THERMAL POWER PLANT AND COAL,

ASH PREPARATION AND HANDLING

BY-
PROF. AFAQAHMED J
AIKTC, NAVI MUMBAI
SUPER CRITICAL POWER STEAM
GENERATION

The power plant which operates above the critical

condition is a SUPER CRITICAL POWER
PLANT

Definition of critical Condition

Critical condition is thermodynamic expression
describing the state of a substance beyond which
there is no clear distinction between the liquid and
gaseous phase.
SITE SELECTION :-

Availability of Coal 400 MW NEEDS 6000

TONS/DAY
Ash Disposal Facility
Major Problem ,
Power generation by coal contains 20 40 % Ash,
Quantity of ash is 1500 2000 tons / day
400 MW Power Station requires 10 Hectares area
/ year of height 6.5 m
Space Requirement
Land Required 3 4 Acres / MW
Cost of Land
 Nature of Land Good Bearing capability to
withstand Load of Machineries and forces
transmitted. Min bearing capacity of land is 15 Bar
Availability of Water
Water required for Condenser, Boiler, Drinking
Condensation need 20 to 30 thousand tons / Hr
for 60 MW
Boiler need 6 10 tons / Hr
Transport Facility
Railway Line for coal and machinery transport
UK decided to locate the power plant to source not
at load
Availability of Labour
Public problem
COAL STORAGE
Purpose -
1. Insurance against complete shutdown due
to shortage
2. Take the advantage of seasonal market.
3. Quarter of annual burn to be stored
4. For 200 MW area required 30 acres of
height 10m
5. Storage of coal is undesirable ( Diff cost )
Major Two types of storage
1. Dead ( Shortage, Mine strikes, Railway S)
2. Live
Scientifically Coal is stored to avoid oxidation
in following

1.Stocking in Heaps
Ground used for stocking of dry and level
Coal is piled at 10 20 m Height
Coal is compacted in layer to prevent air
circulation
Gentle slope is given to pile
Temp maintained below 75
Asphalt , Fine coal dust is used to coat the
exterior surface of pile to prevent oxidation
2. Under Water Storage
Slow oxidation and Spontaneous combustion is
eliminated
Following points should be kept in mind
Free from standing water
Artificial Drainage
Area should free from foreign particals
Handling cost should minimum
Piles built up in successive layers
Effective Ventilation for coal
Temp check
Fire Fighting equipments
 COAL PREPARATION
Converting unsized coal sized coal.

Following Equipments are used for Coal

Preparation

Crushers 600 Tons / Hr

Sizers
Dryers Hot Flue Gases passed
Magnetic Separators Iorn scrap
and metallic particles removed
COAL PREPARATION PLANT
 ASH HANDLING SYSTEM
ASH HANDLED 10-20% OF WEIGHT OF
COAL
60,000 TONS / Annum for 200MW
plant in India which covers area of 4
Hectors of height 1.5 m
GENERAL LAYOUT OF ASH HANDLING
MECHANICAL HANDLING SYSTEM
 MECHANICAL DUST COLLECTORS
1. DRY TYPE
2. WET-TYPE

1. GRAVITATIONAL SEPERATORS(Dry)
2. CYLONE SEPARATOR
High velocity gas stream enters into
conical shell, due to whirling motion the
dust is collected to sides and fall out.
Multi Cyclone dust collectors are also
used
 2. WET TYPE DUST COLLECTORS
LOW SULPHUR CONTENT (SO )
2

LOW SULPHUR FUEL IS EXPENSIVE

H 0 + LIME IS SPREAD ACROSS
2

FINE, SLOW MOVING LIQUID DROPLETS

COLLIED WITH WET DUST PARTICLES.
WETTED PARTICLES AGGLOMERATE
UNTIL HEAVY ENOUGH TO DROP
 ELECTROSTATIC PRECIPITATOR
Developed by Dr. Cottel in 1906
Economically used in 1937
Its generally used to remove fly ash
Use of this collector increased rapidly
because of strict air quality codes
30,000 to 60,000 Volts applied
between conductors
Dust is passed through highly charged
electrodes
Then it is passed through collecting unit
Which consist set of vertical plates.

Alternate plates are positively charged

and earthed.
High intensity electrostatic field exerts
force on +vely charged dust particles and
drives them towards grounded plates.
ELECTROSTATIC PRECIPITATOR (GENERAL
LAYOUT)
 ADVANTAGES
1. It removes very small particles like smoke, mist
and flyash (.01 1.00u)
2. Effective in high dust loaded gas with eff of
99.5%
3. Less maintenance
4. Ease of operation

DISADVANTAGES
1. High voltage and Capital Cost
2. Space requirement is more
3. Effi affected by velocity exceeded
4. Protection is required for plates because of
closeness