CHAPTER 1

Introduction

1.1 Energy Scenario

Energy consumption is one of the most important factors that show the developing stages of
nations and living standards of communities. Population increment, urbanization and technology
development this all are directly affect in increment of energy consumption. This rapid growing
trend brings about the crucial environmental problems like contamination and atmospheric
phenomenon.

Now a day’s around 80% of electricity is produced from the fossil fuels like coal, petroleum, oil
and natural gas, where as remaining 20% of electricity is generated from hydraulic, wind, solar,
nuclear, biogas and geothermal.

India is one of the largest energy consumers in the world, but per capita energy consumption is
very low as compared to world’s consumption. In India major source of electricity generation is
conventional sources such as thermal, hydro and nuclear.

Since 1950’s the installed capacity of all power generation in India has increased to
365980.54MW (as on 30.11.2019). The installed capacity of Indian power generation is given in
following Table 1.1 and Table 1.2;

Table 1.1 Total installed capacity of power generation.

Sector Installed Capacity Percentage

State 103815.14 28.36 %

Central 91496.93 25 %

Private 170668.47 46.64 %

Total 365980.54
Table 2.2 Installed capacity based on Fuel in India.

Fuel Installed Capacity Percentage

Total Thermal 299401.42 45.42 %

Coal 197694.50 30.00 %

Gas 24937.22 3.78 %

Oil 509.71 0.07 %

Hydro 45399.22 6.88 %

Nuclear 6780 1.02 %

Renewable Sources 84399.90 12.80 %

Total 365980.54

World’s net electricity generation up to year 2007 and projected generation up to year 2035 by
different fuels are shown in the Figure 1.1;

Figure 1.1 World’s net electricity generation by fuel (trillion kWh)

Generally, the evolution of thermal power plants performance is based on first law of
thermodynamics and that is called energetic performance, which includes electrical power and
thermal efficiency. In recent year, based on the second law of thermodynamics the performance
is evaluated and that is called exergetic performance which founds useful method in the design,
evaluation, optimization and improvement of thermal power plants.

The purpose of this study is to carry out energetic performance analyses of coal-fired thermal
power plant, at the design conditions. Also identified the needed improvement based on energy
analysis. To perform the aim, this study summarized the thermodynamic model of the considered
thermal power plants on the basis of mass and energy balance equations. At the end of this study
the thermodynamic results are compared in the direction of comprehensive analysis and evaluate
the required performance improvement.

1.2 Energy Analyses of Thermal Power Plants

Coal based thermal power plant generally operates on Rankine cycle. In ideal vapor power cycle
many, such as Carnot cycle has impracticalities associated with it can be eliminated by
superheating the steam in the boiler and condensing it completely in the condenser.

1.2.1 Energy Analysis

In an open flow system there are three types of energy transfer across the control surface namely
working transfer, heat transfer, and energy associated with mass transfer and/or flow. The first
law of thermodynamics or energy balance for the steady flow process of an open system.

The first law of thermodynamics, also known as the conservation of energy principle, provides a
sound basis for studying the relationships among the various forms of energy and energy
interactions. Based on experimental observations, the first law of thermodynamics states that
energy can be neither created nor destroyed during a process; it can only change forms.
Therefore, every bit of energy should be accounted for during a process.
 Fist law thermodynamic basis

1.2.2 Energy Balance

In the light of the preceding discussions, the conservation of energy principle can be expressed as
follows: The net change (increase or decrease) in the total energy of the system during a process
is equal to the difference between the total energy entering and the total energy leaving the
system during that process. That is,

(Total energy entering the system) – (Total energy leaving the system)

= (Change in the total energy of the system)

Ein – Eout = ΔE system

This relation is often referred to as the energy balance and is applicable to any kind of system
undergoing any kind of process.

1.3 Description of Power Plant

Katch Lignite Thermal Power Station (KLTPS) a Government of Gujarat’s Public Sector
Undertaking (PSU) was incorporated on 26th Dec, 2009 under Companies Act, 1956.
KLTPS has been promoted to exploit the lignite resources available in the Katch district in the
Lakhapat region for Power generation purpose.

Hence, it was proposed to install 1 X 75 MW lignite based Thermal power Station at village
Panandhro, taluka Lakhapat of Katch district in Gujarat.

Plant Location PANANDHRO, KUTCH DISTRICT, GUJARAT

Proposed Fuel Lignite

Carbon:26.55% Hydrogen:2.19% Sulphur:3.5% Ash:23.54%

Lignite HHV:2621
Oxygen:7.76% Nitrogen:1.72% Moisture:34.74% kcal/kg

Type of firing : Circulating Fluidised Bed Combustion

Water Wall Natural Area m² : 1277.60

Combustor Circulation

1.4 Purpose

Main aim of the study presented here is to carry out energetic and exergetic performance
analyses of coal fired 75MW thermal power plant at KLTPS in order to identify the needed
improvement. For performing this aim, we summarized thermodynamic models for the
considered power plants on the basis of mass, energy and exergy balance equations. The
thermodynamic model simulation results are compared in the direction of comprehensive
analysis results and the requirements for performance improvement are evaluated.

This analysis finds out the components having maximum loss and minimum efficiency so that it
can help the designers to finding the way to improve the performance of a system. And thus it is
possible to economic optimization of plant.
 CHAPTER 2
Literature Review

Hasan Huseyin Erdem et al [1] studied the performance analyses and compare the nine coal-
fired power plants in Turkey, which have been performed at design conditions by means of
energetic and exergetic methods. This study analyzes the nine coal fired thermal plant by
following steps:

 Thermodynamic models of the plants are developed based on first and second law of
thermodynamics.
 Some energetic simulation results of the developed models are compared with the design
values of the power plants in order to demonstrate the reliability.
 Design point performance analyses based on energetic and exergetic performance criteria
such as thermal efficiency, exergy efficiency, exergy loss, exergetic performance
coefficient are performed for all considered plants in order to make comprehensive
evaluations.

In the analyses, the developed model for each power plant using the mass, energy and exergy
balance equations, and system and component performance criteria such as thermal efficiency,
exergy efficiency, exergy destruction have been determined and compared with each other.
Considering energetic and exergetic performance methods together can enable the designer to
quickly locate and evaluate the inefficiencies in the process. Comprehensive discussions on the
analysis results have been made. As a conclusion, energetic and exergetic analyses and their
results obtained in this study scope is useful to engineers and researchers in terms of the issues of
methods and priorities for performance improvement of both plant components and overall plant.

Boleslaw Zaporowski [2] presents the complex energy analysis of technological systems of gas–
steam power plants integrated with coal gasification. The bases of the performed energy analyses
are the elaborate mathematical models describing the behavior of main elements of the gas steam
power plants integrated with coal gasification, such as the gas generator, raw-gas cooler with the
gas desulphurization system, compressor, combustion chamber, gas turbine, heat recovery steam-
generator and steam-turbine cycle. The effect of coal-gasification technology, coal type,
gasifying medium, fuel-desulphurization technology and gas-turbine design on the efficiency of
electric-energy generation were taken into account.

