Power Plant Engineering: Aditya Engineering College (A) Aditya Engineering College (A)

ADITYA ENGINEERING COLLEGE (A)
POWER PLANT ENGINEERING

Steam Power Plant (Unit – I)
Dr A. Saravanan
Professor
Department of Mechanical Engineering
Aditya Engineering College (A)
Email: saravanan.a@aec.edu.in
Course Outcomes
At the end of the Course, Student will be able to:
CO 1 : Explain the source of energy, resources and development of power

CO 2 : Demonstrate the basic parts and area of steam power plant
CO 3 : Describe the concept of different power plant
CO 4 : Explain the combined operations of different power plants
CO 5 : Analyze the power plant economics and environmental considerations
Power Plant Engineering, Unit - I Dr. A. Saravanan, Professor of Mechanical Engineering Wednesday, Febru
ary 23, 2022
Contents
Introduction
Sources of energy, resources and development of power in India.
Steam Power Plant
Plant layout, working of different circuits, fuel and handling
equipments, types of coals, coal handling, choice of handling equipment,
coal storage, ash handling systems. Combustion: properties of coal –
overfeed and underfeed fuel beds, traveling grate stokers, spreader
stokers, retort stokers, pulverized fuel burning system and its
components, combustion needs and draught system, cyclone furnace,
design and construction, dust collectors, cooling towers and heat
rejection. Corrosion and feed water treatment.
Power Plant Engineering, Unit - I Dr. A. Saravanan, Professor of Mechanical Engineering Wednesday, February 23, 2022
Introduction
Energy is a basic requirement for economic development. Every
sector of the national economy – agriculture, industry, transport,
commercial and domestic – needs inputs of energy.
Conventional Sources of Energy
Commercial Energy Sources:

These are coal, petroleum and electricity. These are called commercial energy
because they have a price and consumer has to pay the price to purchase them.
Non-Commercial energy Sources:

These sources include fuel wood, straw and dried dung. These are commonly
used in rural India. (No need to pay by consumer).
Non-Conventional Sources of Energy
Development of power in India
Steam Power Plant
Converts the chemical energy of a fossil fuels (coal, oil, gas) into mechanical /
electrical energy.
Purpose of steam power plant
1. To produce electric power

2. To produce steam for industrial purpose besides producing
electric power (Textiles, food manufacture, paper mill, sugar
mill etc.)
Classification of Steam power plants:
Central stations
Electrical energy available from this station is for sale to the customers –
Condensing type.
Industrial power stations or captive power stations
Power station is run by a manufacturing company for its own use – not for
sale – non condensing type – Steam coming out from turbine is use for
different manufacturing operations.
Layout of a steam power plant
 Coal and ash circuit

 Air and gas circuit
 Feed water and steam flow circuit
 Cooling water circuit
Components of a Modern Steam power plant:
1. Boiler (Superheater, Reheater, 8. Crusher house

Economiser, Air-preheater) 9. Coal mills
2. Steam turbine 10. Induced draught fans
3. Generator 11. Ash precipitators
4. Condenser 12. Boiler chimney
5. Cooling towers 13. Forced draught fans
6. Circulating water pump 14. Water treatment plant
7. Boiler feed pump 15. Control room
Selection of site for steam power station
1. Availability of raw materials 7. Availability of labour

2. Nature of land 8. Size of the plant
3. Cost of land 9. Load centre
4. Availability of water 10. Public problems
5. Transport facilities 11. Future extensions
6. Ash disposal facilities
Note: 400 MW capacity plant requires 5000 to 6000 tonnes of coal per day
Types of Coal
Anthracite: The highest rank of coal. It is a hard, brittle, and black lustrous coal,
often referred to as hard coal, containing a high percentage of fixed carbon and a
low percentage of volatile matter.
Bituminous: Bituminous coal is a middle rank coal between sub bituminous and
anthracite. Bituminous usually has a high heating (Btu) value.
Sub bituminous: Black in color and dull (not shiny), and has a higher heating value
than lignite.
Lignite: Brown coal, is the lowest grade coal with the least concentration of
carbon.
Thermal Power Plant in India – Top 10
1. Vindhyachal Thermal Power Station, Madhya Pradesh - Singrauli district of

