THERMAL POWER PLANT

TYPES OF THERMAL POWER PLANT

1.

Boiler-Turbine Cycle

2.

Diesel engine type

2.

Gas turbine cycle

BOILER-TURBINE CYCLE

SURFACE CONDENSER

WATER COOLED CONDENSER

Basically it condenses the low pressure/temp steam at the

exhaust of turbine to convert steam into water at the same
pressure and temp. In Indian condition, the pressure and temp.
of steam at condenser inlet is approx. 680 mmHg and 45 degC.

It consists of a shell and bundles of tubes inside. Water will be

passed through the tubes and steam falls directly on the tube

surface.

Water in circulation in the condenser of a 100 MW turbine will

be approx.20,000 cum/hr(20 million litres/hr).

A cooling tower will be necessary for cooling the hot water

leaving the condenser so that the same water can be circulated
to condenser through a set of pumps.

AIRCOOLED CONDENSER

AIRCOOLED CONDENSER

AIR COOLED CONDENSER

It is a variation to the conventional water cooled condenser.

Instead of using water, here atmospheric air through a set of
fans will be impinged on the tube surface.

One major difference is that here steam will be passed through

the tubes and cooling medium, air will be passed over the tube
surface.

Here there is no necessity of cooling tower as in the case of

water cooled condenser.

This is most suitable for project sites where water availability is

scarce.

STEAM JET EJECTOR

STEAM JET EJECTOR

Steam jet ejectors are a reliable and economical means for

producing vacuum. The primary advantages of the ejector design are
its low initial cost, lack of moving parts, and simplicity of operation.

The conventional steam jet ejector has four basic parts; the steam
chest, the nozzle(s), the mixing chamber and the diffuser.

A high pressure motivating fluid (steam) enters and expands

through the converging-diverging nozzle.

The suction fluid enters and mixes with the motivating fluid in the

mixing chamber . Both are then recompressed through the diffuser .

DEAERATOR SPRAY TYPE

DEAERATOR TRAY TYPE

DEAERATOR PRINCIPLE

The removal of dissolved gases from boiler feedwater is an essential

process in a steam system. The presence of dissolved oxygen in
feedwater causes rapid localized corrosion in boiler tubes.

Carbon dioxide will dissolve in water, resulting in low pH levels and

the production of corrosive carbonic acid. Low pH levels in feedwater
causes severe acid attack throughout the boiler system.

While dissolved gases and low pH levels in the feedwater can be

controlled or removed by the addition of chemicals, it is more
economical and thermally efficient to remove these gases
mechanically.

This mechanical process is known as deaeration and will increase the

life of a steam system dramatically.

DEAERATOR PRINCIPLE

The feedwater is sprayed in thin films into a steam atmosphere

allowing it to become quickly heated to saturation.

Spraying feedwater in thin films increases the surface area of the

liquid in contact with the steam, which, in turn, provides more rapid

oxygen removal and lower gas concentrations.

This process reduces the solubility of all dissolved gases and

removes it from the feedwater.

The liberated gases are then vented from the deaerator.

AIR PREHEATER

REGENERATIVE AIR PREHEATER

(TRI SECTOR)

REGENERATIVE AIRHEATER

REGENERATIVE AIRPREHEATER

In regenerative type the heating medium flows through a closely

packed matrix to raise its temperature and then air is passed
through the matrix to pick up the heat.

Either the matrix or the hoods are rotated to achieve this and hence
there is slight leakage through sealing arrangements at the moving
surfaces.

ELECTROSTATIC PRECIPITATOR

ELECTROSTATIC PRECIPITATOR WORKING

PRINCIPLE

An electrostatic precipitator is air pollution control device used to

separate solid particulate matter from a contaminated fluegas
stream.

Contaminated fluegas flows into an ESP chamber and is ionized by

electron emitting electrodes; also known as the corona chamber.

ESP essentially consists of a number of emitting electrodes and

collecting surfaces between which the gas carrying entrained solid
or liquid particles flows.

ELECTROSTATIC PRECIPITATOR
WORKING PRINCIPLE

A unidirectional high potential field is set up between them through

the use of high voltage direct current. The emitting electrodes are at
high tension negative, while the collecting surfaces are at ground
potential. Ionisation of the gas takes place.