The results of the simulation formulate the following conclusions:

 This study found decreases the efficiency of the power plant by around 3% when
supplied coal is wet compared with a dry coal.
 The kind of gaseous-fuel desulphurization technology has also a significant impact on the
efficiency of electricity generation in a gas–steam power-plant. The replacement of the
cold-gas clean-up technology (311 K) with the hot-gas clean-up technology (810 K)
allows the efficiency of the gas-steam power plant to increase by around 1.5%.
 Using simulation this study also found that technology of coal gasification, in which the
temperature of gaseous fuel at the gas generator outlet is much lower (around 1311 K)
than the temperature of the gasification process at the initial step (around 1700 K). This
can be obtained through partial reduction of CO2 to CO at the step two of the gas
generator.
 The gas generator’s construction has a huge impact on the chemical efficiency of the
coal-gasification process. In most cases, the cooling systems (water and steam) are
applied, which decreases the chemical efficiency of coal gasification in relation to the
systems with gas generators without cooling systems.
 The chemical efficiency of brown-coal gasification is lower than the chemical efficiency
of hard-coal gasification.

S.K. Tyagi et al. [3] shows that the growing demand of power has made the power plants of
scientific interest, but most of the power plants are designed by the energetic performance
criteria based on first law of thermodynamics only. The real useful energy loss cannot be
justified by the fist law of thermodynamics, because it does not differentiate between the quality
and quantity of energy. This study deals with the comparison of energy and exergy analyses of
thermal power plants stimulated by coal and gas.
This study concludes that the main energy loss in boiler in coal based thermal power plant and
combustion chamber in gas fired combined cycle thermal power plant. In every plant component
such as a boiler, combustion chamber there is some irreversibility which cannot, owing to the
present state of technological development, be eliminated. In addition exergy methods are useful
in assessing which improvements are worthwhile, and should be used along with other pertinent
information to guide efficiency improvement efforts for steam power plants. Efficiency of some
plant components is improved by increasing their size. For example, heat exchangers of a given
design perform better when the heat transfer areas are increased. However, this involves extra
cost and hence there is a limiting size beyond which further increase would not be justified
economically.

Gholam Reza Ahmadi and Davood Toghraie et al. [4] investigate the steam cycle of Shahid-
Montazeri Power Plant with individual unit capacity of 200MW. All cycle equipment have been
analyzed individually using mass, energy, and exergy balance equations and energy efficiency,
exergy efficiency, and irreversibility has been calculated for each of them as required. For
performance analysis EES (Engineering Equation Solver) software is used. Values and ratios
regarding heat drop and exergy loss have been presented for each of the equipment.

This paper also shows the effect of environment temperature changes on exergy loss and exergy
efficiency for boiler, condenser and turbine.

Amount of energy and exergy losses in power plant and main equipments
In the performed analysis, the condenser has the largest heat loss in the cycle as 69.8% of the
total lost heat which has the highest potential for optimization and output increases according to
first law of thermodynamics. While in exergy analysis, the condenser has only 1.53% of the total
lost exergy which has almost no potential for optimization. Exergy analysis introduces the boiler
as the main equipment destroying the exergy. The boiler has only10.16% of the total lost heat but
85.66% of the total lost exergy.

Gholamreza and Davood at el. [5] analyzed combined heat and power (CHP) system in a
Petrochemical Plant in terms of energy, exergy and environmental (3E) aspects. Cycle Tempo
software was used for the system simulation. The simulation revealed that the energy, exergy,
heat and total efficiencies are 8.22%, 7.87%, 48.92% and 56.8%, respectively. Regarding the
high temperature of the exhaust gases from the boilers, adding an economizer stage can increase
the efficiency of the boiler and decrease the rate of CO2 production.

The energy and exergy equations of the cycle were then studied showing that the boiler has a
major role in exergy waste. The steam turbine comes next of waste. The results showed that an
increase in the ambient temperature affects the exergy efficiency of the condenser to a greater
extent.

The following results were gained through an analysis of the simulations

 The boilers are not efficient enough and should be optimized

 Using feed water pre-heater can increase the efficiency of the cycle.

 Regarding the high temperature of the exhaust gases from the boilers, adding an
economizer stage can increase the efficiency of the boiler.

 Regarding the exergy waste due to desuperheaters in pressure reduction stations, it is

useful to eliminate them.

Raviprakash kurkiya and Sharad chaudhary[6] shows that the Energy analysis helps
designers to find ways to improve the performance of a system. Most of the conventional energy
losses optimization method are frequentative in nature and require the interpretation of the
designer at each time. Typical steady state plant operation conditions were determined based on
available trending data and the resulting condition of the operation hours. The energy loss from
individual components in the plant is calculated based on these operating conditions to determine
the true system losses. In this, first law of thermodynamics analysis was performed to evaluate
efficiencies and various energy losses. This study also perform the variation in the percentage of
carbon (%C) in coal content increases the overall efficiency of plant that shows the economic
optimization of plant.

MATLAB 2008a computer programming is used for the analysis. The energy balance sheet
shows that theoretical losses in various component of boiler. It provides information for selection
of the components which has maximum losses so, that optimization techniques could be used to
make it more efficient. The various energy losses of plant, through different components are
calculated which indicates that maximum energy losses occur in turbine.

Following conclusions are to be identified from this study:

 The coal type affects the first law efficiency of the system.
 It has been also analyzed that a part of energy loss occurs through flue gases.
 The carbon content in the coal has to be proper.
 The presence of moisture has a direct effect on overall efficiency.
 If the usage of heat recovery system to recover the heat losses through flue gases then it
will be more useful for plant efficiency.

With the growing need of the coal, which is an non renewable source of energy and depleting
with a very fast pace, it is desirable to have such optimal techniques (better quality of coal)
which can reduce the energy losses in the coal fired boiler and improves its performance these
create impact on production and optimizations uses of energy sources.

In addition this study shows the better quality of coal giving the high performance of plant and
even though the consumption of coal is been reduced that creates economic condition for overall
plant.
M. Akbari and M. Bidi at el. [7] shows that how to recover a great amount of contained water
and heat of power plant blow down, that entering into wastewater to the environment is
decreased and the total power of power plant is increased.

For preventing boiler tubes and heat exchanger tubes corrosion, some amount of water in the
cycle that contains dissolved solids should be drained as blow down. Because of blow down
water draining which contains high energy, it reduces the net generated work of the power plant.

The schematic of Heat and Water Recovery system

In this study, the effect of adding Heat and Water Recovery system to solar steam power plant is
modeled and by using energy analysis this model is analyzed. And then by using genetic
algorithm, results are optimized.

In this study by using Recovery system, great amount of drained energy of system is returned to
the cycle and also outlet wastewater of the power plant that is harmful for the environment, due
to its contained toxic materials, is reduced considerably. Results show that the net generated
work of the power plant after adding Heat and Water Recovery system is increased from
33.83MW to 34.01MW.

Isam H. Aljundi [8] studied the energy and exergy analysis of Al-Hussein power plant in
Jordan. The primary objectives of this paper are to analyze the system components separately
and to identify and quantify the sites having largest energy and exergy losses. The performance
of the plant was estimated by a component wise modeling and a detailed break-up of energy and
exergy losses for the considered plant has been presented.
In the considered power cycle, the maximum energy loss was found in the condenser where 66%
of the input energy was lost to the environment. Next to it was the energy loss in the boiler
system where it was found to be about 6% and less than 2% for all other components. In
addition, the calculated thermal efficiency of the cycle was 26%.

The use of heat exchange surfaces made of plastic has become feasible, thereby avoiding
corrosion and fouling problems derived from cold-end acid condensate. In this manner, flue gas
temperature can be reduced down, which obviously leads to an increase of boiler efficiency.
Besides, there is an additional energy available for heating the main condensate flow of the

power cycle. If modification of air–gas rotary heaters is also considered, a manifold of

possibilities opens up for plant optimization and integration of components.

