MEEN 4322- Power Generation

BS Mechanical Engineering
Instructor: Dr. Muhammad Farooq
Prince Mohammad Bin Fahd University, Al-Khobar, Saudi Arabia
 Module # 2

Modern Power Plant Layouts

Fossil-Fueled Vapor Power Plant
Nuclear Vapor Power Plant

Pressurized-water reactor nuclear vapor power plant

Concentrating Solar Thermal Vapor Power Plant (CSP)
Geothermal Vapor Power Plant
Components of Steam Power Plant
 Components of Steam Power Plant
▪ Boiler: A device that converts water into steam by using heat energy from burning fuel, forming the
primary source of power in the system.
▪ Steam Turbine (Prime Mover): Converts the thermal energy of high-pressure steam into mechanical
energy by rotating blades, driving the generator.
▪ Generator: Converts mechanical energy from the steam turbine into electrical energy using
electromagnetic induction.
▪ Condensers and Cooling Towers: Condense exhaust steam from the turbine back into water and
dissipate waste heat to the environment to improve efficiency.
▪ Economizer: Recovers residual heat from flue gases to preheat boiler feedwater, improving the
boiler's thermal efficiency.
▪ Air Preheater: Warms incoming air for combustion by utilizing heat from flue gases, enhancing fuel
burning efficiency.
▪ Superheater: Increases the temperature of steam beyond its saturation point to improve the
turbine's efficiency and power output.
▪ Draught System: Ensures proper air supply for combustion and removal of exhaust gases by creating
pressure differences within the boiler.
 1. Boiler
▪ A boiler is closed vessel in which water under pressure is converted into steam
▪ The boiler is the heart of a thermal power plant, responsible for converting water into
high-pressure steam by burning fuel such as coal, oil, or natural gas.
▪ It consists of a furnace, where combustion takes place, heat exchangers, which transfer
heat to water, and various safety and control mechanisms to regulate steam generation.
▪Boilers are classified into two major types based on their
design, including
i. fire-tube boilers (where hot gases pass through tubes surrounded by
water)
ii. water-tube boilers (where water flows inside tubes heated externally by
combustion gases).

▪The efficiency of a boiler is improved by incorporating

economizers, superheaters, and air preheaters, which help
recover residual heat from flue gases and reduce fuel
consumption.
 2. Steam Turbine (Prime Mover)
▪ The steam turbine is a rotating machine that converts the thermal energy of high-
pressure steam into mechanical energy, which is then used to drive an electrical
generator.
▪ When high-pressure steam enters the turbine, it expands and moves through a series
of blades, causing them to rotate and produce mechanical work.
▪Steam turbines are broadly classified into
impulse turbines (where steam expands
through nozzles before hitting blades) and
reaction turbines (where pressure drops
continuously across the blades).

▪The efficiency of a steam turbine is maximized

by ensuring proper steam temperature,
pressure regulation, and minimizing frictional
and heat losses within the turbine casing.
 3. Generator
• The generator is a key component that converts the mechanical energy from the
rotating steam turbine into electrical energy through electromagnetic induction.
• It consists of a rotor (which rotates within a magnetic field) and a stator (where
electricity is generated due to the motion of the magnetic field relative to the
windings).
• Generators used in power plants typically produce alternating current (AC), which
is then stepped up in voltage using transformers for transmission over long
distances.
• Efficient cooling mechanisms, such as hydrogen or water cooling, are often
employed in large generators to prevent overheating and ensure long-term
operation.
 4. Condensers and Cooling Towers
▪ A condenser is a heat exchanger that converts
exhaust steam from the turbine back into water by
removing its latent heat, allowing it to be reused in
the boiler.
▪ Condensers improve plant efficiency by maintaining
low backpressure at the turbine exhaust, thereby
maximizing power output.
▪ Cooling towers are used to dissipate the waste heat
from the condenser to the atmosphere, preventing
thermal pollution of nearby water bodies.
▪ Cooling towers can be classified as wet cooling
towers (where heat is removed by evaporation), dry
cooling towers (where heat is removed using air-
cooled heat exchangers), and hybrid cooling towers
(which combine both methods for better efficiency).
 5. Economizer
▪ The economizer is a heat recovery device that captures
residual heat from the flue gases leaving the boiler and uses
it to preheat the boiler feedwater.
▪ By preheating the water before it enters the boiler, the
economizer reduces fuel consumption and enhances overall
thermal efficiency.

