Heat Rate

Heat rate is the pulse rate of a power plant to

know the health of the plant.

Net heat rate is the single parameter that

encompasses total performance indices of a
power plant.
Some Basics to understand Heat Rate

Efficiency % = Output Energy X 100

Input Energy

Heat rate = Input Energy

Output Energy

Heat rate = 1
Efficiency %

1 kwh = 860 kcal

Heat Heat
Energy of Energy of UT-A Net
Coal Steam Gross
Elect.
Elect.
Energy
Energy

Turbine G GT
Boiler

UT- B
Gross Unit Heat Rate

A “unit” heat rate includes all heat input to the boiler. The heat input to the boiler
should include all forms of chemical energy supplied and the “gross” electrical
generation

Gross Turbine Cycle Heat Rate (GTCHR)

A “Gross Turbine Cycle” heat rate includes only heat input to the turbine cycle. GTCHR
is the ratio of total heat input to the turbine cycle and the gross generator output

Net Unit Heat Rate

A “unit” heat rate includes all heat input to the boiler. The heat input to the boiler
should include all forms of chemical energy supplied and the “net” electrical
generation i.e., auxiliary power is to be subtracted from gross electrical energy

Design Unit Heat Rate

Design heat rate is anticipated heat rate at design parameters at specific load
condition like different MCR, VWO by manufacturer
Heat Heat
Energy of Energy of UT-A Net
Coal Steam Gross
Elect.
Elect.
Energy
Energy

Turbine G GT
Boiler

Heat
Energy of
Coal
UT- B
Gross Unit Heat Rate =
Gross
Elect.
Energy
Heat Heat
Energy of Energy of UT-A Net
Coal Steam Gross
Elect.
Elect.
Energy
Energy

Turbine G GT
Boiler

Heat
Energy of
Steam
UT- B
Gross Turbine Cycle Heat Rate =
Gross
Elect.
Energy
Heat Heat
Energy of Energy of UT-A Net
Coal Steam Gross
Elect.
Elect.
Energy
Energy

Turbine G GT
Boiler

Heat
Energy of
Coal UT- B
Net Unit Heat Rate =
Net
Elect.
Energy
 DESIGN HEAT RATE

2236 kcal
1944 kcal

1kwh
Boiler Turbine G (860kacl) 600 MW

2248 kcal
1951 kcal

1kwh 250 MW
Boiler Turbine G (860kacl)
 Heat Rate Calculation

Heat Rate can be calculated as

1)Direct Method

2)Indirect Method
 Direct Method
• Direct Method of Heat Rate Assessment is suitable
for long duration in which averaging gives almost
actual Heat Rate because Coal consumption
measurement is fairly accurate if taken over a
month/Year.
 Direct Method

Gross Heat rate = Heat Energy of Coal (Kcal)

Gross Electrical Energy Generated(Kwh)

Gross Heat rate = Coal Consumption(kg) x GCV(Kcal/kg)

Gross Electrical Energy Generated(kwh)

Gross Heat rate = Specific Coal Consumption(kg/kWh) x GCV(Kcal/kg)

 Gross Heat rate = Heat Energy of Coal (Kcal)
Electrical Energy Generated(Kwh)

Gross Heat rate = Heat Energy of Coal (Kcal) x Heat Energy of Steam(Kcal)
Electrical Energy Generated(Kwh) x Heat Energy of Steam(Kcal)
 Gross Heat rate = Heat Energy of Coal (Kcal) x Heat Energy of Steam
Heat Energy of Steam x Electrical Energy Generated(Kwh)

Gross Turbine Heat rate = Heat Energy of Steam(Kcal) Boiler Efficiency % = Heat Energy of Steam(Kcal)
Electrical Energy Generated(Kwh) Heat Energy of Coal (Kcal)

Gross Heat rate = Gross Turbine Heat Rate

Boiler Efficiency %
 Net Heat rate
Net Heat rate = Heat Energy of Coal (Kcal)
Net Electrical Energy (Kwh)

Net Heat rate = Heat Energy of Coal (Kcal)

{Gross Electrical Energy (Kwh)- Aux Power(kwh)}

Net Heat rate =. Heat Energy of Coal (Kcal) .

