COAL TO ELECTRICITY

Non-renewable & Renewable Energy

Indian electricity system

NERLDC

Renewables- 7%

Nuclear- 3%

NRLDC

ERLDC

WRLDC

Hydro- 25% Thermal- 65%

SIL
SRLDC

Installed Capacity targeted 200 GW by end of year 2011-12

Why Coal?
RES 5% Nuclear 3%

Advantages of Coal Fuel Shortcomings of Coal

Hydel 26%

Coal 55% Diesel 1% Gas 10%

Abundantly available in India Low cost Technology for Power Generation well developed Easy to handle, transport, store and use

Low Calorific Value Large quantity to be Handled Produces pollutants, ash

Share of Coal in Power Generation

Disposal of ash is Problematic

Reserves depleting fast

Indias Coal Reserves are estimated to be 255 billion tonnes. Present consumption is about 450 million tonnes.

Coal for combustion

Anthracite Semi-anthracite Bituminous Semi-Bituminous Lignite Peat High CV, low VM High CV, low VM Medium CV, medium VM Medium CV, medium VM Low CV, high VM, high TM Very low CV, high VM & TM

Coal to Electricity .. Basics

Pollutants

Coal

Super Heated Steam

Heat Loss In Condenser

Turbine Torque
Mech. Energy Loss

Alternating current in Stator

Elet. Energy Loss

Heat

ASH

Loss

Chemical Energy

Thermal Energy

Kinetic Energy

Electrical Energy

How Generated electricity reached customer

NTPC AT A GLANCE
Installed Capacity Thermal (15) Gas (7) JV 34, 194 MW 26,875 MW 3955 MW 3364 MW

Operating PLF of 88.29 % for FY 2010-11 Awarded MAHARATNA status on 19/05/2010 Target 0f 67000 MW by 2017

NCPS DADRI at a glance

IT HOUSES COAL AND GAS BASED UNITS (THE ONLY STATION IN THE COUNTRY)

COAL (4 * 210 MW)

COAL ( 2 * 490 MW) GAS (4 * 130.19 MW + 2 * 154.51MW)
ANOTHER FEATURE IS 1500 MW - 500 kV HVDC LINK.
LARGEST SWITCHYARD IN ASIA IN TERMS OF POWER HANDLING CAPACITY (4500 MW). 8 OUTGOING FEEDERS. DRY ASH HANDLING SYSTEM, FIRST IN ASIA. NDCT COOLING TOWERS CONTRACT WITH RAILWAYS FOR 100 MW POWER.

NCPS DADRI
PLANT AREA ==> 1150.00 ACRES.

APPROACH ROAD
COLONY RAILWAY LINE ASH DISPOSAL TOTAL

==>
==> ==> ==>

17.00 ACRES.
400.00 ACRES. 345.00 ACRES. 550.00 ACRES.

==> 2462.00 ACRES.

COAL: FROM MINES TO NCPS

Source of Coal : Piparwar Mines North Kranpura (Jharkhand) Near Ranchi Railway 1200 km Khalari-G-M-A-K-T-D BOBR/BOXN 58 of 61 mt capacity
F Grade (raw coal) -3800 kcal/ kg E Grade (washed) -4200 kcal/ kg Imported coal -6200 kcal/kg

Location : Mean of transportation : Total distance : Route of rail : Type of wagon : No. wagons / rakes:
Quality of coal :

Size of coal at unloading point:: (-) 250mm

Unloading of Coal
Track Hopper
Type of track hopper: RCC underground L /W/H of T/H: 201.6 m/6 m/6.350 m Capacity : 6000 mt Type of wagon U/L : BOBR Mode of Bottom relieving : Pneumatic (5-6 ksc)

Wagon Tippler
No. : one Type of wagon tippled: BOXN Capacity : 12 wagons / hr.

Preparation of coal for Pulveriser

W/T

Track hopper
(-250 mm)

Grizzly Feeder

Crushers Coal yard

(-)20 mm

Bunkers

WATER
SOURCE IS DEHRA BRANCH OF UPPER GANGA CANAL WATER IS SOFTENED BEFORE USE. TUBEWELL NETWORK FOR REPLENISHMENT OF THE CONSUMED WATER (IRRIGATION ANGLE) CLOSED COOLING SYSTEM: REDUCTION IN CONSUMPTION.

