NALCO

CAPTIVE POWER PLANT

PRESENTED BY SWARAJ KUMAR SWAIN

RA1711002010065
 ABOUT NALCO

• NALCO is a navaratna CPSE under Ministry of Mines, Govt. of India which was
established on 7th jan.1981.
• The company has a 68.25 lakhs TPA bauxite mines band 22.75 lakh TPA alumina
refinery located at Damanjodi in Koraput.
• A 4.60 lakh TPA aluminium smelter and 1200 MW captive power plant at
Angul,Odisha.
• It is the first company in aluminium company in aluminium sector in the country to
venture into International market in London Metal Exchange since May 1989.
 CAPTIVE POWER PLANT

• It refers to the generation from a unit set up by the industry for its exclusive from
a unit set up by industry for its exclusive consumption.
• It has a capacity of 1200 MW. It provides electric power requirement of
aluminium smelter. It also feeds approx 35 MW to alumina refinery through state
grid.
• It is located at Angul, with supply of coal from Mahanadi Coal Fields, Talcher and
with the help of 18.5 km captive railway system. The water is drawn FROM RIVER
Brahmani through 75KM long triple circuit pipeline.
 SUMMARY OVER THE
INDUSTRIAL TRAINING
• BOILER
• TURBINES
• COAL HANDLING PLANT
• DM AND COOLING PLANT
• SWITCH YARD
 BOILER

• Boilers are used in power plants in order to produce high pressured

steam,sothat the plant can generate electricity.
• It follows RANKINE cycle.
• It takes in energy from a form of fuel coal to heat water into steam.
• It consist of three systems of flow cycle a. Feed water cycle b. Air and Flue
gas cycle c. Steam cycle
 Feed Water cycle
• Feed water cycle is cycle where the water is
ffeded at many stages at the point.
• The water is heated with various heat
exchange.
• The pumps are fitted up for providing the
pressure to the water.
• Those are to put into the drum for the further
purpose.
Air and Flue gas cycle
• This cycle states that air plays an important
role in the industry.
• The coals are brought from the coal handling
plant , to mills.
• The fans such as PAF, FDF are used in the
cycle.
• The heat exchanger such as SCAPH is also
used.
• The units contain 5 total mills for crushing
down the coal to powder form.
• Then the resulted form of coal is sent to the
boiler.
• The air used after work is complete is sent to
ESP,then to IDF at the end of chimney section.
 STEAM CYCLE

• This cycle is the main cycle,where the main purpose is to generate steam.
• It starts from Drum to the condenser.
• The water and the coal is supplied to the boiler as a feeder from mills and drums.
• Then, through various heat exchanger the temp along with the pressure of the
water is maintained.
• The powdered coal is thrown into the boiler from different direction at the high rate
• In the end, the steam is produced to run up the turbines.
 TURBINES
A. High pressure turbines
B. Intermediate Pressure turbines
C. Low Pressure Turbines

A. High pressure turbines

• The turbines with an impulse control stage followed by reaction blading in
each end of the element
• There are about 10 stages with shrouded blades in the HP turbine.
• It is equipped with 3 or 4 self regulating extraction lines.
 Intermediate pressure turbine
• The exhaust steam from HPT drives IPT’
• In the IPT, it is partially exteneded to perform
work expansion in HP turbine,it goes to boiler
for further heating then goes to IPT.
• It is used for reheating purpose in Rankine
cycle.
Low pressure turbine
• The ipt outlet is connected with one or two
LPT rotors. LPT further expands the steam
generating more energy.
• Usually they are in big size, as they have
lowest steam pressure,hence bigger area to
handle the steam flow rate.
 COAL HANDLING PLANT
• The mainwork of this part of the plant is to provide coal to the boiler. It is
handled with track hoopers to mills. Three major components are
crusher,conveyer,captive railway system.

Crusher
• The coal which is received arev (100mm)
roughly in size.
• The main work of the crusher is to crush it to
the (20)mm in size.
• The coal is shifted to crusher from the
unloading bay through conveyer.
Conveyer
• This is the main part of each and every plant
• In CHP, the first of all its work is to sent off the coal
to the unloading bay from track unloading bay
from track hooper.
• Secondly, it transfers coal from unloading Bay to
the crusher.
• Then, it is sent off to the mills of each unit as per
the requirement.
C. Captive Railway System

• Its main purpose is to receive coals for the plant.

• The coals lif of F and G grade comes for the plant and the track hooper is the
part of it where the container with pneumatic Air valve comes up with the
coal.
• Down the rain (100*100) mm of filtter is fitted out irregular coals for the
plant.
 DM and COOLING plant

A. DM PLANT
• De mineralised plant purpose the work of de mineralising the water from
the river.
• It follows major two steps
i) Pre- treatment Plant
ii) Post – Treatment Plant
 Pre treatment plant
• It contains 5 intake pump house with large raw water reservoir.
• A stiling chamber to settle down the water and chlorines for chlorinization.
• Clarificulator process is done for maintain pH (6.8 to 7.8)
• Total pumps
CTMP – 6
ESP – 4
SWP- 3
• Sand filter used filter out tiny impurities
• Then,different bays to take the output to plants and township
 Post Treatment Plant

• The main work of the plant is to add and remove cations and anion which all
are required
• Then the water after treatment is stored and will be sent off to the boiler
plant of the plant as per the requirement
• The following diagram shows various stages of the treatment.
 Cooling water Plant
Cooling Tower CW Pump
• Each cooling tower has around 4 units under it. • The main purpose of CW pumps in plant is to
condense the extra low pressure steam which
• The main purpose is to cooling down the hot
inturns improves the efficiency of the plant.
water and then recycle it to the plants.
• If incase, it has to dispose it maintains the • CW pumps inject raw water into the tubesof
condenser where hot steam flows outside
temp of water without harming the natural
these tubes.
water
 ACW Pump
• The main purpose of the Auxiliary cooling water pump that keeps the circulation of water in the colder side
of the plate heat exchanger.
• It extracts heat from the water dumped into the cooling tower for cooling.
• Fresh water is drawn from the cooling tower basin again through ACW pumps.
• The plant has CWP pumps – 15
ACW pumps- 1 to 6
• Each unit has
1. CW pumps
2. ACW pumps
3. HP pumps
4. Safety pumps
 SWITCH YARD
LOAD DISTRIBUTION
• At the whole production, CPP provides upto
750MW normally to its smelter plant
• The work of the switch yard is to drop down
and up the voltage as per the requirement
• The rest output is given to the grid and used
for the self purpose
BREAKER
• A circuit breaker is an automatically operated
electrical switch designed to protect an
electrical circuit from damage caused by
excess current from an overload or short
circuit.
• As we know fault current is very high and
during interruption of huge current. There
would be large arcing inbetween switching
contracts. So as circuit breaker is used
THANK YOU