WELCOME

TO THE

PRESENTATION
COAL TO ELECTRICITY/POWER
 THOUGHT FOR THE DAY

IF you CAN SEE THE

OPPORTUNITY IN EVERY
OBSTACLE YOU FACE, THEN
NOTHING CAN STOP YOU FROM
YOUR HAPPINESS ANS
SUCCESS…..
THOUGHTS CAN PROVOKE, WORDS CAN INSPIRE-
BUT ONLY ACTION CAN BRING YOU CLOSER TO
YOUR DREAMS……..
 Unit of Electricity
MW: Mega Watt 1 MW= 106 Watt
GW: Giga Watt 1 GW = 109 Watt
TW: Terra Watt 1 TW = 1012 Watt

1 Watt : 1 Joule/Sec
1unit of Electricity : 1 KWh
100 MW Plant Generate Electricity in one day
= 100 x 103 KW x 24 hr = 2400,000 KWh = 24,00,000 units = 2.4 MUS
NTPC – Vindhyachal capacity
Thermal: 4760 MW (Thermal) + 15 MW (Solar) + 8 MW (Hydro) = 4783 MW
NTPC – Vindhyachal Generates Electricity in one day = 4783 x24 /1000 = 114.79 Mus
which can lit 4 crore 78 lacs nos of 100-Watt bulb continuously

4
 BASIC TERMS IN POWER PLANT

Sp Coal ( Kg/Kwh)
Heat Rate (Kcal /Kwh)
APC (% of Kwh Gen)
Cycle Efficiency (%)
ECR (Rs/Kwh)
Environment Parameter
Customer Satisfaction
 BASIC TERMS IN POWER PLANT

Generation (MUs)
PLF (%)
APC (% of Kwh Gen)
LF (%)
SG &AG
DC
POWER ALLOCATION
Coal to Power
Modern Industrial &Utility
Plant
 Coal to Power
Various Systems in a power plant

 WATER MAKE UP SYSTEM

 MGR
COAL HANDLING SYSTEM
DM PLANT
WATER CIRCULATING SYSTEM
 ACW , ECW SYSTEM
 CONDENSATE SYSTEM
 FEED WATER SYSTEM

 STEAM CIRCUIT SYSTEM

TURBINE
 BOILER AIR SUPPLY SYSTEM
 FG SYSTEM
 ASH HANDLING
 ELECTRICAL SYSTEM
 GENERATOR SYSTEM
 POWER EVACUATION SYSTEM (SWITCHYARD)
CHEMICAL ENERGY Combustion
in Furnace THERMAL ENERGY
of Fuel

Steam

Complete Combustion
MECHANICAL ENERGY
in Turbine
Other combustibles&
Non combustibles
 NTPC GADARWARA WATER SUPPLY

CW scheme…
56 cusec

River Intake channel Intake P/P

Make up Sump
Cooling tower

Make up P/P

CW Duct Reservoir

Condenser CWDC/OAC DM plant

CW pumps 11
 CHP LAYOUT
Wagon Tipplers Capacity
& Apron feedrs
5.5 L
A

B TP-1 TP-11 TP-12 TP-13

IR Boxn Wagon

S/R-2
Coal
Unloading
Area
TP-5 TP-6

S/R-1

CRUSHER TP-2 TP-3 TP-4

Towards
Bunkers
 GADARWARA SUPER THERMAL POWER PROJECT
STAGE-I: 2X800MW, COAL HANDLING POINT

MAJOR
NOS CAPACITY BRIEF SEPECIFICATION
EQUIPMENTS

Wagon tippler 03 25 Tips/Hr Side discharge type

Apron feeder 03 2400 TPH Pan & Chain type

Coal Crusher 04 1320 TPH Ring Granulator

 GADARWARA SUPER THERMAL POWER PROJECT
STAGE-I: 2X800MW, COAL HANDLING POINT

MAJOR
NOS CAPACITY BRIEF SEPECIFICATION
EQUIPMENTS
Unidirectional, rail mounted,
A) Stacker Reclaimer 02 2400 TPH
slewing, luffing & hydraulic
bucket wheel type.

B) Coal Yard 04 5 Lakh MT 1.25 Lakh MT each yard

C) Coal conveyors
system
1. Total length of
- 12.5 KM Total 27 No of Conveyors
conveyors
2. Belt speed - - 3.4 M/S
 GADARWARA SUPER THERMAL POWER PROJECT
STAGE-I: 2X800MW, COAL HANDLING POINT

Environment Friendly Equipments

EQUIPMENTS NOS BRIEF SEPECIFICATION

Dust Suppression system 02 1) For Coal yard

(M/s Eagle) SET
2) Wagon Tippler area
Dry Fog Dust Suppression 02 For all conveyors system
System SET
(F.Harley)

Dust Extraction system 01 For Crusher house

(M/s Ricoh)
Introduction to Supercritical
Technology
What is Supercritical Pressure ?