Madhya Pradesh, with an installed capacity of 4,760MW, is currently the
biggest thermal power plant in India. It is a coal-based power plant owned
and operated by NTPC.
2. Mundra Thermal Power Station, Gujarat - Capacity of 4,620MW located in
the Kutch district of Gujarat is currently the second biggest operating
thermal power plant in India. It is a coal-fired power plant owned and
operated by Adani Power.
3. Mundra Ultra Mega Power Plant, Gujarat - Capacity of 4,000MW located
in the Kutch district of Gujarat, ranks as the third-largest thermal power
plant in India. It is a coal-fired power plant owned and operated by Coastal
Gujarat Power Limited (CGPL), a subsidiary of Tata Power.
4. Sasan Ultra Mega Power Plant, Madhya Pradesh - Singrauli district, Madhya
Pradesh, has an installed capacity of 3,960MW. Owned and operated by
Reliance Power, it is one of India’s biggest power plants integrated with a
coal mine.
5. Tiroda Thermal Power Plant, Maharashtra – 3,300MW coal-based power
generation plant in Maharashtra, India. Owned and operated by Adani
Power Maharashtra, the power plant consists of five 660MW units.
6. Talcher Super Thermal Power Station, Odisha - Angul district of Odisha, is a
3,000MW coal-fired power plant owned and operated by NTPC.
7. Rihand Thermal Power Station, Uttar Pradesh - Rihandnagar, Sonebhadra
district, Uttar Pradesh. Owned and operated by NTPC, the coal-fired power
plant has an installed capacity of 3,000MW.
8. Sipat Thermal Power Plant, Chhattisgarh - 2,980MW Bilaspur district,

Chhattisgarh, ranks as the eighth-largest thermal power station in India. It is
a coal-based power plant owned and operated by NTPC.
9. Chandrapur Super Thermal Power Station, Maharashtra - 2,920MW power
plant in Chandrapur, Maharashtra, India.
10.NTPC Dadri, Uttar Pradesh - National Capital Power Station (NCPS) owned
and operated by NTPC is located in the Gautam Budh Nagar district of
Uttar Pradesh, with an installed capacity of 2637MW (1820MW- coal
based and 817MW gas based)
Thermal Power Plant Andhra Pradesh
1. Ramagundem Thermal Power Station – NTPC (2600 MW), Telungana

2. Sri Damodaram Sanjeevaiah Thermal Power Plant -1(2400 MW)
3. Rayalaseema Thermal Power plant ( 1650 MW)
4. Simhadri NTPC (1000 MW)
5. Godavari Gas Power Project (GVK), Kadiyam – 235 MW + 228 MW
6. Vijjeswaram Gas Power plant (389 MW)
Fuel Handling
Three types of fuels used in Steam power plant. (Solid as Coal, Liquid as Oil,
Gaseous as Gas)
Coal handling systems: Mechanical handling due to
Higher reliability
Less power required
Economical for medium and large capacity plants
Operation is easy and smooth
But
Needs continuous maintenance and repair
Capital cost of the plant is increased
Stages of coal Handling
Coal delivery
Unloading
Preparation
If the coal is delivered in the form of lumps (not in proper size) the coal
preparation carried out by
1. Breakers
2. Crushers
3. Dryers
4. Magnetic separators
Transfer
Handling of coal between the unloading point and the final storage point
Belt conveyors
Advantages:
Most economical, Smooth and clean,
Less power consumption, Large quantities of
coal can be discharge
Disadvantages:
Not suitable for greater height and short
distance, maximum inclination of belt is
limited to 20 degree
 Screw conveyors
Diameter of the screw:

15 to 50 cm
Speed : 70 to 120 rpm
Max. Capacity :
125 tonnes / hour
 Grab bucket conveyors
Costly machine, 50 tonnes per hour only
Bucket Elevator
Ash handling system
Huge quantity of ash is produced in central stations (10 to 20% of the total
quantity of coal burnt in a day)
Classification of ash-handling systems

1. Mechanical handling system
2. Hydraulic system
3. Pneumatic system
4. Steam jet system
Ash handling system
Mechanical handling system
Ash handling system
Hydraulic system
Clean and healthy

Working parts do not come into contact
with the ash
Dustless and totally closed
Large ash carrying capacity (large thermal
power plant) -120 tons per hour
Ash handling system
Pneumatic or Vacuum system
The power requirement of mechanical exhauster is approximately 3 kW

per ton of material
The water-Jet exhauster may be used more economically where
large quantities of water are easily and cheaply available (5 to 30 tons per
hour).
Combustion - Steam Power Plant
Anthracite
Properties Wood Peat Lignite Bituminous coal
coal
Lower calorific 10,500 14,650 12,500 32,000 35,500

value (CV) KJ/Kg
Carbon ( %) 48.5 58 66 81 91
H2 ( %) 6 6.3 5 5 3
O2 ( %) 43.5 30.8 20 8 2.5
N2 ( %) 0.5 0.9 1 1.5 0.5
Bihar, Madhya
Neyveli, Tamil Pradesh, Orissa Jammu and
PLACE - -
Nadu and West Kashmir
Bengal

Advantages of solid fuels
1. They can be stored in a convenient place without any risk of spontaneous explosion.
2. They can be easily transported.
3. They have a low ignition temperature.
4. They involve low production cost.
Disadvantages of solid fuels

5. They have large percentage of ash content.
6. The rate of combustion of solid fuels cannot be easily controlled.
7. They produce large amount of smoke.
8. The necessity of various fuel-handling equipments (conveyers, crushers, hoppers,
9. bunkers, etc.) increases the cost of fuel handling.
10. They have a lower CV when compared with liquid fuels.
11. The amount of heat wasted is more due to unburnt and partially burnt fuel.
12. They require excess amount of air for complete combustion.

