Power Plant Engineering

and Energy Conversions

1.1 Introduction
A power plant is assembly of systems or subsystems to
generate electricity, i.e. power with economy and
requirements.
A power plant can be also defined as a machine or assembly of
equipment that generates and delivers a flow of mechanical or
electrical energy.
The main equipment for the generation of electric power is
generator.
Power plant is classified in one of the two major categories.
1 Conventional
1. Steam Engines Power Plants
2. Steam Turbine Power Plants
3. Diesel Power Plants
4. Gas Turbine Power Plants
5. Hydro-Electric Power Plants
6. Nuclear Power Plants
 The Steam Power Plant, Diesel Power Plant, Gas Turbine
Power Plant and Nuclear Power Plants are called Thermal
Power Plant, since these convert heat into electric energy.
2 Non-conventional
Thermoelectric Generator
Thermo-ionic Generator
Fuel-cells Power Plants
Photovoltaic solar cells Power System
Biogas, Biomass Energy Power system
Geothermal Energy
Wind Energy Power System
Ocean Thermal energy conversion (OTEC)
Wave and Tidal Wave
 1.2 Energy

It is the power to change things.

It is the ability to do work.
It lights our cities
It powers our vehicles
It runs machinery in factories.
It warms and cools our homes
It cooks our food
It plays our music and
It gives us pictures on television.
Joule - A unit of energy. One joule equals 0.2388 calories
 Cont…….
• Energy is all around you!
You can hear energy as sound.
You can see energy as light.
And you can feel it as wind.
• You use energy when you:
 Hit a softball.
 Lift your book bag.
 Compress a spring.
 Living organisms need energy for growth and movement.
 Cont…….
• Energy is involved when:
• a bird flies.
• a bomb explodes.
• rain falls from the sky.
• electricity flows in a wire.
 1.3 Forms of Energy

• The five main forms of energy are:

1) Heat
2) Chemical
3) Electromagnetic
4) Nuclear
5) Mechanical
 1 Heat Energy
• The internal motion of the atoms is called heat
energy, because moving particles produce
heat.
• Heat energy can be produced by friction.
• Heat energy causes changes in temperature and
phase of any form of matter.
 2 Chemical Energy
• Chemical Energy is required to bond atoms
together.
• And when bonds are broken, energy is
released.
• Fuel and food are forms of stored chemical
energy.
3 Electromagnetic Energy
• Power lines carry electromagnetic energy into
your home in the form of electricity.
• Light is a form of electromagnetic energy.
• Each color of light (Roy G Bv) represents a
different amount of electromagnetic energy.
• Electromagnetic Energy is also carried by
X-rays, radio waves, and laser light.
 4. Nuclear Energy
• The nucleus of an atom is the
source of nuclear energy.
• When the nucleus splits (fission),
nuclear energy is released in the
form of heat energy and light
energy.
• Nuclear energy is also released
when nuclei collide at high speeds
and join (fuse).
Cont………
The sun’s energy is produced
from a nuclear fusion reaction in
which hydrogen nuclei fuse to
form helium nuclei.

Nuclear energy is the

most concentrated form
of energy
 5. Mechanical Energy
• When work is done to an object, it acquires
energy. The energy it acquires is known as
mechanical energy.
• When you kick a football, you give
mechanical energy to the football to
make it move.
Energy Conversion
• Energy can be changed from one form to another. Changes in
the form of energy are called energy conversions.
• All forms of energy can be converted into other forms.
• The sun’s energy through solar cells can be converted directly into
electricity.
• Green plants convert the sun’s energy (electromagnetic) into
starches and sugars (chemical energy).
• In an automobile engine, fuel is burned to convert
chemical energy into heat energy. The heat energy is
then changed into mechanical energy.
Other energy conversions

• In an electric motor, electromagnetic energy is converted to

mechanical energy.
• In a battery, chemical energy is converted into
electromagnetic energy.
• The mechanical energy of a waterfall is converted to
electrical energy in a generator.
1.4 States of Energy
• The most common energy conversion is the conversion
between potential and kinetic energy.
• All forms of energy can be in either of two states:
• Potential
• Kinetic
• Kinetic Energy is the energy of motion.
• Potential Energy is stored energy.
 Kinetic Energy
• The energy of motion is called kinetic energy.
• The faster an object moves, the more kinetic energy it
has.
• The greater the mass of a moving object, the more kinetic
energy it has.
• Kinetic energy depends on both mass and velocity.