Critical point in water vapour cycle is a

thermodynamic state where there is no clear
distinction between liquid and gaseous state
of water.
Water reaches to this state at a critical
pressure above 22.1 MPa and 374 oC.

16
 WATER WALL ARRANGEMENT

 Bottom spiral & top vertical tube furnace arrangement

 Once through design feature is used for boiler water wall

design

 The supercritical water wall is exposed to the higher heat

flux

 Spiral tube wall design (wrapped around the unit) with

high mass flow & velocity of steam/water mixture through
each spiral

 Higher mass flow improves heat transfer between the

WW tube and the fluid at high heat flux. 17
 800 MW BOILER
• Once Through

• Spiral wall evaporator approx. up to

nose height and remaining vertical
wall evaporator.

• Two-pass

• Radiant reheat

• Balanced draft

• Low load start-up system up to

40%BMCR load.

• Tilting Tangential burners (max heat

input per burner: 60 X106 kcal/hr)
 800 MW BOILER
• Total air: 2808 t/hr
• MS flow: 2335 t/hr
• MS pressure: 257 ksc
• MS temp: 568 deg C
• HRH pressure: 56.14 ksc
• HRH temp: 596 deg C
• Feed water flow: 2241 t/hr
• SH spray flow: 93 t/hr
• RH spray flow: 0 t/hr
• Coal flow: 538 t/hr of GCV: 3200
kcal/kg
• Mills in service: 8/9
• O2 in flue gas: 3.6%
 568°C, 257
KSC 456°C, 274
596°C, 48.6 520 KSC
KSC °C
510°C 353°C, 296
50.4 KSC
KSC ECO O/L
438°C 102
HDR
M 9
277 KSC
9
97. M
FUR
ROOF 4M
I/L HDR

97
M
SEPARAT
OR
9
FINAL
S 2 FINAL SH 7
T
M RH
7 LTRH
O 7
R PLATE M
A
5 N SH
G M
E
6
T 2
VERTICAL 340°
A M
N WW C 51

G K
7
4
KSC ECO
JUNCTIO
N HDR
LPT LPT IPT
M6
HPT
5 ECONOMISER
M
CONDEN
SER
BP LOWER
4 HDR

CRH ECO5
r
ate
LINE I/L
M
l w
ira lls
1 Sp wa
C 4
E M FT
P
DT
LP
HEATER
S DEAERA 6
FEED WATER
TOR BRP M
292°C, 302
KSC
1
5 FUR LOWER
BFP HP FRS
M HDR
HEATERS
 AIR AND FLUE GAS PATH DRAFT SYSTEM
TO MILLS

PAPH-A

PRIMARY
PA FAN -A

SCAPH-A
ECO BYPASS TO ESP

AEROFOIL

SECOND
SCAPH-A
SAPH-A
AA205 AA203 AA202

AA201
AA204
FD FAN -B

SA HDR
HORIZONTAL S.H

ECONOMISER -1

ECONOMISER -2
PANELETTE S.H

ECONOMISER-3

HOT PA HDR
PLATEN S.H

RE HEATER

COMBUSTION
DIVISION

CHAMBER

HOT
AA204 AA201

AA205 AA203 AA202

SAPH-B

SECOND
FD FAN-A

SCAPH-B
AEROFOIL

ECO BYPASS TO ESP

COLD SEC. AIR BIPLANE DAMPER
COLD PRIM AIR

PRIMARY
SCAPH-B
HOT PRIMARY AIR DIVERTER DAMPER

PAPH-B
HOT SEC. AIR
FLUE GAS

PNEUMATICALLY O/P
KNIFE EDGE GATE
TO MILLS
MOTOR O/P LOUVER
DAMPER
PA FAN -A
PNEUMATICALLY O/P
LOUVER DAMPER
November
MOTOR O/P GATE
22, 2023 PMI Revision 00
 Need of Draft System

Combustion Air Boiler Flue Gases

• Air needed for combustion

• Flue are needed to be evacuated
• Losses due to flow need to be overcome
November 22, 2023 PMI Revision 00
S.C. Boilers and its Efficiency - Rankine Cycle
“Supercritical" is a
thermodynamic expression
describing the state of a
substance where there is no
clear distinction between
the liquid and the gaseous
phase.