Liquid Fuels
Liquid fuels are available in nature in the form of crude petroleum. Petroleum is a mixture of
hydrocarbons that can be grouped into the following four categories:
1. Parffins (CnH2n + 2)
2. Olefins (CnH2n)
3. Naphthalenes (CnH3n)
4. Aromatics (CnH4n − 2).
All commercial liquid fuels are derived from crude petroleum or crude oil.
Advantages liquid fuels
1. Higher CV when compared to solid fuels.
2. Require very less excess air for complete combustion due to uniform mixing and atomization of fuels.
3. Can be stored and handled easily when compared to solid fuels.
4. Higher combustion efficiency due to uniform mixing of fuel and air.
5. Combustion process and combustion rate can be easily controlled by varying the quantity of fuel.
6. Less storage space when compared to solid fuels.
Gaseous Fuels
Gaseous fuels are either natural fuels or artificial fuels. Natural gaseous fuels occur in the form
of natural gas near oil-bearing areas under the earth’s surface. Artificial gaseous fuels prepared are
coal gas, coke oven gas, blast furnace gas, producer gas, water gas and Mond gas
Natural gas
It is found dissolved in petroleum or in large quantity under the earth’s surface in oil- and gas-bearing areas.
It mainly contains 85 per cent of methane (CH4) and hydrogen (H2), along with small percentages of ethane and
ethylene.
Coal gas (Town Gas)
It is a by-product obtained during destructive distillation of coal. It mainly contains H 2, CO, CO2, CH4 and
N2. CV - 21,000 to 25,000 kJ/m3
Coke oven gas
It is obtained by the carbonization of bituminous coal. It is used for industrial heating.
Producer gas
It is obtained by partial combustion of coke or coal in the presence of air and steam mixture. It has a CV
ranging between 5000 and 6800 kJ/m3

Advantages of gaseous fuels
1. The rate of combustion and temperature can be easily controlled by regulating the flow rate of gas.
2. Mixing of fuel and air is uniform, and hence combustion is complete.
3. They are free from solid and liquid impurities and burn completely.
4. They burn without leaving traces of smoke and ash.
5. They are eco-friendly and do not pollute atmosphere.
6. They can be conveyed easily through pipelines.
7. Combustion efficiency is more due to the necessity of minimum amount of excess air.
8. They can be directly used as fuels in internal combustion engines.
Disadvantages of gaseous fuels
9. They are highly inflammable.
10. They require larger storage volume capacity
FUEL BURNING
Two commonly used methods for burning the fuel are stoker firing and pulverized fuel firing
1. Stoker is a power-operated fuel feeding mechanism.
2. Coal is pulverized (powdered) to increase its surface exposure thereby permitting rapid combustion. Coal is
reduced to a fi ne powder in grinding mill or pulverizes.

Over feed Principle
1. The primary air enters the grate from the bottom.

2. The air while moving through the grate openings gets and picks up
additional energy. The air then passes through a layer of
incandescent coke where O2 reacts to form CO2 and H2O vapour
reacts with coke to form CO2, CO and free H2.
3. The gases leaving the incandescent coke consist of CO2, CO, H2, N2
and H2O and volatile matter of raw fuel.
4. Then additional air known as secondary air is supplied to burn the
combustible gases. The combustion of gases entering the combustor
is not complete
5. The combustion of the remaining combustible gases is completed in
the combustion chamber.

Underfeed principle
1. Air entering through the holes in the grate comes in
contact with the volatile matter in raw coal is given of
by distillation.
2. Then it passes through the incandescent coke where
reactions similar to overfeed stoker take place.
3. The gases produced then pass through a layer of ash.
4. The secondary air is supplied to burn the combustible
gases.
Advantages:
1. This gives higher thermal efficiency compared with chain grate stokers.
2. The combustion rate is considerably higher.
3. The grate is self-cleaning.
4. Different varieties of coals can be used with this type of stoker.
Chain Grate Stoker
1. Endless chain, which forms a support for the fuel bed.