▪ Typically located in the path of exhaust gases after they exit

the boiler, economizers consist of heat exchanger tubes that
absorb heat from the flue gases.

▪ The use of an economizer reduces energy wastage, lowers

operating costs, and minimizes environmental emissions by
improving fuel efficiency.
 6. Air Preheater
• The air preheater is another heat recovery device used to
improve combustion efficiency by preheating the incoming
air before it enters the furnace.
• It extracts heat from the outgoing flue gases and transfers
it to the air supplied for combustion, thereby reducing the
amount of fuel needed for the same heat output.
• Air preheaters are generally of two types: recuperative air
preheaters (where heat is transferred through a metal heat
exchanger) and regenerative air preheaters (where heat is
stored temporarily in a rotating heat exchanger and then
transferred to fresh air).
• The use of an air preheater increases the temperature of
the combustion air, ensuring better fuel combustion,
reduced emissions, and improved boiler efficiency.
 7. Superheater
• The superheater is a crucial component that increases the temperature of the
steam produced in the boiler beyond its saturation point without increasing
its pressure.
• This superheated steam is then used in the steam turbine to improve power
generation efficiency and reduce condensation losses in the turbine blades.
• Superheaters consist of a series of coils or tubes placed in the flue gas path,
where steam absorbs additional heat before being sent to the turbine.

• Using superheated steam ensures higher thermal

efficiency, reduces wear and tear on turbine
components, and enhances the overall performance
of the power plant.
 8. Draught System
• The draught system plays a vital role in ensuring a
steady supply of air for combustion and the removal
of flue gases from the boiler.
• It creates a pressure difference within the furnace
that allows air to flow in and exhaust gases to exit,
ensuring complete fuel combustion.
• Draught systems can be classified into natural
draught (which relies on chimney height and
temperature difference for airflow), forced draught
(which uses mechanical fans to push air into the
furnace), induced draught (which uses fans to
extract flue gases), and balanced draught (which
combines both forced and induced draught for
better control).
• Proper draught regulation is essential to maintain
efficiency, control emissions, and prevent unburned
fuel losses in thermal power plants.
Circuits in a steam power plant
The flow sheet of a thermal power plant
consists of the following four main
circuits:

1. Coal and ash circuit.

2. Feed water and steam flow circuit.

3. Air and gas circuit.

4. Cooling water circuit.

 1. Coal and Ash Circuit
▪ The coal and ash circuit is responsible for transporting,
processing, and disposing of fuel in a thermal power plant.

▪ Coal is received at the plant through transportation systems

such as rail, road, or conveyor belts and is stored in coal yards
before being processed.

▪ The coal is crushed into fine particles in crushers and fed into
the boiler furnace where combustion takes place to generate
heat energy.

▪ After combustion, ash is produced as a by-product. It consists

of bottom ash (which settles at the furnace base) and fly ash
(which is carried by exhaust gases).

▪ The ash handling system collects, transports, and disposes of

ash using ash handling equipment like electrostatic
precipitators, slurry disposal systems, and ash storage silos.

