Thermal Power Plant

 Thermal Power Plant

• A thermal power plant is a type of power station in which heat
energy is converted to electrical energy.
• In a steam-generating cycle, heat is used to boil water in a large
pressure vessel to produce high-pressure steam, which drives a
steam turbine connected to an electrical generator.
• The low-pressure exhaust from the turbine enters a steam
condenser where it is cooled to produce hot condensate which
is recycled to the heating process to generate more high
pressure steam.
• This is known as a Rankine cycle.
  Thermal Power Plant
• Thermal power plants are the most common type of power plant in the world,
accounting for about 60% of global electricity generation.
• They are used to generate electricity from a variety of fuels, including coal,
natural gas, oil, and nuclear power.
• These are a major source of air pollution, emitting pollutants such as sulphur
dioxide, nitrogen oxides, and particulate matter. They also contribute to climate
change by emitting greenhouse gases such as carbon dioxide.
• However, therse plants are also a reliable and efficient source of electricity. They
can be operated 24 hours a day, 7 days a week, and they can be scaled up or down
to meet demand.
• As the world transitions to a cleaner energy future, thermal power plants will
need to be modified to reduce their emissions. This can be done by using cleaner
fuels, such as natural gas, and by installing pollution control equipment
 Advantages of Thermal Power Plants

• They are relatively inexpensive to build and operate.

• They can be built in a variety of sizes, from small thermal
power plants that can power a single community to large
plants that can power an entire country
• They are reliable and can be operated for a long period of
time without interruption.
 Disadvantages of Thermal Power
Plants

• They emit greenhouse gases, such as carbon dioxide, that

contributes to climate change.
• They can pollute the air with pollutants, such as sulphur
dioxide and nitrogen oxides.
• They consume large amounts of water, that can be a
problem in areas with limited water resources.
 Principle of Thermal Power Plant

