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EST - Basics - Power Plants
EST - Basics - Power Plants
EST - Basics - Power Plants
Code: ME 217
Sem: 4th Sem, Jan-May session, 2021
L-T-P-C: 3-0-0-3
Electrified transmission
Light energy Electrified earth
lines
Unit of Energy- SI unit of energy is the joule, which is the energy transferred to an object by the work of
moving it a distance of 1 metre against a force of 1 newton.
Other units- kWh, BTU, eV, erg (in CGS unit), etc.
1 BTU (British Thermal Unit) = 1.055 x 103 J
1 erg = 10^-7 Joule
1 eV = 1.6 x 10^-19 Joule (used in high energy physics as a unit of momentum)
Energy and Power- Power = Energy/ Time, i.e. energy specify the time period during which the power is
delivered, and power specify the time period during which the energy quantity is being
converted.
Different Forms of Energy
Radiation energy: the radiation from the sun contains energy, and also the radiation from a light or a
fire. More solar energy is available when the radiation is more intense and when it is collected over
a larger area. Light is the visible part of radiation.
Chemical energy: wood and oil contain energy in a chemical form. The same is true for all other
material that can burn. The content of chemical energy is larger the larger the heating value
(calorific value) of the material is and, of course, the more material we have. Also animate energy
(delivered by bodies of human beings and animals) is, in essence, chemical energy. Furthermore,
batteries contain chemical energy.
Potential energy: this is, for example, the energy of a water reservoir at a certain height. The water
has the potential to fall, and therefore contains a certain amount of energy. More potential energy
is available when there is more water and when it is at a higher height.
Kinetic energy: this is energy of movement, as in wind or in a water stream. The faster the stream
flows and the more water it has, the more energy it can deliver. Similarly, more wind energy is
available at higher wind speeds, and more of it can be tapped by bigger windmill rotors.
Thermal energy or heat: this is indicated by temperature. The higher the temperature, the more
energy is present in the form of heat. Also, a larger body contains more heat.
Mechanical energy, or rotational energy, also called shaft power: this is the energy of a rotating
shaft. The amount of energy available depends on the flywheel of the shaft, i.e.:. on the power
which makes the shaft rotate.
Contd/-
Electrical energy: a dynamo or generator and a battery can deliver electrical energy. The higher
the voltage and the current, the more electrical energy is made available.
Energy Conversion
• Utilizing energy means converting energy from one form into another. For e.g. in water lifting, a diesel
engine converts chemical energy of oil into mechanical energy for powering the shaft of a pump which,
in its turn, converts shaft power into potential energy of water (i.e. bringing the water to a higher
height). Also, a wind turbine generates energy, which means it converts kinetic energy from wind into
mechanical energy. And a solar photovoltaic cell generates energy by converting radiation energy into
electricity.
• Energy conversion cannot be done in a cent-percent efficient manner, i.e. why all converters will have
an operational efficiency, which is given by-
• In some of these converters, intermediate forms of energy occur between the form of the input energy
and the form of the output energy. For instance, with diesel engines, the intermediate form is thermal
energy. The overall efficiency equals the product of the efficiencies of the various components of the
system or the various sub-processes of the main conversion process.
Typical examples of energy converters with efficiencies of the converters
• Sun has a temperature of 5762 K in its convective zone and emits radiant flux of 1362 W/m ^2
• Sun is the source of energy for photosynthesis process of plants, i.e. converting light energy
into chemical energy.
• Another example is conversion of light energy into photo-electric current by using
photovoltaic cells.
• Then conversion of light energy into heat energy for domestic and industrial use.
Different energy sources
Source- http://www.bp.com/statisticalreview
Estimated share of total energy consumption
Solid Fuels
• Coal: The main constituents are carbon, hydrogen, oxygen, nitrogen, sulphur, moisture,
and ash. Coal passes through different stages during its formation from vegetation.
Stages of coal
Plant debris Peat Lignite Brown coal Bituminous coal
Note- Moisture content and ash contents decrease, whereas heat contents increase in the
direction from left to right. Hardness also increases from left to right (excluding graphite coal).
Wood Charcoal
• It is obtained by destructive distillation of wood. During the process, the volatile matter
and water are expelled.
