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Steam Rate
SR = 3600/Wnet
SR = 3600/(Wt Wp)
SR = 3600/(889.62)
SR = 4.05 kg/kWh
Heat Rate
HR = 3600/
HR = 3600/0.3452
HR = 10428.74 KJ/kWhr
Rated Capacity
Typical Large Generators Efficiency Ranges form 75 85%
Use 85% efficiency:
Steam Flow, ms
Assumptions: (Typical Efficiencies of Equipments)
t = 80%
g = 85%
m = 95%
Note: Turbine Rated Capacity = T.R.C
T.R.C = Total Capacity / *t x g x m]
T.R.C = 175 / [0.8 x 0.85 x 0.95]
T.R.C = 270.90 MW
T.R.C = Wt x ms
ms = T.R.C / Wt
Boiler Capacity
BC = ms (h1-h18) = 304.51 kg/s (3381 1070)KJ/kg
BC = 703722.61 KJ/s
Volatile
Fixed
Matter
Carbon
33.62
41.34
13.31
Sulfur
Hydrogen
Carbon
Nitrogen
Oxygen
11.73
3.75
5.19
59.07
0.95
19.31
ma = mf (A/F)
ma = (32.26 kgfuel/s)( 7. 927 kg air/kg fuel)
ma = 255.73 kg/s
Factor of Evaporation
FE = (hs hf)/2257 = (3381 1070) / 2257
FE = 1.02
Equivalent Evaporation
EE = ms x FE = 304.51 (1.02)
EE = 310.60 kg/s
ECONOMIZER CALCULATION
Values from CATT3
At 18MPa
Vf = 0.00184 m3/kg
Hf = 1732kj/kg
Tsat = 357.1 C
At 3.53 MPa
V1 = 0.001236m3/kg
H1 = 1052 kj/kg
T1 = 243.1 C
S1 = 2.73 kJ/kg-K
Note: For Flue gas and water heat exchanging, U ranges from 30 to 100 W/m2C
Therefore, Use Average U = 65 W/m2C.
Thickness of Tubes
Material: Titanium
Tensile Strength = 63000 psi
Pressure = 18 MPa = 2611.40 psi
ID = R = 45mm/2 = 22.5mm = 0.8858 in
E = 1.0 (weld joints efficiency)
Outside Diameter
OD = ID + 2t
OD = 45 mm + 2(1 mm)
OD = 47 mm
Number of Tubes
REF: Power Plant Engineering by Nag,
Velocity of water, vw, must not exceed 1.2 m/s.
Therefore,
Use vw = 1 m/s
ms = n ID2/4 (vf/vw)
304.51 = n (0.045)2/[4(0.00184/1)]
n = 352.29 tubes
Use 353 tubes
Length of Tubes
A = n OD L = 7580.57 m2
6781.65 m2 = 353 (0.047m)L
L = 130.11 m
Number of Turns
Assumption:
W=5m
Clearance = 20 mm
nt = L / (W-2C)
nt = 130.11 m / (5 m 2 (0.02))
nt = 26.23
use 27 turns
Height of Economizer
Use 60 mm pitch.
H = nt x Pitch
H = 27 x 0.06 m
H = 1.62 m
Length of Economizer
L = n x Pitch
L = 353 x 0.06 m
L = 21.18 m
Header Dimensions
Inlet Header
Length of header is the same as length of economizer
L = 21.18 m
Note: Since water flows to the header constantly, it can be assumed that the mass of water inside the
header is equal to the Steam flow rate.
ms = 304.51 kg
at 7.97 MPa, 294.8 oC
v = 0.001383 m3/kg
V = v (mass)
V = 0.001383 m3/kg (304.51 kg)
V = 0.421 m3 = (D2/4) (21.18 m)
D = 0.159 m = 159 mm
Outlet Header
At 18 MPa, Saturated Liquid
vf = 0.00184 m3/kg
V = 0.00184 m3/kg (304.51 kg)
V = 0.56 m3 = (D2/4) (21.18 m)
D = 0.183 m = 183 mm
SUPERHEATER CALCULATIONS
Tg1= 932.10 oC (temperature inlet of economizer)
T3 = 357.1 oC
T4 = 538 oC
H1 = 3381 kJ/kg
Hb = 2509 kJ/kg
v at 538 oC = 0.01824 m3/kg
Note:
For Flue gas and water heat exchanging, U ranges from 30 to 100 W/m2 C
Therefore,
Use Average U = 65 W/m2C.
