency of the
ideal Rankine cycle since none of the compression and expansion processes are isentropic.
This is because these processes on completion are non-reversible causing entropy to
increase during compression in boiler feed pump (the isentropic process 3-4s increases to
process 3-4) as well as during expansion in turbine (the isentropic process 1-2s increases
to process 1-2), which further results in an increase in power required by the boiler feed
pump and decrease in power generated by the turbine.

12
 Figure 3-3 Real Rankine cycle

3.1.2.2 Reheat Rankine cycle

Reheat Rankine cycle is used for large steam power plants, it is vital to maximize thermal
efficiency and minimize specific steam consumption. Hence, these plants operate on high-
pressure and high-temperature steam cycles. However, the problem encountered by raising
the turbine inlet pressure is that the steam coming out of the turbine (at state 2, Figure 1.10)
is very wet. Water droplets accompanying steam impinge turbine blades and damage the
blades severely, impairing the efficiency of the turbine.

3.1.2.3 Regenerative Rankine Cycle

If this additional heat to the feed water could be transferred reversibly from the steam part
of the cycle, then the heat supplied to the boiler would be transferred to the feedwater at a
somewhere between T4 and T1. This cycle, where efficiency is raised as explained, is
known as the regenerative cycle. In this cycle, a specified quantity of energy remains
circulating within the cycle, and as a result, irreversibility in the process of mixing
relatively cold water with hot steam gets reduced.

3.1.3 Otto Cycle

The Otto cycle is also known as constant volume combustion or spark ignition cycle. This
cycle can configure as either a two-stroke cycle in which the piston produces power on
every downward stroke or a four-stroke cycle in which the piston produces power every
other downward stroke.

3.1.4 Diesel Cycle

The diesel cycle is also known as constant pressure combustion or compression ignition
cycle. This cycles also like Otto cycle can configure as either a two-stroke cycle in which

13
 the piston produces power on every downward stroke or a four-stroke cycle in which the
piston produces power every other downward stroke.

3.2 Steam Generator

A steam generator is a complex combination of economizer, boiler, superheater, reheater, and
air heater. In addition, it has various auxiliaries, such as stokers, pulverizers, burners, fans,
emission control equipment, stack, and ash-handling equipment.

Figure 3-4 Steam Generator (www.coalhandlingplants.com)

3.2.1 Superheater
Superheaters are one of the most important accessories of boiler that improves thermal
efficiency. In Superheaters, there should not be any fins as it increases the thermal stresses
and carful should be taken when choosing the superheater material that stands for high
temperature and corrosion resistance. Generally, there are three types of Superheaters:
Convection, Radiant, and combined superheaters.

14
 Figure 3-5 A superheater unite (Wikipedia)

3.2.2 Reheater
They are the same as the superheaters, but, as their exit temperature is a little bit less than
superheaters and their pressure is 20%-25% less than the superheater, they can stand less
quality material alloys.

Figure 3-6 Moisture Separator reheater (http://www.mac-tpi.com)

15
3.2.3 Economizers
The economizer is the heat exchanger that raises the temperature of the water leaving the
highest-pressure feed-water heater to the saturation temperature corresponding to the boiler
pressure, which is done by the gases leaving the last superheater or reheater that still have
enough heat to transfer before it leaves it to the stack, that is why it is called economizer.

Figure 3-7 Economizers (Pinterest)

3.2.4 Air heater

They are simply heaters that heat the air before it enters the combustor, thence result in fuel
consumption and increasing the thermal efficiency. The fuel savings are nearly directly
proportional to the air temperature rise in the pre-heater. Typical savings are 4% for a 200
0F air temperature rise and about 11% for a 5000F temperature rise in the pre-heater. Air
preheater is also a requirement for the operation of pulverized-coal furnaces to dry that
fuel.

16
 Figure 3-8 Air Heater (exportersindia.com)

3.3 Steam Turbine

The working fluid of a steam power plant is “water.” The plant is comprised of a steam
generator, in which water receives heat from the heat of combustion of fossil fuels and gets
converted to high-energy steam, which then expands through a steam turbine and undergoes
changes in pressure, temperature, and heat content. During this process of expansion, the
high-energy steam also performs mechanical work. The plant also consists of a condenser,
where steam rejects heat in cooling water and returns to the original state. In addition to fossil
fuels, energy from gas turbine exhausts, nuclear reactors, solar, biomass, etc., may also be
used to generate steam.

