PROJECT REPORT

VOCATIONAL TRAINING AT
Kanti Bijlee Utpadan Nigam Limited . (A Joint
Venture Of NTPC Ltd.) Kanti , Muzaffarpur.

FROM 04/06/2019 TO 02/07/2019

TOPIC: - “STUDY OF BOILER”

Submitted by: - Submitted to:-

SUMIT KUMAR HR Department

MECHANICAL ENGINEERING KBUNL Kanti
VII sem/IV year Muzaffarpur, Bihar
ARYA COLLEGE OF ENGINEERING
AND INFORMATION TECHNOLOGY
(SP-42,RIICO,KUKAS,JAIPUR)
 ACKNOWLEDGMENT
I am highly indebted to HOD of MM Department, all faculty members of
department for providing me an opportunity to have practical exposure at
KBUNL Kanti (Joint venture of NTPC Ltd).

I express my sincere thanks to DR.ABHAY KUMAR DUBEY(AGM, MM) for

giving me an opportunity to take such valuable vocational training in his
department.

I also pay my sincere gratitude to Mr. ARIF KHAN (Sr.Manager, BMD) for
their continuous assistance, guidance and valuable suggestions.

My special thanks to HR department for facilitating me to impart training at

this project.

Sig.of training officer

 ABSTARCT
Any thermal power plant is converting the chemical energy of fossil
fuel (coal) into electrical energy. The process involved for this
conversion is based upon the Modified Rankine Cycle. The major
components that are used to accomplish the modified Rankine cycle
are

➢ Boiler feed pump,

➢ The steam generator water walls (evaporator),
➢ Steam generator super heaters,
➢ Steam turbine,
➢ Reheater,
➢ Condenser,
➢ Regenerative feed heaters etc.

All components of a power generating cycle are vital and critical in

operation. In Modified Rankin Cycle, the two most important aspects
that are added are reheating & regenerative heating. By reheating we
used to send the steam coming from exhaust of the turbines back to
the reheater of the boiler so that its enthalpy increases and more work
can be done by this steam the other purpose is to make steam dry so
that no harm will be done to the blades of the turbine.

In KBUNL Kanti, we have three turbines in Tandem coupling namely

one H.P Turbine, one I.P Turbine & one L.P Turbine coupled with the
generator to which is synchronized with the grid to produce
electricity at 50Hz.
 CONTENTS

S. No. Description Page-No

01 Introduction 05

02 An Over View 06

3.1 Boiler 07-12

3.2 Turbine 13-14

3.3 Cooling Tower 15-18

3.5 Coal Handling Plant Package 19-21

3.6 Ash Handling Plant Package 22-24

04 Generation Of Electricity 25-27

06 Conclusions 29

07 References 30
 INTRODUCTION
A thermal power station is a power plant in which heat energy is converted
to electric power. In most of the places in the world the turbine is steam-
driven. Water is heated, turns into steam and spins a steam turbine which
drives an electrical generator. After it passes through the turbine, the
steam is condensed in a condenser and recycled to where it was heated;
this is known as a Rankine cycle.

The greatest variation in the design of thermal power stations is due to the
different heat sources; fossil fuel dominates here, although nuclear heat
energy and solar heat energy are also used. Some prefer to use the term
energy center because such facilities convert forms of heat energy into
electrical energy. Certain thermal power plants also are designed to
produce heat energy for industrial purposes of district heating, or
desalination of water, in addition to generating electrical power.
 AN OVERVIEW:
NTPC
NTPC was set up in 7th November 1975, the MAHARATNA power giant
today generates more than one fourth of the total power in the country,
Ranked 5th largest power generating utility in the world, NTPC is the
second most efficient in capacity utilization among the top ten thermal
generating companies according to a survey conducted by Data Monitor,
United kingdom. In a short span of two decades, NTPC has earned its
prime status by setting up a total generating capacity of 22,249 MW.
With 19.14% of India’s operating capacity, the company generates
26.7% of country electricity through its 13 coal and 7 gas based power
plants spread all over the country.
 Today, the country needs a 10 percent sustained growth in power
generation to ensure the momentum for a 7 percent overall growth in
the economy. Recognizing this, NTPC has committed itself to achieving
the status of a 30,000MW plus company by the year 2007 and
40,000MW plus company by the year 2012 and power generating
capacity addition programme of 51,000 MW (Including nuclear energy
and non-conventional sources of energy) for the tenth plan.