Sergio Espatolero et al. [9] shows that the objective of this paper is to analyze this class of
schemes for increasing power output and net efficiency of a reference supercritical plant. A
complete simulation of the steam cycle is assembled using Aspen Plus and different plant
configurations are examined under reduced exit gas temperatures. Several uses of flue gas energy
are considered, taking into account limits of temperature and realistic efficiencies of heat
exchangers. Mass flow rates, point of extraction of condensate, pressures and temperatures are
selected heuristically to optimize performance. Finally, required exchange areas are estimated,
and a cost analysis is carried out in order to economically assess the new configurations and
estimate the additional profit for the plant.

Direct use of gas energy

The use of “plastic” heat exchangers in the boiler FGHRS that reduce flue gas temperatures

down to 80–90 0C could result in a significant increase of power plant efficiency. Calculations

show a maximum of 0.5 efficiency points (around 1.11%) for an indirect FGHRS with two (LP
and HP) feed water heaters. Simpler modifications of the FGHRS lead to lower efficiency
increments, with a minimum of 0.59%.
 CHAPTER 3
Lignite Based Thermal Power Plant
3.1 Introduction

KTLPS (Kutch Lignite Thermal Power Station), GSECL with capacity 2X70 MW + 2X75 MW
(4 number of units) is located near the Panandhro village in Taluka, Lakhpat, Dist: Kutch.
KLTPS was pit head power station as Gujarat Mineral Development Corporation, Panandhro
mines located nearby KTLPS came in to existence and now lignite is stacked from panandrho
mines (which is on edge of exhaust) as well as Mata Na Madh mines since 03-08-2017. The
purpose of setting up this TPS is to utilize large quantity of lignite resources available in this area
as a fuel and thus reducing running cost of the project as economical measures by saving
transportation on charges of fuel. Lignite is conveyed to crusher house to reduce its sizing (small
pieces) and fed to bunkers of the unit via shuttle conveyor.

75 MW KLTPS Unit-IV

Unit 4 is CFBC (Circulating Fluidized Bed Combustion) tangential fired, balanced draft with FD
and ID Fans, natural circulation, having PA Fans to fluidize the bed material and lignite mixture
& SA Fans for direct combustion and tubular air heaters.
The Furnace of boiler is made up to water tubes which are called water walls, connected
with the boiler drum via down comers and ring headers. Water in the drum gets converted into
the wet steam from which water particles are separated in turbo separator. The dry saturated
steam passes through various stages of the super heater headers and finally fed to the turbine
with design pressure & temperature at 90 kg/cm2 and 540 °C.

The heat of flue gas is utilized to raise feed water temperature in economizer zone in the second
pass of the boiler. The electrostatic precipitators are placed to remove ash particles from the
bottom hopper and disposed off in the form of ash slurry in ash dykes.

The water treatment plant includes chlorination plant, Aerator, turbo circulator, sand filters, Dual
media filter, RO Plant (RO water for service water generation) and DM Plant (DM water for
steam generation). The Osmoses-l water received from R.O. Plant is used in DM Plant for DM
water production and Osmoses-ll water used for bearing cooling of auxiliaries service waters and
Domestic use.

3.2 Major Components of the Power Plant Cycle

Following are the major component of thermal power plant

1. Boiler
2. Turbine and Generator
3. Condenser
4. Pumps
5. Feed Water Heater
6. Economizer
 Figure Thermal power plant cycle.

Boiler

A boiler (or steam generator) is a closed vessel in which water, under pressure, is converted into
steam. In here the heat is transferred to the boiler by all three modes of heat transfer i.e.
conduction, convection and radiation.

There are major two types of boiler:

(i) Fire tube boiler and

(ii) Water tube boiler

Note: - Water tube type boiler is used in Kutch lignite thermal power plant.

Water Tube Boiler

 In this type of boiler, the water flows inside the tubes and hot gases flow outside the tube
 The circulation of water in the boiler natural.
 The boiler drum contains both steam and water, the former being trapped from the top of
the drum where the highest concentration of dry steam exists.
 Figure Water tube type bolier

Steam Turbine

A turbine is a rotary mechanical device that extracts energy from a fluid flow and converts it into
useful work. The work produced by a turbine can be used for generating electrical power when
combined with a generator.

Steam entering from a small opening attains a very high velocity. The velocity attained during
expansion depends on the initial and final content of the steam. The difference in initial and final
heat content represent the heat energy to be converted to kinetic energy.

There are two types of steam turbines:

1. Impulse turbine and

2. Reaction Turbine

The impulse steam turbine consists of a casing containing stationary steam nozzles and a rotor
with moving or rotating buckets. When the steam passes through the stationary nozzles and is
directed at high velocity against the rotor buckets. The rotor buckets starts to rotate at high speed.
The impulse turbine pressure drops and the velocity increases as the steam passes through the
nozzles. When the steam passes through the moving blades the velocity drops but the pressure
remains the same.

In the case of reaction turbine, the moving blades of a turbine are shaped in such a way that the
steam expands and drops in pressure as it passes through them. As a result of pressure decrease
in the moving blade, a reaction force will be produced. This force will make the blades to rotate.

Condenser

The function of the condenser is to condense the steam exiting the turbine. The condenser helps
maintain low pressure at the exhaust.

There are two types of condensers are used;

1. Jet type condenser

2. Surface type condenser

Note: - Surface type condenser is used in Kutch lignite thermal power plant.

Surface condenser (non-contact type)

 Steam and water are not mix with each other.

 Condensate temperature is higher than the cooling water temperature at the outlet of
condenser
 Recovered water in the condenser is fed back to the boiler
 Heat transfer is occurred by convection.
 There is a high initial cost
 Here condensate water is not wasted, so pumping power is less.
 Figure: Surface type condenser

Boiler feed pump

They supply high pressure feed water to the steam generator. The centrifugal pump is commonly
used for this purpose. The pump consists of a casing and a rotating element, known as impeller,
fitted on the shaft of the pump. When the pump is switched on the centrifugal force generated by
the rotating impeller will pump the feed water from one place to another place.

The phenomenon of "Cavitation" should be avoided in pumps. This occurs when the liquid
pressure on the surface of the impeller falls below the vapour pressure of the liquid. These results
in the formation of vapour bubbles on the surface of the impeller. These bubbles will collapse
when they move into a region of high pressure. The sudden collapse of these bubbles causes
severe impact loads on the impeller and can also cause erosion of the impeller surface. All this
leads to marked lowering of the mechanical efficiency of the pump and its operation becomes
noisy.

The phenomenon of cavitation can be avoided by increasing the fluid pressure at the pump inlet.
This pressure minus the vapour pressure of the fluid is called the "net positive suction head".
This pressure is generally specified by the pump manufacturer.
Feed Water Heater

These heaters are used to heat the water which is feed to the boiler by means of blend steam
before it is supplied to the boiler. Necessity of heating feed water before feeding to the boiler due
to the following reasons;

 Feed Water heating improve overall efficiency.

 The dissolved oxygen which would otherwise cause boiler corrosion is removed in the
feed water heater.
 Thermal stresses due to cold water entering the boiler drum are avoided.
 Quantity of steam produced by the boiler is increased.