{Gross Electrical Energy (Kwh)- Aux Power (kwh)} x Gross Electrical Energy(kwh)
Gross Electrical Energy(kwh)

Net Heat rate = . Gross Unit Heat Rate(kcal/kwh)

{1 - Aux Power (kwh)}
Gross Elect. Generation(kwh)
Net Heat rate = . Gross Unit Heat Rate
{1 - Aux Power%}

Example given-
GCV of Coal = 3200 Kcal/KG
Sp.Coal Consumption = 0.72 Kg/Kwh
Gross Heat Rate = 3200X0.72=2304 Kcal/Kwh
Net Heat Rate=2304/(1-.0592)=2449 Kcal/Kwh
If APC =5.92 %
 Indirect Method
• Indirect method of Heat Rate Measurement is
an instantaneous method which is used for
short duration and not possible throughout
the year.
• It is a very complex method and basically a
loss based method of measurement of Heat
Rate.
• This method is generally adopted during the
Energy Audit Studies.
 Indirect Method
• Gross Heat Rate = Design Heat rate + Heat rate
losses( Accountable + Unaccountable)

• Accountable Parameters – Parameters deviated from the design

values. Correction factors and general thumb rules are applied to
calculate.

• Accountable parameters are required to be operated closest to

design value to optimize heat rate.

• Unaccountable deviations are due to drain valve passing,

Instrument measurement errors, radiation losses etc.
 Unit # : Date 12-Jul-15

Parameters
Heat Rate Deviation
Sl. No. Parameter Unit
Design Actual Deviation
Kcal/kwh
1 Load MW 600 409.6 -190.4 66.979
Accountable HR Deviation
2 Main Steam Press before ESV Kg/cm2 170 126.9 -43.1
3 Main Steam Temp before ESV o
C 537 537.8 0.8 -0.5
4 Hot Reheat Temp before IV o
C 537 525.4 -11.6 6.4
5 Reheat Attemperation TPH 0 2.33 2.3 1
6 Condenser back pressure mmhg 75.9 71.4 9.2 18.4
7 CW Inlet Tempertaure o
C 33 30.5 2.53 -15.2
8 Makeup Water % %MCR 0 0.084 0.08 0.5
9 FW Temperature at Eco I/L o
C 253.7 222.4 13.7 12.3
Dry Flue Gas Loss(DFG) % 4.5 5.6 1.1 27.9
Effect of Coal on DFG % 0.8
10 a) Oxygen at APH inlet % 3.6 4.1
b) APH Exit Temperature(Corrected) C
o
140 128.2
c) APH Leakage % 11.6
Wet flue Gas loss % 6.36 6.9 0.5 12.5
11 a) Moisture in coal % 2.33 2.4
b) % Hydrogen in coal % 3.85 4.4
12 Combustible in Fly ash % 0.21 -0.1 -3.3
13 Combustible in Bottom ash % 2.20 1.5 6.3
14 Startup oil consumption % 0 0 0.0
15 HP Turbine Cylinder Efficiency(VWO) % 92.36 90.98 1.38 6.1
16 IP Turbine Cylinder Efficiency % 93.16 91.62 1.54 6.8
17 Total Accountable HR deviation(A) Kcal/kwh 146

18 Unaccountable HR Deviation (B) Kcal/kwh 22

19 Total Heat Rate Deviation (A+B) Kcal/kwh 168

Expected Design HEAT RATE at Full
20 Kcal/kwh 2236
Load and Rated condition(C)
21 Goss Heat Rate (A+B+C) Kcal/kwh 2404