17
 Figure 3-9 Steam Turbine (techcenter.com)

3.4 Condenser
Condenser is a device or unit used to condense a gaseous substance into a liquid state through
cooling. In so doing, the latent heat is released by the substance and transferred to the
surrounding environment. Condensers are used for efficient heat rejection in many industrial
systems. Condensers can be made according to numerous designs, and come in many sizes
ranging from rather small (hand-held) to very large (industrial-scale units used in plant
processes). For example, a refrigerator uses a condenser to get rid of heat extracted from the
interior of the unit to the outside air.

Figure 3-10 Condenser (India MART)

18
3.5 Feed Water Pump
A boiler feedwater pump is a specific type of pump used to pump feedwater into a steam
boiler. The water may be freshly supplied or returning condensate produced as a result of the
condensation of the steam produced by the boiler. These pumps are normally high-pressure
units that take suction from a condensate return system and can be of the centrifugal pump
type or positive displacement type

Feedwater pumps range in size up to many horsepowers and the electric motor is usually
separated from the pump body by some form of mechanical coupling. Large industrial
condensate pumps may also serve as the feedwater pump. In either case, to force the water
into the boiler, the pump must generate sufficient pressure to overcome the steam pressure
developed by the boiler. This is usually accomplished through the use of a centrifugal pump.
Another common form of feedwater pumps run constantly and are provided with a minimum
flow device to stop over-pressuring the pump on low flows. The minimum flow usually
returns to the tank or deaerator.

Figure 3-11 Feed Water Pump (India MART)

3.6 Generator
In electricity generation, a generator is a device that converts motive power U.S. NRC image
of a modern steam turbine generator (STG). (mechanical energy) into electrical power for
use in an external circuit. Sources of mechanical energy include steam turbines, gas turbines,
water turbines, internal combustion engines, wind turbines, and even hand cranks. The first
electromagnetic generator, the Faraday disk, was invented in 1831 by British scientist
Michael Faraday. Generators provide nearly all of the power for electric power grids.

19
The reverse conversion of electrical energy into mechanical energy is done by an electric
motor, and motors and generators have many similarities. Many motors can be mechanically
driven to generate electricity and frequently make acceptable manual generators.

Figure 3-12 U.S. NRC image of a modern steam turbine generator (STG)

3.7 Clean coal technology

Clean coal technology may be an assortment of technologies being developed in makes an
attempt to reduce the negative environmental impact of coal energy generation and to mitigate
worldwide global climate change. once the coal is employed as a fuel supply, the
vaporized emissions generated by the thermal decomposition of the coal embody Sulphur
dioxide (SO2), chemical element oxides (NOx), mercury, and different chemical byproducts
that fluctuate looking on the sort of the coal getting used. These emissions are established to
own a negative impact on the surroundings and human health, tributary to acid precipitation,
carcinoma, and disorder. As a result, clean coal technologies area units being developed to get
rid of or cut back waste material emissions to the atmosphere. a number of the techniques that
will be accustomed accomplish this embody with chemicals laundry minerals and impurities
from the coal, chemical process, improved technology for treating flue gases to get rid of
pollutants to progressively demanding levels and at higher potency, carbon capture and storage
technologies to capture the CO2 from the flue gas and dewatering low-status coals (brown
coals) to enhance the hot worth, and so the potency of the conversion into electricity.
Issues exist relating to the economic viability of those technologies and also the timeframe of
delivery, doubtless high hidden economic prices in terms of social and environmental

20
injury, and also the prices and viability of taking out removed carbon and different cytotoxic
matter.

In its original usage, the term "Clean Coal" was used to refer to technologies that were designed
to reduce the emission of pollutants associated with burning coal, such as washing coal at the
mine. This step removes some of the sulfur and other contaminants, including rocks and soil.
This makes coal cleaner and cheaper to transport. More recently, the definition of clean coal
has been expanded to include carbon capture and storage. Clean coal technology usually
addresses atmospheric problems resulting from burning coal. Historically, the primary focus
was on SO2 and NOx, the most important gases in the causation of acid rain, and particulates
which cause visible air pollution and have deleterious effects on human health.

Figure 3-13 Rocky Mountain Coal Mining Institute

21
 Chapter 4

Design Calculation and Selection of Equipment

4.1 Generator Selection (Electrical)
As mentioned in the second chapter a load of Parwan, Baghlan and Panjshir province is
calculated which is 135.7 MW and 25% of future load is 169.625 MW and in here 5%
transmission loss is considered.

Notwithstanding a generator is designed by MVA (Mega Volt Ampere) so in the bellow, all
the load converted to MVA and 0.8 power factor is assumed.