BOILER:

A boiler is a closed vessel in which water or other fluid is heated. The fluid does not
necessarily boil. (In North America, the term "furnace" is normally used if the purpose is
not to boil the fluid.) The heated or vaporized fluid exits the boiler for use in various
processes or heating applications, including water heating, central heating, boiler-based
power generation, cooking, and sanitation.

Main Boiler Components

The major accessories of a steam-generating unit are listed as below:

➢ Furnace
➢ Economizer
➢ Boiler drum
➢ Downcomers
➢ Water walls
➢ Riser tubes
➢ Superheaters
 ➢ Reheaters
➢ Desuperheaters

1. Furnace
A boiler furnace is the first pass of the boiler in which fuel is burned and from which the
combustion products pass to the super heater and second pass of boiler.
The combustion process is a continuous process, which takes place in first pass of the
boiler and controlled by fuel input through coal feeders. It is a radiant type and water-
cooled furnace and enclosure is made up of water wall.

The furnace is open at the bottom to allow ash/clinkers to fall freely into the furnace
bottom ash hopper (through a ‘furnace throat’), and at the top of its rear wall, above the
arch, to allow hot gases to enter the rear gas pass.

The basic requirements that a furnace must satisfy are:

1. Proper installation, operation and maintenance of fuel burning equipment.
2. Sufficient volume for combustion requirements.
3. Adequate refractories and insulation.

2. Economiser
The function of an economizer in a steam-generating unit is to absorb heat from the flue
gases and add this as sensible heat to the feed water before the feed water enters the
evaporative circuit of the boiler. This additional heating surface in the path of the feed
water increases the efficiency of the steam generating cycle, saving in fuel consumption,
thus this additional surface was named as ‘economizer’.

The economizer is placed in the path of the flue gases leaving the boiler, in the boiler
rear gas pass below the rear super heater.

The economizer is continuous ‘unfinned loop type’ and water flows in upward direction
and gas flows in the downward direction. Since water flow is from bottom to top so if
any steam is formed during the heat transfer it also moves along with water and
prevent the lock up steam which will cause overheating and failure of economizer tube.

A recalculation line with a stop valve and non return valve is incorporated to keep
circulation in economizer into boiler drum when there is fire in furnace but it prevents
the feed water flow into the boiler drum.
3. Boiler drum

The boiler drum is a cylindrical pressure vessel with hemispherical ends. It contains two
rows of cyclone separators, four rows of drier boxes, a perforated feed water
distribution pipe, and a chemical dosing pipe.
The boiler drum is located on the upper front of the boiler. It is suspended from roof
steelwork by two u-shaped slings.
It forms a part of the water circulation system of the boiler. The drum serves mainly two
functions:
➢ The first and primary one is that it separates steam from the mixture of water
and steam discharged into it and to reduce the dissolved solid contents of the
steam to below the prescribed limit of 1 ppm.
➢ Secondly, the drum houses all equipments used for purification of steam after
being separated from water. These equipments are known as ‘drum internals’.

Drum Internals:

These are the equipments, which are used to separate water from steam and to direct the
flow of water and steam to obtain an optimum distribution of drum metal temperature in
boiler operation. The drum internals consists of baffle arrangements, devices which change
the direction of flow of steam and water mixture, separators employing spinning action for
removing water from steam or steam purifiers as washers and screen dryers. Steam output.
So, the drum size is determined by the space required to accommodate the steam
separating and purifying equipments. The level of water in the stream is monitored by
control and interlock equipment. Drum level is monitored by four level transmitters which
are connected across individual drum mounted, short-range constant head chambers.
Water level gauge is mounted on each end of the steam drum. If water level goes outside of
the prescribed operating limit then the boiler is tripped.

Transformers:

A transformer is an electrical device which works on the principle of mutual induction.

The autotransformer used in power station. It has three windings primary, secondary
and tertiary. The 220kv voltage is fed as input to primary by step down 132kv fed KBUNL
as input.

4. Downcomers

Down comers provide a passage for water from the boiler drum to bottom ring header.
From bottom ring header the water goes to water walls for heat absorption and
conversion into steam heating .To achieve the circulation of water into water wall Boiler
circulation pumps are provided in down comers.
5. Water walls

Water walls are the necessary elements of the boiler. They serve as the means of
heating and evaporating the feed water supplied to the boiler from the economizers via
boiler drum and down comers.