2. The chain receives coal at its front through a hopper and carries it into the
furnace. The ash is carried
3. over the rear end of the stoker and deposited in the ash pit. The air enters
through the air inlets
4. situated below the grate. Initial cost is high and operations and maintenance
cost are low.
Classifications:
1. Travelling Grate Stoker
2. Spreader Stoker
3. Retort Stoker

Travelling Grate Stoker
1. Grate bar supports the fuel bed
2. The travelling stoker may be chain grate type or
bar grate type.
3. The coal is fed by gravity from a hopper located
in front of the stoker.
4. The combination of primary air and overfire air
supplied provide turbulence required for rapid
5. combustion.
6. suitable for low rating of fuel because
7. the fuel must be burnt before it reaches the rear
end of the furnace.
Any type of fuel except caking bituminous coal can be
used with chain grate stoker because of the formation of large
percentage of fine particles resulting in increased carbon loss.

Travelling Grate Stoker
Advantages
1. It is simple in construction and its initial cost is low.
2. It is more reliable in service, therefore maintenance charges
are low.
3. It gives high heat release rates per unit volume of the furnace.
4. The heat release rates can be controlled just by controlling the
speed of chain.
5. It is self-cleaning stoker.
Disadvantages
1. The amount of coal carried on the grate is small as the increase in grate size creates
additional problems. This cannot be used for high-capacity boilers 200 t/h or more.
2. The clinker troubles are very common.
3. Ignition arches are required.
4. There is always some loss of coal in the form of fine articles carried with the ashes.

1. The fast rotating blades hit the coal particles coming from
the feeder and throw it into the furnace.
Spreader Stoker
1. Coal burns on this stoker remains partly in suspension and

partly on the grate
2. Spreader stoker distributes the coal evenly over the entire
grate area. The spreader speed depends on the size of coal.
3. The fast rotating blades hit the coal particles coming from the
feeder and throw it into the furnace.
4. The feeder is a slow-speed rotating drum. (Speed is
controllable)
5. A wide variety and poor quality coal can be burnt efficiently
with this type of stoker.
Boiler capacities from 80 to 150 tons of steam per hour.
Spreader Stoker
Advantages
1. The high-temperature preheated air can be used.
2. The coking tendency of the coal is reduced before it reaches the grate by the release of volatile gases,
which burn in suspension.
3. high rate of combustion (350 kg/m2 h) giving quick response to the load change
4. It gives quick response to load change similar to pulverized fuel system due to small amount of fuel on the
grate at any time and most of heat is released during burning of the coal in suspension.
5. The fire bed gives equal pressure drop and proper air distribution so that combustion can be completed
with minimum quantity of excess air.
6. Its operation cost is considerably low.
Disadvantages
7. It is difficult to operate the system with varying sizes of coal and with varying moisture content.
8. Due to suspension, burning of fine fuel particles is the entrainment of ash in the products of combustion; a
dust collector is necessary with this stoker.
9. Many fine unburnt carbon particles are also carried with the exhaust gases resulting in a loss to the
combustion system.
Retort Stoker
 Underfeed stokers, the fuel is fed from underneath the fire and moves gradually upwards.
 The fuel releases the volatile matter as it passes through the initial fuel bed from bottom.
 The released volatile matter mixes with fresh air and enters into the combustion zone.
 The entire combustion process is highly efficient and gives high rates of heat release.
 Bituminous and semi-bituminous coals with small ash content and fusing temperature
above 1300°C (caking or non-caking) can be burnt very effectively using these stokers.
The underfeed stokers can be divided into the following two main types:
1. Single retort stoker
2. Multi-retort stoker

Single retort stoker
2. Then it is further fed by
reciprocating ram or screw
conveyor into the bottom of
1. The fuel is placed on a the horizontal trough
large hopper on the front of 3. The air is supplied through the
the furnace. tuyeres provided along the
upper edge of the grate.
The coal-feeding capacity of a single retort stoker varies from 100 to 2000 kg/h.
2. Each retort is fitted with a

Multi-retort stoker 1. It consists of a series of alternate retorts and tuyeres
reciprocating ram for feeding
boxes for supply of air
and pusher plates for the
uniform distribution of coal.
6 .The primary air is
supplied from main
3. The coal falling from
wind box to the fuel
the hopper is pushed
bed situated below the
forward during the inward
stoker.
stroke ram.
7. The partly burnt 4. The distributing rams

coal moves on to the (pushers) push the entire
extension grate. The coal down the length of the
air pressure in the stoker.
main wind box
under the stoker is
also varied to meet 5. The number of retorts may vary from 2 to 20 with local
variable load. burning capacity ranging from 300 to 2000 kg/h/retort.

Advantages
1. The building space requirement compared with pulverized system is less.
2. The capital investment as compared to pulverized system is less. The maintenance and
operating costs are less.
3. The auxiliary plant required is considerably reduced.
4. It also works for few hours in the event of coal-handling plant failure as large amounts of
coal are stored on the grate.
5. The dust collection problems are less severe compared with pulverized system as most of
the ash is removed from the grate.
6. The stoker firing systems are more reliable.
Disadvantages
7. The loss of coal is more through riddling.
8. There is heavy wear and tear of moving parts due to abrasive action of coal.
9. The troubles of clinkering of combustion chamber walls are very common.
10. The sudden variations of load cannot be met to the same degree of efficiency as in the case
of pulverized fuel firing.