The ions formed attach themselves to the solid or liquid particles

entrained

Accumulate particulate matter is removed from the collection plates

at periodic intervals by rapping or hitting the plates with rappers

(mallets type hammers).

Heavy particles fall to the base of the ESP where hoppers hold the
removed particles for disposal.

FUNCTION OF ESP

RAPPING OF THE COLLECTING ELECTRODES

BOILERS

CROSS SECTION OF BOILER

TYPES OF BOILER

Grate Type boiler

Travelling grate type boiler

Fluidised bed combustion type

Bubbling fluidised bed combustion or

Atmospheric fluidised bed combustion (AFBC)

Circulating fluidised bed combustion (CFBC)

Pressurised fluidised bed combustion (PFBC)

Pulverised coal fired type (PC fired)

BOILER TYPES AND CLASSIFICATIONS

Fire in tube or Hot gas through

tubes and boiler feed water in
shell side

Fire Tubes submerged in water

Application

Used for small steam capacities

( upto 12000 kg/hr and
17.5kg/cm2
Merits

Low Capital Cost and fuel

Efficient (82%)

Accepts wide & load fluctuations

Steam pressure variation is less

(Large volume of water)

Packaged Boiler

FIRE TUBE BOILER

BOILER TYPES AND CLASSIFICATIONS

Water flow through tubes

Water Tubes surrounded by hot

gas
Application

Used for Power Plants

Used for high pressure high

capacity steam boiler

WATER TUBE BOILER

TRAVELLING GRATE BOILER

CHAIN GRATE OR TRAVELING GRATE STOKER BOILER

Coal is fed on one end of a

moving steel chain grate

Coal burns and ash drops off at

end

Coal grate controls rate of coal

feed into furnace by controlling
the thickness of the fuel bed.

Coal must be uniform in size as

large lumps will not burn out
completely

Bed thickness decreases from

coal feed end to rear end and so
more air at front and less air at
rear end to be supplied

BASIS OF FBC TECHNOLOGY BUBBLING BED TYPE

FBC TECHNOLOGY

FLUIDIZED BED COMBUSTION (FBC) BOILER

When an evenly distributed air or gas is passed upward through a finely
divided bed of solid particles such as sand supported on a fine mesh, the
particles are undisturbed at low velocity. As air velocity is gradually
increased, a stage is reached when the individual particles are suspended in
the air stream
Further, increase in velocity gives
rise to bubble formation, vigorous

turbulence and rapid mixing and

the bed is said to be fluidized.

Coal is fed continuously in to a hot

air agitated refractory sand bed, the
coal will burn rapidly and the bed
attains a uniform temperature

Fluidized Bed Combustion

TYPES OF FLUIDIZED BED COMBUSTION SYSTEM

There are three basic types of fluidized bed combustion boilers:

1. Atmospheric Fluidized Bed Combustion System (AFBC)
2. Circulating Fluidized Bed Combustion system (CFBC)

SCHEMATIC DIAGRAM OF AFBC

FLUIDISED BED COMBUSTION

The 3 Ts as required for complete combustion which is satisfied by

fluidised bed combustion boiler are as follows:
Time
Temperature
Turbulence

Turbulence is promoted by fluidisation making the entire mass of

solids behave much like a liquid

Improved mixing generates heat at a substantially lower and more

uniformly distributed temperature typically 800 to 9000C

ATMOSPHERIC FLUIDIZED BED COMBUSTION

(AFBC)

In AFBC, coal is crushed to a size of 1 10 mm depending on the

rank of coal, type of fuel feed and fed into the combustion chamber.

The atmospheric air, which acts as both the fluidization air and
combustion air, is delivered at a pressure and flows through the bed
after being preheated by the exhaust flue gases.

The velocity of fluidizing air is in the range of 1.2 to 3.7 m /sec.

The rate at which air is blown through the bed determines the
amount of fuel that can be reacted.

ATMOSPHERIC FLUIDIZED BED COMBUSTION

(AFBC)

Almost all AFBC/ bubbling bed boilers use in-bed evaporator tubes

in the bed of limestone, sand and fuel for extracting the heat from
the bed to maintain the bed temperature.