In large boilers, water walls completely cover the interior surfaces of the furnace
providing practically complete elimination of exposed refractory surface. They usually
consist of vertical tubes membrane and are connected at the top and at the bottom to
headers. These tubes receive water from the boiler drum by means of down comers
connected between drum and water walls lower header.

Water walls absorb 50 percent of the heat released by the combustion of fuel in the
furnace, which is utilized for evaporation of feed water. The mixture of water and steam
is discharged from the top of the water walls into the upper wall header and then
passes through riser tubes to the steam drum.

The design and construction of the water walls depends upon the combustion and
steam conditions and the size of the boiler.

6. Riser tubes

A riser is a tube through which the mixture of water and steam pass from an upper
water wall header to the steam drum.

7. Superheater

The steam generated by the boiler is usually wet or at the most dry saturated because it
is in direct contact with water. So, in order to get superheated steam, a device known as
superheater has to be incorporated in the boiler. The function of the superheater
system is to accept dry saturated steam from the steam drum and to supply
superheated steam at the specified final temperature of 540 oC, by means of a series of
heat transfer surfaces arranged within the boiler gas passes.

A superheater is a surface type heat exchanger generally located in the passage of hot
flue gases. The dry saturated steam from the boiler drum flows inside the superheater
tubes and the hot flue gases flows over the tubes and in this way its temperature is
increased at the same pressure. The super heater consists of three sections classified as
primary super heater, secondary super heater and final super heater. In Kanti, there are
14 super heater coils which are divided into above different sections where temperature
is increased from approx. 340oC to 540oC.Dry saturated steam from the drum passes
through the three sections of super heater, increasing the temperature to approx.
540oC as it travels through each section.

8. Reheater
A reheater is a device that is incorporated in the upper arch of the boiler near the
gooseneck in the path of the outgoing flue gases. As the name indicates, it reheats the
outlet steam from the HP turbine and thus increasing its temperature up to the desired
value. The reheater accept cold reheat steam from the HP turbine exhaust and supply
hot reheat steam at the specified outlet steam temperature of 540 oC by means of heat
transfer surfaces arranged within the boiler gas passes.

The reheater consists of 2 heating coils which finally raise the temperature of the steam
to the required level. Steam from the HP turbine exhaust enters the reheater system
through two parallel mounted spray water desuperheaters liners located in the cold
reheat pipe work, then passes through reheater, increasing the temperature as it travels
through it. Reheater outlet temperature is controlled by raising or lowering the angle of
burner tilt. When this reheated steam enters the IP turbine, the net efficiency of the
cycle is increased.

9. Desuperheaters

A. Superheater Desuperheater

The superheater desuperheater is fitted after 10th coil to control the superheated
steam at the specified terminal temperature of 540oC. The maximum design
temperature reduction at the superheater desuperheater is from 446 oC to 388 oC.
The desuperheater comprises a spray nozzle shell and associated spray assembly
projecting into a section of the superheater steam line. This section of the steam
line forms the desuperheater shell. Steam assisted spray nozzle assembly provides
a fine spray of water which attemperates the steam passing through the
desuperheater. Spray water for desuperheater is taken from the boiler feed water
pump discharge. In addition, spray water regulating stations are provided further
downstream in each line.

B. Reheater Desuperheater

The reheater desuperheater is only brought into use when the reheater outlet
temperature rises above the normal temperature. The reheater desuperheater
comprises of a spray nozzle shell and associated spray nozzle assembly projecting
into a section of the steam line between the HP turbine outlet and the reheater
inlet headers. This section of the steam line forms the desuperheater shell. Water
is fed into the shell from the discharge side of the boiler feed pumps via a reheater
desuperheater spray water regulating station. When the reheater desuperheater is
called into service water is fed via the water tube and passes through the spray
nozzle thereby forming a spray which attemprates the steam passing through the
desuperheater and thus decreasing the quantity of water in the boiler. Drum is
relatively small compared to the total steam output. So, the drum size is
determined by the space required to accommodate the steam separating and
purifying equipments.
TURBINE:

A steam turbine is a device that extracts thermal energy from pressurized steam and
uses it to do mechanical work on a rotating output shaft. Its modern manifestation was
invented by Sir Charles Parsons in 1884.Because the turbine generates rotary motion, it
is particularly suited to be used to drive an electrical generator – about 90% of all
electricity generation in the United States (1996) is by use of steam turbines. The steam
turbine is a form of heat engine that derives much of its improvement in thermodynamic
efficiency from the use of multiple stages in the expansion of the steam, which results in
a closer approach to the ideal reversible expansion process.