PREPARATION AND BURNING OF PULVERIZED COAL
1. Coal is pulverized (powdered) to increase its surface exposure thereby permitting

rapid combustion.
2. Coal is reduced to a fine powder in grinding mill or pulverizers.
There are two methods used to feed pulverized fuel to the furnace.
Unit or Direct System
Bin or Central System
Note : The efficient utilization of pulverized coal depends to a large extent upon the
ability of the burners to produce uniform mixing of coal, air and turbulence within
the furnace.

The pulverized coal burners should satisfy the following requirements:
1. It should mix the coal and primary air thoroughly and project the same in the
furnace properly with secondary air which is generally added around the
burner.
2. It should create proper turbulence and maintain stable combustion of coal and
air throughout the operating range of the plant.
3. It should control the flame shape and its travel in the furnace.
The factors affect the performance of the pulverized fuel burner are, the
characteristics of the fuel used, fineness of the powdered coal, volatile matter, the
geometry of the burner, place of mixing the fuel and air, proportions of primary and
secondary airs, furnace design and patterns of load changes.

Unit or Direct System
1. A separate pulverizing unit is

provided for each furnace and
the fuel is fired directly into the
furnace without being stored.
2. The raw coal from overhand

coal bunker falls into a feeder
and there it is dried by Disadvantages
Advantages
supplying hot air. 1. System is simple and cheaper. 1. Mill operates at variable
2. Direct control of combustion load.
3. The coal is then transferred to the from pulverizing mill is 2. System is less flexible.
pulverizing mill where it is pulverized. possible. 3. No reserve.
Primary air is supplied to the mill by the 3. Coal transportation system is 4. Fan handles air + coal
fan. simple. mixture.

Bin or Central System
1. The pulverized coal from the mill is

transferred to pulverized coal bunker.
2. The air from the coal is separated in the
cyclone separator and returned to the
mill.
3. The primary air is mixed at the feeder and
the mixture is supplied to the burner.
Advantages
 Pulverizing mill grinds the coal at steady rates irrespective of the load.
 Exhaust fan handles clean air.
 For a given boiler capacity, pulverizing mill of smaller capacity will be required

Advantages of Pulverized Coal Burning
1. By breaking, a given mass of coal into smaller pieces exposes more coal surface
area for combustion.
2. Greater surface area of coal per unit mass of coal allows faster combustion as more
coal surface is exposed to heat and oxygen.
3. The system is perfectly free from clinker and slagging problem.
4. Wide variety and low-grade coal can be burnt more easily.
5. The external heating surfaces are free from corrosion and fouling as smokeless
combustion is possible.
6. The boilers can be started from cold very rapidly and efficiently.
7. Rate of feed of the fuel can be regulated
8. The life of the system is more and the operation is less troublesome due to the
absence of moving parts in the furnace.
Disadvantages of Pulverized Coal Burning
1. As additional equipment is essential to pulverize the coal, the initial

cost is more.
2. Pulverized coal firing produces fly ash, which requires separate fly
ash removal equipment.
3. The furnace has to be designed to withstand high temperature.
4. There will be a chance of explosion.
5. Special equipment is required for starting the system.


Bowl Mill (Pulverizer)

FUEL-BURNING EQUIPMENTS
Stream-line burner
1. It is also known as long-flame or U-flame burner
2. It is designed to fire downwards in the furnace

without any turbulence.
3. This type of burner is suitable for burning fuels

with low volatile matter as fuel flows at low
velocity (15–45m/s)
4. Hence takes more time to travel in the furnace.
Tangential burner
Fuel and air streams are

ejected in a horizontal direction
tangent to an imaginary circle at
the centre of the furnace.

Cyclone burner
1. Used to burn crushed coal instead of pulverized coal. This is to

eliminate fly ash-handling problems.
2. Crushed coal of about 8mm size is fed from the feeder to the
centre of the cyclone along with primary air.
3. The secondary air is supplied separately to increase the vortex
flow.
4. Due to centrifugal action most of the fly ash is thrown against
the furnace wall and is drained out along with molten slag.
Thus, flue gases leaving the furnace are clean.
Draught System
 Boiler draught is the pressure difference required to maintain constant flow
of air into the furnace and to discharge the flue gases to the atmosphere
through a chimney.
 Thus, boiler draught is one of the most essential systems of a thermal
plant.
Draught System
Natural draught
The draught produced by the chimney is due to the difference in temperature of hot
flue gases inside the chimney and the atmospheric air.
Artificial or mechanical draught
This type of draught is preferred when the draught produced by the chimney is not
sufficient or when a certain draught is to be maintained irrespective of atmospheric
temperature.
1. Forced draught
2. Induced draught
3. Balanced draught
Draught System
Forced draught
1. A blower is installed near the base
of the boiler that blows air into the
furnace.
2. The pressure of air throughout its
path is above atmospheric pressure.
3. This system also uses a chimney to
discharge hot flue gases into the
atmosphere.
Draught System
Induced draught
A blower is installed near the base of the chimney so as to facilitate sucking

