DECLARATION

I declare that this dissertation does not incorporate, without acknowledgement, any material previously submitted for a degree or diploma in any University and to the best of my knowledge and belief, it does not contain any material previously published or written by another person or myself except where due reference is made in the text. I also hereby give my consent for my dissertation, if accepted, to be made available for photocopying and for interlibrary loads, and for the title and summary to be made available to outside organizations.

Names of candidates M. Pathmavel (E/07/249) S.Tharani (E/07/331) G. Thivaran (E/07/369) S. Vinoth (E/07/378)

Signatures

Date 20/01/2012 20/01/2012 20/01/2012 20/01/2012

Name Dr. W. P. D. Fernando Ms. S. Mangalika Mr.S.K.S.Seneviratna

Signatures . .. ..

Date 20/01/2012 20/01/2012 20/01/2012

ABSTRACT
The project is cycle and boiler design for power generation by using coconut shells (for 20,000 coconut shells per day) The aim of this project is design and fabricate a boiler for a small scale steam power plant and select a feed water pump. The objectives of our project are study about steam power cycle, boiler, and pump, design a boiler and select a pump. The chapter 1 gives an introduction about our project. In chapter 2, about biomass, types of biomass and calorific values, biomass system in Sri Lanka, reason for using coconut shells in our project, and experiments for calorific value of coconut shells (bomb calorimeter) are explained. The chapter 3 explains about steam power plant, components of a steam power plant, thermal power stations, steam power plant cycle, and calculation of the steam cycle. The chapter 4 explains about boiler, history of the boiler, classifications of boilers, requirements of perfect steam boilers, requirements of a perfect steam boilers, design and operation, components of a boiler system, steam system, boiler accessories, boiler selection, energy efficiency opportunities, heat balance in a boiler, and boiler blow down. In chapter 5, the design and calculations are clearly explained and chapter 6 explains about pump selection. Finally conclusion, appendix, acknowledgement, and references are given.

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TABLE OF CONTENTS
DECLARATION
ABSTRACT

Page No
I
II

1. INTRODUCTION 2. BIOMASS
2.1 Introduction 2.2 Types of biomass and calorific values 2.3 Biomass System in Sri Lanka 2.4 Reason for Using Coconut Shells in Our Project 2.5 Experiments for Calorific Value of Coconut Shells

01 02 02 03 04 05 06 11 11 11 12 14 15 21 21 21 22 23 26 26 29 32 32 37 39 41 42
1

3. STEAM POWER PLANT

3.1 Introduction 3.2 Components of A Steam Power Plant 3.3 Thermal Power Stations 3.4 Steam Power Plant Cycle 3.5 Calculation of the Steam Cycle

4. BOILER
4.1 Introduction 4.2 Introduction To Early Stage Boilers 4.3 Early Boilers 4.4 Classifications of Boilers 4.5 Requirements of A Perfect Steam Boilers 4.6 Design and Operation 4.7 Components of A Boiler System 4.8 Steam System 4.9 Boiler Accessories 4.10 Boiler Selection 4.11 Energy Efficiency Opportunities 4.12 Heat Balance in A Boiler 4.13 Boiler Blow Down

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5. DESIGN AND CALCULATION

5.1 Overall Coefficient Calculation 5.2 Design Of Super Heater 5.3 Design Of Steam Drum And Mud Drum 5.4 Material Selection

43 43 57 65 67 70 70 74 75 76

6. PUMP SELECTION
6.1Introduction 6.2 Pump calculation 6.3 Centrifugal pumps 6.4 Pumps selection and sizing

7. COST EVALATION CONCLUSION ACKNOWLEDGEMENT REFERENCES APPENDIX A APPENDIX B APPENDIX C APPENDIX D APPENDIX E
88

77
78

79
80 81 82

89 90

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List of Figure
Figure No 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 Description Overview of the different biomass fuels Coconut shells Layout if bomb calorimeter Rankine cycle flow Rankine cycle flow and T-S diagram Early boiler Fire tube boiler Water tube boiler Packaged boiler Heat balance in boiler Typical losses from boiler Temperature variation of counter flow arrangement One shell pass and one tube pass Temperature correction factor Tube arrangement Shell- bundle clearance Tube-side heat transfer factor Convective boiling enhancement factor Tube side friction factor Shell-side friction factor Temperature variation of counter flow arrangement One shell pass and one tube pass Temperature correction factor Tube arrangement Idealized main stream flow Cross-section area and wetted parameter Cross section of drum Corrosion of solids in the fluid Pipe fraction Vs Reynolds number and relative roughness Piping system Centrifugal pump efficiency T-S Diagram for 15 bar ,20 bar T-S Diagram for 15,20 bar T-S Diagram for 15, 20 bar P-H Diagram Drawings of the accessories Page No 02 05 06 11 16 22 23 24 25 40 40 44 44 45 46 49 51 53 55 57 58 59 60 61 63 64 66 54 72 73 76 88 88 89 89 90

List of Table
Table No 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 Description Types of biomass and calorific values Inlet and out let conditions Difference between FTB And WTB Data of the gas and the water Physical Properties Constants Data of super heater Physical Properties Relative cost & maximum skin temperature Maximum allowable stress Pipe roughness Max allowable working pressure for steel tubes for w/t boilers Properties of water at 15bar,115.150c Properties of water at 15 bar Properties of water at s=7.1718kJ/kg Properties of water at 32oc Properties of air at 1 bar Properties of water at 32oc,0.05 bar Properties of water at 0.05bar Page No 03 16 25 43 43 48 57 58 68 69 72 81 82 83 84 85 86 87 87

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Nomenclature
Symbol Ai Ao As At A CVf CVNi CP Cp Cw d D De e Gs h h1 h2 hi hsh hsw K K Description Inside heat transfer area Outer heat transfer area Area of cross flow Cross section area of tube Area of convective heat surface Calorific value of nickel wire Heat of combustion of nickel wire Specific heat of water Specific heat of air Specific heat capacity of water Inter diameter of tube Outside diameter of tube Equivalent diameter Thickness of factor Mass velocity Enthalpy Inter enthalpy of pump Outer enthalpy of pump Inside heat transfer coefficient Enthalpy of superheated steam Enthalpy of feed water Thermal conductivity of water Thermal conductivity of air

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L mc mf mi g mw Nu P Pr Pt Pr Re r S t T T1 T2 U us Vw

Length of tube Mass flow rate Water equivalent to the calorimeter Mass of fuel Mass of ignition wire Mass flow rate of gas Mass of the water in the inner cylinder Nusselt number Pressure Prandtl number of water Tube pitch Prandtl number of air Reynolds number Inner radius of tube Allowable stress Minimum wall thickness Temperature Initial temperature of the water Maximum temperature reached by the water Overall heat transfer coefficient Gas linear velocity Velocity of the flow Viscosity of water Viscosity of air Density of water Density of air Area
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T TLM T1 T2

Temperature different between inlet and outlet of air Log mean temperature different Temperature different between gas and water Temperature different between gas and water

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