1
K .E  mV 2

2
 Potential Energy
• Potential Energy is stored energy.
 Stored chemically in fuel, the nucleus of atom, and in foods.
 Or stored because of the work done on it:
• Stretching a rubber band.
• Winding a watch.
• Pulling back on a bow’s arrow.
• Lifting a brick high in the air.
 Gravitational Potential
Energy
• Potential energy that is dependent on
height is called gravitational potential
energy.

ELASTIC Potential Energy

Energy that is stored due to being stretched or
compressed is called elastic potential energy.
 Gravitational Potential
Energy
• “THE BIGGER THEY ARE THE HARDER THEY FALL” is not
just a saying. It’s true. Objects with more mass have
greater G.P.E.
• The formula to find G.P.E. is
G.P.E. = Weight X Height.
Kinetic vs. Potential
Energy

At the point of maximum potential energy, the car has

minimum kinetic energy.
 The Law of Conservation of Energy

• Energy can be neither created nor destroyed by ordinary

means.
• It can only be converted from one form to another.
• If energy seems to disappear, then scientists look for it –
leading to many important discoveries.
 1.5 Sources of Energy
 Fossil fuels
 Hydro power plant
 Biomass
 Wind energy
 Solar energy
 Geo thermal energy
 Ocean thermal energy
 Tidal energy
 Wave energy
 Nuclear energy.
 The above sources of energies are classified in to two major groups
as non-renewable and renewable energy sources.
 Non-renewable energy sources cannot be replaced in a short amount
of time; limited
 Renewable energy sources
 Can be regenerated in a relatively short period of time; unlimited
Non-conventional energy are sources that are
continuously replenished by natural processes.
 Most of the renewable energy comes either directly or indirectly
from SUN AND WIND
 Can never be exhausted, and therefore they are called renewable.
 Most of the world's energy sources are derived from conventional
sources-fossil fuels such as coal, oil, and natural gases.
 Renewable energy sources are essentially flows of energy,
 Fossil and nuclear fuels are, in essence, stocks of energy.
Various forms of renewable energy are:
© Solar energy
© Wind energy
© Bio energy
© Hydro energy
© Geothermal energy
© Wave and tidal energy.
 1.6 Power
Power is the rate doing work, which equals
energy per time. Energy is thus required to
produce power. We need energy to run power
plants to generate electricity. We need power
to run our appliances, and heat our homes.
Without energy we would not have electricity.
1.7 Fuels and Combustion
1.7.1 Introduction
• Fuel፡ is composed of chemical elements which, in
rapid chemical union with oxygen, produce
combustion.
• Combustion፡ is that rapid chemical union with
oxygen of an element whose exothermic heat of
reaction is sufficiently great
• The various types of fuels like liquid, solid and
gaseous fuels are available for firing in boilers,
furnaces and other combustion equipment.
• Fuels are classified as Primary and Secondary
Cont…
• Primary fuels are occur naturally such as coal, crude
petroleum and natural gas.
• Coal and crude petroleum, formed from organic matter many
millions of years ago, are referred to as fossil fuels.
• Secondary fuels are derived from naturally occurring ones by
a treatment process such as coke, gasoline, coal gas etc.
• On the basis of physical state fuels are classified in to three
 Liquid
 Gaseous
 Solid
 1.7.2 Types of Fuels
• There are various types of fuels available are differ in terms of availability,
storage, handling, pollution etc.
• A good knowledge of the fuel properties helps in selecting the right fuel
for the right purpose and for efficient use.
I. Liquid Fuels:- are predominantly used in industrial applications
1. Furnace oil
2. Light diesel oil
3. Petrol
4. Kerosine
5. Ethanol
6. LSHS (low sulphur heavy stock)
Properties of liquid fuels
• The various properties of liquid fuels that will be explained are
1) Density
2) Specific gravity
3) Specific heat and calorific value
4) Viscosity
5) Flash point
6) Pour point
7) Sulphur content
8) Ash content
9) Carbon residue
10) Water content and storage of fuel.
  Density
• It is defined as the ratio of the mass of the fuel to the volume of the
fuel at a reference temperature of 15°C
• It is useful for determining fuel quantity and quality
 Specific gravity
 Ratio of weight of oil volume to weight of same water volume at
a given temperature
• Specific gravity of water is 1
• Hydrometer used to measure
Fuel oil type LDO Furnace oil LSHS

Specific Gravity 0.85-0.87 0.89-0.95 0.88-0.98

 Viscosity
• It is a measure of its internal resistance to flow.
• It depends on the temperature and decreases as the temperature increases.
• Any numerical value for viscosity has no meaning unless the temperature
is also specified.
• Measurement is made with an instrument called a Viscometer.
• It is the most important characteristic in the storage and use of fuel oil.