1. HP Turbine:-

HP turbine is a single flow design with eight stages of blading. Each stage comprises
stationary and moving blades which are positioned into the rotor mounted on the
diaphragms, directs steam into the rotor mounted on the moving blades. H.P. turbine is
double shell construction comprising inner and outer casing. H.P steam enters the H.P.
turbine inner casing through vertical inlet connection are mounted on the top and
bottom outer casing .The steam directed through the diaphragm expands through the
rotor blades and diaphragm towards the fronts of the cylinder. The steam exhausts
through the two branches in the bottom half casing and returns to the boiler to be
reheated to increase the temperature of the steam to 538oC so that the efficiency of
Rankine Cycle increases.

2. I.P. Turbine:-

Intermediate pressure turbine is a double flow design with seven stage of blading on
either side of central steam inlet. Each stage comprises stationary and moving blades
which are positioned so that the stationary blades mounted on diaphragm, directs the
steam into the rotor mounted moving blades. Turbine is double shell construction inner
casing , two diaphragm carries the ring, and outer casing .The first 4 stage of each flow
are located within the inner casing and remaining stage within the diaphragm carries
the ring .The inner casing, diaphragm carrier ring and outer casing are made in halves
bolted together in the horizontal centre.
 3. L.P. Turbine:-

LP turbine is of double flow design incorporating six stages in each of its front and rear
flow paths. Each stage consists of number of stationary blades incorporating in the
diaphragm located in the casing and a set of rotating blades mounted on a rotor disc.
A spray water system design to operate automatically ,ensure that excessive
temperature are not produced in the exhaust flow during prolonged operation at low
turbine load /low condenser vacuum.

ASSEMBLY OF TURBINE GENERATOR EXCITER AND BARRING GEAR

Full Turbine View

COOLING TOWER:

A cooling tower is a heat rejection device that rejects waste heat to the atmosphere
through the cooling of a water stream to a lower temperature. Cooling towers may
either use the evaporation of water to remove process heat and cool the working fluid
to near the wet-bulb air temperature or, in the case of closed circuit dry cooling towers,
rely solely on air to cool the working fluid to near the dry-bulb air temperature.

Common applications include cooling the circulating water used in oil refineries,
petrochemical and other chemical plants, thermal power
stations and HVAC systems for cooling buildings. The classification is based on the type
of air induction into the tower: the main types of cooling towers are natural draft and
induced draft cooling towers.
Cooling towers vary in size from small roof-top units to very large hyperboloid structures
(as in the adjacent image) that can be up to 200 meters (660 ft) tall and 100 meters (330
ft) in diameter, or rectangular structures that can be over 40 meters (130 ft) tall and 80
meters (260 ft) long. The hyperboloid cooling towers are often associated with nuclear
power plants, although they are also used in some coal-fired plants and to some extent
in some large chemical and other industrial plants. Although these large towers are very
prominent, the vast majority of cooling towers are much smaller, including many units
installed on or near buildings to discharge heat from air conditioning.
 Terminology:-

 Windage or Drift — Water droplets that are carried out of the cooling tower
with the exhaust air. Drift droplets have the same concentration of impurities as the
water entering the tower. The drift rate is typically reduced by employing baffle-like
devices, called drift eliminators, through which the air must travel after leaving the
fill and spray zones of the tower. Drift can also be reduced by using warmer entering
cooling tower temperatures.




 Blow-out — Water droplets blown out of the cooling tower by wind, generally at
the air inlet openings. Water may also be lost, in the absence of wind, through
splashing or misting. Devices such as wind screens, louvers, splash deflectors and
water diverters are used to limit these losses.