The bed depth is usually 0.9 m to 1.5 m deep and the pressure drop
averages about 1 inch of water per inch of bed depth.

Very little material leaves the bubbling bed only about 2 to 4 kg of

solids are recycled per ton of fuel burned.

The combustion gases pass over the super heater sections of the

boiler, flow past the economizer, the dust collectors and the air
preheaters before being exhausted to atmosphere.

CIRCULATING BED BOILER

CIRCULATING FLUIDISED BED COMBUSTION

(CFBC)

Circulating Fluidised Bed Combustion (CFBC) technology has

evolved from conventional bubbling bed combustion as a means to
overcome some of the drawbacks associated with conventional
bubbling bed combustion .

This CFBC technology utilizes the fluidized bed principle in which

crushed (6 12 mm size) fuel and limestone are injected into the
furnace or combustor.

The particles are suspended in a stream of upwardly flowing air (6070% of the total air), which enters the bottom of the furnace through
air distribution nozzles.

The fluidising velocity in circulating beds ranges from 3.7 to 9

m/sec. The balance of combustion air is admitted above the bottom
of the furnace as secondary air.

CIRCULATING FLUIDISED BED COMBUSTION

(CFBC)

The combustion takes place at 840-900 C, and the fine particles

(<450 microns) are elutriated out of the furnace with flue gas
velocity of 4-6 m/s.

The particles are then collected by the solids separators and

circulated back into the furnace. Solid recycle is about 50 to 100 kg
per kg of fuel burnt.

The particles circulation provides efficient heat transfer to the

furnace walls and longer residence time for carbon and limestone
utilization.

CIRCULATING FLUIDISED BED COMBUSTION

(CFBC)

Similar to Pulverized Coal (PC) firing, the controlling parameters in

the CFB combustion process are temperature, residence time and

turbulence.

For large units, the taller furnace characteristics of CFBC boiler

offers better space utilization, greater fuel particle and sorbent
residence time for efficient combustion and SO2 capture, and easier
application of staged combustion techniques for NOx control than
AFBC generators.

CFBC BOILER

POWER PLANT CYCLE WITH CFBC BOILER

TECHNOLOGY

COMPARISION BETWEEN AFBC Vs CFBC

Sl.
No.

Description

AFBC

CFBC

1.

Availability

High

High

2.

Control
of
environmental
aspects

Good

Very good

3.

Fuel flexibility

Suitable for wide variety and mix

of fuel like coal, lignite, coal
blended with petcoke, bagasse, etc.
Can also fire furnace oil or NG
upto 50 % in combination with
coal or such solid fuel.
However, a boiler designed for a
particular mix of fuel cannot
accept a very wide variation.

Suitable for wide variety

and mix of fuel.
Boiler can accept greater
fuel mix including petcoke,
FO, NG etc., and heat value
variation, than AFBC

4.

NOx control

Low NOx emission due to low

temperature of combustion

Low NOx emission due to

low
temperature
of
combustion

5.

SOx control

Reduction of SOx in the order of

70% is possible with lime charging
This is adequate for boilers firing
Indian or Indonesian/South
African coal with low sulphur
content. For burning of petcoke
blended with coal, chimney stack
to be designed accordingly.

About 90 to 95 % SOx
removal is possible by lime
charging

6.

Combustion
efficiency

Good
83-85 %

Very good better by about

2% for same range of fuel

COMPARISION BETWEEN AFBC Vs CFBC

Sl.
No.

Description

AFBC

CFBC

7.

Auxiliary power
consumption

Low normative aux. power

consumption is in the order of
about 10%

High Normative aux. power

consumption is in the order
of about 12% i.e. higher by
~2%

8.

Refractory
material & its
maintenance

Low

High

9.

Price

Low

High

10.

Capacity

Limited 200 TPH

And pressure <100 ata

Experience upto 1000 TPH

and pressure upto 150 ata

11.

Operational
efficiency

Easy to operate and maintain

Can not accept frequent or abrupt
load variation

Maintenance cost is
generally higher.
More responsive than AFBC

12

Fluidizing
velocity

The flue gas velocity is less than

that in CFBC boilers.
Consequently, tube erosion is
much less

Due to higher flue gas

velocities, chances of tube
erosion are comparatively
high.