Electrical Demand Calculation (MVA)

Current Demand 25% Future Load 5% Transmission Loss Total
Provinces (MVA)
(MVA) (MVA) (MVA)
Panjshir 6.61 1.65 0.41 8.68
Baghlan 98.01 24.50 6.13 128.64
Parwan 65.00 16.25 4.06 85.31
Total 169.63 42.41 10.60 222.63
Note: Power Factor is assumed 0.8

Table 4-1 Electrical Demand Calculation (MVA)

According to the above demand a generator is selected which is one of the Siemens products
and has the following detail:

Electrical Generator
Company GE Steam Power
Model GEN-A: Air-Cooled
Frequency 50 Hz
Power factor 80%
Apparent Power 200 MVA to 400 MVA
Terminal Voltage 11.5 kV to 22 KV
Reliability 99.91%
Efficiency 98.90%
Table 4-2 Electrical Generator

Through the total electrical demand of Parwan, Baghlan and Panjshir by consideration of 25%
future load and 5% transmission loss is 222.63 MVA and in here the selected electrical

22
generator apparent power range is between 200 MVA- 400 MVA so it is proper one for the
above demand.

Figure 4-1 Selected Electrical Generator GEN-A

4.2 Steam Turbine Selection

The steam turbine is selected by considering the generator’s apparent power and efficiency
which its apparent power range is between 200 MVA – 400 MVA and efficiency is 98.9%.
Therefore, the selected steam turbine which is products of General Electric Company (GE) its
output power is equal and greater to 250 MW and has been selected.

Steam Turbine
Model SST-700/900
Output SPP (MW) ≤ 250
Frequency (Hz) 50/60
Inlet Pressure (bar) 180
Inlet Temperature (oC) 585
Reheat Temp (oC) 565
Speed (rpm) 3000-3600
Extraction Pressure (bar) 72
Exhaust Pressure (bar) 0.3/4.4

Table 4-3 Steam Turbine Catalogue

23
 Figure 4-2 Selected Steam Turbine GE STF-D250

4.3 Steam Generator (Boiler) Selection

Reheat Rankine Cycle has been selected for this power plant in this cycle steam is extracted
from a suitable point in the turbine and reheated generally to the original temperature by flue
gases. Reheating is generally used when the pressure is high say above 100 kg/cm2.

Figure 4-4 T-S (Temperature entropy) diagram Figure 4-3 Diagram of Reheat Cycle

In here assume a power plant which works between two pressure which the highest pressure is
18 MPa and the lowest is 30 KPa. The calculations have been done by considering the steam
turbine properties and using thermodynamic equations and the property of steam has been
selected from thermodynamics tables. These calculations have been done for finding the steam
characteristics in different points of the figure (4-3).

The following tables show the calculation results of the selected Rankin Cycle for Baghlan
province coal-fired power plant.

24
 P2 (KPa) 18150
P3 (KPa) 18000
T3 (0C) 585
T5 (0C) 565
P4 (KPa) 7200
P6 (KPa) 30
P1 (KPa) 25
s3 (KJ/Kg.K) 6.6
h3 (KJ/Kg) 3519.45

Table 4-4 Calculated Result of Pressures and Temperatures

MID pressure LOW pressure

sf (KJ/Kg.K) 3.121 sf (KJ/Kg.K) 0.944
sg (KJ/Kg.K) 5.813 sg (KJ/Kg.K) 7.769
sfg (KJ/Kg.K) 2.692 sfg (KJ/Kg.K) 6.825
hf (KJ/Kg) 1267 hf (KJ/Kg) 289.23
hg (KJ/Kg) 2772.1 hg (KJ/Kg) 2625.3
hfg (KJ/Kg) 1505.1 hfg (KJ/Kg) 2336.07
x4 1.284 x6 0.881
h5 (KJ/Kg) 3564.56 h6 (KJ/Kg) 2601
s5 (KJ/Kg.K) 6.954 h1 (KJ/Kg) 289.230
h2 (KJ/Kg) 307.759
h4 (KJ/Kg) 3198.802
vf1 (m3/Kg) 0.0010223

Table 4-5 Properties of Steam in Different Point of Cycle

Pressure Drops efficiency

From 6-1 5 Turbine Isentropic Efficiency 0.84

From 2-3 150 Pump Isentropic Efficiency 0.89

Table 4-6 Isentropic Efficiencies of Turbine and Boiler

25
 h3 (KJ/Kg) 3519
h4a (KJ/Kg) 3250.1
h5 (KJ/Kg) 3564.6
h6a (KJ/Kg) 2755.169
h1 (KJ/Kg) 289
h2a (KJ/Kg) 310.0
wturbine (KJ/Kg) 1078.7
wgenerator (KJ/Kg) 1058
qin (KJ/Kg) 3523.9
qout (KJ/Kg) 2465.9
Efficiency (%) 30.022
ṁ (Kg/sec) 213
Qin (MW) 749.8
Qout (MW) 524.7
Table 4-7 Calculated Properties of Cycle

