cola) Tat-Msin eal Ms [reyetn rest aca of a coal fired BoilerName: Kota. Bhanu Prakash, B Tech (Mech), MBA(Fin) , MTech (IIT Delhi) Computational Fluid Dynamics, Multiphase dynamics Heat exchangers, Turbo machinery Steam generators design, Heat transfer and Radiation 500MW Boiler Computational fluid Dynamics Job profile: 1988, * Hindustan Aeronautics limited (design of Aero engines) 1989 -2010: NTPC Commissioning of coal fired units of capacities 210 MW,S500MW, Performance testing of the boilers, turbines and associated auxiliaries, Environment Management systems 2010: — Steag Energy Services System Technologies, Engineering thermal power plants, O&M. Currently: Chief Executive Officer for a Steag O&M CompanySteag is the Germany's fifth largest producer of electricity, Operates15 power plants at 11 sites throughout Germany, Installed generating capacity of about 8,600 MW; eight of these power plants use hard coal as primary energy source. Steag O&M Company is a JV of Steag Energy Services,India And Hinduja Energy India SOMC currently operates the 2X520MW coal fired units in Vishakapatnam SeePower plant efficiencyPEON AES e CO ewigirra alae Marl ae 1d Efficiency: [Electrical output/Fuel input] A 500 MW coal fired power plant consumes 300T/hr of coal (CV 4000Kcal/Kg) will have an efficiency [500 X 10%6(W]x3600 S) | [300X10%3(Kg)*4000*4180 J)] = 35.85% In power plant terminology, Unit Heat rate is defined as the ratio of Turbine heat rate and Boiler efficiency.Sub critical and Super critical * Subcritical steam cycles(Pressure < critical pressure 225 bar) have unit heat rates in the order of 2400 Kcal/Kwh * Higher the heat rate, poorer is the cycle in efficiency because coal consumption is high. * Super critical cycles because of higher steam parameters have a better cycle efficiency than sub critical unitsRankine Cycle Tuesday. 8 December 15 FuzalenextLosses in the cycle Peeling the Heat Rate Improvement Onion ! (Finding solutions to common problems) F Low Main Steam High Excess Air Low Main Steam (0,) Temperature. Pressure \ \ ye High Exit Gas \ Temperature N“ an High Unburned Low Reheat Steam Temperature \_ High Condenser Backpressure Carbon __ High Moisture Level in Coal High Superheat as Excessive Aux. Sprays Load High Reheat Operation at \ Sprays wy antoedy Frequent Unit Reduced Load ee tery Buenos Or une co near a Cray Demineralized make up Co Rep Reno PenneAnalysis of Operating parameters on Plant CaN i Effects of ct TULL RCo s§ HP Turbine ‘Superheater ~ Furnace—¢7~s, Reheater Effects of ere Im eee Oe RegenerationPCN e 1a Temperature (1) 600 700 200 — ‘Mekel Alloys: =>", ‘900 1000 1900 1200 1900 1400 1600 16001700 Temperature (F) Maximum Allowable Siresfea (Riite(autad (oy 5 sak (4a) N \ 303° © (-0.004 MPa) Carnot Cycle 1-3-5-6 Ty-Tc 523-303 220 N= FEE 2 = 42% Th 523 523 Rankine Cycle 1-2-4-5-6 126 kJikg 130 kJikg 535 kdikg 2802 kJikg 1835 kJikg hs-h, 2802-1835 976 0.36 = 36% hg-h, 2802-130 2676ONC EMU ML ACt LLCS + The obstacles to calculating an accurate heat rate for a coal-fired unit using this method are: * The difficulty in accurately assessing the quantity of coal + The inaccuracies of the as-received coal + Uncertainty associated with measurements made over long periods of time. + The use of an average heating value for a fuel whose heating value may vary widely with different fuel suppliers. Tuesday 8 December 15 Fuzaleiext 13Peat Rete Re (cleft te McLee Lk eT Blo ele) + [pelx| lA) le) elle) villas <)>) als) es | ree) aa ws vet sages ee ats ET a y cnet s oles) roel — ergs ia co y y ohPw) Ueceustay —foVbeFP) Hd OHS wi COND 4 steacCost of Heat rate deviation ¢ Ifaplant’s target heat rate is 2300 Kcal/KWh and the actual value is 2350Kcal/ kWh, what is the increase in annual fuel cost? * Change in Annual Fuel Cost (Rs/yr) = HRD/BE x FC x PLF x UGC x T Where: ¢* HRD Heat Rate Deviation (net unit or turbine cycle heat rate) ©” BE Boiler Efficiency = 0.88 © FC Fuel Cost/1,000,Kcal PLE Unit Capacity Factor = 0.85 * UGC Unit Gross Capacity = 500,000 kw e T= 8760 hr/year * ForaHRD of 50 Kcal/Kwh the cost is 86.5Million INR for a 5S0oMW unit * [@fuel cost is 3600 Rs/1000 Kg]Boiler losses Fouling of Boiler heating surfaces: Naa nao Teed Mn anc Poor coal calorific value: Tare Mccann tsfe) | ieete] ots Sub optimized equipment operation: Poor design; Poor insulation High pressure drops steai i) = & rc és GAir preheaterIssues with Air Heater Hot combustion products Leakage flows | ; air Figure I Fluid flows in rotary regeneratorRYE Ue Rotem PAU »vattern, voard APHOnline efficiency and diagnosticsHide cat vow Int HTML Parameter Process Sheets Oncuneratn Window Help Blo eale) + [eolelx) lel ole) eolelc| Yivl lA) <1>} asl [Swe =] [aeweme2smopu2m00PM =) BOILER FLUE Gas TEMP ‘Status -—Uat oir ant e_| ape Genero ap poner Unt eticeny et Unthette ose bd patty ‘SOOTOLOWING OPTIMIZATION Woot Etcncies Sento eo Lee sutece | act | oin | SBWo Fanacaho) (SST BT ow 15) Sino SH Dion Pan th os v0f Cone SE SH Pin eo 11 119 Snare Reheat 7 hr9124| Wes ow Tens SH ETOSR| “2506315 m] Saipan 57250 conan a 506m | Sopenae "ACT-7REF-COMPARISON Bet—[ Fal | onstage [02 aco outed Ss alate acer Burner tit 7 yor an Siew Sa con Ts) TFS eco cut —_ 0 oa Batre Soot Blowing Legend Coney 58 fear se, ase) CREA esses) SB Notreais rea) HH 58 0 irted SuanTire coe vow tnt MTMLLite Parameter Process Sheets Oocimertton Who Heb Blsiele! slesjelx elf ale} dele! vival) <>] als! 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