13.

Capital
Investment
required

Lower

High

Overview of Pressurized fluidized bed boiler

PRESSURISED FLUIDISED BED COMBUSTION

The underlying concept is to create a combined cycle plant when a

coal fired system with a steam turbine is combined with a gas
turbine to increase overall efficiency.

A compressor pressurises the combustion air to 12 to 20

atmospheres.

This air is then fed to a pressure vessel that fully encloses a

fluidised bed combustor where coal is burned to produce steam plus
a pressurised gas stream.

The steam is used in a conventional steam turbine cycle to generate

part of the electric power .

The pressurised gas is cleaned sufficiently of particulate and other

contaminants and used in gas turbine to generate the balance of
electric power and compressed air for the combustion process.

PULVERISED FUEL FIRED BOILER

PULVERIZED FUEL BOILER

Coal is pulverised to a fine powder, so that less than 2% is +300 microns,
and 70-75% is below 75 microns.
Coal is blown with part of the combustion air into the boiler plant through
a series of burner nozzles.

Combustion

takes

place

at

temperatures from 1300-1700C

Particle residence time in the boiler is

typically 2-5 seconds

One of the most popular system for

firing pulverized coal is the tangential
firing using four burners corner to
corner to create a fire ball at the
center of the furnace. See Figure

Tangential firing

TYPES OF PULVERISERS

Slow speed mills These mills will be rotating between 15 to 25

rpm depending on the mill size. E.g. Drum mills or Tube mills or
Ball mills

Medium speed mills - These mills will be rotating between 50 to

100 rpm. E.g. Vertical shaft mills, Bowl mills, Ball & Race mills,
Roller mills etc.,

High Speed mills These are directly coupled to the driving motor
and run at 750 to 1000 rpm. E.g., Hammer or Beater mill

DRUM MILLS

The mill drum carrying the ball charge rotates on the antifriction
bearings.

Rawcoal is fed to the drum through the inlet elbow and gets crushed
to powder inside the mill drum.

The ball charge and the coal are carried to a certain height inside
the drum and allowed to fall down.

Due to the impact of balls on coal particles and due to attrition as

the particles slide over each other and also over the liners, the coal
get crushed.

Hot flue gases are used for drying and transporting the pulverised
coal from the mill to the classifier.

The coarser particles are returned by the classifier for further

grinding.

BALL MILLS

BALL & RACE MILL

BALL MILLS

Coal fed from the top and fall in the center of the mill table and
passess through the grinding elements which consists of hollow

steel balls carried between two grinding rings.

Upper ring is stationary and applies pressure to the balls from

pneumatic loading cylinders containing pressurised inert gas.

The bottom ring rotates and inturn rotates the balls and in this
process coal trapped in between the grinding elements get
pulverised.

Hot primary air is fed to the mill which carries the finely ground coal
to the classifier.

The coarser particles are returned by the classifier for further

grinding

BOWL MILL

BOWL MILL

Coal is fed from the bunkers by drag link feeder.

The coal falls on the mill grinding table and is carried under the
spring loaded, free running grinding rolls, which reduce the coal to
pulverised fuel of the required fineness.

Hot primary air is fed to the mill which carries the finely ground coal
to the classifier. These passages surround the lower part of the mill.

The coarser particles are returned by the classifier for further

grinding

HAMMER MILL

HAMMER MILLS

Coal fed to the mill is crushed by the impact against the armour
plates and by attrition.

The hot air supplied dries the coal in the mill and transports the
coal powder to the classifier.

The coarser particles are returned by the classifier for further

grinding.

STEAM
DRUM

RADIATION
PANEL

AFTER BURNING CHAMBER

GAS FLOW

ECONOMISER
EVAPORATOR
SUPER HEATER

TYPICAL CROSS SECTION OF WASTE HEAT RECOVERY BOILER

LIST OF WHRB PROJECT REFERENCE EXECUTED BY DASTURCO

Sl.
No.

Name of the Client

Capacity

Commissioned in
the year

1.