A = Q / (LMTD x U)
A = 265532.72 kJ/s / (698.32 oC x 65 W / m2- oC)(1/1000)
A = 5849.91 m2
t = PR / (SE 0.6P)
A = nODL
5849.91 m2 = 126(0.079m)L
L = 187.07 m
OD = 79 mm
Use 60 mm pitch.
L = nt x Pitch
L = 38 x 0.06 m
L = 2.28 m
W = n x Pitch
W = 126 x 0.06 m
W = 7.56 m
Note: Since water flows to the header constantly, it can be assumed that the mass of water inside the
header is equal to the steam flow rate.
ms = 304.51 kg
at 18 MPa, saturated gas
v = 0.00749 m3/kg
V = v x mass
V = 0.00749 m3/kg (304.51 kg)
V = 2.28 m3 = D2/4 (2.28 m)
D = 1.128 m
D = 1128 mm
L = 2.28 m
Mass = 304.51 kg
At 18 MPa, 538 oC
v = 0.01824m3/kg
V = 0.01824 m3/kg (304.51 kg)
V = 5.55 m3 = D2/4 (2.28 m)
D = 1.761 m
D = 1761 mm
Therefore,
Use Average U = 45 W/m2C.
A = nODL
5108.36 m2 = n(0.05 m)(15 m)
n = 2168.05
n = 2169 tubes
Fan Capacity
ma = 255.73 kg/s
f = 0.005 (air against steel)
air duct diameter = 2.5 m
Length = 40 m (length from fan to furnace)
Elevation = 10 m
v = 12 m/s
H2 = 10 m
H3 = v2/2g = (12 m/s)2/2(9.81 m/s2)
H3 = 7.34 m
HT = H1 + H2 + H3
HT = 0.587 m + 10 m + 7.34 m
HT = 17.93 m
Note:
At 28 oC, Specific weight () of air is 11.502 N/m3.
P = VHT
P = 218.03 m3/s(11.502 N/m3)(17.93 m)
P = 44964.22 W
P = 44.96 kW
CONDENSER CALCULATIONS
Condenser Capacity
Qc = (h10 h11)(1-m1-m2-m3-m4-m5-m6)(ms)
Qc = (2431 359.8)(0.5222)(304.51)
Qc = 329352.12 KW
Assumption:
Outlet Temperature of cooling water = 55 oC
Solving for LMTD:
Tmax = 85.94 oC 27 oC = 58.94 oC
Tmin = 85.94 oC 55 oC = 30.94 oC
Qc = 329352.12 kJ/s
A = Qc / (LMTD x U)
A = 329352.12 kJ/s / (43.45 oC x 17.44 kW / m2-K)
A = 434.67 m2
Water Velocity
mcw = Q / CpT
mcw = 329352.12 kJ/s / (4.1868 kJ/kg-K) (55-27) K
mcw = 2809.44 kg/s
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Assumptions:
Friction Head = 15 m
Static Head = 7.5 m
Length of Pipe = 250 m approx.
