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FD or ID fans are used for supply the air to combustion chamber of the boiler through airpreheater The air preheater is placed in the path of flue gases to preheat the air The flue gases produced by combustion of fuels in the boiler furnaces after passing around boiler tubes and super heater tubes Pass through a dust collector or precipitator where most of dust is removed before venting it of to atmosphere through chimney
Various equipments
1. A furnace to burn the fuel. 2. Steam generator or boiler containing water. Heat generated in the furnace is utilized to con- vert water in steam. 3. Main power unit such as an engine or turbine to use the heat energy of steam and perform work. 4. Piping system to convey steam and water. In addition to the above equipment the plant requires various auxiliaries and accessories depending upon the availability of water, fuel and the service for which the plant is intended. The flow sheet of a thermal power plant consists of the following four main circuits : (i) Feed water and steam flow circuit (ii) Coal and ash circuit (iii) Air and gas circuit (iv) Cooling water circuit. A steam power plant using steam as working substance works basically on Rankine cycle. Steam is generated in a boiler, expanded in the prime mover and condensed in the condenser and fed into the boiler again. (ii) The different types of systems and components used in steam power plant are as follows : (i) High pressure boiler (ii) Prime mover (iii) Condensers and cooling towers (iv) Coal handling system (v) Ash and dust handling system (vi) Draught system (vii) Feed water purification plant (viii) Pumping system (ix) Air preheater, economizer, super heater, feed heaters.
Coal is the principal energy source for India because of its large deposits and availability Coal originated from vegetable matter, which grew millions of years ago Trees and plants falling into water decayed and later produced peat bogs Huge geological upheavals buried these bogs under layers of silt Subterranean heat, soil pressure and movement of earth's crust distilled off some of the bog's moisture and hardened it to form coal Basically classification of coal is based on Physical and chemical composition Peat Lignite and brown coal Bituminous coal Anthracite
Coal
Coal analysis
Proximate Analysis Gives: Behavior of coal when heated FC + VM + M + A = 100% by mass Ultimate Analysis Gives: chemical elements along with ash and moisture C + H + 0 + N + S + M + A = 100% by mass
Peat
Low grade coal First stage coal formation Contains 90% moisture Small amount of volatile matter Not suitable for power plants Used in domestic purposes Requires 1-2 months for drying in sunlight
Bituminous coal
Containing 46-86% of fixed carbon and 20-40% of VM Ash content may vary 6-12 % High percentage of volatile matter CV of 32 MJ / Kg Sub-Bituminous is having less moisture, ash than lignite , used in briquette or pulverized form Semi-Bituminous coal high carbon and heating value, contain less moisture, ash, sulphur, &VM, Has tendency to break into pieces
Anthracite Coals
Contains more than 86% fixed carbon &VM around 8% Ignites slowly has high CV of 36 MJ / Kg Low ash, zero CAKING power Difficult to pulverize Anthracite coal
Coal handling
In Case of Rail Delivery Most Commonly Used are : Wagon Tippler Hopper Hydraulic Gates Opening
Operation The gates bellow the wagons are hydraulic controlled By opening the gates the coal flows downwards due to gravitational force and is moved to the bellow pit Demerits Due to the dust the Hydraulic will not work smoothly Require a lot of maintenance
Preparation
Crushers and breakers used to crus the big size coal into small size coal
Driers used to dry the coal if it contains lot of moisture it is also further done in the pulverizes
Magnetic sprayers used to separate the iron parts that come along with the coal from the mines these may damage the parts of pulverizes or may have a bad effect on the boiler
Coal Crushers
Why? Reduce size from 200mm to 20mm Types of crushers 1.Ring Type Coal Crusher 2.Hammer Mill Coal Crusher 3.Brad Ford Breaker
Operation
The coal is fed at the top left corner Is crushed in between the plane loose rings and the adjustable plates. The loose rings with the jaws used to take the crushed coal down words Adjustable plate and the screen determine the maximum size of the discharged coal
OPERATION
The coal is fed at the top Is crushed by the action of rings that pivot off center on a rotor or by swinging hammers attached to it Adjustable screen bars determine the maximum size of the discharged coal
Transfer
Belt Conveyor
Belt conveyor
Belt conveyor
Screw conveyor
Grate
Chamber type
Overfeed stoker
Underfeed stoker
Overfeeding
Overfeeding
Receives fresh coal from top surface has following distinct zones
Fresh or green coal Coal losing moisture (Drying zone) Coking layer (loosing of VM) Distillation zone Incandescent coke ( Fixed carbon is consumed) Combustion zone Ash layer progressively cooled
Operations
Primary air gets warmed up as it flows through the ash layer As it passes through the incandescent coke layer(1200 C) Carbon converted to Carbon dioxide releasing heat continues till oxygen is consumed, if layer is thick CO2 is converted to CO reducing layer temperature The stream while passing through distillation zone VM is added In distillation zone moisture is added now stream contains N,CO2,CO,H2,VM&moisture
Turbulence
Providing secondary air at right angles to up-flowing gas stream emerging out of fuel bed
Results
Carbon is in CO, CO2 both are color less Carbon with hydrogen in VM which will be cracked to form free carbon at high temperature suspended in gas stream If Burner is not designed properly or operated properly leads to unburnt carbon particles this appears as black smoke on chimney top
Underfeeding
Underfeeding
In underfeeding coal is fed from below Primary air passing through holes diffuses through spaces in the raw green coal picking up moisture In distillation zone to stream VM is added In incandescent zone VM breaks readily burns with secondary air present above it where it is fed from top VM burning is somewhat cooler need longer time to ignite and burn
Mechanical Stokers
Overfeeding 1. Traveling grate stoker 2. Chain grate stoker 3. Spreader stoker 4. Vibrating grate stoker Underfeed stoker 1. Single retort 2. Multiretort
Spreader stoker
Spreader stoker
Coal from hopper is fed by rotating feeder Feeder normally will have Blades fitted on the drum Fine particles burn in suspension Speed of the feeder varies with the steam output of boiler Grate is made up of CI bars, Links underneath the grate are connected to a lever Fuels used may be Bituminous, lignite, wood waste, baggase Coal size used in 6-36 cm
Underfeed stokers
Multiple retort
Pulverised coal
Why pulverisers?