 Plume — The stream of saturated exhaust air leaving the cooling tower. The plume is
visible when water vapor it contains condenses in contact with cooler ambient air, like
the saturated air in one's breath fogs on a cold day. Under certain conditions, a cooling
tower plume may present fogging or icing hazards to its surroundings. Note that the
water evaporated in the cooling process is "pure" water, in contrast to the very small
percentage of drift droplets or water blown out of the air inlets.
 • Draw-off or Blow-down — The portion of the circulating water flow that is
removed (usually discharged to a drain) in order to maintain the amount of Total
Dissolved Solids (TDS) and other impurities at an acceptably low level. Higher TDS
concentration in solution may result from greater cooling tower efficiency. However
the higher the TDS concentration, the greater the risk of scale, biological growth and
corrosion. The amount of blow-down is primarily designated by measuring by the
electrical conductivity of the circulating water. Biological growth, scaling and
corrosion can be prevented by chemicals (respectively, biocide, sulfuric acid,
corrosion inhibitor). On the other hand, the only practical way to decrease the
electrical conductivity is by increasing the amount of blow-down discharge and
subsequently increasing the amount of clean make-up water.

• Zero bleed for cooling towers, also called zero blow-down for cooling towers,
is a process for significantly reducing the need for bleeding water with residual
solids from the system by enabling the water to hold more solids in solution

 Make-up — The water that must be added to the circulating water system in
order to compensate for water losses such as evaporation, drift loss, blow-out,
blow-down, etc.




 Noise — Sound energy emitted by a cooling tower and heard (recorded) at a given
distance and direction. The sound is generated by the impact of falling water, by the
movement of air by fans, the fan blades moving in the structure, vibration of the
structure, and the motors, gearboxes or drive belts.




• Approach — The approach is the difference in temperature between the cooled-
water temperature and the entering-air wet bulb temperature (twb). Since the cooling
towers are based on the principles of evaporative cooling, the maximum cooling tower
efficiency depends on the wet bulb temperature of the air. The wet-bulb temperature is
a type of temperature measurement that reflects the physical properties of a system
with a mixture of a gas and a vapor, usually air and water vapor
  Range — The range is the temperature difference between the warm water inlet
and cooled water exit.




 Fill — Inside the tower, fills are added to increase contact surface as well as
contact time between air and water, to provide better heat transfer. The efficiency
of the tower depends on the selection and amount of fill. There are two types of fills
 that may be used:
  Film type fill (causes water to spread into a thin film)
 Splash type fill (breaks up falling stream of water and interrupts its vertical
 progress)
 Full-Flow Filtration — Full-flow filtration continuously strains particulates out
of the entire system flow. For example, in a 100-ton system, the flow rate would be
roughly 300 gal/min. A filter would be selected to accommodate the entire 300
gal/min flow rate. In this case, the filter typically is installed after the cooling tower
on the discharge side of the pump. While this is the ideal method of filtration, for
higher flow systems it may be cost-prohibitive.




 Side-Stream Filtration — Side-stream filtration, although popular and
effective, does not provide complete protection. With side-stream filtration, a
portion of the water is filtered continuously. This method works on the principle
that continuous particle removal will keep the system clean. Manufacturers typically
package side-stream filters on a skid, complete with a pump and controls. For high
flow systems, this method is cost-effective. Properly sizing a side-stream filtration
system is critical to obtain satisfactory filter performance, but there is some debate
over how to properly size the side-stream system. Many engineers size the system
to continuously filter the cooling tower basin water at a rate equivalent to 10% of
the total circulation flow rate. For example, if the total flows of a system is 1,200
gal/min (a 400-ton system), a 120 gal/min side-stream system is specified.




 Cycle of concentration — Maximum allowed multiplier for the amount of
miscellaneous substances in circulating water compared to the amount of those
substances in make-up water.




• Treated timber — A structural material for cooling towers which was largely
abandoned about 10 years ago.[when?] It is still used occasionally due to its low initial
 costs, in spite of its short life expectancy. The life of treated timber varies a lot,
depending on the operating conditions of the tower, such as frequency of shutdowns,
treatment of the circulating water, etc. Under proper working conditions, the estimated
life of treated timber structural members is about 10 years.
 Leaching — The loss of wood preservative chemicals by the washing action of
 the water flowing through a wood structure cooling tower.
• Pultruded FRP — A common structural material for smaller cooling towers,
fiber-reinforced plastic (FRP) is known for its high corrosion-resistance capabilities.
Pultuded FRP is produced using pultrusion technology, and has become the most
common structural material for small cooling towers. It offers lower costs and
requires less maintenance compared to reinforced concrete, which is still in use for
large structures.
COAL HANDLING:

Coal needs to be stored at various stages of the preparation process, and conveyed
around the CPP facilities. Coal handling is part of the larger field of bulk material
handling, and is a complex and vital part of the CPP.
Stockpiles provide surge capacity to various parts of the CPP. ROM coal is delivered with
large variations in production rate of tonnes per hour (tph). A ROM stockpile is used to
allow the wash plant to be fed coal at lower, constant rate. A simple stockpile is formed
by machinery dumping coal into a pile, either from dump trucks, pushed into heaps with
bulldozers or from conveyor booms. More controlled stockpiles are formed using
stackers to form piles along the length of a conveyor, and reclaimers to retrieve the coal
when required for product loading, etc. Taller and wider stockpiles reduce the land area
required to store a set tonnage of coal. Larger coal stockpiles have a reduced rate of
heat loss, leading to a higher risk of spontaneous combustion.
Travelling, luffing boom stackers that straddle a feed conveyor are commonly used to
create coal stockpiles.
Tunnel conveyors can be fed by a continuous slot hopper or bunker beneath the
stockpile to reclaim material. Front-end loaders and bulldozers can be used to push the
coal into feeders. Sometimes front-end loaders are the only means of reclaiming coal
from the stockpile. This has a low up-front capital cost, but much higher operating costs,
measured in dollars per tonne handled. High-capacity stockpiles are commonly
reclaimed using bucket-wheel reclaimers. These can achieve very high rates.

1. COAL BUNKER: -
These are in-process storage silos used for storing crushed coal coming from the coal
handling plant through conveyor belts. There are six coalbunkers supplying coal to each
mill and are located at top of the mills to aid in gravity feeding of the coal. Each bunker
can store coal, which can be used for 12hrs.

2. COAL FEEDER: -

The purpose of coal feeder is to transfer coal at a pre- determined rate, from coalbunker
to the mill. The coal feeder comprises two continuous chains with L sections flight bars
mounted between the chains at every fifth link .The chains runs on sprockets mounted
at each end of the feeder to given an upper strand movement towards the driven ends
and a lower strand movement in the opposite direction. The drive shaft is supported on
two self aligning bearing mounted in the Plummer block on support outside the
feedercasing,shaft sealing is achieved by the lip seals in the sealing housing and
mounted in board of the bearing to abut the feeder casing.

The tail sprocket shaft is mounted in adjustable bearing blocks adjacent to the feeder
casing with positioned which allow the feeder chain to be tensioned. Both upper and
lower strands run over full width carrying plates with the lower strands located by angle
section guides mounted on the feeder wall. The upper and lower carrying plates and the
inside wall are protected from wear by replaceable stainless steel panels, chains are
kept clean by rubber wiper.

Feeder input is achieved by roller chain drive to the conveyor via a fixed speed electric
motor driving a variable speed gear box, torque limiter and fixed output gear box. The
electric motor is flanged mounted to variable speed gear box, coupled to the fixed
output gear box by a flexible coupling and torque limiter.

The principle of operation of coal feeder is that coal flows from the bunker into the
chain feeder via feed hopper and is conveyed to the mill, when the feeder is in the
operation, the conveyor chain drag a fixed head of coal towards the driven ends of the
feeder. At the end of the carrying plates the coal falls through the conveyor onto the
bottom plate, where it is picked up by the returning flight bars and dragged back along
the feeder to fall into the mill.

3. PULVERISER MILL:-

There are six mills located adjacent to the furnace at 0 m level .These mills pulverize coal
to desired fineness to be fed to the furnace for combustion . The main structure of the
pulverisering mill is fabricated from mild steel in three cylindrical sections, the bottom
section (the mill housing support )which support the entire unit and encloses the mill
drive gear unit, a center section (the mill housing)that contains the rotary grinding
element and upper section (the classifier housing )comprising an accommodate the gas
loading cylinders of the mill loading gear .A platform around the upper section provide
an access to an inspection door and to the top of the mill routine maintenance and is
served by detachable ladder. The grinding element comprises of 3 rotatory rollers.

The raw coal enter the mill through inlet and fall into the grinding zones ,where rotating
bottom grinding and transport coal through the grinding element into the primary air
stream .The primary air enters through the inlet duct in the mill while goes to the
furnace from four outlet ducts at the top of the mill.