Coke
• It consists of carbon, mineral matter with about 2% sulphur and small quantities of hydrogen,
nitrogen, and phosphorus. It is obtained by the destructive distillation of coal.
• It is smokeless and mainly used in blast furnace to produce heat and at the same time to reduce the
iron ore
Briquettes
• These are prepared from fine coal or coke by compressing the matter under high
pressure.
Analysis of coal
• Proximity analysis: percentage of moisture, volatile matters, fixed carbon and ash are
determined without determining individual elements.
• Ultimate analysis: percentage of various elements are determined, for e.g. C, H2, O2,
N2, S, and ash.
Liquid Fuels
• The chief source of liquid fuel is petroleum, which is proved to be more advantageous than solid fuels.
• Petroleum: It has originated from organic matter like fish and plant life by bacterial action or by their
distillation under pressure and heat. It consists of a mixture of gases, liquids, and hydrocarbons with
small amount of nitrogen and sulphur compounds. The refining of crude oil or heavy fuel oil supplies
the most important product called Petrol. Petrol can also be made by polymerization of refinery gases.
• Other liquid fuels are kerosene, fuel oils, colloidal fuels and alcohol.
• Specific gravity. (ratio of fuel density to water density; higher the sp. Gravity, higher its C/H)
• Flash point (lowest temperature at which chemical can vapourize to form an ignitable mixture in air)
• Fire point (higher temperature at which the oil vapours will continue to burn when ignited, i.e. observed
temperature when burning becomes continuous)
• Volatility (it refers how easily a fuel can vapourize)
Contd/-
• Pour point (it’s a temperature below which liquid loses flow characteristics. Its low value is required)
• Viscosity (it should be low in the range 0-10 Centi-stokes, else affect the fuel atomization)
• Carbon residue (it’s an indication of fuel to form carbonaceous material at high temperature in an inert
atmosphere, after oil’s evaporation; it should not be high)
• Octane no. (higher this number, higher can be the compression ratio and the thermal efficiency)
• Cetane no. (higher value is required of diesel oil to shorten the ignition delay, i.e. speed of self-ignition
of diesel oil)
• Corrosive property (low corrosive tendency is required)
• Ash content (should be low)
• Gum content (should be low)
• Heating value (calorific value and it should be high)
• Sulphur content (should be low)
Gaseous Fuels
• Natural gas: The main constituents are methane and ethane; has a calorific value (CV) about
21000kg/m^3 .
• Coal gas: consists of hydrogen, CO and HCs; prepared by carbonization of coal; finds use in boiler.
• Coke-oven or Coke gas: obtained during production of coke from bituminous coal; it’s volatile coal
matter; used in gas engines and heating the ovens.
• Blast furnace gas: obtained when air is forced through coke layers and iron ore layers in pig iron
manufacturing.
• Producer gas: results from partial oxidation of coal, coke, or peat when burnt with an insufficient
quantity of air; used in steel industry for firing open hearth furnace
Contd/-
• Water gas: produced by blowing steam into white hot coke or coal having free carbon particles;
liberates hydrogen and CO
• Sewer gas: obtained from sewage disposal through fermentation and decay.
Note: majority of these gases have low heating or calorific value, but can be used in gas engines
(after filtration) to drive the plant pumps and agitators
Then steam flows to a steam turbine, where part of its energy is converted to mechanical energy that is
transmitted by rotating shaft to drive an electrical generator. The reduced-energy steam flowing out of
the turbine condenses to liquid water in the condenser. A feed water pump returns the condensed
liquid (condensate) to the steam generator.
Fig- Schematic of modern coal-fired steam power plant
Salient features of a modern coal-fired steam power plant
• Boiler- tall chimney like structure of about 40 m height, lined with tubes inside; fire tube or water tube.
• Super heater- used to raise steam temperature above saturation temperature to say 540 deg C.
• Re-heater- to raise steam temperature to initial temp after partial expansion in the high pressure turbine.
• Economiser- to absorb heat from flue gases to raise temperature of feed water from the condenser.
• Air heater- to raise temperature of air using flue gases before air is led to the furnace for fuel combustion.