Size reduction (mm to micron) Other things: Drying (primary airapprox 300 degree) Feeding
Types of Pulverisers
Ball and tube mill (low speed < 75 rpm) Ball and tube race mill (medium speed 75225 rpm) Bowl mill (medium speed 75-225 rpm) Impact or hammer mill (> 225 rpm) .depending upon the nature of coal
Unit system
Advantages (i) The system is simple and cheaper than the central system. (ii) There is direct control of combustion from the pulverising mill. (iii) Coal transportation system is simple
Bin or Central System. Crushed coal from the raw coal bunker is fed by gravity to a dryer where hot air is passed through the coal to dry it. The dryer may use waste flue gases, preheated air or bleeder steam as drying agent. The dry coal is then transferred to the pulverising mill. The pulverised coal obtained is transferred to the pulverised coal bunker (bin) The transporting air is separated from the coal in the cyclone separator. The primary air is mixed with the coal at the feeder and the mixture is supplied to the burner. Advantages l. The pulverising mill grinds the coal at a steady rate irrespective of boiler feed. 2. There is always some coal in reserve. Thus any occasional breakdown in the coal supply will not effect the coal feed to the burner. 3. For a given boiler capacity pulverising mill of small capacity will be required as compared to unit system. Disadvantages 1. The initial cost of the system is high. 2. Coal transportation system is quite complicated. 3. The system requires more space.
Bowl Mill
Bowl Mill
Bowl mill
Bowl mill
Replacement of grinding elements takes lesser time. Capacity and product fineness deteriorate with wearing out of grinding elements. Rate of erosion of bowl and rings are very high. Frequent shutdown of mills are required for adjustment of loading springs which becomes loose for wearing out of roller and bowl. Ingress of non crushable material may damage mill internals. Reject rate is very high. Elaborate mill reject system becomes essential for larger units. Disposal of mill reject is another problem to be tackled by power station.
Impact/Hammer Mill
Impact/Hammer Mill
Impact/Hammer Mill
A simple, compact and low cost mill. Mill can be designed for very high temperature. This facility makes this mill suitable for use with high moisture lignite fuel. Wear of grinding elements reduces mill capacity. Product fineness is low.
Pulverization
Advantages Low excess air requirement Less fan power Ability to use highly preheated air reducing exhaust losses Higher boiler efficiency Ability to bum a wide variety of coals Fast response to load changes Ease of burning alternately with, or in combination with gas and oil Ability to release large amounts of heat enabling it to generate about 2000 t/h of steam or more in one boiler Ability to use fly ash for making bricks etc. Less pressure losses and draught need.
Disadvantages
1. Added investment in coal preparation unit 2. Added power needed for pulverizing coal 3. Large volume of furnaces needed to permit desired heat release and to withstand high gas temperature
Ash handling
Electrostatic Precipitators. It has two sets of electrodes, insulated from each other that maintain an electrostatic field between them at high voltage. The flue gases are made to pass between these two sets of electrodes. The electric field ionises the dust particle; that pass through it attracting them to the electrode of opposite charge. The other electrode is maintained at a negative potential of 30,000 to 60,000 volts. The dust particles are removed from the collecting electrode by rapping the electrode periodically. The electrostatic precipitator is costly but has low maintenance cost and is frequently employed with pulverised coal fired power stations for its effectiveness on very fine ash particles and is superior to that of any other type.
ESP
4.13.1 FLY ASH SCRUBBER It is similar to a mechanical ash collector but has a flowing water film on its inner walls. Due to this film, the collected ash is removed more rapidly from the apparatus to the bin. The degree of ash collection in scrubbers varies from 0.82 to 0.90. The dust laden gas enters through the inlet pipe. Cinder Catcher. Cinder catcher is used to remove dust and cinders from the gas. In this catcher the dust laden gas is made to strike a series of vertical baffles that change its direction and reduce its velocity. The separated dust and cinders fall to the Hopper for removal. Cinder catchers are ordinarily used with stoker firing.