EFFLUENTS: THROUGH HASANPUR DRAIN TO A TRIBUTORY OF YAMUNA

Fuel Oil
The liquid fuels used in power plants are
Heavy Fuel Oil (HFO) LSHS (Low Sulfur Heavy stock) High speed Diesel (HSD) Light diesel oil (LDO)

Oil firing is preceded by Lowering viscosity and increasing flowability on heating for better combustion in given turn down ratio(125oC) Droplet formation on atomization (by steam/ compressed air/ mechanical pressurization) Combustion initiation by High energy spark ignition (HEA)

Latent Heat Addition in Evaporator (constt. Pressure) T E M P E R A T U R E

Super Heating

Sensible heat Addition in Economizer

Adiabatic Expansion in Turbine Pump Work L+V

Constant Pressure Heat Rejection in Condenser

ENTROPY

BASIC RANKINE CYCLE (SUB-CRITICAL)

BASIC CONSIDERATIONS
BOILER

Qi Wi
PUMP TURBINE

Wo

CONDENSER

Qr Net change in internal energy is zero Net heat transfer = Net work output Qi Qr = Wo-Wi Efficiency = 1-(Qr/Qi)

EQUIVALENT CARNOT MODEL OF RANKINE MODEL

Tm

Tr

SMIN

SMAX

INCREASING THE EFFICIENCY

Efficiency = 1- (Qr /Qi)

= 1- (Tr/ Tm)
Improving the condenser Vacuum ( lowering Tr) Using a higher initial steam temperature ( Super Heat) Using higher initial steam pressure Re- Heating Re- Generative Heating of Condensate and feed water

All the methods (except first) improve the mean temperature at which heat is added to the cycle

LOWERING CONDERNSER PRESSURE

Lowers the temperature at which condensation takes place thereby increasing the cycle efficiency.

Lower limit is the saturation pressure corresponding to the temperature of cooling media. Increases moisture content of the steam at the final stages of turbine

INCREASING INLET TEMPERATURE

Superheating the steam to higher temperature without increasing the boiler pressure increases thermal efficiency. Decreases the moisture content of the steam at the turbine exit. Highest temperature of superheated steam is limited by the metallurgical constraint.

INCREASING INLET PRESSURE

Raises the mean temperature at which heat is added in the boiler thereby increasing the efficiency. Increases moisture content at the final stages of the turbine that limits the maximum inlet pressure.

EFFECT OF REHEAT

Reheating allows a greater inlet pressure to be used for the same dryness fraction at the turbine exhaust The efficiency depends on ratio of reheat pressure to initial steam pressure.

POWER PLANT CYCLE

The Working fluid is Water. Working principle is based on the Modified Rankine Cycle ( With Single Re- Heat )

The closed cycle consists of three intermediate cycles: Condensate cycle Feed Water Cycle Steam Cycle

CONDENSATE CYCLE

Sensible Heat addition to condensate extracted from condenser by CEP

Starts from Condenser and ends at De- Aerator

COND

GSC, LPH 1,2,3 and Drain Cooler are the heat exchangers Driving force is CEP
GSC

CEP

DEA

LPH3

LPH2

LPH 1

D/C

FW CYCLE

Sensible Heat addition to feed water being pumped by BFP

Starts from De- Aerator and ends at Economizer

HPH 5 and HPH 6 are the heat exchangers

Driving force is BFP

ECONOMIZER

FRS

HPH6

HPH 5 BFP

FST

LTSH DRUM

PSH

FSH

E C O

F U R N A C E

HPT

IPT

LPT

COND R/H
CEP GSC

HPH6 HPH 5 DEA LPH3 LPH2 LPH 1

D/C

BFP

Boiler/ Steam Generator (SG)

Steam generating is a machine that safely, reliably and efficiently transfers heat released during the combustion of fuel to both feedwater and steam Boiler A closed vessel in which water is vaporized by the application of heat
1. 2. 3. Raw materials for boilers Coal from mines Ambient air Water from natural resources (river, ponds)

o Generating heat energy o Air for combustion o Working fluid for steam generation, possessing heat energy

Types of Boilers
Water Tube Boiler: Here the heat source is outside the tubes and the water to be heated is inside. Most high-pressure and large boilers are of this type. In the water-tube boiler, gases flow over water-filled tubes. These water-filled tubes are in turn connected to large containers called drums.