• Thermal power plant” as the title infers is the place of mechanism

which converts heat energy into electric power.
• A thermal power plant is a large facility that converts heat energy into
electric power.
• The heat energy is typically generated by burning fossil fuels, such as
coal, oil, or natural gas.
• The hot combustion gases are used to heat water in a Steam boiler,
which produces steam.
• The steam is then used to turn a turbine, which is connected to an
electric generator.
• The generator converts the mechanical energy of the turbine into
electric power.
Working of Thermal Power Plant
 Working of Thermal Power Plant
• A thermal power plant is a large facility that converts heat
energy into electric power. Heat energy is typically generated
by burning fossil fuels, such as coal, oil, or natural gas.
• The hot combustion gases are used to heat water in a boiler,
which produces steam.
• The steam is then used to turn a turbine, which is connected
to an electric generator.
• The generator converts the mechanical energy of the turbine
into electric power.
Basic Layout
 THERMAL POWER STATION
• A Thermal Power Station is a power plant in which the
prime mover is steam driven.
• There are mainly three primary inputs given to thermal
power generating plants for producing electricity.
• These three most essential elements are coal, air, and water.
• Coal is used as fuel which creates required heat energy by
combustion in the furnace.
 THERMAL POWER STATION
• Air is supplied to the furnace to accelerate the combustion rate of
the coal and to continue the flow of flue gases inside the heating
system.
• Water is required in a thermal power plant inside a boiler to
produce steam. This steam drives the turbine.
• The turbine is coupled to the shaft of a generator which generates
electrical power as the output of the system.
• Depending on these three primary inputs there are three basic
flow circuits that work on a thermal power generating plant.
 THERMAL POWER STATION
• A thermal power generating plant works based on the
Rankine Cycle.
• Water is heated, turns into steam and spins a Steam
Turbine which drives an electrical generator
(Alternator).
• After it passes through the turbine, the steam is
condensed in a Condenser; this is known as a Rankine
cycle.
 Rankine Cycle
• The Rankine cycle is an idealized thermodynamic
cycle describing the process by which certain heat
engines, such as steam turbines or reciprocating
steam engines, allow mechanical work to be
extracted from a fluid as it moves between a heat
source and heat sink.
• There are four processes in the Rankine cycle, each
changing the state of the working fluid. These
states are identified by number in the diagram to
the right.
• Process 1-2: The working fluid is pumped from
low to high pressure, as the fluid is a liquid at this
stage the pump requires little input energy.
 Rankine Cycle
• Process 2-3: The high pressure liquid enters a boiler where
it is heated at constant pressure by an external heat source
to become a dry saturated vapor.
• Process 3-4: The dry saturated vapor expands through a
turbine, generating power. This decreases the
temperature and pressure of the vapor, and some
condensation may occur.
• Process 4-1: The wet vapor then enters a condenser where
it is condensed at a constant pressure and temperature to
become a saturated liquid. The pressure and temperature
of the condenser is fixed by the temperature of the cooling
coils as the fluid is undergoing a phase-change.
What is a boiler?
• The steam generating Boiler is basically a heat
exchanger which has to produce steam at the high
purity, pressure and temperature required for the
steam turbine that drives the electrical generator.
Boiler Parts
• The Boiler includes the Economizer, the steam
drum, the chemical dosing equipment, and the
furnace with its steam generating tubes and the
super heater coils. Necessary safety valves are
located at suitable points to avoid excessive
boiler pressure. The air and flue gas path
equipment include: forced draft (FD) fan, air
preheater (APH), boiler furnace, induced draft
(ID) fan, fly ash collectors (electrostatic
precipitator or baghouse) and the flue gas stack.
Air Pre-Heater (APH)
• APH is a heat exchanger in which air temperature is
raised by transferring heat from other fluid such as
flue gases.
 APH TYPES
1. Recuperative Type : Heating medium is on one side & air is
on the other side of tube /plate & heat transfer is by
conduction through the material which separates the media.
2. Regenerative Type : Heating medium flows through a
closely packed rotating matrix to raise its temperature and
then air is passed through the matrix to take up the heat.
APH(TRISECTOR TYPE)
• Tri-sector types are the most common in modern power
generation facilities.In the tri-sector design, the largest
sector (usually spanning about half the cross-section of the
casing) is connected to the boiler hot gas outlet. The hot
exhaust gas flows over the central element, transferring
some of its heat to the element, and is then ducted away for
further treatment in dust collectors and other equipment
before being expelled from the flue gas stack. The second,
smaller sector, is fed with ambient air by a fan, which
passes over the heated element as it rotates into the sector,
and is heated before being carried to the boiler furnace for
combustion. The third sector is the smallest one and it heats
air which is routed into the pulverizers and used to carry
the coal-air mixture to coal boiler burners. Thus, the total
air heated in the RAPH provides: heating air to remove the
moisture from the pulverised coal dust, carrier air for
transporting the pulverised coal to the boiler burners and
the primary air for combustion.
Boiler Draft Control
• Induced draft: This is obtained one of three ways, the first being the
"stack effect" of a heated chimney, in which the flue gas is less dense than the
ambient air surrounding the boiler. The denser column of ambient air forces
combustion air into and through the boiler. The second method is through
use of a steam jet. The steam jet oriented in the direction of flue gas flow
induces flue gasses into the stack and allows for a greater flue gas velocity
increasing the overall draft in the furnace. This method was common on
steam driven locomotives which could not have tall chimneys. The third
method is by simply using an induced draft fan (ID fan) which removes flue
gases from the furnace and forces the exhaust gas up the stack. Almost all
induced draft furnaces operate with a slightly negative pressure.
• Forced draft: Draft is obtained by forcing air into the furnace by means
of a fan (FD fan) and ductwork. Air is often passed through an air heater;
which, as the name suggests, heats the air going into the furnace in order to
increase the overall efficiency of the boiler. Dampers are used to control the
quantity of air admitted to the furnace. Forced draft furnaces usually have a
positive pressure.
• Balanced draft: Balanced draft is obtained through use of both induced
and forced draft. This is more common with larger boilers where the flue
gases have to travel a long distance through many boiler passes. The induced
draft fan works in conjunction with the forced draft fan allowing the furnace
pressure to be maintained slightly below atmospheric
ESP
• An electrostatic precipitator is a large, industrial emission-control
unit. It is designed to trap and remove dust particles from the
exhaust gas stream of an industrial process.
Steam turbine
• A steam turbine is a mechanical device that extracts
thermal energy from pressurized steam, and converts
it into rotary motion.
• Because the turbine generates rotary motion, it is
particularly suited to be used to drive an electrical
generator – about 80% of all electricity generation in
the world is by use of steam turbines.
Turbine Shaft
Principle of Operation
• An ideal steam turbine is considered to be an
isentropic process, or constant entropy process,
in which the entropy of the steam entering the
turbine is equal to the entropy of the steam
leaving the turbine. No steam turbine is truly
“isentropic”, however, with typical isentropic
efficiencies ranging from 20%-90% based on the
application of the turbine. The interior of a
turbine comprises several sets of blades, or
“buckets” as they are more commonly referred
to. One set of stationary blades is connected to
the casing and one set of rotating blades is
connected to the shaft. The sets intermesh with
certain minimum clearances, with the size and
configuration of sets varying to efficiently exploit
the expansion of steam at each stage .
Impulse Turbines
• An impulse turbine has fixed nozzles that orient the
steam flow into high speed jets. These jets contain
significant kinetic energy, which the rotor blades, shaped
like buckets, convert into shaft rotation as the steam jet
changes direction. A pressure drop occurs across only the
stationary blades, with a net increase in steam velocity
across the stage.
• As the steam flows through the nozzle its pressure falls
from steam chest pressure to condenser pressure (or
atmosphere pressure). Due to this relatively higher ratio
of expansion of steam in the nozzle the steam leaves the
nozzle with a very high velocity. The steam leaving the
moving blades is a large portion of the maximum velocity
of the steam when leaving the nozzle. The loss of energy
due to this higher exit velocity is commonly called the
"carry over velocity" or "leaving loss".
Reaction Turbines
• In the reaction turbine, the rotor blades themselves
are arranged to form convergent nozzles. This type of
turbine makes use of the reaction force produced as
the steam accelerates through the nozzles formed by
the rotor. Steam is directed onto the rotor by the fixed
vanes of the stator. It leaves the stator as a jet that fills
the entire circumference of the rotor. The steam then
changes direction and increases its speed relative to
the speed of the blades. A pressure drop occurs across
both the stator and the rotor, with steam accelerating
through the stator and decelerating through the rotor,
with no net change in steam velocity across the stage
but with a decrease in both pressure and temperature,
reflecting the work performed in the driving of the
rotor.
Steam Condenser
• Surface condenser is the commonly used term
for a water cooled shell and tube heat exchanger
installed on the exhaust steam from a steam
turbine in thermal power stations. These
condensers are heat exchangers which convert
steam from its gaseous to its liquid state at a
pressure below atmospheric pressure. Where
cooling water is in short supply, an air-cooled
condenser is often used. An air-cooled condenser
is however significantly more expensive and
cannot achieve as low a steam turbine exhaust
pressure as a surface condenser
Alternator