• Steam turbine- to convert heat energy of steam into shaft power; it’s a 3-cyl tandem compound machine.
• Generator-to convert mechanical into electrical energy; produces electricity at 11kV.
• Condenser- to condense steam discharged from low-pressure turbine; type of cross-flow heat exchanger.
• Cooling Towers- to cool hot cooling water coming out of condenser; tall ferro-concrete structure.
• Circulating water pump- to circulate cooling water in a closed system of turbine, condenser, & cooling
tower.
• Boiler feed pump- supply feed water coming from condenser to boiler at high pressure.
• Wagon tippler- coal unloaded from wagon at the site by means of wagon tipplers.
• Crusher house- coal is crushed to a size of 10 mm in crusher house.
• Coal mill- to pulverize coal into a fine powder before it is burnt in the boiler furnace.
• Induced Draught (I.D.) fans- to exhaust ash laden flue gas through boiler interior, then dust extracting
equipment and then to the chimney.
• Ash Precipitators- to avoid air pollution, outgoing flue gases are freed from dust particles before
escaping to atmosphere through chimney; mechanical and electrostatic types.
• Boiler chimney- to let off the flue gases to the atmosphere through it after removing fly ash in precipitator.
• Forced Draught (F.D.) fans- to draw air from top of boiler house, then to pass to air preheater.
Contd/-
• Water treatment plant- to avoid any scale formation in boiler tubes & avoid foaming problems;
chemical treatment of cooling water
• Switch yard- electricity at 11 kV is stepped up by transformer to 132/220 kV for transmission through
lines in a switch yard
• Control room- operational nerve centre of a thermal power plant; has sophisticated instrumentation
& controllers
Internal combustion (Diesel) engine power plant
• In a diesel engine power plant, diesel engine is used as the prime mover. The products of diesel engine
combustion are used to produce mechanical energy.
• Diesel power stations find application in places with less demand of power. As generation cost is
considerably high, such power stations are used to produce small power.
• Its essential components are- an air compressor (C), combustion chamber (CC), and a gas
turbine. In addition, a regenerative heat exchanger (H.E) can also be installed ahead of the CC
to improve the thermal efficiency of the cycle by lowering the heat addition in the CC. A high
pressure turbine (HPT) is used to run the compressor by spending about 3/4 th of the total
turbine power, and the remaining 1/4th is produced by the low pressure turbine (LPT), which
drives an alternator to produce electrical power.
Fig- Open cycle GT plant with & without regenerator (H.E), source- google image
Cycle Diagram & efficiency
• In this above configuration, an intercooler is introduced between the low pressure compressor
(LPC) and the high pressure compressor (HPC). Its role is to reduce the overall compression
work, thereby improve the net work output of the plant and its efficiency.
• The role of the reheater is to increase the turbine work and the overall efficiency of the plant.
Closed cycle Gas Turbine plant
• The major problem with an open cycle GT, i.e. the erosion of turbine blades due to the
combustion gases coming in contact with the blades, is overcome in a closed cycle GT. This
happens as the fuel is directly mixed with the working medium, which can be air or any gas.
• In the closed cycle GT, the working medium is heated externally and is continuously
circulated through compressors, heat exchangers, intercoolers, heaters, reheaters, and gas
coolers.
• In closed cycle GT, any fuel can be used, for e.g., gasoline fuel, kerosene, residual oils, blast
furnace gas, etc. as the heating is done externally.
• As the working pressure in the circuit is more, the specific volume of working medium is less,
so component dimensions can be reduced and the maximum unit capacity can be raised.
• Working medium superior to air, for e.g. helium, argon, hydrogen, neon, etc. an be used.
• The plant can be operated with highest efficiency than open cycle GT plant at initial working
temperature of the working fluid.
• The part-load efficiency is more compared to open cycle GT.
• The drawback is the requirement of cooling water and gas to cool the working medium.
• The size is bulky and hence this plant cannot be used in aviation and aeronautical industries.
Fig- Closed cycle GT plant
• Uranium as a nuclear fuel has 2 million times the energy of the coal.
• It is estimated that the world’s reserves of uranium is 25 million tonnes.