Prakash Industries Ltd,

Champa, Chhattisgarh

2 x 7.5MW TG set &

1 x 50 tph WHRB.
(150,000 Tons/annum Sponge Iron
production)

1991

2.

Orissa Sponge Iron Ltd,

Palaspanga, Orissa

1 x 10MW TG set &

1 x 46 tph WHRB
(120,000 Tons/annum Sponge Iron
production)

1997

3.

Tata Sponge Iron Ltd,

Joda, Orissa

1 x 7.5MW TG set &

1 x 35 tph WHRB
(110,000 Tons/annum Sponge Iron
production)

2001

4.

Bellary Steels and Alloys

Ltd, Bellary, Karnataka

1 x 12MW TG set,
2 x 12 tph WHRB &
1 x 40 tph FBC
(2 x 30,000 Tons/annum Sponge
Iron production)

1996 (Project
implementation
partly completed in
1996. Presently
under HOLD)

LIST OF WHRB PROJECT REFERENCE EXECUTED BY DASTURCO

Sl.
No.

Name of the Client

Capacity

5.

Tata Sponge Iron Ltd,

Joda, Orissa

1 x 18.5MW TG set
1 x 350 tpd; 33tph WHRB
1 X 500 tpd; 45tph WHRB

6.

Shree Virangana Steels

Ltd, Nagpur, Maharashtra

1 x 12MW TG set &

2 x 11 tph WHRB,
1 x 47 tph FBC Boiler
(Biomass, Dolochar as fuels)
(2 x 60,000 Tons/annum Sponge
Iron production)

7.

S.A.L. Steel Ltd,

Ahmedabad

1 x 40MW TG set
1 x 55 tph WHRB
1 x 12 tph WHRB and
1 x 110 tph AFBC boiler
(1 x 150,000 Tons/ annum
Sponge Iron production) and
1 x 30,000 Tons/annum Sponge
Iron production

Commissioned in
the year
2007

Project under
execution since
February 2004
presently under
Hold

2005

LIST OF WHRB PROJECT REFERENCE EXECUTED BY DASTURCO

Sl.
No.

Name of the Client

Capacity

Commissioned in
the year

8.

Vandana Global Ltd,

Raipur

1 x 33MW TG set
1 x 55 tph WHRB
2 x 90 tph AFBC boiler
(1 x 150,000 Tons/annum &
1 x 60,000 Tons/annum
Sponge Iron Kiln

Project
commissioned in
September 2007

9.

Abhijeet Infrastructure
Ltd, Raipur (Jayaswals
NECO Group)

1 x 15MW CPP
1 x 39 tph WHRB
1 x 33 tph AFBC boiler
(1 x 1,15,500 tons/annum
Sponge Iron Kiln)

Commissioned in
April 2007

10.

Corporate Ispat Alloys Ltd,

Raipur (Jayaswals NECO
Group)

1 x 15MW CPP
1 x 56 tph WHRB
(1 x 1,65,000 tons/annum
Sponge Iron Kiln)

Project
Commissioned in
August 2007.

LIST OF WHRB PROJECT REFERENCE EXECUTED BY DASTURCO

Sl.
No.

Name of the Client

Capacity

Commissioned in
the year

11.

Surana Industries Ltd,

Chennai

1 x 35MW
4 x 10.5 tph WHRB
1 X 110 tph AFBC boiler
(4 x 100 tpd Sponge Iron Kiln)

Project activities in
progress. Scheduled
for commissioning in
December 2008.

12.

Janki Corp Ltd, Bellary

1 x 15MW CPP
6 x 100 tpd;
6 x 10.5 tph WHRB

Project under
execution

DIESEL GENERATOR POWER PLANT

Diesel Engine

DIESEL ENGINE SYSTEMS

This

system

provides

process heat or steam

from engine exhaust.
The

engine

cooling

jacket

water

heat

exchanger and lube oil

cooler
used

may
to

also

provide

water or hot air.

be
hot

RECIPROCATING ENGINE BASED COGENERATION SYSTEM WITH UNFIRED

WHRB

GAS TURBINE CYCLE

1. Using conventional fuels like Natural Gas, Diesel oil

& Naphtha
2. Integrated gasification combined cycle (IGCC)

GAS TURBINE COMBINED CYCLE

GAS TURBINE

The fuel is burnt in a pressurized combustion chamber using

combustion air supplied by a compressor that is integral with the
gas turbine.

