IDP A

SOLUTION

AIM OF THE PROBLEM STATEMENT IDP-A

To do a comparative study of two boiler option and find out

which option is more economically viable.

To find optimum pressure / superheat from boiler in the option

which is more economical.

OPTION 1

BLOCK DIAGRAM

CALCULATIONS OF OPTION 1

BOILER EFFICIENCY = 81%

GCV of coal = 5000 Kcal/kg= 20929 KJ/kg

Cost of coal = Rs 5200/Mt

boiler efficiency is given by ;

0.81=

Cost of coal/yr = 4285.66 330 days 24

hr 5.2

CAPITAL COST
Rs 10 crores

COST OF COAL
Rs 17.6 crores

= Rs 17.6 10^7
= Rs 17.6 crores
PAYBACK PERIOD

NO RETURN

OPTION 2 :

CASE 1 BLOCK DIAGRAM

CASE 1 : CALCULATION
THE INLET AND OUTLET CONDITIONS FROM THE TURBINE ARE AS SHOWN IN

DIAG
Now we find out the ideal work done by the turbine
Isentropic efficiency = 55%
efficiency

Actual work = 0.55 19.68 = 10.824 KJ/Kg

As we have, steam flow rate = 30,000 Kg/hr = 8.3333 Kg/

sec
So we get actual work as = 10.824 8.3333= 90.2 KW
Now we calculate the actual outlet enthalpy,

=
actual work
=2840.57-10.824
=2829.745 KJ/Kg
Now at this enthalpy and 20 bar outlet pressure, we get the
temperature of steam as 223.13 C instead of 220C.

RETURN ON INVESTMENT

Electricity savings =(90.2*8*330*24)/10^7

= 0.5715 crore
Cost of boiler and turbine = 10+0.2+1.75
= Rs 11.95 crore
Mass of coal =(30*1000*(2840.57-376.993))/20929*0.81
= 4359.673 kg
Cost of coal = 4359.673*5.2*330*24/10^7

= 17.95487 crore

Incremental cost of boiler + turbine as compared to 20 bar

10 crore
=11.95-10
=1.95 crore
Savings compared to electricity generated
=0.5715-(17.9548-17.6)
= 0.2167 crore
Payback

=1.95/0.2167
=9.0014 yrs

 This proves that there is entropy being generated and that

the turbine is inefficient. Higher the pressure of steam

produced by the boiler more is the disorder generated, i.e.
the entropy of the steam at the turbine outlet increases so
the outlet temperature goes above 220C.
Due to the inefficient turbine higher superheated steam is

generated which then has to be desuperheated to 220C.

In this process we are spending more amount of cooling

water at 110C and burning more amount of coal initially

which leads to more pollution and higher costs so this is not
the best option.

CASE

From case 1 considering the entropy at the inlet and the outlet to be

the same we got the outlet temperature of the steam much higher
than what we had fixed at 220C.
This is because the turbine is inefficient having an efficiency of only
55%.So now we fix the outlet enthalpy of the steam at 2820.89KJ/Kg
which is the enthalpy of steam at 220C and 20bar.
Now we have to decrease the superheat to the turbine to such an
extent that we get the outlet at 220C only. The work done will
remain the same and so we will get a lower inlet enthalpy.
This will result in less coal consumption and less use of cooling
water. Overall the payback period will decrease.
In this option, we fix the enthalpy of the outlet steam at 2820.89
KJ/Kg,i.e. the enthalpy at 220C
Since the real work remains the same, by fixing the temperature of
steam at the outlet of turbine as 220C, we calculate the inlet
conditions of steam to the turbine which will be,

Enthalpy of steam at outlet of turbine at 220C and 20 bar, =2820.89 KJ/Kg

Real work =

90.2 KW (will remain same)

=
KJ/Kg =
-2820. 89

Therefore,

=2831.7904 KJ/Kg

So, Temperature of steam at 22 bar and 2831.7904 KJ/Kg = 227.793 C

The work done by the turbine is W=90.2 KW
This work is converted into electricity savings whcich is shown below;
Electricity savings =

90.2 330 days 24 hrs. x Rs8 / KWHr

= 0.5717 Crores

Mass of coal = 301000 (2831.7904-376.993)/0.81

20929
=4344 kg
Cost of coal =(4344 5.2 330x 24) / 10^7
= 17.8903 crore
Incremental of boiler + turbine = 1.95 crore (same as case
1)
Savings compared to electricity generated
=0.5715-(17.8903-17.6)
=0.2812 crore
Payback
=1.95/0.2812
=6.9352 yrs

Pressure
FROM
(bar)

Superheated
OPTION
2

steam temperat
ure
C

Electricity savings
(Rs
crores )

Incremental
cost of boiler &
turbine
(Rs crores)

Additional
Electricity
savings (Rs
crores

Pay -back
Period
(in years )

22

227.793

0.57150718

1.95

0.281174

9.002

28

248.413

2.07345592

2.55

1.5758

1.9007

32

260.406

2.94088068

2.95

1.9913

1.27

35

268.694

3.5376

3.25

2.8379

1.18

44

290.767

5.1165574

4.525

4.1988

1.078

46

295.213

5.43280298

4.808

4.471

1.076

48

299.517

5.73830377

5.09167

4.734

1.0765

54

303.693

6.59904934

5.94167

5.9365

1.097

60

322.201

7.3883565

6.792

6.157

1.104

65

331.637

8.00081008

7.6

6.6849

1.137

pay - back period (years)

GRAPH :

0.0

5.0

10.0

15.0

20.0

25.0

30.0

35.0

pressu re (bar a)

40.0

45.0

50.0

55.0

60.0

65.0

Conclusion
From the above two options it is clear that as there is no payback in

the first option the option 1 totally a loss option

As option 2 is giving payback , this option should be considered to

find the max return on investment

Thus we have worked on option 2 and at different pressures and

superheats we have tried to find out the min payback period

Thus the optimum pressure is 46 bar and superheat 295.213

degC