▪ Proper ash disposal and utilization are essential to minimize

environmental impact and maintain plant efficiency.
 2. Feed Water and Steam Flow Circuit
Components:
[Link] Water Pump: Transfers feed water from the hot well to the steam generator.
2. Economizer: The feed water is first heated using an economizer to recover waste heat from the flue gases before
entering the boiler.
[Link] Generator (Boiler): Converts feed water into steam using heat from coal combustion.
[Link] Tubes: Further heat the steam to produce superheated steam, enhancing its thermal efficiency.
[Link] Mover (Turbine): Utilizes superheated steam to generate mechanical power, which is converted into electrical
energy.
[Link]: Condenses the exhaust steam from the turbine back into water.
[Link] Well: Collects condensed water and feed water for recirculation.
Process Flow:
•Feed water from the hot well is pumped into the steam generator.
•Steam produced in the boiler is superheated in the superheater tubes.
•Superheated steam is directed to the prime mover (turbine) to generate power.
•Exhaust steam from the turbine is condensed in the condenser and returned to the hot well.
•Water lost in the system is replenished by treated feed water from an external source.
Feed Water Treatment:
•External feed water must be treated in a Feed Water Treatment Plant to remove impurities
3. Air and Gas Circuit
▪ The air and gas circuit ensures the proper supply of air
for combustion and the removal of exhaust gases from
the boiler.
▪ Fresh air is drawn into the boiler furnace using a forced
draught fan, where it mixes with fuel to support
complete combustion.
▪ The combustion process generates hot flue gases that
pass through the boiler, transferring heat to water and
producing steam.
▪ After heating the boiler tubes, the exhaust gases are the
passed through superheater, economizers and air
preheaters to recover waste heat before being expelled
through the chimney.
4. Cooling Water Circuit
▪ The cooling water circuit is essential for maintaining
the efficiency of the power plant by condensing
exhaust steam and dissipating excess heat.
▪ After expanding through the steam turbine, the
exhaust steam enters the condenser, where it is
cooled and converted back into water.
▪ Cooling water from natural sources (rivers, lakes, or
cooling towers) is circulated through the condenser
to absorb heat from the steam and condense it.
▪ The heated cooling water is cooled down in cooling
towers before being reused in the circuit.
▪ The loss of water due to evaporation (about 5%) is
compensated by supplying water directly from the
river
▪ Cooling towers play a significant role in heat
dissipation by evaporating a portion of the cooling
water and releasing heat into the atmosphere.
 Advantages of Coal Driven Steam Thermal Power Plant
▪ Abundant and Reliable Fuel Supply: Coal is one of the most widely available and cost-effective fuels,
ensuring a steady and reliable energy supply for power generation.

▪ Stable and Continuous Power Generation: Unlike renewable sources such as solar and wind, coal-
fired power plants can operate continuously without dependency on weather conditions.

▪ High Efficiency with Modern Technologies: Advanced technologies such as supercritical and ultra-
supercritical boilers improve thermal efficiency and reduce fuel consumption.

▪ Lower Initial Investment Costs: Compared to nuclear or renewable power plants, coal-fired power
plants require relatively lower capital investment and shorter construction time.

▪ Scalability and Large Power Output: Coal power plants can be scaled up to meet high electricity
demand, making them suitable for industrial and urban power supply.

▪ Job Creation and Economic Benefits: The coal power industry supports mining, transportation, and
plant operations, contributing to economic growth and employment opportunities.
Disadvantages of Coal Driven Steam Thermal Power Plant
▪ Environmental Pollution and Greenhouse Gas Emissions: Burning coal releases CO₂,
sulfur dioxide (SO₂), nitrogen oxides (NOₓ), and particulate matter, contributing to air
pollution and climate change.
▪ High Water Consumption: Coal power plants require significant amounts of water for
steam generation and cooling processes, which can strain local water resources.
▪ Coal Mining Hazards and Land Degradation: The extraction of coal causes deforestation,
soil erosion, and habitat destruction, while underground mining poses safety risks for
workers.
▪ Waste Generation and Ash Disposal Issues: Large quantities of coal ash and slag must be
managed properly to prevent soil and water contamination.
▪ Health Impacts on Communities: Airborne pollutants from coal combustion can cause
respiratory diseases, cardiovascular problems, and other health issues among nearby
populations.
▪ Finite Resource with Rising Costs: While coal is abundant, its reserves are finite, and
stricter environmental regulations may increase the cost of coal-based power generation
in the future.
 Energy Analysis of the Ideal Rankine Cycle

The ideal Rankine cycle does not involve any internal irreversibilities and consists of the following four processes:
 Energy Analysis of the Ideal Rankine Cycle
▪ Water enters the pump at State 1 as saturated liquid and is
compressed isentropically to the operating pressure of the
boiler. The water temperature increases somewhat during this
isentropic compression process due to a slight decrease in the
specific volume of water.
▪ Water enters the boiler as a compressed liquid at State 2 and
leaves as a superheated vapor at State 3.
▪ The superheated vapor at State 3 enters the turbine, where it
expands isentropically and produces work. The pressure and
the temp. of steam drop during this process to the values at
State 4, where steam enters the condenser. At this state, steam
is usually a saturated liquid–vapor mixture with a high quality.
Steam is condensed at constant pressure in the condenser.
Steam leaves the condenser as saturated liquid and enters the
pump, completing the cycle.
All four components associated with the Rankine cycle (the pump, boiler, turbine, and condenser) are steady-flow
devices, and thus all four processes that make up the Rankine cycle can be analyzed as steady-flow processes.