Gases enter the turbine at a temperature range of 900 to 1000oC

and leave at 400 to 500 oC.

Hot pressurized gases are used to turn a series of turbine blades,

and the shaft on which they are mounted, to produce mechanical

energy.

The available mechanical energy can be applied in the following

ways:
to produce electricity with a generator (most applications);
to drive pumps, compressors, blowers, etc.

SOME GAS TURBINE BASED POWER PLANTS

Agency/Promoter

State

Installed
capacity (MW)

Faridabad CCGT

NTPC

Haryana

430

Anta GT

NTPC

Rajasthan

413

Auraiya GT

NTPC

Uttar pradesh

652

Dadri GT

NTPC

Uttarpradesh

817

Kawas GT

NTPC

Gujarat

644

Gandhar GT

NTPC

Gujarat

648

Kayakulam GT

NTPC

Kerala

350

Urban GT

MSEB

Maharastra

672.0

Andhra pradesh gas

power corporation

Andhraprades
h

272.3

TNEB

TamilNadu

2 x 95.0

GVK Industries

Gujarat

235.4

Kondapalli GT

Lanco Kondapalli

Andhraprades
h

350

P.Nallur CCGT

PPN power generating

company

TamilNadu

330.5

GVK Industries

Andhraprades
h

230

Power station

Vijeswaram GT
Valuthur GT
Jegurupadu GT

Jegurupadu GT Extn

INTEGRATED GASIFICATION
COMBINED CYCLE (IGCC)

INTEGRATED GASIFICATION
COMBINED CYCLE (IGCC)

GASIFIER

LIST OF GE INSTALLATIONS
Project

Power , MW

Gas Turbine

Main fuel - back

up fuel

Coolwater

120

107E

Coal

SUV Vresova

350

209E

Coal

70

1x106B

Coal

Wabash

250

107FA

Coal/Pet Coke

Tampa Polk

250

107FA

Coal

40

6B

Pet Coke

Shell Pernis

120

206B

Oil

Sarlux

550

3x109E

Vis breaker tar

Motiva

180

2-6FA

Pet Coke

Exxon Singapore

173

2-6FA

Oil

Nexen/Opti

160

2-7EA

Asphaltene

Coal IGCC Experience

SVZ

Refinery IGCC Experience

Frontier

LIST OF ANSALDO INSTALLATIONS

Project

Power,
MW

Gas
Turbine

Main fuel - back

up fuel

Enil power
Ferrera

255 MW

1x
V94.2K

77% Tar syngas +

13% Natural gas
Backup fuel natural gas

ISAB Priolo

2 x 250
MW

2x
V94.2K

100% Tar syngas

Backup fuel - fuel
oil

POWER PLANT BASIC VARIANT

Utility Power Plant : It will generate and supply only Electric power.

Mostly owned by SEBs, PSU, IPPs

Cogeneration Power Plant:

Simultaneous generation of Electric power and

low/medium

pressure & temperature steam.

Most ideal for process industries wherein both
power (for driving electric motors) and
process fluids will be required.

electric

steam for heating

POWER PLANT BASIC VARIANT

Captive Power Plant (CPP) : It refers to power plant set up by an

Industry for its own consumption.

Depending upon the type of Industry, CPP will be designed either as

an utility power plant or cogeneration plant.

The boilers will be designed for firing by-product fuels if any

available in the plant along with conventional fuels. (Eg.Blast

furnace gas and coke oven gas in steel plant; dolochar in sponge
iron plant; bagasse in sugar plant)

In some cases, the hot waste gases generated in the plant will be

used for producing steam (eg. waste gas from Sponge iron kiln, coke
oven)

BACKPRESSURE STEAM TURBINE BASED COGENERATION SYSTEM

EXTRACTION-CUM-CONDENSING STEAM TURBINE BASED

COGENERATION SYSTEM

GAS TURBINE BASED COGENERATION SYSTEM WITH SUPPLEMENTARY

FIRED WHRB

RECIPROCATING ENGINE BASED COGENERATION SYSTEM WITH

UNFIRED WHRB