• A nuclear power plant is similar to a coal based steam power plant; only the boiler is
replaced with a nuclear reactor.
• The basic nuclear power plant may be either single fluid plant or dual fluid plant.
• A nuclear reactors are primarily classified according to the cooling done in the reactor-
water cooled, gas cooled, organic substance cooled, and liquid metal cooled reactors.
Fig- Single fluid nuclear power plant Fig- Dual fluid nuclear power plant
Light water cooled reactor based nuclear Power Plant
• In the first design, bulk boiling of water is prevented as the water is pressured to about 150
atm.
• In the second design, the feed water coming from the condenser is circulated through the
reactor. The steam generated leaves at the top and is led to the steam turbine.
Liquid metal cooled reactor based nuclear Power Plant
• Sodium is circulated through the reactor core and the intermediate heat exchanger (IHE).
• This is done to prevent steam becoming radioactive. This design is a dual fluid plant design.
• Heat from the sodium is transferred to NaK liquid metal and then to the feed water or the
condensate circulated in the next heat exchanger.
• The system should be leak tight to avoid violent reaction of Na with air or water.
• High boiling point of liquid metal eliminates pressure on the reactor.
• It permits high reactor temperature and steam is also generated at high pressure &
temperature.
Advantages of Nuclear Power Plant
• Since the requirement of fuel is very small, so the cost of fuel transportation, storage etc. is
small.
• Nuclear power plant needs less space as compared to any other power station of the same
size. Example: A 100 MW nuclear power station needs 38 - 40 acres of land whereas the
same capacity coal based thermal power plant needs 120-130 acres of land.
• This type of power plant is very economical to produce large electric power, i.e. using a
small amount of fuel, this plant produces large electrical energy..
• Since, the large number of nuclear fuel is available in this world. So, a nuclear power plant
can generate electrical energy thousands of years continuously.
• It uses a dam to store river water in a reservoir. Water released from the reservoir flows
through a turbine, spinning it, which in turn activates a generator to produce electricity.
• Thus, a mass of water moving down a height difference contains energy which can be
harvested using some waterwheel or turbine. The moving water drives the waterwheel and
this rotation either drives machinery directly (e.g. mill, pump, hammer, etc.) or is coupled
with a generator which produces electric power.
• Next to thermal power hydro power is important in regard to power generation. It can fulfill
the base load requirement for power.
• Modern trend is to use hydro power plant in an interconnected system with thermal stations.
• Catchment area- area behind the dam draining into stream or river across the
dam
• Reservoir- natural or artificial reservoir, used for storage of water
• Dam- built of concrete or stone masonry for creating the head.
• Spillways- to relieve reservoir of excess water; it’s a safe guarding structure
• Conduits- canals, flumes, tunnels, pipelines, & penstocks for carrying water from
reservoir to turbine
• Surge Tanks- small reservoir or tank in which water level rises or falls to reduce
pressure swings
• Prime movers- hydro turbine and the turbo-generator
• Draft tubes- to convert kinetic head at exit of turbine into pressure head, i.e. to
release water to the tailrace
• Power house and equipment- houses the prime movers and other electrical
equipment.
• Tailrace- here water is finally discharged from the power house
Fig- Essential features of hydroelectric power plant
Classifications of Hydroelectric Power Plant
• Pumped storage power plant- it can supply peak load power for base load power plants;
uses extra power not supplied to the grid (during night or
off-peak hours) to raise water from the tailrace to the
headrace to obtain a potential head, which during peak
hours is released from the headrace level and passed
through the turbine to produce excess power for meeting
peak load demand.
Fig- High head hydroelectric power plant
• Turbines in such a plant are able to work with less than 1m or even without head, called
zero head.
• These turbines can generate power at pico- power level.
• The zero-head hydro power plant utilizes the free-stream kinetic energy of the river current
to convert into rotational power. They have specialized design of hydro turbines, which are
able to harness the kinetic energy of the free-flowing water.
• In such zero head turbines, the requirements of storage reservoir, or pond, or complicated
head works, tunnels, pipelines, etc. are not required. Therefore, the losses are also less.
Some photographs of Micro-hydro and Pico-hydro turbine