P = Vf x x H
P = 2.84 m3/s x 9.71 kN/m3 x 22.5 m
P = 620.65 kJ/s
P = 621 KW
PUMPS
Pump 1
Qp1 = ms (1-m1-m2-m3-m4-m5-m6)(v11)(P12-P11)
Qp1 = 304.51(1.033)(0.52)(3.53 - 0.06)
Qp1 = 567.59 kJ/s
Assumption:
TDH = 10 m
Note: Specific Weight = 9.81 kN/m3
V = 567.59 (kN-m)/s / (9.81 kN/m3 * 10 m)
V = 5.79 m3/s
V = 20829.99 m3/hr = 91710
Pump 2:
Qp2 = ms (1 - m6)(v17)(P18 - P17)
Qp2 = 304.51(0.66)(1.236)(18 - 3.53)
Qp2 = 3594.45 kJ/s
Assumption:
TDH = 15m
Note: Specific Weight = 9.81 kN/m3
V = 3594.45 (kN-m)/s / (9.81 kN/m3 * 15m)
V = 24.43 m3/s
V = 87937.62 m3/hr = 387200
COAL STORAGE
mf = 51.26 kgfuel/s(3600s/hr) =
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Bunker/Silo Capacity
Storage silos are typically 10 to 90 ft (4 to 30 m) in diameter and 30 to 275 ft (10 to 84 m) in height
Bunker/Silo Capacity for 1 Day Operation
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BACK-UP FUEL
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)
(
)
of coal that will be used for back up
STACK SPECIFICATION
from Sual power plant
H= 226 m
Dry average Flue gas temperature of 300 C at the Stack and 32 C outside air temperature
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Density Of Air,
(
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Draft Head, hw
(
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)
)
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1.28
Volatile
Fixed
Matter
Carbon
12.84
73.69
Ash
Sulfur
Hydrogen Carbon
Nitrogen Oxygen
12.21
2.01
3.74
1.37
77.29
3.36
Since the Ultimate Analysis of coal is not available, an approximate formula to obtain the theoretical airfuel ratio where the heating value of the fuel is known:
( )
From Power Plant Theory and Design by Philip Potter page 191.
The amount of excess air that is required by a boiler depends on many factors, including the type of
burner, fuel, and combustion chamber. Well-designed pulverized coal boilers may operate with
complete combustion as slightly less than 15% excess air; i.e., 15% more than the theoretical air
calculated from the chemical equations. Other boilers may require 50% or even 100% excess air.
Use 50% excess air for safety purposes.
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(
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ASH
Ash To Be Collected Per Day
Ash content of 18% for the fuel to be used.
(
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FLYASH
Fly Ash To Be Collected Located Under The Precipitator
From Power Plant Engineering by Frederick Morse page 341.
For pulverized coal there is entrainment of 60-70% of the ash as Fly ash
Since the height of a single bottom ash silo is too high. It is recommended to use 3 silos to be collected
twice a day.
BOTTOM ASH
Bottom Ash To Be Collected Located Under The Boiler
Since 70% of the ash is the fly ash therefore the other 30% that will complete the total number of ash is
the bottom ash.
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CONVEYOR
Conveyor Capacity = (
Length of Conveyor:
L1 = L2 = 40 m
Where
S = speed of Conveyor, m/min
b = width of belt, cm
Conveyor Capacity = capacity of conveyor, ton/hr
b = 46.82 cm
Where:
K = horsepower constant
T = capacity of conveyor, ton/hr
S = speed of conveyor
From PPE by Morse, Table 12-3:
K = 31.3
P = [{(40 + 45.72)/9000} {0.06(31.3)(150) + 132.87}]
P = 3.95 hp
b= 46.82 cm
THP = 1.03+0.0045T
THP = 1.03+0.0045(132.87)
THP = 1.63 hp
Note: No. of plies provided by the table are for 4, 6 and 8 plies. Therefore interpolate the value of
Minimum Pulley diameter for a 5 ply belt.
PUMP CALCULATION
Assumption
TDH1 = 10 m
TDH2 = 20 m
Note: Specific Weight = 9.81 kN/m3
V1= 783.29 (kN-m)/s / (9.81 kN/m3 * 10m)
V1= 7.98 m3/s
V1=28744.98 m3/hr
V2 = 6805.30 (kN-m)/s / (9.81 kN/m3 * 20m)
V2 = 34.69 m3/s
V2 = 124867.89 m3/hr