of flue gases from the furnace
Draught System
Balanced draught
 FD fan installed near the boiler helps in

overcoming the resistance of fuel bed by
supplying sufficient air for combustion.
 An ID fan installed near the chimney
base removes the flue gases that come
from the furnace, allowing the furnace
pressure to be maintained slightly below
atmospheric pressure.
DUST COLLECTION
 The exhaust gases leaving the boiler contain fine particles of solid matter in
suspension in the form of smoke, dust, soot, fly ash or cinder.
 In the case of pulverized fuel firing, about 80 percent of total ash produced
in the furnace escapes through the chimney in the form of fine particles
(particulates varying from 1 to 80 μ).
Dust collectors may be either mechanical or electrical type.
DUST COLLECTION
Mechanical Dust Collectors
Mechanical dust collectors may be either dry or wet type. In the case of wet-type collectors, dust
is washed away by spraying water on it.
Gravitational separators
The gas velocity reduces due to

increased duct area. Heavier dust
particles settle at the bottom
DUST COLLECTION
Cyclone separator
 High-velocity flue gas carrying dust is made
to pass through a conical separator in a
tangential direction a centrifugal action
(whirling motion), throwing away the
heavier dust particles to the sides of the
conical chamber.
 Dust-free gas from the conical shell is
passed through a secondary chamber to the
chimney.
 Heavier dust particles accumulate on the
inner surface of the shell and settle at the
bottom.
DUST COLLECTION
Electrical Dust Collector (Electrostatic Precipitators) 2. Collecting electrodes
are connected to the
Basic elements: positive polarity of the
1. Source of high voltage source and earthed
2. Ionizing and collecting electrodes
3. Dust-removal mechanism
4. Shell to house the elements
It consists of two sets of electrodes 3. Collecting electrode

• Emitting or discharging having large contact
electrode surface.
• Collecting electrode
4. Efficiency of this
1. Emitting electrodes are placed in the centre of the
collector was 90%.
pipe. The emitting electrodes are connected to negative
polarity of high-voltage (20–100 kV) DC source.
DUST COLLECTION
Electrostatic Precipitators
DUST COLLECTION
Electrostatic Precipitators
Advantage
1. Can effectively remove very small particles like smoke, and fly ash
2. Easy operation
3. Maintenance charges are minimum compared with other types of
collectors
Disadvantage
1. Space requirement is more. (than wet system)
2. Capital cost of equipment is high
3. If gas velocity exceeds the limit means efficiency will reduces.
4. Collect mostly very small particles.
COOLING TOWER
 Specialized heat exchanger in

which air and water are brought
into direct contact with each
other in order to reduce the
water's temperature.
 As this occurs, a small volume
of water is evaporated, reducing
the temperature of the water
being circulated through
the tower.
COOLING TOWER
Natural draft spray filled tower
1. The air enters through the louvered sides and

flows across the unit in a transverse direction.
2. The air circulation through the tower depends
on wind velocity.
3. The capacity of this tower varies from 50 to 100
liters per minute per m2 of base area depending
upon the air velocity.
Note : This is not used for high capacity thermal plants

as cooling range is limited, wind losses are high and
there is no control over the outlet temperature of water.
COOLING TOWER
Forced draught Cooling tower
Cooling tower fill is to put

as much water surface area
in contact with as much air
as possible, for the longest
amount of time possible.
(Film fills allow the water
to form thin flowing sheets
to expose as much water
surface area as possible to
the interacting flow.)
COOLING TOWER
Induced draught Cooling tower
 In cooling tower, there is evaporative water

loss to the environment.
 When liquid water becomes entrained in the
leaving air stream, however, drift
eliminators are used to minimize the
amount of water carried out of the cooling
tower with the exhaust air.
COOLING TOWER
Advantage and Disadvantage Comparison
Forced draught Cooling tower Induced draught Cooling tower
Low Effective (Low space is

More Effective
required)
Air velocity through the packing are
No problem of fan blade erosion (dry
un even. Humidity air is flowing
air only)
through the blade
More Safe Less Safe
Higher HP motor is required to drive
Vibration and noise is minimum
the fan (Noisy)
Power required is less More power is required
Cold weather – Ice forming in blade
No ice formation in cold weather
surface
FEED WATER TREATMENT
 Natural water contains impurities in colloidal or suspension

form in addition to dissolved impurities.
 Major impurities found in colloidal or suspension form
include mud, silt, clay, silica, etc., and that found in the
dissolved form include carbonates, bicarbonates, phosphates
and sulphates of calcium, magnesium, sodium and gases such
as CO2 and O2.
 These impurities when operated at high pressure get
deposited on the heat transfer surfaces, thereby reducing the
rate of heat transfer.
 In a modern steam-condensing plant, it is very essential to
use nearly 3–5 percent of external water as make-up to
counterbalance the losses. For a power plant of 500 MW
capacity, the make-up water requirement is anywhere
between 200 and 225 t/h.

