CUST (DEPARTMENT OF MECHANICAL

ENGINEERING)
PROJECT REPORT
DESIGNING STEAM POWER PLANT

GROUP MEMEBERS:
Hasnat Iqbal BME163097
Ahmad Iqbal BME 163080
M. Hamza Zaheer BME 163097

SUBMITTED TO:
Atif Bin Asghar

Section 1

9th Nov, 2017

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Contents pg

1. Abstract 3
2. Introduction 3
3. Limitations 3
4. Objectives 4
5. Design Calculations 4
6. Enthalpies 5
7. Turbine work 5
8. Pump work 5
9. Efficiency 5
10. Boiler type 6
(a) Working 7
(b) Components 8
(c) Advantages 9
(d) Disadvantages 9
11. Pump type 9
(a) Advantages 10
(b) Design Features 10
(c) Construction materials 11
12. Environmental Aspects 12
13. Cost 13
14. References 14

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ABSTRACT:
In today’s world the most common source of producing electricity are the steam power
plants. The electricity produced in them is much cheaper and economical which is why
they are widely used. In such a power plant fuel such as coal, oil, gas or nuclear energy
is used to boil water and convert it into steam. This steam is then thrown on the turbine
blades which in turn rotate the turbine shaft. The shaft is connected with a generator
which produces electricity. Although steam power plants are a cheap way of producing
electricity they have harmful effects on the environment.

In the following project report we had to design a steam power plant which had a
minimum efficiency of 40% and should produce at least 300MW of electricity.

INTODUCTION:
The important components of a steam power plant are boiler and condenser. In a boiler
fossil fuels combust with air to produce hot gases. These gases are then passed over
the tubes in the steam generator. Water in the steam generator is first converted into
saturated liquid and upon further heating becomes superheated steam. Steam flows to
a turbine, where part of its energy is converted to mechanical energy that is transmitted
by rotating shaft to drive an electrical generator. The reduced-energy steam flowing out
of the turbine condenses to liquid water in the condenser. The condenser rejects this
heat to a nearby lake or river. Steam power plants reuse the water because purifying
fresh water again and again is costly.

LIMITATIONS:
We had to design the steam power plant with the following constraints

a. Boiler Pressure 10Mpa_20Mpa

b. Super heater Temperature 500°C-600°C
c. Turbine Exhaust Temperature 90°C-110°C
d. Mass flow rate of steam 30kg/sec-150kg/sec
e. Max no. of open feed water heaters 1-3
f. Max no. closed feed water heater 2-4
g. No. of reheaters 1-3

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OBJECTIVES FOR DESIGNING THE STEAM
POWER PLANT:
a. Steam as a working fluid
b. Coal as a fuel
c. Select an appropriate boiler and pump type
d. Minimize the environmental aspects of the power plant
e. Capacity =300MW
f. Thermal efficiency should be greater than 40%

DESIGN CALCULATIONS:

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Enthalpies:
h1=3041.8 h10=640.23
h2=3145.3 h11=640.24
h3=3075.65 h12=1491.21
h4=2757 h13=149.28
h5=3349 h14=1213.40
h6=2769.8 h15=1231
h7=2431.6 h16=1087.3
h8=376.70 h17=107.3
h9=376.72

Turbine Work
o Wt1= 23.2 MW
o Wt2= 110.1 MW
o Wt3= 52.18 MW
o Wt4= 26.26 MW

W total = 211.74

Pump Work
o Wp1= 9.01 MW
o Wp2= 2.1 MW

W total = 11.11 MW

Efficiency
W cycle = W (total) turbine – W(total) pump

W cycle = 200.63 MW

Q in = h7 – h8

Q in = 3305.02 kj/kg

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η = Wcyc/ Qin

η = 60.6%

BOILER TYPE:
Forced Circulation Water Tube Boiler

The boiler type we used is La-Mont Boiler. The main reason for selecting this boiler is
that it can operate within the limitations that were provided to us. This boiler is also not
costly as it was first developed in early 18th century. It is a forced circulation- water tube
boiler which was first introduced in 1925 by La Mont.

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WORKING:

The feed water from hot well is supplied to a storage and separating drum (boiler)
through the economizer. Most of the sensible heat is supplied to the feed water passing
through the economizer. A pump circulates the water at a rate 8 to 10 times the mass of
steam evaporated. This water is circulated through the evaporator tubes and the part of
the vapour is separated in the separator drum. The large quantity of water circulated (10
times that of evaporation) prevents the tubes from being overheated. The centrifugal
pump delivers the water to the headers at a pressure of 2.5 bar above the drum
pressure. The distribution headers distribute the water through the nozzle into the
evaporator. The steam separated in the boiler is further passed through the super-
heater. To secure a uniform flow of feed water through each of the parallel boiler circuits
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a choke is fitted entrance to each circuit. These boilers have been built to generate 45
to 50 tons of superheated steam at a pressure of 120 bar and temperature of 500°C.

IMPORTANT COMPONENTS:

 Steam separating drum

The feed water from the hot well is stored in the drum. The steam is
separated from water in the drum and the steam is usually collected
at the top
of the drum.
 Circulating pump
Water from the steam separating drum is drawn by a circulating
pump and it circulates water through the evaporator tubes. Pump
circulates water at a rate of 8-10 times the mass of steam
evaporated. Forced circulation is necessary to prevent the
overheating of tubes.
 Distribution header
The distribution header distributes the water through the nozzle into
the evaporator.
 Superheater
The steam from the steam separating drum enters the superheater
tubes where it is superheated by the hot flue gases passing over
them. The superheated steam then enters the steam turbine to
develop power.
 Economiser
The waste hot flue gases pass through the economiser where feed
water is pre-heated. By pre-heating the feed water, the amount of
fuel required to convert water into steam is reduced.
 Air pre-heater
The hot flue gases then passes through the air pre-heater where
the air required for combustion is pre-heated.

