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Journal of ermodynamics
Volume 2014, Article ID 520183, 10 pages
http://dx.doi.org/10.1155/2014/520183
Research Article
Thermal Performance and Economic Analysis of
210 MWe Coal-Fired Power Plant
Ravinder Kumar,1 Avdhesh Kr. Sharma,1 and P. C. Tewari2
1
2
Department of Mechanical Engineering, D.C.R University of Science and Technology, Murthal, Sonepat, India
Department of Mechanical Engineering, N.I.T Kurukshetra, Haryana, India
1. Introduction
Thermal power plant working is based on Rankine cycle,
where the thermal efficiency of cycle can be thermodynamically improved by increasing the mean temperature of heat
addition, that is, by introducing feedwater heating systems.
Numerous researchers [13] have reported enhancement in
thermal efficiency by dividing overall enthalpy equally via
feedwater heaters. It was proposed by [4] that the thermodynamic performance of Rankine cycle power plant can be
improved by reducing volumetric flow rate of steam. Later,
researchers tried to improve the efficiency of the plant by
increasing steam pressure, which resulted in degradation
of the steam quality at the turbine exhaust. To overcome
such problems, steam reheating was introduced after high
pressure turbine exhaust, which leads to decrease of the
moisture content at low-pressure turbine exhaust. The effect
of reheat pressure on cycle efficiency was investigated [5].
They reported best performance of steam power plant at
optimal reheat pressure. All the modifications/improvements
in Rankine cycle (like feed water heating and reheating) lead
to a substantial improvement in cycle efficiency. The study [6]
Journal of Thermodynamics
CM
1a
1b
G
C1 B1
d1
d2
B2 C 2 C 3 B 3
Z2
d4
d3
HPT
32
B6
C6
B4 C4 C 5 B5
LPT
IPT
LPT
SH
1d
ECO
1c
1e
RH
2
3
Boiler
4
5
6
7
10
14
COND
Z1
X2
X1
X3
X6
X5
X4
31
29
HP-1
30
X1
HP-2
30 26
28
X9
X8 8
BFP
27
25
26
20
24
DR
LP-1
23
X 1+ X 2
22
23
X4
LP-2
21
21
18
17
15
LP-3
DC
18
19
13
16
10
GM
CM
GSC EJE
O
11
9 11a
10a
11b O, H, I,
J, K
CEP
12
J
14
X4 + X 5 X 4 + X 5 + X 6
Journal of Thermodynamics
LPT from IPT is divided into four streams, and out of these
four streams, three streams are sent towards low pressure
feedwater heater (LP-1, LP-2 and LP-3) and one stream is
sent towards condenser, respectively. The steam after doing
useful work in the turbine is condensed in condenser. The
condensate is sent by condensate extraction pumps (CEP)
towards gland steam cooler (GSC), drain cooler (DC) and
remaining is sent towards low pressure feedwater heaters.
Since the extracted steam upon condensation gets subcooled
so the drain cooler (DC) is used. From the last low pressure
feedwater heater (LP-1) outlet, the condensate enters in deaerator shell. Boiler feed pump (BFP) supplies this condensate
quantity from deaerator (DR) to Low Pressure Feedwater
Heaters and High Pressure Feed Water Heaters respectively.
Boiler feed pump (BFP) is a multistage pump provided for
pumping feedwater (FW) to economizer. Three pumps each
of 50% of total capacity are provided out of which two pumps
work in parallel and third will be reserve. After HP-1 the
condensate passes through economizer (ECO) and finally it
enters into the boiler drum. Hence the cycle is completed.
Steam
FW
DS
Desuperheater
1 hs(i)
h(i)g
TTD
31 h
f(i)
FW
DC
Drain cooler
Condensate
h(i)l
30
Condenser
Bled steam
h (i)lg
hc(i)
ETD
FW
h f(i+1) 29
DS
DC
C
L
3. Thermodynamic Modeling
Energy and mass balance equations have been used for the
mathematical modeling of each component. The empirical
relations have been also derived based on thermodynamic
relations.