Feed Water Impurities
Dissolved solids
Undissolved and suspended solids
These include carbonates and bicarbonates of calcium
(i) Turbidity and sediments
and magnesium, namely calcium carbonates (CaCO3),
Turbidity in water is due to suspended soluble
calcium bicarbonate [Ca(HCO3)2], magnesium
matters such as mud, sand, sediments, etc., which
rapidly settle down when there is no disturbance. carbonate (MgCO3) and magnesium bicarbonate
Turbidity of feed water should not exceed [Mg(HCO3)2].

5–10 ppm. These produce hard stony deposits on Other solids include calcium sulphate (CaSO4);
heating, which cling to the heat transfer surface. sodium bicarbonate; sodium sulphate; magnesium
(ii) Chlorides, sodium and potassium salts sulphate; nitrates of calcium and magnesium;
Chlorides of calcium, sodium and magnesium; silica;
iron oxide; and gases such as O2 and CO2.
Mechanical Methods
Sedimentation
1. In this method, water with suspended solid matter is made to either stand still or flow with very
low velocity.
2. The solid matter settles down due to gravity and is removed regularly.
3. Clear water is drained from the surface.

Filtration
1. This method is useful to remove suspended solid matter
that cannot be removed by sedimentation.
2. Water is allowed to flow downwards through a fine
strainer or porous beds of graded sand.
3. By increasing the fineness of the filtering element,
maximum suspended impurities are removed.
4. The suspended matter clings to the filter material and clear
water drains from the bottom.
5. To improve the filtering process, coagulants such as
aluminium sulphate and sodium aluminate are used with
water.
6. These additives react with alkaline salts in water to
produce gelatinous substance that settles down or gets
filtered very easily.

Thermal Methods
Distillation
It is the process of evaporating raw water using steam. Vapours are collected and condensed to
supply pure feed water.
Deaerative heating
 Gases such as oxygen, carbon dioxide, air, H2S, etc.,

which are in dissolved form in water, can be
removed by using Deaerative heating method.
 This is done by heating water between 105 and
110°C added by agitation in a deaerator.
 Water is then passed through a spray distributor from
where it falls in the form of spray over heating trays
and air separator trays.
Chemical Methods
Hot lime–soda process
 Hot lime (calcium hydroxide) and soda ash (sodium carbonate) are used to treat calcium and
magnesium salts.
 The reactions are carried out in the presence of hot water (100°C) heated by steam.
The carbonate hardness is removed by hot lime as follows:

Ca(HCO3) + Ca(OH2) → 2CaCO3(↓) + 2H2O
Calcium hydroxide
Mg(HCO3)2 + 2Ca(OH2) → 2CaCO3(↓) + Mg(OH)2(↓) + 2H2O
Chemical Methods
Hot lime–soda process
The sulphate hardness of calcium and magnesium is removed by soda ash as follows:
MgSO4 + Na2CO3 → MgCO3(↓) + CaCl2
The magnesium carbonate further reacts with lime to form magnesium hydroxide sludge.
MgCO3 + Ca(OH2) → Mg(OH2)(↓) + CaCO3(↓)
 The magnesium oxide formed has coagulating properties and helps in rapid precipitation.
 It also absorbs soluble silica from the solution. Hence, it is purposely added to water to
remove silica
Chemical Methods
The chloride hardness of calcium and magnesium are removed by soda and lime, respectively, as
follows:
CaCl2 + Na2CO3 → CaCO3(↓) + 2NaCl
MgCl2 + Ca(OH)2 → Mg(OH)2(↓) + CaCl2

Trisodium phosphate and caustic soda can also be used in addition to lime and soda. Phosphate is
very effective in removing calcium and magnesium salts.
3Ca(HCO3)2 + 6NaOH → 3CaCO3(↓) + 3Na2CO3 + 6H2O
Mg(HCO3)2 + 4NaOH → Mg(OH2)(↓) + 2Na2CO3 + 2H2O
3CaSO4 + 2Na3PO4 → Ca3(PO4)2(↓) + 3Na2SO4