Steam Generator
Company GE Steam Power
Model CFB Boiler
Anthracite through
Typical fuels
lignite A and B
Efficiency 89%
Steam flow Reheater 1390 ton/h
Steam flow Superheater 1671 ton/h
Up to 660 MWe for
Capacity lignite, higher for
hard coal
Pressure Up to 30 Mpa
Temperature 600oC/620oC
Table 4-8 Boiler Catalog

4.3.1 Economizer
Economizer which is a simple tool of boiler which raise the temperature of feed water has
been selected from Victory energy which its capacity is up to 223.2 Kg/sec.

26
 Figure 4-5 Economizer

4.3.2 Air Heater

The air heater which has been selected for the power plant is plate type air preheater
which made of steel and include plates and tubes.

Figure 4-6 Sdwintech Air Heater

4.4 Condenser Selection

Condenser has been selected by considering the steam that that rejected to sink (Qout) which
has the following characteristics.

27
 Condenser
Company GE Steam Power
Capacity 600 MW
Condenser vacuum type Dual
Condenser thermal load (MW) 583
Absolute pressure at turbine/condenser connection (KPa) 32/42
Max condensate O2 content at 100% load with make-up (ppm) 15
Terminal temperature difference (oC) 2.5/2/5
Circulating water temperature design (oC) 18.4/22.9
Circulating water nature Cooling tower water
Circulating water flow (m3/s) 16
Circulating water temperature rise (oC) 4.5/4.3
Exchange surface (m2) 18810/20630
Material Stainless steel
Length (m) 12.8/11.7
Tube to tube sheet joint Expanded
In operation (tons) 1140
Overall width (m) 6.7/6.7
Overall length (m) 21.6
Overall height (m) 16.8
Table 4-9 Condenser Catalog

Figure 4-7 GE Steam Power Condenser

4.5 Feed Water Pump Selection

The feed water pump has been selected by considering the cycle pressure which is 18 MPa and
steam flow rate which is 213 kg/sec.

28
 Feedwater Pump
Company
Model HLV/HLAV
Capacity up to 6840 m3/h
Total Head up to 320 m
Operation Temp. 10 to 420 oC
Operation Pre. up to 33 Mpa
Speed up to 3600 rev/min
Size 40 to 400 mm
Motor Rating 1500 kW
Voltage 400 v to 11 kV
Table 4-10 Feed Water Pump

4.6 Coal Consumption Calculation

Karkar coal mine which has been selected to feed the power plant mostly consist bituminous
coal and has heating value of 32,000 MJ/ton and according to this heating value the coal
consumption per hour has been found which written in the below table.

Coal Type Bituminous

Heating Value (MJ/ton) 32000
Qin (MW) 749.8154645
Boiler Efficiency (%) 0.89
Coal Consumption (ton/hr) 75.07527338
Table 4-11 Power Plant Coal Consumption

4.7 Coal Handling System Selection

The boiler which has been selected for this power plant is combined with coal mill therefore
there is no necessity for addition coal handling system. The mill properties have been given
in the below table.

Mill Specification
Company GE Steam Power
Model Bowl mills-SM Type
Capacity (t/h) 12 to 170
Classifier Static, Dynamic and Combined
Loading Hydraulic (Spring Option)
Coal Bituminous/sub-bituminous, Lignite A, Anthracite, Petroleum coke

Table 4-12 Specification by Mill

29
 Figure 4-8 Coal Handling System by Mill

4.8 Clean Carbon Technology Selection

As shown in table 4-8 this power plant coal consumption is 75ton/hr, as Petro Roosen lecturer
of FH Aachen University of Applied Science claim that for complete combustion of 1Kg coal
11.232 Kg air is needed, so according to this we calculate the total amount of air which needed
for this power plant and it is 843.25ton/hr. By finding this data we can find the amount of CO2
emission which is 176 metric tonne of CO2 equivalent (mtCO2e). Therefore, the following
carbon capture system has been chosen for this power plant.