Aux Power consumption 6.5%

22 Net Heat Rate on the basis of coal Kcal/kwh 2572

Design Heat Rate for 600MW at various load
PLF Load Efficiency % Gross HR Aux Power Net HR
100.00% 600 36.15 2236 6 2379
95.00% 570 35.92 2244 6.25 2394
90.00% 540 35.67 2254 6.5 2411
85.00% 510 35.39 2266 6.75 2430
80.00% 480 35.04 2282 7 2454
75.00% 450 34.68 2300 7.25 2480
70.00% 420 34.28 2321 7.5 2509
65.00% 390 33.82 2346 7.75 2543
60.00% 360 33.35 2373 8 2579
55.00% 330 32.84 2403 8.25 2619
50.00% 300 32.32 2435 8.5 2661
 2500 LOAD VS GROSS HEAT RATE
2450
Heat Rate (in Kcal/Kwh)

f(x) = 0.00158119658119657 x² − 2.08580419580419 x + 2918.73426573426

2400

2350

2300

2250

2200

2150

2100
250 300 350 400 450 500 550 600 650

Load in MW
 Impact of Performance Parameters Deviations on
Heat Rate for 4 x 600 MW
Average HR loss
Sl.No. Parameters Units Deviations kcal/kwh
1 HP Turbine Efficiency % 1 4.01
2 IP Turbine Efficiency % 1 3.78
3 LP Turbine Efficiency % 1 10.35
3 Main Steam Pressure Kg/cm2 (a) 1 1.33
4 Main Steam Temperature C
o
1 0.67
5 Reheat Temperature C
o
1 0.56
6 Reheat Spray TPH 10 2.23
7 Excess Air ( O2) % 1 6.64
8 Flue gas exit temperature C
o
1 1.2
9 Condenser pressure mmHg (a) 1 2
10 Unburned Carbon % 1 8.5
11 Coal Moisture % 1 4.4
12 DM Makeup % 1 7.76
13 FW Temperature C
o
1 0.8
15 HPH Out - - 79
16 Startup oil for 8 Mu gen in a day KL 20 25
 1 Kcal/KWh
1526 MT 1908 MT CO2 45.78 Lakhs
Heat Rate
Coal (Yearly) (Yearly) (Yearly)
improvement

Assumptions: Coal Cost = 3000 Rs / Tonne

GCV = 3100 kcal / kg
PLF = 90 % = 4730.4 MU (Yearly)

1 kcal / kWh Saving = 4730.4 x 106 x1 kcal Yearly Saving

Coal Saved = 4730.4 x 106 / 3100 kg
= 1525935.5 kg
= 1526 Tons
1 Kg coal releases 1.25 kg CO2
Hence, CO2 Emission Reduced = 1908 MT CO2
Revenue Saved = 45.78 Lakhs
3000

2744
Heat Rate of Various Power Stations
2500 2469 2470
2387 2378
2248 2244 2236 2261
2126 2166
2042
1951 1948 1993 1951
2000 1944 1906
1860 1873
1778.2 1757 1792

Pr – 133 bar 1598.16666666667

1500 Temp- 540 oC /
540 oC Pr – 147 bar
Temp- 540 oC /
540 oC Pr – 170 bar
Temp- 540 oC /
1000 540 oC Pr – 181 bar
Temp- 540 oC /
540 oC Pr – 247 bar
Temp- 540 oC /
566 oC Pr – 280 bar
500 Temp- 565 oC /
593 oC Pr – 252 bar
Temp- 605 oC /
605 oC Pr – 310 bar
Temp- 705 oC /
0 705 oC

Turbine Heat Rate Gross Unit Heat rate Net Heat Rate
50.00
Efficiency of Various Power Plants
45.12
45.00 44.08

39.71 Pr – 310 bar

40.00 38.03 Temp- 705 oC /
36.03 36.16 705 o C
34.81
35.00 Pr – 252 bar
31.35 Temp- 605 o C /
605 o C
30.00 Pr – 280 bar
Temp- 565 o C /
593 o C
25.00 Pr – 247 bar
Temp- 540 o C /
566 o C
20.00 Pr – 181 bar
Temp- 540 oC /
540 oC
15.00 Pr – 170 bar
Temp- 540 oC /
540 oC
10.00 Pr – 147 bar
Temp- 540 oC /
Pr – 133 bar 540 oC
5.00 Temp- 540
o
C / 540 oC
0.00
Thanks