Figure: Water steam flow diagram

ECONOMIZER

 Boilers are provided with economizer and air pre-heaters to recover heat from the flue
gases. An increment in boiler efficiency is achieved by providing both economizer and
air pre-heaters.
 For pressure of 70 Kg/cm2 or more economizer becomes a necessity.
 Feed water flows through the tubes and the flue gases outside the tubes across them.
 The feed water from the high pressure heaters enters the economizer and pick up the heat
from the flue gases after the low temperature super heater.
 The temperature of the feed water entering the economizer should be high enough so that
moister from the flue gases does not condense on the economizer tubes.
 The feed water should be sufficiently pure not to cause forming of scales and cause
internal corrosion and under boiler pressure.
CFBC Technology

Fluidized bed boilers were developed to create combustion systems to minimize NOx production
remove SOx, and burn a wide range of fuels. A large mass of solid particles, once heated help in
maintaining combustion temperature and stabilize combustion over wide ranges of heating
values of fuels thus allowing a range of poor quality and waste fuels, as well as usual fuels, to be
combusted.

Fig. CFBC Technology

The CFBC boilers operates under a special fluid dynamic condition, in which the fine solid
particles are transported and mixed through the furnace at a gas velocity exceeding the average
terminal velocity of the particles. The major fraction of solids leaving the furnace is captured by
solid separator and re-circulated back to the base of the furnace. CFB uses greater combustor
superficial gas velocities than the bubbling fluidized bed technology. CFB system operates in a
fluid dynamic region between that of BFB and a transport reactor. This fluidization regime is
characterizes by high turbulence, solid mixing and the absence of a defined bed level. Instead of
a well-defined solids bed depth, the solids are distributed throughout the furnace with a steadily
decreasing density from the bottom to the top of the furnace.

A combustor bed temperature between 850 0C to 900 0C is usually selected in CFBC.

Combustion stability is provided by the high thermal inertia of the large mass of fuel and inert
material in the bed. Acceptable burnout of fuel results from the long residence time of fuel in the
bed and by recycle of material captured in the mechanical collectors above the bed. A wide range
of fuels may be fired in fluidized bed boilers because the design is for combustion temperatures
that are lower than the ash softening temperatures of most of the fuels.

Advantages of CFBC:-

 Ability to handle low grade, high ash and high sulphure contain fuels.
 Low oil Support: Oil firing 0 to 30% load and Solid fuel firing 30 to 100% load.
 Ability to maintain constant combustor temperature.
 Better sulfur capture and combustion efficiency.
 High heat transfer rate.
 Multi-fuel capability.
Mechanical Arrangement

The CFB combustor, cyclones, fluid bed heat exchangers and pertaining seal pots form an
integral system and constitute the main components of the circulating fluidized bed combustion
system.

Material circulation cycle in CFBC System

In the CFB combustor, the lignite is burnt in a circulating fluidized bed, In the process, the solid
particles (ash) are continuously carried out of the combustor with the flue gas. The flue gas
leaving the combustor is routed to the recycling cyclones where the solids are separated and
returned to the combustor via the fluidized seal pots. The seal pots provide a pressure seal
between the cyclones and the CFB combustor. The cyclone is operating with high collection
efficiency. Only the fine ash particles are carried with the flue gas into the convective pass.
These fine particles are collected in the electrostatic precipitators.
Part of the ash collected in the cyclones is drawn off via the spiess valves at the seal pots and
routed to the empty chamber of the fluid bed heat exchangers. In the FBHE, the thermal content
of the hot ash is put to the effective use for steam superheating and steam generation, the cooled
ash is returned directly to the combustor.

Seal Pot

The refractory lined seal pots downstream of the recycling cyclones are fluidized with all and are
ensuring a pressure seal between the recycling cyclones and the CFR combustor.

The ash discharged from the cyclones is returned via the seal pots to the combustor. A branch
stream of the ash is flowing from the seal pots via the spiess valves to the fluid bed heat
exchangers. The ash rate is controlled by the spiess valves located at the seal pots depending on
boiler load and combustor temperature.

Seal pot
The seal pot fluidizing air is supplied by the seal pot blowers to the two legs of a seal pot. The air
rates to the individual seal pot legs can be adjusted by means of locally operated dampers;
however, they stay fully open during normal operation.

Air distribution to the nozzles is accomplished by wind boxes located underneath the seal pots.

Fluid Bed Heat Exchangers

The fluid bed heat exchangers are arranged downstream of the recycling cyclones and supplied
with ash via the spiess valves from the seal pots.

Fluid Bed Heat Exchangers water circulation

The FBHES have refractory lined walls, and consist of the following 2 chambers, which are
separated from each other by weirs:

 Chamber 1: empty chamber to steady the ash flow entering the FBHES,
 Chamber 2: chamber equipped with a bundle:
1. FBHE SH has a super heater bundle.
2. FBHE Evaporator has an evaporator bundle.

Steam is heated after intermediate super heater in FBHE SH and after that it goes to final SH in
convective pass, where as in FBHE Evaporator water from the drum is directly heated.
In the chambers the ash is fluidized by means of a constant airflow admitted via nozzle grates
supplied by rotary piston blowers. As the ash is passing through the FBHES, the ash is cooled
down.

Bed Ash system

Bed ash system shown in figure, which is used to maintain the combustor pressure. There are
three ways to maintain the combustor pressure:

 Ash cooler 1
 Ash cooler 2
 SH to Ash cooler 2

Here, Ash cooler 1, Ash cooler 2 and SH to Ash cooler is a spiess valve which is operated by
electrically to open and close.

Bed Ash system

Primary Air System

The preheated primary air is fed to the CFB combustor ensures the circulation of the bed material
which is dependent on the velacity of the primary air both on solid fuel firing and oil firing. The
primary air is fed to the combustor on controlled load to suit the requirements of material
circulation with regard to heat transfer in the CFB combustor and a sufficient ash supply to the
FBHE via the spiess valves.

Primary air rate adjustment is accomplished by means of vane control of the primary air fan.

Primary Air System

Main function of the primary air is shown following:

 Fluidization and Circulation of the bed material.

 Controls Solids circulation rate on heat transfer.
 Primary combustion of Fuel.
 PA Nozzles for optimum distribution.
 Contributes 40% of total combustion air.
 98 % through nozzle grate.
 2 % through oil lances.
 Two PA fans with 60% capacity.
 Preheated in APH.

Secondary Air System

For staged combustion secondary air is fed to the combustor at two secondary air levels:

 Level 1 (burners): 2 start-up burners

 Level 2 (top): 8 injection nozzles

The secondary air is preheated in the tubular air heater and controlled in such a way that a preset
air to fuel ratio is attained in the CFB combustor.

Secondary Air System

Other air streams entering the CFB combustor and thus participating in the combustion process
are:

 fluidizing air to ash coolers,

 fluidizing air to seal pots,
 fluidizing air to FBHES,
 seal and purge air

These air streams are compressed in rotary piston blowers and injected into the CFB combustor.

Total Air Flow @ Design condition

Total Air Flow circulation in boiler

Air flow rate at 100 % MCR conditions (in kg/s)
• PA through nozzles : 45.1
• PA through oil lances : 0.6
• SA -Upper levels : 50
• SA -Burner level : 12.5
• Fluidizing air - FBHEs : 2 x 2.1
• Fluidizing air - seal pots : 2 x 0.5
• Fluidizing air - ash coolers : 2.1
• Seal and purge air - various purposes : 1.3

Fuel system

Oil Firing

 Two Start Up Burners with capacity of 2460 kg/hr each.