Then the steady-flow energy equation per unit mass of steam is:

The boiler and the condenser do not involve any work, and the pump and the turbine are assumed to be
isentropic. Then the conservation of energy relation for each device can be expressed as follows:

OR

Where
 Thermal Efficiency of Rankine Cycle
The thermal efficiency of the Rankine cycle is determined from

𝑾𝒏𝒆𝒕 𝑸𝒊𝒏 − 𝑸𝒐𝒖𝒕

𝜼𝒕𝒉 = =
𝑸𝒊𝒏 𝑸𝒊𝒏

𝑸𝒐𝒖𝒕 𝒉𝟒 − 𝒉𝟏
=𝟏− =𝟏−
𝑸𝒊𝒏 𝒉𝟑 − 𝒉𝟐

Also
 Example – Simple Rankine Cycle Based Steam Power Plant
Consider a steam power plant
operating on the simple ideal
Rankine cycle. Steam enters the
turbine at 3 MPa and 350°C and is
condensed in the condenser at a
pressure of 75 kPa. Determine the
thermal efficiency of this cycle.
Solation: Example – Simple Rankine Cycle Based Steam Power Plant
1st Step
Draw the T-s diagram of the cycle

We note that the power plant operates on the ideal Rankine cycle.
Therefore, the pump and the turbine are isentropic, there are no
pressure drops in the boiler and condenser, and steam leaves the
condenser and enters the pump as saturated liquid at the condenser
pressure

2nd Step
Determine the enthalpies at various points in the cycle, using data from steam tables (Tables A–4, A–5, and A–6):
Solation: Example – Simple Rankine Cycle Based Steam Power Plant
Solation: Example – Simple Rankine Cycle Based Steam Power Plant

= 3000 kPa
Solation: Example – Simple Rankine Cycle Based Steam Power Plant
 Increasing Efficiency in the Rankine Cycle
Why Improve Efficiency?
• Steam power plants produce the majority of global electricity, making even small
efficiency improvements can results in significant fuel savings and emission
reductions.
• Higher efficiency reduces operating costs and environmental impact.

Fundamental Principle:
• Increase the average temperature at which heat is added in the boiler.
• Decrease the average temperature at which heat is rejected in the condenser.
 Methods to Improve Rankine Cycle Efficiency

(1) Lowering Condenser Pressure → Lowers Tlow,avg

(2) Superheating Steam to Higher Temperatures → Increases Thigh,avg

(3) Increasing Boiler Pressure → Increases Thigh,avg

(4) Reheat Rankine Cycle → Reduces moisture content in the turbine.

(5) Regenerative Rankine Cycle → Increases efficiency by preheating feedwater.

 Lowering Condenser Pressure
Concept:
• Reducing the pressure inside the condenser lowers the
temperature of the rejected heat.
• Since the cycle efficiency depends on the temperature
difference, lowering Tlow​ increases efficiency.

Implementation:
• Power plants use condensers operating below atmospheric
pressure (vacuum conditions).
Limitations:
• The condenser pressure cannot be lower than the
saturation pressure of the cooling medium.
• Example: If cooling water is from a river at 15°C, the The colored area on this diagram represents the increase
condenser steam temperature must be above 25°C, in net work output as a result of lowering the condenser
pressure from P4 to P’4. The heat input requirements also
requiring a minimum condenser pressure of 3.2 kPa. increase (represented by the area under curve 2’-2), but
• Side Effect: Increases moisture content in the final this increase is very small. Thus the overall effect of
turbine stages, which can cause blade erosion and lowering the condenser pressure is an increase in the
efficiency losses. thermal efficiency of the cycle.
 Superheating Steam to High Temperatures
Concept:
• Increasing the steam temperature before it enters
the turbine raises the average heat addition
temperature and improves efficiency.

Advantages:
• More work output from the turbine.
• Reduces moisture content at turbine exit → Less
blade erosion.

Limitations: The effect of superheating the steam to higher

temperatures on the ideal Rankine cycle.
• Metallurgical constraints: Current materials allow
The colored area on this diagram represents the
steam temperatures up to 620°C (1150°F). increase in the net work. The total area under the
• Future improvements depend on advanced process curve 3-3’ represents the increase in the heat
input. Thus both the net work and heat input increase
materials like ceramics for higher temperature as a result of superheating the steam to a higher
tolerance. temperature. The overall effect is an increase in thermal
efficiency, however, since the average temperature at
which heat is added increases
 Increasing Boiler Pressure
Concept:
• Higher boiler pressure increases the steam
temperature at which heat is added, leading to a higher
thermal efficiency.