3.1. High Pressure Feedwater Heater (HP-1). High pressure
feedwater heater receives superheated steam bled from the
turbine at state 1, the steam is first desuperheated then
condensed and finally subcooled, whereas the feedwater gets
heated as shown in Figure 2. The schematic diagram of high
pressure feedwater heater HP-1 (for = 1) is shown in
Figure 3.
Mass balance:
in = out .
xi , h s(i)
1, h f (i+1)
1, h f(i)
xi , h c(i)
(1)
Energy balance:
() + 1 (+1) = 1 () + () ,
=
(() (+1) )
(() () )
x ib , h ib
HPT
(2)
RH
id
ic
ie
xi , hs(i)
1, hf(i)
1 , hf(i + 1)
31
29
(3)
The formulations of high pressure feedwater heater (HP2) (Figure 13), deaerator (Figure 14), low pressure feedwater
heaters (LP-1, LP-2, LP3) (Figures 15, 16, and 17), drain cooler
(Figure 18), gland steam condenser (Figure 19), and ejector
(Figure 20) are detailed in Appendix A.
xi , hc(i)
30
Journal of Thermodynamics
Table 1: Design data of pressure (bar) of bled stream at various locations from turbine.
Sr. no.
MWe
1.
2.
3.
1
25.36
33.26
41.27
126
168
210
2
10.60
13.84
16.25
1a
1e
700
600
28
27
26
4
25
T
24 23
5
22
20
1d
31
29 30
500
400
300
200
100
21
0
100
6
7
10
18
11
140
120
100
80
60
40
40
35
30
25
20
100
20
0
100
150
200
Electric power output (MWe)
Predictions
Operating data
6
0.288
0.356
0.431
150
200
Electric power output (MWe)
150
200
Electric power output (MWe)
Predictions
Operating data
(4)
1100
1000
1000
900
900
Journal of Thermodynamics
800
700
600
500
400
300
200
800
700
600
500
400
300
200
100
100
0
0
2
3
4
Number of boiler feed pump
0
0
Operating
Revenue
Coal
Maintenance
Insurance and general
1
2
3
4
Number of condensate extraction pump
Operating
Revenue
Coal
Maintenance
Insurance and general
1250
1050
1200
950
1100
850
1000
750
650
1150
550
450
350
250
150
900
800
700
600
500
400
2
3
4
Number of boiler feed pump
300
200
Fixed cost
Net present value
100
0
Figure 10: Cost (Crore INR) versus number of boiler feed pump.
1
2
3
4
Number of condensate extraction pump
Fixed cost
Net present value
Mass balance:
2
=1
=1
=1
Figure 12: Cost (Crore INR) versus number of condensate extraction pump.
1 = + + + 1 ,
(5a)
1 = 1 + 1 .
(5b)
(6)
10 = 10 + ,
(8a)
= 1 + 2 + 3 .
11 = 10 + 11 .
(8b)
(7)
=1
Journal of Thermodynamics
xi , hs(i)
xi , hs(i)
3
1, hf(i)
1, hf(i+1)
xi1, hc(i1)
xi + xi1, hc(i)
xi1 , hf(i1)
Figure 13: Mass and energy balance for high pressure feedwater
heater (HP-2).
xi + xi1 , hc(i)
Figure 16: Mass and energy balance for low pressure feedwater
heater (LP-2).
xi , hs(i)
xi , hs(i)
3
(1 + xz1 ) xk
k=1
1 + xz1 , hf(i)
k=1
xk , hc(i1)
k=4
xk , hc(i)
k=4
k=1
xk , hc(i1)
k=4
xi , hc(i)
Figure 15: Mass and energy balance for low pressure feedwater
heater (LP-1).
xk , hc(i)
k=4
Figure 18: Mass and energy balance for drain cooler (DC).
uw (1 (1 31 ) + 1 (1 1 ))
.
(boiler CVcoal )
(8c)
plant = 1000
MWe
.