 Minimum flow through SUB is 492 kg/hr.
 4 Bed lances with capacity of 1845 kg/hr each.
 Minimum flow through Bed lances is 575 kg/hr.

Note: - 1kg/hr = 0.017 L/min

Lignite firing

 Two lignite bunkers.

 Two Drag link chain conveyors.
 Two Self cleaning rotary valves.
 Two Master Fuel trip valves.
 CHAPTER 4
DESIGN AND ANALYSIS

3.1 Plant Analysis

This study analyze the cumulative coal fired thermal power plant with all methods of the
efficiency increasing techniques like superheating the steam to high temperatures, increasing the
boiler pressure, regenerative Rankine cycle etc. which is shown in Fig. 1.

Thermal power plant model diagram.

A continuous mass flow diagram for one unit of the power plant modeled in this study includes
the main components such as turbines (T), a boiler (B), number of pumps (P), a deaerator (D), a
generator (G), a condenser (C), low and high pressure feed water heaters (LPH and HPH).

The thermodynamic models are based on fundamental mass and energy balances. Using the
energy and mass balance equations for each component in the power plant model, it is possible
to compute energy content in terms of turbine power outputs, pump power consumptions, boiler
heat requirements, energy flow at each node of the plants, component first law efficiency,
component irreversibilities in the plants, and so on.

Energy Analysis

In an open flow system there are three types of energy transfer across the control surface namely
working transfer, heat transfer, and energy associated with mass transfer or flow transfer. The
first law of thermodynamics or energy balance for the steady flow process of an open system is
given by:

1 1
Q + m (hi + 2Ci2 + g Zi) = m (ho + 2Co2 + g Zo) +W

Where Q = heat transfer to system from source at temperature T,

W = Net work developed by the system,

m = Mass floe rate,

h = Enthalpy,

C = Bulk velocity of the working fluid,

Z = Altitude of the stream above the sea level,

g = Specific gravitational force

The energy or first law efficiency η of a system component is defined as the ratio of energy
output to the energy input to component,

Desired output energy

𝛈=
Input energy supplied

Data Collection

The ultimate analysis (as received basis) of lignite coal are given in Table

Ultimate Analysis

Table 1 Ultimate analysis of coal

Description Coal sample Unit

C 26.55 %

H 2.19 %

N 1.72 %

O 7.76 %

S 3.5 %

Ash 23.54 %

Moisture 34.74 %

This study is based on the energy analysis of an industrial boiler. Data has been collected from
Kutch lignite thermal power plant. Fuel consumption, excess air, steam production rate, pressure
and temperature, air temperature, inlet and outlet temperature of water and steam, inlet and out-
let temperature of flue gas of boiler etc. are collected for the analysis.
Parameters Used for Efficiency Calculation

Following table parameters are calculated for the energy analysis at different state point of Kutch
lignite thermal power plant

Table Energy analysis for 75 MW

State Pressure Temperature Mass Enthalpy Entropy Energy
Point (bar) (0C) (T/H) (KJ/kg) (KJ/kg-K) (KW)

0 90 530 301 3462.079 6.755 289468.3

1 32.16 388 25 3199.923 6.845 22221.69
2 14.42 309 16.54 3059.4 6.974 14056.24
3 5.14 212 19.09 2880.513 7.1 15274.72
4 2.92 169 9.943349 2801.826 7.185 7738.759
5 0.63 112 37.24 2704.269 7.647 27974.16
6 0.9 52 193.1867 2594.573 8.043 139232.5
7 0.62 52 300 217.112 0.728 18092.67
8 10.07 59 242 247.176 0.816 16615.72
9 0.56 104 47.18335 435.354 1.35 5705.961
10 10.07 106 327 444.457 1.372 40371.51
11 1.9 128 9.943349 537.211 1.612 1483.799
12 6.85 128 242 537.506 1.611 36132.35
13 8 154 330 649.062 1.881 59497.35
14 142 159 311 678.698 1.916 58631.97
15 9.8 166 41.54 701.059 2.001 8089.442
16 141 191 311 817.388 2.225 70613.24
17 28.32 203 25 865.259 2.358 6008.743
18 108 233 311 1005.098 2.621 86829.3
19 108 293 311 1302 3.175 112478.3
Following are the various parameters shown in table used for the energy analysis of steam power
plant:

Table . 75MW parameter

Parameters Quantity Unit

Turbine power 75 MW
0
Steam temperature 530 C

Steam pressure 90 Bar

Coal Feeding Rate 87 T/H

Steam Flow 300 T/H

Feed Flow 315 T/H

Total Air Flow 360-400 T/H

Analytical Approaches

An analysis means detail examination of all the components, so analyses of different components
of thermal power plant are as follows

Energy Analysis of Combustion Chamber

Combustion chamber is the most important part of the boiler. The combustor in a boiler is
usually well insulated that causes heat dissipation to the surrounding almost zero. It also has no
involvement to do any kind of work (w=0). In addition, the kinetic and potential energies of the
fluid streams are usually negligible. Then only total energies of the incoming streams and the
outgoing mixture remained same for analysis. The conservation of energy principle requires that
these two equal each other’s that is shown in the figure.
 Combustor flow diagram

Therefore, the total heat released by complete combustion of 1 kg of coal is:

𝑂
HHV = 33.91 C + 143 (𝐻 − ( 8 )) +9.094 S MJ/Kg

= (33.91*0.2655) +143 (0.0219-(0.0776/8)) + (9.094*0.035)

= 9 + 1.74 + 0.32

= 11.06 MJ/Kg

In energy efficiency case, we assume that the combustion chamber there is no heat losses.
Therefore, η = 100%

Overall Energy Analysis of Boiler Plant

Basically boiler efficiency can be tested by the following methods:

1) The Direct Method: Where the energy gain of the working fluid (water and steam) is
compared with the energy content of the boiler fuel.

2) The Indirect Method: Where the efficiency is the difference between the losses and the
energy input.
Direct Method

This is also known as ‘input-output method’ due to the fact that it needs only the useful output
(steam) and the heat input (i.e. fuel) for evaluating the efficiency.

Combustor flow diagram

Calculation:

Table Efficiency calculation of boiler by direct method parameter

Heat output data Value Unit

Heat Input

Steam pressure / temperature 90/530 Bar/ ºC

Enthalpy of steam, H 3462 KJ/kg

Quantity of steam generated (output) Q 300 T/H

Feed water temperature 315 ºC

Enthalpy of feed water h 1005 KJ/kg

Heat Output

Quantity of coal consumed (Input) q 87 T/H

GCV of coal 2642 Kcal/kJ

𝑄∗(𝐻−ℎ)∗100
Boiler efficiency (η) = 𝑞∗𝐺𝐶𝑉 𝑜𝑓 𝐶𝑜𝑎𝑙

300∗(3462−1005)∗100
= 76.6 %
87∗2642∗4.184

Indirect Method

There are reference standards for Boiler Testing at Site using indirect method namely British
Standard, BS 845: 1987 and USA Standard is ‘ASME PTC-4-1 Power Test Code Steam
Generating Units’.

Indirect method is also called as heat loss method. A de-tailed procedure for calculating boiler
efficiency by indirect method is given below. However, it may be noted that the practicing
energy mangers in industries prefer simpler calculation procedures.