Implementation:
• Modern power plants operate at supercritical
pressures (>22.06 MPa) for maximum efficiency.
• Example: Early 20th-century plants operated at 2.7
MPa (400 psia), while today’s plants exceed 30 MPa
(4500 psia).

Limitations:
• Increases moisture content at turbine exit, which is
undesirable. The effect of increasing the boiler pressure on
• This problem can be mitigated using Reheat Rankine the ideal Rankine cycle.
Cycle.
 The Ideal Reheat Rankine Cycle
Why Reheat?
• High boiler pressures increase moisture at turbine exit,
reducing efficiency and damaging turbine blades.

Solution: Reheat Cycle

• Instead of a single expansion, steam expands in two stages:
• High-Pressure Expansion: Steam expands in the first
turbine stage.
• Reheating: Steam returns to the boiler for reheating.
• Low-Pressure Expansion: Steam expands in the second
turbine stage.

Efficiency Gains:
• Increases cycle efficiency by 4–5%.
• Reduces moisture content in the turbine.
• The optimum reheat pressure is about 1/4 of boiler
pressure (e.g., for 12 MPa, reheat pressure ≈ 3 MPa).
 The Ideal Regenerative Rankine Cycle
Problem in Basic Rankine Cycle:
• Heat is added at low temperatures during process 2 → 2’,
reducing cycle efficiency.

Solution: Regeneration
• Extract some steam from the turbine at different stages to
preheat the feedwater before it enters the boiler.
• This reduces fuel consumption and increases efficiency.

Efficiency Gains:
• Used in all modern steam power plants since the 1920s.
• Also removes air from feedwater to prevent boiler corrosion.
 Summary – Improving Rankine Cycle Efficiency
Method How It Improves Efficiency Challenges / Limitations

Lowering Condenser Increases work output by reducing heat Higher moisture in the turbine,
Pressure rejection potential air leaks.

Increases work output and reduces turbine

Superheating Steam Limited by material strength.
blade erosion

Increases moisture content at

Increasing Boiler Pressure Raises average heat addition temperature
turbine exit.

Reheat Cycle Reduces moisture content at turbine exit Increases cycle complexity.

Preheats feedwater to increase heat Extracted steam reduces available

Regeneration
addition efficiency turbine work.
 Numerical Problem – Ideal Reheat RankineCycle
The Ideal Reheat Rankine Cycle Consider a
steam power plant operating on the ideal
reheat Rankine cycle. Steam enters the
high-pressure turbine at 15 MPa and 600 °C
and is condensed in the condenser at a
pressure of 10 kPa. If the moisture content
of the steam at the exit of the low-pressure
turbine is not to exceed 10.4 percent,
determine
(a) the pressure at which the steam should
be reheated and
(b) the thermal efficiency of the cycle.

Assume the steam is reheated to the inlet

temperature of the high-pressure turbine.
 Solution
Problem Statement:

❖ Steam enters the high-pressure turbine at 15 MPa and 600°C.

❖ It is condensed at 10 kPa in the condenser.
❖ The moisture content at the exit of the low-pressure turbine
should not exceed 10.4%.
❖ Determine:
o The reheat pressure required.
o The thermal efficiency of the cycle

Assumptions for Analysis

❑ Steady-state operation (no accumulation of mass or energy).
❑ Isentropic expansion in turbines (ideal case, no entropy generation).
❑ No pressure drops in the boiler, reheater, and condenser.
❑ Saturated liquid at pump inlet (condenser exit).
❑ Steam reheated to the same inlet temperature as the high-pressure turbine
 Solution

Cycle Stages:

1 → 2: Pump (isentropic compression)

2 → 3: Boiler (heat addition at constant pressure)

3 → 4: High-pressure turbine (isentropic expansion)

4 → 5: Reheater (heat addition at constant pressure)

5 → 6: Low-pressure turbine (isentropic expansion)

6 → 1: Condenser (heat rejection at constant pressure)

 Solution
1st Step
Draw TS Diagram
 Solution
Required:
1. Reheat Pressure
2. Thermal efficiency of the cycle

qin = Heat Input in Boiler and Reheater = (h3 – h2) + (h5 – h4)
qout = Heat Rejected in Condenser = (h6 – h1)
Solution
Solution
Solution
Solution