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ADVANTAGES:

1. La-Mont boilers can generate 45 to 50 tons of superheated steam at a pressure

of 120 bar and temperature of 500°C.
2. Drum is of small size.
3. Tendency of scale formation is eliminated due to forced circulation of water.
4. Initial costs are low.

DISADVANTAGES:

1. Bubbles are formed on the inside of the water tubes and this bubbles reduce the
heat transfer rate.
2. Operating costs are high.
3. Maintenance costs are very high.

FUEL USED:
The fuel we used was Lignite coal. We chose this type of coal because it is cheap and
easily available in Pakistan. The only drawback of this type of coal is that it is not of
superior quality and produces a lot of smoke.

PUMP TYPE:
We used a single stage horizontal split case centrifugal pump. In such a pump the
casing is split into two separate chambers. It’s different from an end suction pump or
inline pump in which the casing, the suction nozzle, and the discharge nozzle are all
included in a single chamber. When the casing is split along a vertical plane in relation
to the impeller, it’s known as a vertical split case pump; when it’s on a horizontal plane,
it’s known as a horizontal split case pump. This type of casing design is more

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economical for higher flow applications, and the impeller can be supported by bearings
on both sides, an advantage for larger, higher flow pumps.

ADVANTAGES:
1. High Efficiency design.
2. Single stage, horizontal split case centrifugal pump.
3. Horizontally split casing, double volute minimizes thrust loads and allows
operation over wide range of capacity.
4. Clockwise or counter clockwise rotation.
5. Double ended shaft available.

DESIGN FEATURES

 Oil or grease lubricated bearings

 Stuffing box configured for packing or mechanical seals
 Horizontal or vertical mounting configurations
 Renewable wear rings

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STANDARD CONSTRUCTION MATERIALS

 Cast iron
 Cast iron, stainless steel fitted
 bronze
 WCB grade carbon steel
 stainless steel

ENVIRONMENTAL ASPECTS

Coal power plants are the nation's top source of carbon dioxide (CO2) emissions, the
primary cause of global warming. A typical coal plant generates 3.5 million tons of CO2
per year. Burning coal is also a leading cause of smog, acid rain, and toxic air pollution.
An ordinary coa; power plant has the following environmental aspects:

Poisonous Gases

A coal power plant produces poisonous gases such as sulphur dioxide (SO2) which
takes a major toll on public health, including by contributing to the formation of small
acidic particulates that can penetrate into human lungs and be absorbed by the
bloodstream. SO2 also causes acid rain, which damages crops, forests, and soils, and
acidifies lakes and streams.

Nitrogen Oxides (NOx) pollution causes ground level ozone, or smog, which can burn
lung tissue, exacerbate asthma, and make people more susceptible to chronic
respiratory diseases.

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Mercury: Coal plants are responsible for more than half of the human-caused emissions
of mercury, a toxic heavy metal that causes brain damage and heart problems. Just
1/70th of a teaspoon of mercury deposited on a 25-acre lake can make the fish unsafe
to eat. A typical uncontrolled coal plants emits approximately 170 pounds of mercury
each year.

PREVENTIVE MEASURES FOR ENVIRONMENTAL ISSUES

Flue gas desulphurization

Flue-gas desulfurization (FGD) is a set of technologies used to remove sulfur
dioxide (SO
2) from exhaust flue gases of fossil-fuel power plants, and from the emissions of other
sulfur oxide emitting processes. Most FGD systems employ two stages: one for fly
ash removal and the other for SO2 removal. Attempts have been made to remove both
the fly ash and SO2 in one scrubbing vessel. However, these systems experienced
severe maintenance problems and low removal efficiency. In wet scrubbing systems,
the flue gas normally passes first through a fly ash removal device, either an
electrostatic precipitator or a baghouse, and then into the SO2-absorber. However, in
dry injection or spray drying operations, the SO2 is first reacted with the lime, and then
the flue gas passes through a particulate control device. We will use wet scrubbing
because it is more effective and efficient.

Coal Cleaning:
Coal cleaning is a process by which impurities such as sulfur, ash, and rock are
removed from coal to upgrade its value. Coal cleaning processes are categorized as
either physical cleaning or chemical cleaning. We will be using coal washing by
aqueous media. All of the coal preparation techniques now used commercially use
physical processes for the separation of impurities and these methods are unable to
remove all of either ash or Sulphur. It is possible to leach out ash and part of Sulphur
through the use of water.

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TRW Inc. is an American corporation that has investigated the Sulphur removal by water. The
results showed that pyritic Sulphur was easily soluble in water when coal was washed.

AVERAGE COST
 Boiler US $ 19 million
 Steam Generator US $ 14 million
 Turbine US $ 11.2 Million
 Pump US $ 9 million

Total Cost US $ 53.5 Million

CONCLUSIONS
The power plant we designed had these characteristics

 Electricity generation capacity = 211.7MW

 Efficiency = 60.6 %
 Boiler pressure = 12 Mpa
 Close feed water heaters = 2
 Open feed water heaters = 1
 No. of reheaters = 3

References

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http://www.brainkart.com/article/La-Mont-Boiler

http://www.ruhrpumpen.com/products/between-bearing-pumps/hsc-pump

http://www.pumpscout.com/all-pump-types/horizontal-split-case-pumps

http://www.ucsusa.org/clean-energy/coal-and-other-fossil-fuels/coal-air-pollution

https://www.phxequip.com

http://marketrealist.com/2015/01/important-issues-facing-coal-fired-power-plants/

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