The principle losses that occur in a boiler are:

L1- Loss of heat due to dry flue gas (Sensible heat)

L2- Loss due to hydrogen in fuel (H2)

L3- Loss of heat due to moisture in fuel (H2O)

L4- Loss of heat due to moisture in air (H2O)

L5- Loss of heat due to incomplete combustion

L6- Loss of heat due to radiation and unaccounted

L7- Unburnt losses in fly ash (Carbon)

L8- Unburnt losses in bottom ash (Carbon)

 Boiler Efficiency by indirect method =

= 100 – (L1 + L2 + L3 + L4 + L5 + L6 + L7 +L8)

In the above, loss due to moisture in fuel and the loss due to combustion of hydrogen are
dependent on the fuel, and cannot be controlled by design.

Heat Loss due to Dry Flue Gas (L1)

DATA VALUE UNIT

Mass of dry flue gas m 5.42 Kg / Kg of fuel

Specific heat of flue gas Cp 0.24 KCal/Kg-K

0
Flue gas temperature Tf 145 C

0
Ambient temperature Ta 35 C

This is the greatest boiler loss and can be calculated with the following formula:

𝐦 𝐂𝐩 (𝐓𝐟−𝐓𝐚)∗𝟏𝟎𝟎
𝑳𝟏 = 𝐆𝐂𝐕 𝐨𝐟 𝐂𝐨𝐚𝐥

5.42∗0.24∗(145−35)∗100
=
2642

= 5.42 %
Heat Loss due to Evaporation of Water formed due to H2 in Fuel (%L2)

The combustion of hydrogen causes a heat loss because the product of combustion is water.

This water is converted to steam and this carries away heat in the form of its latent heat.

DATA VALUE UNIT

Hydrogen present in fuel on 1 kg basis H2 0.0219 Kg

Specific heat of superheated steam CP 0.45 Kcal /Kg-0C

0
Flue gas temperature Tf 145 C

0
Ambient temperature Ta 35 C

𝟗∗𝐇𝟐∗{𝟓𝟖𝟒+ 𝐂𝐩 (𝐓𝐟−𝐓𝐚)}∗𝟏𝟎𝟎
𝐋𝟐 = 𝐆𝐂𝐕 𝐨𝐟 𝐂𝐨𝐚𝐥

9∗0.0219∗{584+0.24∗(145−35)}∗100
=
2642

= 4.55 %
Heat Loss due to Moisture present in the Fuel (%L3)

Moisture entering the boiler with the fuel leaves as a superheated vapour. This moisture loss is
made up of the sensible heat to bring the moisture to boiling point, the latent heat of evaporation
of the moisture, and the superheat required bringing this steam to the temperature of the exhaust
gas.

DATA VALUE UNIT

Moisture in fuel in 1 kg basis M 0.3474 Kg
Specific heat of superheated steam CP 0.45 Kcal /Kg-0C
0
Flue gas temperature Tf 145 C
0
Ambient temperature Ta 35 C
Latent heat corresponding to partial pressure of water 584 Kcal /Kg
vapor
This loss can be calculated with the following formula:
𝑴∗{𝟓𝟖𝟒+ 𝑪𝒑 (𝑻𝒇−𝑻𝒂)}∗𝟏𝟎𝟎
𝑳𝟑 = 𝑮𝑪𝑽 𝒐𝒇 𝑪𝒐𝒂𝒍

0.3474∗{584+0.45∗(145−35)}∗100
=
2642

= 8.33 %
Heat Loss due to Moisture present in Air (%) (L4)

Vapour in the form of humidity in the incoming air, is superheated as it passes through the
boiler. Since this heat passes up to the stack, it must be included as a boiler loss.

DATA VALUE UNIT

Actual mass of air supplied AAS 4.4 kg/kg of fuel

Humidity factor 0.016 kg of water/kg of dry

air
Specific heat of superheated steam Cp 0.45 Kcal /Kg-0C

0
Flue gas temperature Tf 145 C

0
Ambient temperature Ta 35 C

This loss can be calculated with the following formula:

𝑨𝑨𝑺∗𝑯𝒖𝒎𝒊𝒅𝒊𝒕𝒚 𝒇𝒂𝒄𝒕𝒐𝒓∗ 𝑪𝒑 (𝑻𝒇−𝑻𝒂)∗𝟏𝟎𝟎
𝑳𝟒 = 𝑮𝑪𝑽 𝒐𝒇 𝑪𝒐𝒂𝒍

4.4∗0.016∗0.45∗(145−35)}∗100
= 2642

= 0.13 %

Heat Loss due to Incomplete Combustion (L5) can be neglected because this study assume
Combustion is Perfect Combustion
Heat Loss due to Radiation and Convection is taken as L6= 2-3 %

The other heat losses from a boiler consist of the loss of heat by radiation and convection from
the boiler casting into the surrounding boiler house.
Source: https://beeindia.gov.in/
Heat loss due to Unburnt in Fly Ash (L7)

DATA VALUE UNIT

Total ash collected 0.22 Kg/kg of fuel burnt

GCV of fly ash 150 kCal/kg ºC

GCV of fuel 2642 kCal/kg ºC

This loss can be calculated with the following formula:

𝐓𝐨𝐭𝐚𝐥 𝐚𝐬𝐡 𝐜𝐨𝐥𝐥𝐞𝐜𝐭𝐞𝐝
∗𝐆𝐂𝐕 𝐨𝐟 𝐟𝐥𝐲 𝐚𝐬𝐡∗𝟏𝟎𝟎
𝐤𝐠 𝐨𝐟 𝐟𝐮𝐞𝐥 𝐛𝐮𝐫𝐧𝐭
L1 =
𝐆𝐂𝐕 𝐨𝐟 𝐟𝐮𝐞𝐥

0.22∗150∗100
= 2642

= 1.25 %

Heat loss due to Unburnt in Bottom Ash (%) (L8)

DATA VALUE UNIT

Total ash collected 0.22 Kg/kg of fuel burnt

GCV of bottom ash 200 kCal/kg ºC

GCV of fuel 2642 kCal/kg ºC

This loss can be calculated with the following formula:
𝑻𝒐𝒕𝒂𝒍 𝒂𝒔𝒉 𝒄𝒐𝒍𝒍𝒆𝒄𝒕𝒆𝒅
∗𝑮𝑪𝑽 𝒐𝒇 𝒃𝒐𝒕𝒕𝒐𝒎 𝒂𝒔𝒉∗𝟏𝟎𝟎
𝒌𝒈 𝒐𝒇 𝒇𝒖𝒆𝒍 𝒃𝒖𝒓𝒏𝒕
L8 =
𝑮𝑪𝑽 𝒐𝒇 𝒇𝒖𝒆𝒍

0.22∗200∗100
= 2642

= 1.66 %

Efficiency of boiler = 100-(sum of all losses)

= 100 – (5.41+4.55+8.33+0.13+2+1.25+1.66)

= 76.6%

Note: - Thus indirect efficiency is less than direct efficiency because of losses.

Due to limitation of direct method indirect method is used in analysis.

Energy Analysis of Turbine

Energy analysis in turbine can be expressed by the finding the energy at all state point, which is
shown in figure.