Critical Pr./Temp.(°C):
225.56 Kg/cm2 /374.15°C

This "critical point" is at

the apex of the saturation
line on T-s coordinates.
Source :
Wikipedia
 Combustion Safeguards and Controls

• Furnace Explosion : The ignition and almost instantaneous combustion of

highly inflammable gas or vapour or dust accumulated in furnace.
• Conditions leading to Furnace Explosion:
– Accumulation of unburned fuel.
– Air and fuel in an explosive mixture.
– Source of ignition. -- hot furnace walls, improper ignition timing, faulty
ignitor etc.
• Types of Furnace Explosions:
– Gas explosions and coal dust explosions.
– Primary and Secondary.
• Reasons for increased number of furnace explosions:
– Large Boilers -- higher burner capacity
– Compact furnaces.
– Low fire box temperatures in water tube boilers.
– New fuels.
 Causes of Fire Explosions

• Flame failure due to liquids or inert gases entering the

boiler fuel system.
• Insufficient purge before lighting the first burner.
• Human error.
• Faulty automatic fuel regulating controls.
• Fuel shutoff valve leakage.
• Unbalanced fuel/air ratio.
• Faulty fuel supply systems.
• Loss of furnace draft.
• Faulty pilot igniters.
 ASH HANDLING
Furnace ESP
(1300 - 1500°C)

Economizer Electrostatic Stack

Precipitator
Air
preheater
Pulverize APH
d
Coal

Coal Bottom Ash Eco Ash APH Ash Fly ash

100 % 10-20 % 1% 1% 80-90 % Ash
Fineness
November 22, 2023 PMI Revision 00 28
 HEAT RATE

Total fuel input

Heat Rate = ------------------
Electrical generation (KW)

2150 Kcal/kwh
1832 Kcal/kwh
2237 Kcal/kwh
Boiler Eff – 85.26 %
Cycle Eff -- ~40 %
APC 6.25 %
S.C. Boilers and Efficiency – Circulation in Boiler
 Once through forced circulation system is used for
generating steam in Supercritical Boiler above min.
load.
 C.R. of Once through forced circulation system = 1

 During Startup and low load operation (below 45%

load) recirculation system assisted by BRP maintains
circulation in Boiler with Separator carrying out
separation of steam water mixture.
 In once through forced circulation system, at high load
the slightly sub cooled water enters economizer,
evaporate in evaporator and gets slightly superheated
while existing evaporator.
S.C. Boilers and its Efficiency

 CYCLE EFFICIENCY IS ~40%

 INCREASE IN CYCLE EFFICIENCY IS MAINLY

CONTRIBUTED BY:
USE OF HIGH PRESSURE AND HIGH
TEMPERATURE STEAM @ TURBINE INLET :
247 KG/CM2 AND 567 & 593 Deg C for HRH
 USE OF HIGH FEED WATER TEMPERATURE-
290°C
 REHEATING.
 Coal to Power
2x15 STAGES

18 STAGES

2 X2 X 5
STAGES

Turning gear: hydraulic, 50~60 RPM

MS pressure: 247 ksc

Two series cooled condensers

MS/HRH temp: 565/593 deg C

2 TDBFPs 2X50% and 2 MDBFPs 2X30%

 941MVA ,
Siemens Make

27KV, 20122
KA, H2 cooled
rotor and
water cooled
stator

Stator Cooling
Rotor Cooling
Core Cooling
H2 Gas sealing
Excitation System
Generator: Generator Efficiency=98.92%

Faradays laws of electromagnetic induction:

First law:
Whenever a conductor is placed in a rotating magnetic field, an emf will be induced in it
Second law:
The magnitude of emf is proportional to rate of change of flux linking the conductor
E = k* flux linking the conductor
 Clickevacuation
Power to edit Mastersystems
title style

Copyright © 2016 Your Company All Rights Reserved. 34

 Electrical Terminology :
 A switchgear essentially consists of switching and protecting devices such as switches, fuses,
circuit breakers, relays etc. The apparatus used for switching, controlling and protecting the
electrical circuits and equipment is known as switchgear.

 Isolator or disconnecting switch It is essentially a knife switch and is designed to open a circuit
under no load. Its main purpose is to isolate one portion of the circuit from the other and is not
intended to be opened while current is flowing in the line.

 Fuse A fuse is a short piece of metal, inserted in the circuit, which melts when excessive current
flows through it and thus breaks the circuit.

 Contactor is an electrically controlled switch used for switching an electrical power circuit.
Circuit breaker: A circuit breaker is an equipment which can open or close a circuit under
all conditions viz. no load, full load and fault conditions. It is so designed that it can be
operated manually (or by remote control) under normal conditions and automatically
under fault conditions.

Relay: A relay is an automatic device which senses an abnormal condition in an electric

circuit and closes its contacts. These contacts in turn close the circuit breaker trip coil
circuit, thereby it opens the circuit breaker and the faulty part of the electric circuit is
disconnected from the rest of the healthy circuit
 भगवद् गीता 6.5

उद्धरेदात्मनाऽऽत्मानं नात्मानमवसादयेत्।
आत्मैव ह्यात्मनो बन्धुरात्मैव रिपुरात्मनः

Uplift yourself by yourself, do not deprecate yourself. Only

you are your friend, and only you are your enemy.

A Powerful message in this shloka.

Message is that in order to progress we have to lift ourselves by our
own efforts. We are our own friend if we do so, and if we don’t, we
become our own enemy. In other words, our success and failure is
entirely in our hands. No other person can do it for us