(coal CVcoal )
(9)
4. Economic Analysis
The economic analysis of the plant has been carried out on
the basis of initial capital investment, operating costs, and
annual revenue. The equipment cost include boiler, steam
turbine, condenser, generator, and auxiliary equipment such
Journal of Thermodynamics
xi = xC , hs(i)
k=1
xi = xC , hs(i)
k=1
k=1
138300
633000
9000
1340000
35000
398000
Equipments
Generator
Steam turbine
Condensate extraction pumps
Steam boiler
Boiler feed pumps
Condenser
0.6107
0.398
0.4425
0.694
0.6107
0.333
xC , hc(i)
k=1
Table 3: Operating data for calculating average salary of plant personnel in a typical 210 MWe plant unit.
Figure 19: Mass and energy balance for gland steam condenser
(GSC).
6025000
25858.36
xi = xZ , hs(i)
k=1
k=1
xi = xZ , hc(i)
k=1
(12)
NPV =
as condensate extraction pump, feed water pump, and so
forth. Thus, fixed (equipment) cost, , can be written in
terms of redundancies of respective components (if any) as
= (boiler + turbine + condenser + ce (condpump )
(10a)
represents fixed cost. The coal storage, ash handling,
electrical works, civil works, and fumes treatment costs are
neglected in the present work. The initial cost for each equipment/component has been obtained from [11] empirically
in following form
(10b)
(1 + )
(13)
+ fb (boilerfeedpump ) + generator ) .
= (MWe) ,
=1
(an OP )
(11)
Journal of Thermodynamics
Table 4: Input data collected from literature and plant records.
Parameter
Value
233
Lab
25858.36 (INR)
coal
2696.81 (INR/Tone)
CVcoal
17656 (kJ/kg)
1.87
pl
20 (year)
hrs/yr
4555
= ((1 + 1 )
(() (+1) )
((1 + 2 )
((1) (+1) )
(() (+1) )
(B.1)
)
(B.2)
+ 1 (
(() () )
).
(A.1)
(C.1)
(C.2)
(C.3a)
() = () ETD Cpw.
(C.3b)
(() () )
+ (1
(() () )
9%
B. Deaerator (DR)
Appendix
Mwe
0.9
6. Conclusions
(() (+1) )
ep
4000 (Rs/MW-hr)
(() (1) )
(() () )
)
(D.1)
),
(D.2)
(D.3a)
() = () ETD Cpw.
(D.3b)
Empirical relations:
= (
= 0.077 MWe + 0.83,
(A.2)
() = () TTD Cpw,
(A.3)
(A.4)
+ (
=4
(() (1) )
(() () )
)
(E.1)
),
(E.2)
Journal of Thermodynamics
:
() = () TTD Cpw,
(E.3a)
() = () ETD Cpw.
(E.3b)
Conflict of Interests
((1) () )
() = (
((1 + 1 ) 3=1 )
=4
) + (+1) .
(F.1)
References
G. Gland Steam Condenser (GSC)
Energy balance, for = 8:
6
(() () )
=1
((1 + 1 ) 3=1 )
() = (
) + (+1) . (G.1)
H. Ejector (EJE)
Energy balance, for = 9:
2
(() () )
=1
((1 + 1 ) 3=1 )
() = (
) + (+1) . (H.1)
Nomenclature
coal :
:
CVcoal :
:
:
10
[14] J. Davison, Performance and costs of power plants with capture
and storage of CO2 , Energy, vol. 32, no. 7, pp. 11631176, 2007.
[15] J. Manninen and X. X. Zhu, Thermodynamic analysis and
mathematical optimisation of power plants, Computers and
Chemical Engineering, vol. 22, supplement 1, no. 1, pp. S537
S544, 1998.
[16] M. Peters, K. Timmerhaus, and R. West, Plant Design and Economics for Chemical Engineers, McGraw-Hill, New York, NY,
USA, 1991.
[17] Thermal Power Plant Efficiency and Performance Monitoring,
National Power Training Institute (NPTI), Faridabad, India,
2000.
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