Fig. Energy analysis of turbine

EIN = m0 * h0

EOUT = m1 * h1 + m2 * h2 + m3 * h3 + m4 * h4 + m5 * h5 + m6 * h6 + WT

𝐸𝑜𝑢𝑡
𝜂= 𝐸𝑖𝑛

Work done by turbines actually = 75MWH

EIN = 83*3462

= 287346 kW

EOUT = (22221.69) + (14056.24) + (15274.72) + (7738.759) + (27974.16) + (139232.5) + 20.833

= 226518.83 kW

η = 78.83 %

Energy Analysis of Condenser

The condenser efficiency is defined as:

𝐴𝑐𝑡𝑢𝑎𝑙 𝑟𝑖𝑠𝑒 𝑖𝑛 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑜𝑓 𝑐𝑜𝑜𝑙𝑖𝑛𝑔 𝑤𝑎𝑡𝑒𝑟

Condenser efficiency = 𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑝𝑜𝑠𝑠𝑖𝑏𝑙𝑒 𝑟𝑖𝑠𝑒 𝑖𝑛 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒𝑜𝑓 𝑐𝑜𝑜𝑙𝑖𝑛𝑔 𝑤𝑎𝑡𝑒𝑟

Fig. Performance of condenser

TCWI = Cooling water inlet temperature

TCWO = Cooling water outlet temperature

TS = Saturation temperature corresponding to condenser pressure

𝑇𝑐𝑤𝑜−𝑇𝑐𝑤𝑖
𝜂= 𝑇𝑠−𝑇𝑐𝑤𝑖

TCWI = 34 0C

TCWO = 42.8 0C

TS = 43.6 0C at 0.1bar condenser pressure.

TCONDENSER = 51.8 0C

𝑇𝑐𝑤𝑜 − 𝑇𝑐𝑤𝑖
𝜂=
𝑇𝑠 − 𝑇𝑐𝑤𝑖

8.8
= 9.6

= 91.66 %

Energy Analysis of Boiler Feed Pump

Pump efficiency is defined as:

𝑂𝑢𝑡𝑝𝑢𝑡 𝑝𝑜𝑤𝑒𝑟
Pump efficiency = 𝐼𝑛𝑝𝑢𝑡 𝑝𝑜𝑤𝑒𝑟

Fig. Energy analysis of feed pump

Shaft power (PS) = motor input × motor efficiency

= 185× 6.6

= 1221 kW

Ein = m* h13 + PS

Eout = m* h14

𝐸𝑜𝑢𝑡
𝜂= 𝐸𝑖𝑛

Ein = 59497.35 + 1221 = 60718.35 kW

EOUT = 58631.97 kW

𝐸𝑜𝑢𝑡
𝜂= 𝐸𝑖𝑛

58631.97
= 60718.35

= 0.9656

= 96.56 %

Motor efficiency = 80 %

Overall efficiency = η × ηm

= (0.9656 × 0.8)

= 0.7724

= 77.24 %
Energy Analysis of LPH 1

Feed water heater is defined in terms of efficiency as:

𝑂𝑢𝑡𝑝𝑢𝑡 𝑒𝑛𝑒𝑟𝑔𝑦 𝑇𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑑𝑖𝑓𝑓𝑒𝑟𝑒𝑛𝑐𝑒 𝑜𝑓 ℎ𝑒𝑎𝑡𝑒𝑑 𝑤𝑎𝑡𝑒𝑟

Feed water heater efficiency = =
𝐼𝑛𝑝𝑢𝑡 𝑒𝑛𝑒𝑟𝑔𝑦 𝐼𝑛𝑝𝑢𝑡 ℎ𝑒𝑎𝑡 𝑖𝑛 𝑡𝑒𝑟𝑚𝑠 𝑜𝑓 𝑠𝑡𝑒𝑎𝑚

𝑚8∗(ℎ10−ℎ8)
= (𝑚5∗ℎ5)+(𝑚11∗ℎ11)

Fig. Energy analysis of LPH 1

EIN = m5 * h5 + m8 * h8 + m11 * h11

EIN = 27974.16+ 16615.72 + 1483.799

= 46073.68 kW

EOUT = m10 * h10

EOUT = 40371.51 kW

40371.51
𝜂 = 46073.68 = 0.8762

= 87.62 %
Energy Analysis of LPH 2

Feed water heater is defined in terms of efficiency as:

𝑂𝑢𝑡𝑝𝑢𝑡 𝑒𝑛𝑒𝑟𝑔𝑦
Feed water heater efficiency = 𝐼𝑛𝑝𝑢𝑡 𝑒𝑛𝑒𝑟𝑔𝑦

Fig. Energy analysis of LPH 2

EIN = m4 * h4 + m10 * h10

EIN = 7738.759 + 40371.51

= 48110.27 kW

EOUT = m12 * h12

EOUT = 36132.35 kW

36132.35
𝜂 = 48110.27 = 0.7510

= 75.10 %
Energy Analysis of HPH 4

Feed water heater is defined in terms of efficiency as:

𝑂𝑢𝑡𝑝𝑢𝑡 𝑒𝑛𝑒𝑟𝑔𝑦
Feed water heater efficiency = 𝐼𝑛𝑝𝑢𝑡 𝑒𝑛𝑒𝑟𝑔𝑦

Fig. Energy analysis of HPH 4

EIN = m2 * h2 + m14 * h14 + m17 * h17

EIN = 14056.24+ 58631.97 + 6008.743

= 78696.95 kW

EOUT = m16 * h16

EOUT = 70613.24 kW
70613.24
𝜂= = 0.8973
78696.95

= 89.73 %
Energy Analysis of HPH 5

Feed water heater is defined in terms of efficiency as:

𝑂𝑢𝑡𝑝𝑢𝑡 𝑒𝑛𝑒𝑟𝑔𝑦
Feed water heater efficiency = 𝐼𝑛𝑝𝑢𝑡 𝑒𝑛𝑒𝑟𝑔𝑦

Fig. Energy analysis of HPH 5

EIN = m1 * h1 + m16 * h16

EIN = 22221.69 + 70613.24

= 92834.93 kW

EOUT = m18 * h18

EOUT = 86829.3 kW
86829.3
𝜂 = 92834.93 = 0.9353

= 93.53 %
 CHAPTER 5
Results and Discussion
Results on Design Data
This study implemented an energy analysis on kutch lignite thermal power plant and got the
following results:

Component Energy loss Efficiency

Boiler 234490 KW 76.6 %

Turbine 60848 KW 78.8 %

Condenser 121140 KW 22.39 %

Pump 2087 KW 96.56 %

LPH 1 5702 KW 87.62 %

LPH 2 11978 KW 75.10 %

HPH 4 8083 KW 89.73 %

HPH 5 6005 KW 93.53 %

Efficiency Analysis Result:

Efficiency
120.00%
96.56%
100.00% 87.62% 89.73%93.53%
76.60%78.80% 75.10%
80.00%

60.00%

40.00% Efficiency
22.39%
20.00%

0.00%

Figure 6.1 Efficiency of different components of thermal power plant.

Power destruction kW
250000 234490

200000

150000 121140

100000
60848 power in kW
50000
2087 5702 11978 8083 6005
0

Figure 6.2 Energy destruction in different components of thermal power plant.