Carbon Capture System

Company GE Steam Power
Model Oxy-combustion-Gas processing
Flue gas inlet conditions

Temp. (oC) 20-100

Press. (KPa) 100
Flow Rate (t/h) Up to 875
CO2 Vol (% dry basis) 70-95
H2O (%) 2-25
N2 Vol (%dry basis) 2-5
O2 Vol (%dry basis) 20-50
CO2 Capture Rate (%) 90
Specific steam consumption (GJ/tCO2)
consumption

Specific electricity consumption

122-160
Utilities

(kWh/tCO2)
Solvent make-up rate (kg/Tco2)
Cooling water need (t/tCO2) 32-43
Chemical make-up rate (kg/Tco2) Depending on feed gas composition
Temp. (oC)
and Conditions

20-50
Specification
Production

Press. (KPa) 1900-20000

CO2

Flow Rate (t/h) Up to 276

CO2 Vol (% dry basis) >99
H2O (%) <10

Table 4-13 Carbon Capture System

30
Figure 4-9 Carbon Capture System Diagram

31
 Chapter 5

Environmental Impacts of Coal-Fired Power Plant

5.1 SO2 Emission Calculation
Typically, about 1.5% of coal consists of Sulfur.

Amount of SO2 Emission in an hour

S content in % of by mass 1.5
Total amount of coal (ton/h) 75.08

Total amount of SO2 (ton/h) 2.25

Amount of SO2 in coal ppm 2452.58

Table 5-1 Amount of SO2 emission from coal in an hour from Power Plant

As calculated and has been shown in the above table the total emission of SO2 is 2.25 ton/hr
(2452.6 ppm) so for reducing this amount we select the following technology as shown below.

SO2 Control
Company GE Steam Power
Model WFGD OST
Maximum gas flow rate per absorber (Nm/h) 3200000
Power plant size (MW) Up to 1300
Fuel Coal, lignite, oil
Maximum SO2 content at the inlet (mg/Nm3) 17000
SO2 removal rate with GGH (%) > 99 achieved
SO2 Emissions (mg/NM3) 15
Load range (% MCR) 20-100
HCI Removal Rate (%) > 99
HF Removal Rate (%) > 99
Reagent Limestone, line or sodium
Table 5-2 SO2 Control System

32
 Figure 5-1 GE Steam Power SO2 Control System

5.2 NOx Emission Calculation

Typically, about 1.3% of coal consists of Nitrogen.

Amount of NOx Emission in an Hour

Nitrogen content in % of by mass 1.3
Total amount of coal (ton/h) 75.08
Total amount of NOx (ton/h) 0.37
Amount of NOx in coal in ppm 398.55
Table 5-3 Amount of NOx Emission in an hour

As calculated and has been shown in the above table the total emission of NOX is 0.037 ton/hr
(398.6 ppm) so for reducing this amount we select the following technology as shown below.

33
 NOX Control
Company GE Steam Power
Model SCR
Reactor size (m3/h) Up to 5400000
Fuel type All type
High dust SCR for power plants and CHP plants, tail end SCR for power
Reactor position
plants and industrial applications
Reactor flow direction Coal application: Vertical down
Cleaning method Soot blower using steam compressed air, sonic air horns, air sweepers
NOX Removal efficiency Up to 95
NH3 Slip (ppm) 2
Operation temp. (oC) 300-435 for coal/oil
NOX inlet concentration (ppm) 1000
O2 (%) 1 (minimum)
SO2(ppm) Up to 3500
SO2/SO3 Conversion (%) 0.5-2
Ash load (mg/Nm3) Up to 35000
Reagent type Anhydrous ammonia, aqueous ammonia, urea
Table 5-4 NOx Control System

Figure 5-2 GE Steam Power NOx Control System

34
 Chapter 6
Conclusion
The coal-fired power plant is a conventional power plant, which has been in use for a while,
and more than thousands of coal-fired power plants are already constructed world widely.
However, Afghanistan has a good potential for coal-fired power plant implementation, but,
unfortunately, even on plant did not build in the country up to now. This project is a summary
of the design of a coal-fired power plant which, will build in the Kilagai desert in Baghlan
province. The plant can supply electrical power to Baghlan, Parwan, and Panjshir provinces.
The feeding coal of the plant is supplied by Karkar min which is located just 13 miles away for
the plant, and also the water required for the power plant will be supplied from Andarab River.

The total electrical demand of these three provinces have been found which is 178.11 MW,
according to this demand, generator and turbine have been selected. For designing this plant, a
reheat Rankin cycle has been selected and further calculations have done. The boiler pressure
and temperature have been selected 18 MPa and 565 oC respectively. According to the results
of calculations further related parts of the power plant have been selected. The calculation of
sorbent for SO2 and NOx is much more difficult and required high knowledge of chemistry,
but the total amount of SO2 and NOx are found and for capturing them proper technologies
have been selected. And also for carbon capture, a proper technology has been selected,
whereby using both of these technologies the total emission of pollutants will be reduced to a
desirable amount, which will be safe for release to the environment, and did not cause serious
environmental problems.

35
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