 Flash point
• Lowest temperature at which a fuel can be heated so that the
vapour gives off flashes when an open flame is passes over it
• Flash point of furnace oil: 66oC
 Pour point
• It is the lowest temperature at which it will pour or
flow when cooled under prescribed conditions.
• It indicates the lowest temperature at which fuel oil
is ready to be pumped.

 Specific heat
• It is the amount of kCals needed to raise the
temperature of 1 kg of oil by 10C.
• Its unit is kcal/kg0C.
• It determines how much steam or electrical energy
it takes to heat oil to a desired temperature.
 Calorific value
• It is the measurement of heat or energy produced
• It is measured either as gross calorific value (GCV) or net calorific value
(NCV).
• The difference is determined by the latent heat of condensation of the
water vapour produced during the combustion process
• GCV assumes all vapour produced during the combustion process is
fully condensed.
• NCV assumes the water leaves with the combustion products without
fully being condensed.
Fuel Oil Gross Calorific Value (kCal/kg)
Kerosene 11,100
Diesel Oil 10,800
L.D.O 10,700
Furnace Oil 10,500
LSHS 10,600
 Sulphur content
• The amount of sulphur in the fuel oil depends mainly on the source of
the crude oil
• The normal sulfur content for the furnace oil is in the order of 2 - 4 %.
• The main disadvantage of sulphur is the risk of corrosion by sulphuric
acid formed
• It condense in cool parts of the chimney or stack, air pre heater and
economizer.

 Ash content
• It is related to the inorganic material or salts in the fuel oil.
• Excessive ash in liquid fuels can cause fouling deposits in the combustion
equipment.
• Ash has an erosive effect on the burner tips.
• Causes damage to the refractories at high temperatures and gives rise to
high temperature corrosion and fouling of equipments.
 Carbon residue
• It indicates the tendency of oil to deposit a carbonaceous solid residue
on a hot surface, such as a burner or injection nozzle.
• Residual oil contains carbon residue of 1 percent or more.

 Water content
• The water content of furnace oil when it is supplied is very low
• An upper limit of 1 % is specified as a standard.
• Water may be present in free or emulsified form
• Can cause damage to the inside surfaces of the furnace.
• It can also cause spluttering of the flame at the burner tip, possibly
extinguishing the flame, reducing the flame temperature or lengthening
the flame.
 Solid fuels (Coal)
• Include coal, wood, tyres, waste and other solid materials that can
be used as fuel.
• Coal is the main source of solid fuel in industry
• Coal is classified into three major types
 Anthracite
 Bituminous
 lignite.
• Anthracite is hard and the oldest coal from geological perspective.
• It is composed mainly of carbon with little volatile content and practically no
moisture.
• Lignite is the youngest coal from geological perspective.
• It is a soft coal composed mainly of volatile matter and moisture content with
low fixed carbon.
 Properties of Coal
 Are broadly classified as physical and chemical
properties.
 Physical properties
 Physical properties of coal include the heating or calorific
value, moisture content, volatile matter and ash.

 Chemical properties
 Refers to the various elemental chemical constituents
such as carbon, hydrogen, oxygen, and sulphur.
 Moisture content
• Since it replaces combustible matter, it decreases the heat content per kg of
coal.
• Typical range is 0.5 to 10%
 Volatile matter are
• Methane
• hydrocarbons
• hydrogen
• carbon monoxide
• incombustible gases like carbon dioxide and nitrogen found in coal.
• High volatile matter content indicates easy ignition of fuel.
• crushed coal is weighed, heated, cooled and weighed.
• Loss of weight represents moisture and volatile matter.
• The remainder is coke (fixed carbon and ash).
 Ash
• It is an impurity that will not burn.
• Reduces burning capacity
• Increases handling costs
• Affects combustion efficiency and boiler efficiency
• Causes clinkering and slagging
• Fixed carbon
• It is the solid fuel left in the furnace after volatile matter is distilled
off.
• It consists mostly of carbon
• It also contains some hydrogen, oxygen, sulphur and nitrogen not
driven off with the gases.
• Fixed carbon gives a rough estimate of the heating value of coal.
• Fixed carbon acts as a main heat generator during burning.
• Fixed Carbon or FC is derived by subtracting from 100 the
percentage of moisture, volatile matter and ash.
• Fixed carbon = 100 – (moisture + volatile matter + ash)