Calculation of Energy Analysis at Different Load

Boiler

Data Different Loads Unit

75 70 60 54 MW
kg/kg of
Mass of dry flue gas m 14.4 15.1 17.5 16.4 fuel
0
Flue gas temperature Tf 136 145 140 138 C
0
Ambient temperature Ta 35 35 35 35 C

Moisture in fuel in 1 kg 30.76 23.29 30.4 37.38 Kg

basis M

H 0.0126 0.0162 0.0124 0.0144 kg

kg / kg of
Total ash collected 0.22 0.2 0.2 0.2 fuel burnt
kcal/kg
CV 2367 2517 2404 2423
Boiler Efficiency

Losses Different Loads Unit

Generating Load 75 70 60 54 MW

L1 14.74 15.84 18.34 16.73 %

L2 2.91 3.53 2.82 0.25 %

L3 8.18 5.86 7.9 9.72 %

L4 0.13 0.14 0.14 0.13 %

L5 0 0 0 0 %

L6 1.5 1.5 1.5 1.5 %

L7 1.5 1.19 1.24 1.23 %

L8 2.02 1.58 1.66 1.6 %

Boiler Efficiency 69.02 70.36 66.4 68.84 %

Boiler efficiency
71 70.36
70
69.02 68.84
69

68

67 Boiler efficiency
66.4
66

65

64
75MW 70MW 60MW 54MW

Figure 6.3 Boiler efficiency at different load.

Turbine

Data Different Loads Unit

1 2 3 4 5

Generating 75 70 60 54 50 MW
Load

state 0 289468.2719 250033.3333 225991.6667 201950 kW

state 1 22221.6875 20309.66667 15822.22222 14824.03333 kW

state 2 14056.24333 12475.77222 10999 8482.065 kW

state 3 15274.72033 12538.88333 12807.11111 13426.71417 kW

state 4 7738.759376 7160.913194 5305.5575 4892.254444 kW

state 5 27974.16043 14398.93333 13398.96397 12267.8425 kW

state 6 139232.4635 128302.1967 121307 103155.03 kW

Wt 20.83333333 19.44444444 16.66666667 15

Ein 289468.2719 250033.3333 225991.6667 201950 kW

Eout 226518.8678 195205.8099 179656.5215 157062.9394 kW

Efficiency 0.782534356 0.780719144 0.794969674 0.777731812

Turbine efficiency
80
79.4969674
79.5
79
78.5 78.2534356
78.0719144
78 77.7731812 Turbine efficiency

77.5
77
76.5
75 70 60 54

Figure 6.3 Turbine efficiency at different load.

Condenser

Data Different Loads Unit

Temperature 1 2 3 4 5

75 70 60 54 50 MW
0
TCWI 34 29 31 25 C
0
TCWO 42 40 38 32 C
0
Tsaturation 45 45 43 39 C

Efficiency 72.72 68.75 58.33 53.84 %

Ein 139232.5 128302.2 121307 103155 kW

Eout 18092.67 16206.67 13883.33 11932 kW

Eloss 121139.83 112095.53 107423.67 91223 kW

Condenser Efficiency
80 72.72
68.75
70
58.33
60 53.84
50
40
Condenser Efficiency
30
20
10
0
75MW 70MW 60MW 54MW

Figure 6.3 Turbine efficiency at different load.

 Condenser Energy destruction
140000
121139.83
120000 112095.53 107423.67
100000 91223

80000

60000 Eloss

40000

20000

0
75 69 60 53

Figure 6.3 Turbine efficiency at different load.

LPH 1

Data Different Loads Unit

1 2 3 4 5

Generating 75 70 60 54 50 MW
Load

state 5 27974.16 14398.93 13398.96 12267.84 kW

state 8 16615.72 14311.11 12458.33 8925 kW

state 11 1483.799 1336.111 959.075 879.5944 kW

state 10 40371.51 26817.78 24065.17 19583.06 kW

EIN 46073.679 30046.151 26816.365 22072.4344 kW

EOUT 40371.51 26817.78 24065.17 19583.06 kW

Efficiency 87.62 89.25 89.74 88.72 kW

LPH 1 Efficiency
90 89.74061175

89.5 89.25529263

89 88.721795
88.5

88 Efficiency
87.6238036
87.5

87

86.5
75 70 60 54

Figure 6. LPH 1 efficiency at different load.

LPH 2

Data Different Loads Unit

1 2 6 7 8

Generating 75 69 60 54 50 MW
Load

state 4 7738.759 7160.913 5305.558 4892.254 kW

state 10 30494.7 26817.78 24065.17 19583.06 kW

state 12 36132.35 32641.78 28415.83 23596.94 kW

EIN 38233.459 33978.693 29370.728 24475.314 kW

EOUT 36132.35 32641.78 28415.83 23596.94 kW

Efficiency 94.50 96.06 96.74 96.41 %

LPH 2 Efficiency
97 96.74881058
96.41118394
96.5
96.06543724
96
95.5
95
94.50452809 LPH 2 Efficiency
94.5
94
93.5
93
75 70 60 54

Figure 6. LPH 2 efficiency at different load.

HPH 4

Data Different Loads Unit

1 5 6 7 8

Generating 75 69 60 53 50 MW
Load

state 2 14056.24 12475.77 10999 8482.065 kW

state 14 58631.97 52952 46902.56 41490.56 kW

state 17 6008.743 5338.959 3989.623 3603.025 kW

state 16 70613.24 63668 56233.09 48755.97 kW

EIN 78696.953 70766.729 61891.183 53575.65 kW

EOUT 70613.24 63668 56233.09 48755.97 kW

Efficiency 89.72 89.96 90.85 91.00 %

HPH 4 Efficiency
91.5
91.00397289
91 90.8579983

90.5

89.96883267 HPH 4 Efficiency

90
89.7280483

89.5

89
75 70 60 54

Figure 6. HPH 4 efficiency at different load.

HPH 5

Data Different Loads Unit

1 5 6 7 8

Generating 75 69 60 53 50 MW
Load

State 1 22221.69 20309.67 15822.22 14824.03 kW

State 16 70613.24 63668 56233.09 48755.97 kW

State 18 86829.3 78640 69361.5 59977.22 kW

EIN 92834.93 83977.67 72055.31 63580 kW

EOUT 86829.3 78640 69361.5 59977.22 kW

Efficiency 93.53 93.64 96.26 94.33 %

HPH 5 Efficiency
96.5 96.26146914
96
95.5
95
94.5 94.33346964

94 HPH 5 Efficiency
93.53085094 93.6439413
93.5
93
92.5
92
75 70 60 54

Fig.6. HPH 5 efficiency at different load.

 Chapter 6
Conclusion

Fossil fuels used in power plant are non-renewable so it is very necessary to use fuels effectively.
In present work, this study can minimize the wastage of energy and also finds the efficiency of
various components by which this study can determine the performance.

Advantages

This study finds the following results after energy analysis of thermal power plant:

 The components having maximum energy loss.

 The efficiency of various components.
 Inspect survey and analyze the flow of energy.
 Heat recovery can be possible.
 Economic optimization of the plant
 Performance of the component can be improved.

Scope of Future Work

 Present work includes Energy analysis of CFBC plant system based on Thermodynamic
topics.
 It is clear that improving a system thermodynamically without considering economics is
misleading. By using energy analysis, this study can inspect survey and analyze the
whole flow of energy. Next step of this work is exergy analysis which is very useful for
determining causes and types of irreversibility. The second law efficiency of the plant can
help to differentiate between “QUALITY” and “QUANTITY” energy.

 Next most wide scope of the energy analysis is the “ENERGY AUDIT” which is very
useful in conservations and management of energy and improves economics of energy.
Limitations

This study has calculated the efficiency of the various components but cannot reach to the points
where there is decrease in efficiency.

This study also cannot find the points where losses occur and irreversibility are present. Energy
and exergy are two sides of coin, So that this study cannot reach at final point without exergy
analysis. Hence this study cannot increase the efficiency and only inspect survey and analyze the
flow of energy.