Lecture 3

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POWER STATION

EEN 455 – Lecture 3


STEAM POWER STATIONS

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MAIN UNITS OF STEAM
POWER STATION

• Coal and ash handling arrangement


• Steam generating plant
• Steam turbine
• Alternator
• Feed water
• Cooling arrangement

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COAL AND ASH HANDLING
ARRANGEMENT

• The coal is transported to the power station by road or rail or ship and is
stored in the coal storage plant.
• From the coal storage plant, coal is delivered to the coal handling plant where
it is crushed into small pieces (pulverized) in order to increase its surface
exposure, thus promoting rapid combustion without using large quantity of
excess air.
• The pulverized coal is fed to the boiler by belt conveyors. The coal is burnt in
the boiler and the ash produced after the complete combustion of coal is
removed to the ash handling plant and then delivered to the ash storage plant
for disposal.
• A 100 MW station operating at 50% load factor may burn about 20,000 tons of
coal per month and ash produced may be 10% ~ 15% of coal fired i.e., 2,000
~ 3,000 tons.
• About 50% to 60% of the total operating cost consists of fuel purchasing and
its handling.
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STEAM GENERATING
PLANT

Steam generating plant unit consists of the followings:


• Boiler
• Superheater
• Economizer
• Air preheater

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BOILER

• A boiler is closed vessel in which water is converted into steam


by utilizing the heat of coal combustion. The heat of combustion
of coal in the boiler is utilized to convert water into steam at
high temperature and pressure. The flue gases from the boiler
make their journey through superheater, economizer, air pre-
heater and are finally exhausted to atmosphere through the
chimney.

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TYPES OF BOILER

• Vessel in which water is converted into steam by utilizing


the heat of coal combustion.
• Steam boilers are broadly classified into the following
two types :
• Water tube boilers
Water flows through the tubes and the hot gases of
combustion flow over these tubes.
• Fire tube boilers
The hot gases of combustion pass through the tubes
surrounded by water.
• Water tube boilers require less space, smaller size of
tubes and drum, have high working pressure due to small
drum, less liable to explosion and for these reasons 8

water tube boilers are used in large capacity steam


WATER TUBE BOILER VS
FIRE TUBE BOILER

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FLUE GAS

• Flue gas is the gas exiting to the atmosphere via a flue, which is a
pipe or channel for conveying exhaust gases from a fireplace, oven,
furnace, boiler or steam generator. Quite often, the flue gas refers to
the combustion exhaust gas produced at power plants.
• Flue gases are a mixture of combustion products including water
vapor, carbon dioxide, particulates, heavy metals, and acidic gases
generated from direct (incineration) or indirect (gasification and
pyrolysis) oxidation of RDF or intermediate syngas.

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SUPERHEATER

• The steam produced in the boiler is wet and is passed through a


superheater where it is dried and superheated (i.e., the steam
temperature increased above that of boiling point of water) by
the flue gases on their way to chimney.
• Superheating provides two principal benefits. Firstly, the overall
efficiency is increased. Secondly, too much condensation in the
last stages of turbine (which would cause blade corrosion) is
avoided. The superheated steam from the superheater is fed to
the steam turbine through the main valve.

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SUPERHEATER (CONT.)

Superheaters raise the temperature of steam above boiling point of


water. This increases the overall efficiency of the plant. A superheater
consists of a group of tubes made of special alloy steels such as
chromium-molybdenum. These tubes are heated by the heat of flue
gases during their journey from the furnace to the chimney.
a) Radiant superheater (b) Convection superheater
The radiant superheater is placed in the furnace between the water
walls and receives heat from the burning fuel through radiation
process. It has two main disadvantages. Firstly, due to high
furnace temperature, it may get overheated and requires a careful
design. Secondly, the temperature of superheater falls with increase in
steam output.
A convection superheater is placed in the boiler tube bank and receives
heat from flue gases entirely through the convection process. As the
temperature of superheater increases with the increase in steam
output, this type of superheater is commonly used these days.

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ECONOMIZER

• An economizer is essentially a feed water heater and derives


heat from the flue gases. The feed water is fed to the
economizer before supplying to the boiler. The economizer
extracts a part of the heat of flue gases to increase the feed
water temperature. This results in raising boiler efficiency,
saving in fuel and reduced stresses in the boiler due to higher
temperature of feed water. An economizer consists of a large
number of closely spaced parallel steel tubes connected by
headers of drums. The feed water flows through these tubes
and the flue gases flow outside. A part of the heat of flue gases
is transferred to feed water, thus raising the temperature of the
latter.

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AIR PREHEATER

• An air preheater increases the temperature of the air supplied for


coal burning by deriving heat from flue gases. Air is drawn from
the atmosphere by a forced draught fan and is passed through
the air preheater before supplying to the boiler furnace. The air
preheater extracts heat from flue gases and increases the
temperature of air used for coal combustion. The principal
benefits of preheating the air are: increased thermal efficiency
and increased steam capacity per square meter of boiler surface.