Proximate analysis of coal

• There are two methods to analyze coal:
 ultimate analysis and proximate analysis.
• The proximate analysis determines only the fixed carbon,
volatile matter, moisture and ash percentages
• It can be determined with a simple apparatus.
 Ultimate analysis of coal
• It determines all coal component elements, solid or gaseous.
• It indicates the various elemental chemical constituents such as
carbon, hydrogen, oxygen, and sulphur, etc
• It is determined in a properly equipped laboratory by a skilled
chemist
• It is useful in determining the quantity of air required for
combustion.
• It is useful to find out heating value (GCV)
• This information is required for the calculation of flame
temperature and the flue duct design etc.(furnace design )
 Gaseous Fuels
 They are the most convenient because
 they require the least amount of handling.
 are used in the simplest and most maintenance-free burner
systems
 Environmental benefits :lowest GHG and other emissions
 Classification of gaseous fuels
 Fuels naturally found in nature:
• Natural gas
• Methane from coal mines
 Fuel gases made from solid fuel
• Gases derived from coal
• Gases derived from waste and biomass
• From other industrial processes (blast furnace gas)
 Gases made from petroleum
• Liquefied Petroleum gas (LPG)
• Refinery gases
• Gases from oil gasification
• Gases from some fermentation process
Liquefied Petroleum Gas (LPG)

• LPG may be defined as those hydrocarbons, which are gaseous at

normal atmospheric pressure but may be condensed to the liquid state
at normal temperature by moderate pressures.
• LPG is a predominant mixture of propane and butane and small
percentage of unsaturates and some lighter C2 as well as heavier C5
fractions
• Are normally used as gases
• Are stored and transported as liquids under pressure for convenience
and ease of handling.
• LPG vapour is denser than air: Butane is about twice as heavy as air and
propane about one and a half times as heavy as air.
• Leaking gases can flow long distances from the source and be ignited at
a considerable distance from the source
Natural gas
• Methane is the main constituent of natural gas and accounts for
about 95% of the total volume.
• Other components are: ethane, propane, butane, pentane,
nitrogen, carbon dioxide, and traces of other gases.
• Properties of methane are used when comparing the properties
of natural gas to other fuels.
• Natural gas is a high calorific value fuel that doesn’t require
any storage facilities.
• It mixes with air readily and does not produce smoke or soot.
• It has no sulphur content.
• It is lighter than air and disperses into air easily in case of
leak.
1.7.3 Combustion
• Refers to the rapid oxidation of fuel accompanied by the
production of heat, or heat and light.
• Complete combustion of a fuel is possible only in the presence of
an adequate supply of oxygen.
• Rapid fuel oxidation results in large amounts of heat.
• Solid or liquid fuels must be changed to a gas before they will
burn.
• Usually heat is required to change liquids or solids into gases.
• Fuel gases will burn in their normal state if enough air is present.
• Nitrogen is considered to be a temperature reducing diluter that
must be present to obtain the oxygen required for combustion .
Cont..
• Nitrogen reduces combustion efficiency by absorbing heat
from the combustion of fuels and diluting the flue gases.
• It also increases the volume of combustion by-products
• Nitrogen also can combine with oxygen particularly at high
flame temperatures to produce oxides of nitrogen (NOx)
• Carbon may also combine with oxygen to form carbon
monoxide, which results in the release of a smaller quantity of
heat.
• Carbon burned to CO2 will produce more heat per unit of fuel
than when CO or smoke are produced
Control the 3 Ts to optimize combustion

• The objective of good combustion is to release all of the heat in

the fuel.
• This is accomplished by controlling the "three T's”
1) Temperature: high enough to ignite and maintain ignition of
the fuel
2) Turbulence: or intimate mixing of the fuel and oxygen
3) Time: sufficient for complete combustion.
• Commonly used fuels like natural gas and propane generally
consist of carbon and hydrogen.
• Water vapor is a by-product of burning hydrogen.
• This removes heat from the flue gases.
 Principles of Combustion
• Too much, or too little fuel with the available combustion air
may potentially result in unburned fuel and carbon monoxide
generation.
• A very specific amount of oxygen is needed for perfect combustion and
some additional air is required for ensuring complete combustion.
• However, too much excess air will result in heat and efficiency losses.
• Not all of the heat in the fuel are converted to heat and absorbed
by the steam generation equipment.
• The main challenge in combustion efficiency is directed toward
unburned carbon that forms CO instead of CO2.
Principles of Combustion
THANK YOU
FOR YOUR
ATTENTION!!
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Cont..
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