• An alternator is an electromechanical device that

converts mechanical energy to alternating current
electrical energy. Most alternators use a rotating magnetic
field but linear alternators are occasionally used. In
principle, any AC electrical generator can be called an
alternator, but usually the word refers to small rotating
machines driven by automotive and other internal
combustion engines
Principle of operation
• Alternators generate electricity by the same principle as DC generators,
namely, when the magnetic field around a conductor changes, a current is
induced in the conductor. Typically, a rotating magnet called the rotor turns
within a stationary set of conductors wound in coils on an iron core, called
the stator. The field cuts across the conductors, generating an electrical
current, as the mechanical input causes the rotor to turn.
• The rotating magnetic field induces an AC voltage in the stator windings.
Often there are three sets of stator windings, physically offset so that the
rotating magnetic field produces three phase currents, displaced by one-
third of a period with respect to each other.
• The rotor magnetic field may be produced by induction (in a "brushless"
alternator), by permanent magnets (in very small machines), or by a rotor
winding energized with direct current through slip rings and brushes. The
rotor magnetic field may even be provided by stationary field winding, with
moving poles in the rotor. Automotive alternators invariably use a rotor
winding, which allows control of the alternator generated voltage by varying
the current in the rotor field winding. Permanent magnet machines avoid the
loss due to magnetizing current in the rotor, but are restricted in size, owing
to the cost of the magnet material. Since the permanent magnet field is
constant, the terminal voltage varies directly with the speed of the generator.
Brushless AC generators are usually larger machines than those used in
automotive applications.and the large alternators in power station which are
driven by steam turbine are called turbo alternators
Poles verses RPM Poles RPM at
50Hz
2 3000
• The output frequency of an
alternator depends on the 4 1500
number of poles and the 6 1000
rotational speed. The speed
corresponding to a particular 8 750
frequency is called the 10 600
synchronous speed for that
frequency. This table gives 12 500
some examples: 14 428.6
16 375
18 333.3
20 300
CLZS Parameters
• Captive Power Plant in Chanderiya consists
of 3 units (2X77 MW + 1X80 MW).
• All three units are supplied by BHEL,
Hyderabad.
• While supplying uninterrupted and reliable
power to Chanderiya Lead Zinc Smelter, the
CPP has been additionally wheeling power
to its Agucha, Debari and Dariba units of
Hindustan Zinc Limited.
• Recently sale of power has also been
initiated with both RSEB and power
exchange.
• In the Financial year 2008-’09,the 234 MW CPP the
operating parameters for U1,2,3 were PLF (100.2%, 93.4%
and 95.0 % respectively), Availability (98.5%,97.3% and
88.9% respectively), Auxiliary consumption(8.93%,9.35%
and 9.53% respectively.
• With a vision to reduce Cost of generation, usage of Indian
Coal has been increased.
• The Plant is actually designed for pulverized fuel with
coal imported from Indonesia and South Africa having
10% moisture,12% ash,55% fixed carbon,23% volatile
matter and 6000Kcal/Kg.
• In comparison to pure imported coal being used earlier,
blending of around 40 % Indian coal was started thereby
reducing the cost of coal significantly.
• Day-to-Day operational and maintenance hurdles
were faced as per an action plan and overcome.
• Usage of linkage coal, which has a potential to
reduce coal cost by around Rs.1200/MT has been
started.
• Chanderiya CPP has upheld highest standard of
Environmental consciousness by discharging
minimum effluents, both gaseous and liquid, into
the atmosphere.
• The SPM, SOX, NOx and other gaseous effluents
have been maintained well below the pre-defined
norms set by the governing bodies.