The ground fuel particle are picked up by the primary air stream after it is passed
through the throat plates and carried upwards towards the classifier .The larger particle
are initially carried upwards by the air stream and circulate over the upper grinding ring
before falling back into the grinding zone by virtue of their weight .The coal /air mixture
then passes into the classifier ,where any remaining oversize particle are separated out
and fall down to the return skirt until their commutative weight is sufficient to deflect
the flaps and return them into the grinding zone .

The setting of the classifier vane controls the fineness of the ground product. Heavy
material such as pyrites and tramp iron which has passed through grinding zone without
being pulverized is carried around throat plate and discharged through a counter
balance relief gate into the space below the yoke.
ASH HANDLING PACKAGE:
The ash handling system handles the ash by bottom ash handling system, coarse ash
handling system, fly ash handling system, ash disposal system up to the ash disposal
area and water recovery system from ash pond and Bottom ash overflow. Description is
as follows

Bottom Ash Handling System

Bottom ash resulting from the combustion of coal in the boiler shall fall into the over
ground, refractory lined, water impounded, maintained level, double V-Section type/ W
type steel- fabricated bottom ash hopper having a hold up volume to store bottom ash
and economizer ash of maximum allowable condition with the rate specified. The slurry
formed shall be transported to slurry sump through pipes.
Coarse Ash (Economizer Ash) handling System
Ash generated in Economizer hoppers shall be evacuated continuously through flushing
boxes. Continuous generated Economizer slurry shall be fed by gravity into respective
bottom ash hopper pipes with necessary slope.

Air Pre Heater ash handling system

Ash generated from APH hoppers shall be evacuated once in a shift by vacuum
conveying system connected with the ESP hopper vacuum conveying system.

Fly Ash Handling System

Fly ash is considered to be collected in ESP Hoppers. Fly ash from ESP hoppers extracted
by Vacuum Pumps up to Intermediate Surge Hopper cum Bag Filter for further Dry
Conveying to fly ash silo. Under each surge hopper ash vessels shall be connected with
Oil free screw compressor for conveying the fly ash from Intermediate Surge Hopper to
silo. Total fly ash generated from each unit will be conveyed through streams operating
simultaneously and in parallel.

Ash Slurry Disposal System

Bottom Ash slurry, Fly ash slurry and the Coarse Ash slurry shall be pumped from the
common ash slurry sump up to the dyke area which is located at a distance from Slurry
pump house.

Electrostatic precipitator

The ash content in the Indian coal is of the order of 30% to 40%. When coal is fired in
the boiler, ashes are liberated and about 80% of ash is carried along with the flue
gases. If this ash is allowed to atmosphere, it is hazardous to health. So, it became
necessary to incorporate an electrostatic precipitator in the path of the flue gases
going in the atmosphere. The electrostatic precipitators are preferred to mechanical
precipitators because they are capable of precipitating particles from sub micron to
large sizes of particles. The efficiency of the modern ESP’s is of the order of 99.9%.

The electrostatic precipitator consists of a large chamber, which comprises of

parallel rows of sheet type collecting electrodes suspended from the precipitator
casing with wire type discharge electrodes arranged mid-way between them. At
the inlet of the chamber, gas distributor screens for uniform distribution of the
gases in the chamber, are provided.
 The collectors are connected to earth at positive polarity while the discharge
electrodes are connected to a high voltage dc supply at negative polarity. When
dust-laden gas flows between the electrodes, the corona discharge causes the dust
particles to become charged, the particles then being attracted towards and,
eventually, deposited on the collector electrodes.

This dust falls as the collecting electrodes are continuously rapped through a
rapping system and is collected into the pyramid type hoppers, located beneath
each collecting electrodes, from where it is removed by the ash handling system.

GENERATION OF ELECTRICITY:
The conversion from coal to electricity takes place in three stages:

Stage 1:

The first conversion of energy takes place in the boiler. Coal is burnt in the boiler
furnace to produce heat. Carbon in the coal and Oxygen in the air combine to
produce Carbon Dioxide and heat.

Stage 2:

The second stage is the thermodynamic process.

1. The heat from combustion of the coal boils water in the boiler to produce steam. In
modern power plant, boilers produce steam at a high pressure and temperature.
2. The steam is then piped to a turbine.
3. The high pressure steam impinges and expands across a number of sets of blades
in the turbine.
4. The impulse and the thrust created rotate the turbine.
5. The steam is then condensed and pumped back into the boiler to repeat the cycle.