Types of Boilers
Fire-Tube Boilers Fire-tube boilers rely on hot gases circulating through the boiler inside tubes that are submerged in water Electric Boilers Electric boilers are very efficient sources of hot water or steam, which are available in ratings from 5 to over 50,000 kW

BOILER CHARACTERESTICS
BOILER MEANS ANY CLOSED VESSEL EXEECDING 22.75 L(5 Gallons) IN CAPACITY WHICH IS USED FOR GENERATING STEAM UNDER PRESSURE AND INCLUDES ANY MOUNTINGS OR OTHER FITTINGS ATTACHED TO SUCH A VESSEL WHICH IS WHOLLY OR PARTLY UNDER PRESSURE WHEN STEAM IS SHUT OFF

NATURAL CIRCULATION BALANCED DRAFT DIRECT PF FIRED/OIL FIRED TANGENTIAL TILTING TYPE SINGLE REHEAT DOUBLE PASS,SINGLE DRUM

BOILER arrangement

BOILER arrangement
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Economizer Boiler drum Down comers Water walls LTSH Platen super heater Final super heater Reheater Burners Ignitors Furnace

BOILER Auxiliaries
1. 2. 3. 4. 5. 6. Mills FD fans PA fans ID fans APH ESP

210 MW Boiler: Water and Steam Circuit

Final SH. Platen SH. 500-540C 375C-425C

LTSH

330-37

Economizer Water Wall 240-310C 310C

Gravimetric Feeder

Pictures of Bowl Mill

Coal Entry

Hot Air Flow from PA Fan

Classifiers To burners Rollers

Typical Mill (Pulveriser)

Tangential Firing System

Flame Inside Furnace

Air System

AIR PRE HEATER

BYPASS SEAL RADIAL SEAL

HOT END

AXIAL SEAL

COLD END

HOT INTERMEDIATE

Draught Control

Coal Consumption /Day/Unit= 3000T

Ash Generation /Day/Unit( 34%) = 1000T (Approx.)

APH
Economiser ESP

Bottom Ash Hopper

CAT APH + ESP =80% of Total Ash

BA + CA =20% of Total Ash

Slurry System (200 T/Day/Unit)

Dry System (800 T/Day/Unit)

LOCATION OF ESP

ECO

APH

ESP

CHIMNEY

1.Electron emission
1

ESP PROCESS STEPS

Dust layer

2.Dust particle charging

2 3

Collecting electrode, grounded

3.Migration
5.Rapping 4 4.dust collection 5

Discharge electrode with Negative high tension (20-60kV)

Rapping mechanism

Collecting electrodes

Emitting electrodes

TURBINE
BHEL Make ( KWU Design) Tandem Compound Regenerative Re Heat 3 cylinder (HP, IP, LP)

HPT: 1*25 IPT : 2*20 LPT :2*8 HPT contributes 28 %, IPT contributes 26 % and LPt contributes 46 % of overall load.

Steam Flows from Boiler to turbine

Bypass

The Steam/Gas Turbine

Motive power in a steam/gas turbine is obtained by the rate of change in momentum of a high velocity jet of steam impinging on a curved blade which is free to rotate. The steam/gas is expanded in a nozzle, resulting in the emission of a high velocity jet This jet of steam impinges on the moving vanes or blades, mounted on a shaft Here it undergoes a change of direction of motion which gives rise to a change in momentum and therefore a force

Diagram of Large Power Plant Turbine

Simplified Diagram

210 MW ASSEMBLED TG

210 MW TG STATOR

210 MW WOUND ROTOR

Electrical Systems in Power Plant

Switchyard One line Diagram

Transfer Bus 220 KV Main Bus II Main Bus I

Bus Isolator

CB CB CB Transfer Bus Bay

GT 16.5/ 220 kV Gen Bay Feeder Bay

400 KV CIRCUIT BREAKER

400 KV CURRENT TRANSFORMER

400 KV LIGHTENING ARRESTOR

400 KV ISOLATOR

400 KV BUS BAR

VIEW OF SWITCHYARD

Power Generation, Transmission and Distribution

THANK YOU