Power Plant Engineering, Unit - I
3MgSO + 2Na3PO4 → Mg3Dr.(PO
4
A. Saravanan, Professor of Mechanical Engineering
4)2(↓) + 3Na2SO4
Wednesday, February 23, 2022
Chemical Methods
Demineralizing water treatment
1. Most economical method of supplying

mineral-free water to high-pressure boilers.
2. The system consists of a catexer

(cation exchanger) and an anexer (ion
exchanger) along with degasifying tower
and silica absorber.
Chemical Methods
3. The anion exchange resins
in the anexer remove anions
such as chlorides, sulphates
1. Raw water is first passed and nitrates from the water in
through the catexer that contains addition to removing acid
a weak acid to remove radicals.
bicarbonates.
2. The acidic water that contains

weak acids such as carbonic acid,
hydrochloric acid and sulphuric
acid is then passed through the
anexer.
Chemical Methods
4. Water free from dissolved solids now enters the degasifier containing porcelain packing. As water flows downwards, it
comes in contact with the air blown from a blower.
6. Water is then
5. Carbon dioxide is pumped to the silica
liberated and escapes from absorber that contains
the vent. The degassed a strong base anion
water is collected in the
resin. The resin
tank below the degasifier.
absorbs silica and
reduces it to 0.02
ppm.
JNTU UNIVESITY QUESTIONS

1. What are renewable and non - renewable energy sources? Discuss with reference to Indian scenario.
2. Why ash and dust handling is more difficult than coal handling?
3. Classify and explain the working of mechanical dust collectors.
4. Make neat sketch and explain the working of (i) Chain stoker (ii) Spreader stoker
5. Explain with a simple sketch working of travelling grate stoker with its Limitations.
6. What are problems caused by impurities in feed water in a boiler?
7. What are the different ash handling systems? And explain mechanical handling system.
8. Explain with the neat diagram the working of different types of wet type mechanical dust collectors.
9. Describe the various types of grates used with hand fired furnace.
10. Explain with a simple sketch working of thermal power plant.
11. What are the methods available for feed water treatment, explain them briefly?
12. Explain with a simple sketch, working of a cyclone separator.
13. Distinguish between forced draught and induced draught cooling towers.
14. What are belt conveyors and what are its advantages and limitations?
15. What are the advantages of mechanical draught in a boiler?

Power Plant Engineering: Aditya Engineering College (A) Aditya Engineering College (A)

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Power Plant Engineering: Aditya Engineering College (A) Aditya Engineering College (A)

Uploaded by

Copyright:

Available Formats

ADITYA ENGINEERING COLLEGE (A)

POWER PLANT ENGINEERING

At the end of the Course, Student will be able to:

CO 1 : Explain the source of energy, resources and development of power

Conventional Sources of Energy

Commercial Energy Sources:

Non-Commercial energy Sources:

Non-Conventional Sources of Energy

Development of power in India

Steam Power Plant

Purpose of steam power plant

1. To produce electric power

Classification of Steam power plants:

 Coal and ash circuit

Components of a Modern Steam power plant:

1. Boiler (Superheater, Reheater, 8. Crusher house

Selection of site for steam power station

1. Availability of raw materials 7. Availability of labour

Thermal Power Plant in India – Top 10

1. Vindhyachal Thermal Power Station, Madhya Pradesh - Singrauli district of

Thermal Power Plant in India – Top 10

Thermal Power Plant in India – Top 10

8. Sipat Thermal Power Plant, Chhattisgarh - 2,980MW Bilaspur district,

Thermal Power Plant Andhra Pradesh

1. Ramagundem Thermal Power Station – NTPC (2600 MW), Telungana

Stages of coal Handling

Stages of coal Handling

Stages of coal Handling

Stages of coal Handling

Diameter of the screw:

Stages of coal Handling

 Grab bucket conveyors

Costly machine, 50 tonnes per hour only

Stages of coal Handling

Ash handling system

Classification of ash-handling systems

Ash handling system

Mechanical handling system

Ash handling system

Clean and healthy

Ash handling system

Pneumatic or Vacuum system

The power requirement of mechanical exhauster is approximately 3 kW

Combustion - Steam Power Plant

Lower calorific 10,500 14,650 12,500 32,000 35,500

Combustion - Steam Power Plant

Disadvantages of solid fuels

Combustion - Steam Power Plant

Combustion - Steam Power Plant

Combustion - Steam Power Plant

Combustion - Steam Power Plant

Combustion - Steam Power Plant

1. The primary air enters the grate from the bottom.

Combustion - Steam Power Plant

Combustion - Steam Power Plant

Chain Grate Stoker

1. Endless chain, which forms a support for the fuel bed.

Combustion - Steam Power Plant

Combustion - Steam Power Plant

Combustion - Steam Power Plant

1. Coal burns on this stoker remains partly in suspension and

Combustion - Steam Power Plant