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R E LAT I V E PO S I T I O N O F
SU PE R H E AT E R , E C O N O M I Z E R , A IR
PR E H E AT E R

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STEAM TURBINE

• The dry and superheated steam from the superheater is fed to


the steam turbine through the main valve. The heat energy of
steam when passing over the blades of the turbine is converted
into mechanical energy. After giving heat energy to the turbine,
the steam is exhausted to the condenser which condenses the
exhausted steam by means of cold water circulation.

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ALTERNATOR

• The alternator is coupled to a steam turbine which converts the


mechanical energy of the turbine into electrical energy.
• The electrical output from the alternator is delivered to the bus
bars through the transformer, circuit breakers, and isolators.
• Some other electrical equipment:
• Transformers
• Switchgears

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FEED WATER

• The condensate from the condenser is used as


feed water to the boiler. The feed water on its
way to the boiler is heated by water heaters and
economizer. This helps in raising the overall
efficiency of the plant.

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COOLING ARRANGEMENT

• In order to improve the efficiency of the plant, the steam


exhausted from the turbine is condensed ( water vapor is
changed to liquid water) by means of a condenser. Water is
drawn from a natural source of supply such as a river, canal or
lake and is circulated through the condenser. The circulating
water takes up the heat of the exhausted steam and itself
becomes hot. This hot water coming out from the condenser is
discharged at a suitable location down the river. In case the
availability of water from the source of supply is not assured
throughout the year, cooling towers are used. During the
scarcity of water in the river, hot water from the condenser is
passed on to the cooling towers where it is cooled. The cold
water from the cooling tower is reused in the condenser.
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CONDENSER

A condenser is a device which condenses the steam at the exhaust of turbine. It serves
two important functions. Firstly, it creates a very low pressure at the exhaust of
turbine, thus permitting expansion of the steam in the prime mover to a very low
pressure. This helps in converting heat energy of steam into mechanical energy in the
prime mover. Secondly, the condensed steam can be used as feed water to the boiler.
There are two types of condensers, namely :
(i) Jet condenser (ii) Surface condenser
In a jet condenser, cooling water and exhausted steam are mixed together. Therefore,
the temperature of cooling water and condensate is the same when leaving the
condenser. Advantages of this type of condenser are : low initial cost, less floor area
required, less cooling water required and low maintenance charges. However, its
disadvantages are : condensate is wasted and high power is required for pumping
water.
In a surface condenser, there is no direct contact between cooling water and exhausted
steam. It consists of a bank of horizontal tubes enclosed in a cast iron shell. The cooling
water flows through the tubes and exhausted steam over the surface of the tubes. The
steam gives up its heat to water and is itself condensed. Advantages of this type of
condenser are : condensate can be used as feed water, less pumping power required
and creation of better vacuum at the turbine exhaust. However, disadvantages of this
type of condenser are high initial cost, required large floor area and high maintenance
charges.
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WATER TREATMENT PLANT

• Boilers require clean and soft water for longer life and better
efficiency. However, the source of boiler feed water is generally a
river or lake which may contain suspended and dissolved
impurities, dissolved gases etc. Therefore, it is very important that
water is first purified and softened by chemical treatment and then
delivered to the boiler.
• The water from the source of supply is stored in storage tanks. The
suspended impurities are removed through sedimentation,
coagulation and filtration. Dissolved gases are removed by aeration
and degasification.
• The water is then ‘softened’ by removing temporary and permanent
hardness through different chemical processes. The pure and soft
water thus available is fed to the boiler for steam generation.
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SITE SELECTION OF
STEAM POWER PLANT

Factors need to be considered while selecting a


site of steam power plant:
• Supply of fuel
• Availability of water
• Transportation facilities
• Cost and type of land
• Nearness to load centers
• Distance from populated area
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EFFICIENCY OF STEAM
POWER STATION

The efficiency of a steam power station is quite low due to


the following two reasons:
• Huge amount of heat is lost in the condenser
• Heat losses at various stages of the plant.
The heat lost in the condenser cannot be avoided as the
heat energy cannot be converted into mechanical energy
without temperature difference. The higher the temperature
difference, the higher is the heat energy converted into
mechanical energy. This necessitates to keep the steam in
the condenser at the lowest temperature. On the contrary,
the higher the temperature difference, the higher is the
amount of heat lost. This explains for the low efficiency of
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such plants.
EFFICIENCY OF STEAM
POWER STATION

• 𝑇h𝑒𝑟𝑚𝑎𝑙 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦, 𝜂thermal=


• 𝐸𝑙𝑒𝑐𝑡𝑟𝑖𝑐𝑎𝑙 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦, 𝜂electrical=
• 𝑂𝑣𝑒𝑟𝑎𝑙𝑙 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦, 𝜂overall= 𝜂thermal x 𝜂electrical

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