Stage 3:

In the third stage, rotation of the turbine rotates the generator rotor to
produce electricity based of Faraday’s Principle of electromagnetic induction.

 In practice to effect these three stages of conversion, many systems and sub systems
have to be in service. Also involved are different technologies, like combustion,
aerodynamics, heat transfer, thermodynamics, pollution control, and logistics.

As an example consider these facts for typical coal fired power plant of capacity 500 MW.
  Around 2 million tons of coal will be required each year to produce the continuous
 power.
 Coal combustion in the boiler requires air. Around 1.6 million cubic meter of air in
an hour is delivered by air fans into the furnace.

  The ash produced from this combustion is around 200,000 tons per year. 
• Electrostatic precipitators capture almost all of this ash without dispersing this to
the atmosphere. Pollutants from coal power plants like carbon dioxide, sulphur
dioxide, and nitrogen oxide can also affect the environment. Thermal power plants
are the biggest producers of Carbon Dioxide.
 The boiler for typical 500 MW units produces around 1600 tons per hour of steam at
a temperature of 540 to 600 degrees Centigrade. The steam pressures is in the
range of 200 bar. The boiler materials are designed to withstand these conditions
 with special consideration for operational safety.
 Heat transfer from the hot combustion gases to the water in the boiler takes place
 due to Radiation and convection.
 The Electrical generators carry very large electric currents that produce heat and are
 be cooled by Hydrogen and water.
 The steam leaving the turbine is condensed and the water is pumped back for reuse
in the boiler. To condense all the steam it will require around 50,000 cubic meter
per hour of cooling water to be circulated from lakes, rivers or the sea. The water is
returned to the source with only an increase of 3 to 4 degrees centigrade to prevent
 any effect to the environment.
• Apart from the cooling water the power plant also requires around 400 cubic meters
per day of fresh water for making up the losses in the water steam cycle.
Production:
1. Heat is created:
Before the coal is burned, it is pulverized to the fineness of talcum powder. It is then
mixed with hot air and blown into the firebox of the boiler. Burning in suspension, the
coal/air mixture provides the most complete combustion and maximum heat possible.

2. Water turns to steam:

Highly purified water, pumped through pipes inside the boiler, is turned into steam by
the heat. The steam reaches temperatures of up to 1,000 degrees Fahrenheit and
pressures up to 3,500 pounds per square inch, and is piped to the turbine.

3. Steam turns the turbine:

The enormous pressure of the steam pushing against a series of giant blades turns the
turbine shaft. The turbine shaft is connected to the shaft of the generator, where
magnets spin within wire coils to produce electricity.

4. Steam turns back into water:

After doing its work in the turbine, the steam is drawn into a large chamber in the
basement of the power plant. In this important step, millions of gallons of cool water
from a nearby source (such as a river or lake) are pumped through a network of tubes
running through the condenser. The cool water in the tubes converts the steam back
into water that can be used over and over again in the plant. The cooling water is
returned to its source without any contamination, and the steam water is returned to
the boiler to repeat the cycle.

Typical Coal Fired Power Station:

CONCLUSIONS:
Coal fired thermal power plants meet the growing energy demand, and hence special attention
must be given to define a strategy for the optimization of these systems. Energy analysis
presented for a coal fired thermal power plant has provided information on the irreversibilities
of each process.

High grade coal from Barapukuria (Bangladesh) is appropriate for the electricityproduction due
to its chemical properties. We have to utilize this coal for perfect manner.

Condenser pressure has little influence on the energy efficiency. However, a reduction in
condenser pressure results in an increase of the energy efficiency. With Barapukuria (BM) coal,
the energy loss in the combustor was about 35%.In the case of steam generator, the energy loss
reduced to 12% from about 18%as the steam parameters were increased from sub-critical to
supercritical conditions using this (BM) coal. Due to condenser pressure limitation, the
maximum possible overall energy efficiency was found to be about 36.7% with the ultra-
supercritical power plant. Decreasing the condenser pressure by 100mbar will increase the
power output by 2.5%.Thus, installing coal-based thermal power plants based on advanced
steam parameters in Bangladesh will be a prospective option aiding energy self-sufficiency.
REFERENCES:

➢
Thermodynamics by P. K. Nag

➢
Steam Engineering by D. S. Kumar
➢ www.slideshare.com
➢ www.google.com