Final Project Report: Power Plant Design
1.INTRODUCTION
Göynük placed in southwest of Bolu. Local toys, sweat beans, some of wraps are the popular products of Göynük.You can also run across Ottoman culture with todays Turkey culture in there.Farming and stock raising are the most common economical business of the district.Beside of them there is thermal power plant.
Thermal power plants are used for to generate electricity. They are also called as generation station,powerhouse,generating plant. Almost each of them contaions one or more generators and also rotating machines to convert mechanical power into electrical power. They have basic working principle.Power plants consist of alternator which is working with the help of steam.Steam comes from high prsessure boilers. Generally in India, bituminous coal, brown coal and peat are used as fuel of boiler. The bituminous coal is used as boiler fuel has volatile matter from 8 to 33 % and ash content 5 to 16 %. To increase the thermal efficiency, the coal is used in the boiler in powder form.
In coal power plant systems steam comes from boiler again but this time steam generated by the burning of coal.This type of steam also called as ‘Super Heated Steam’.This steam enters the turbine and make the blades turn. After entering in turbine the steam pressure suddenly falls and corresponding volume of the steam increases. After this process steam passes turbine and goes to the condenser. In the condenser the cold water is circulated with the help of pump which condenses the low pressure wet steam. This condensed water is further supplied to low pressure water heater where the low pressure steam increases the temperature of this feed water, it is again heated in high pressure. [8]
Figure 1: Overview of TP
3.Types of Coals
3.1. Lignite
It is geologically younger than the other kinds.It is brown and can be both soft or fibrous.Contains discernible plant material.It has low energy such as 8-10 megajoule per kg. This coal is mined extensively in the Latrobe Valley south east of Melbourne, Australia. As the coal develops it loses its fibrous character and darkens in colour. Ref no:8
Figure 2:Lignite
3.2. Anthracite
It is a hard,black,shinny type of coal.There is no moisture and small amount of volatile inside of it.Because of this there will be no or less smoke while it is burning so thats why it is also called as smokless fuel. In Australia, coals only approach anthracite composition where bituminous coal seams have been compressed further by local crustal movements.It has 32 megajoules of energy per kg. Coal rank has little to do with quality as a coal matures its ash content actually increases as a proportion because of the loss of moisture and volatiles. Lower rank coals may have lower energy contents, but they tend to be more reactive because of their porosity and resultant higher surface area. Ref no :11
Figure 3:Anthracite
3.3.Bituminous Coal
Bituminous coal is an organic sedimentary rock formed by diagenetic and sub metamorphic compression of peat bog material. It has vitrinite, and liptinite inside of it. 60-80% of them is carbon the rest is composed of water, air, hydrogen, and sulphur, which have not been driven off from the macerals. Bank density is approximately 1346 kg/m³. Bulk density typically runs to 833 kg/m³ . The heat content of bituminous coal ranges from 24 to 35 MJ/kg on a moist, mineral-matter-free basis. Ref no 9
Figure 4: Bituminous Coal
3.4. Sub-Bitominous Coal
It is a type of coal whose properties range from those of lignite to those of bituminous coal and are used primarily as fuel for steam-electric power generation.It may be brown to black ,dull ,soft and crumble at lower end of the range.Contains %15-%30 moisture and they are non cocking. The heat content of sub-bituminous coals range from 8300 to 11,500 BTu/lb or 19,306 to 26,749 kJ/kg. A major source of sub-bituminous coal in the United States is the Powder River Basin in Wyoming.In USA typical types of sub-bitominous coal have a sulfur percantage of less than %1.So they are good for power plants to reduce SO2 emission.
Figure 5: Sub-Bitominous Coal
ref no 10
The Bolu Göynük plant was designed with “fluidized bed combustion” technology that is an alternative to thermal plants which work with pulverized coal. Combustion is realized with the solid fuel that consists of coal and limestone on the air cushion formed with the air given under the combustion room due to fluidized bed boiler. This process ensures that coal remains in the boiler combustion room for longer, thereby enabling combustion reaction at lower temperatures. This technology reduces harmful Nitrous Oxide emissions, which are harmful to the environment, to a minimum. Ref no 1-3-4
4.1. Operation Values of Power Plant
In Göynük Power Plant AKSA Company choose turbine from SKODA. They choose thıs tribune because of materials and construction that ensure resilience to water drop erosion at high temperatures, when using moist steam applications at high pressures. Special construction techniques are also applied when moist steam is applied over the entire pressure range during expansion in the turbine. This model of turbines have been developed to handle the enormous steam flow parameters that are generated, which make extraordinary demands on the steam turbine structure. Ref no 6
Figure-6
5.2. HP Bypass Station
For matching of live steam and turbine metal temperatures for a quick start up, bypass stations have been provided, which dump the steam to the condenser through pressure reducing station and de-super heaters, during the period steam parameters at the boiler can be change. These stations, in addition to the quick start of turbine and low noise level, also economize the consumption of water. With the use of turbine by-pass station it is possible to build up the matching steam parameters at the boiler outlet during any regime of starting, independent of the steam flow through turbine. The steam generated by boiler, and not utilized by the turbine during start up or shut down, is conserved within the power cycle and losses of steam into the atmosphere is cut down to the barest minimum. By pass system enables to shorten the start-up time.
Figure-7
5.2. Boiler:
İ
n Göynük they use SES Tlmace-SLOVAKIA (Fluid Bed, Lignite Combusted). [4]
Fluidized beds suspend solid fuels on upward-blowing jets of air during the combustion process. The result is a turbulent mixing of gas and solids. The tumbling action, much like a bubbling fluid, provides more effective chemical reactions and heat transfer. The mixing action of the fluidized bed results brings the flue gases into contact with a sulfur-absorbing chemical, such as limestone or dolomite. More than 95 percent of the sulfur pollutants in coal can be captured inside the boiler by the sorbent. Pressurized fluidized-bed combustion (PFBC) builds on earlier work in atmospheric fluidized-bed combustion technology. Atmospheric fluidized bed combustion is crossing over the commercial threshold, with most boiler manufacturers currently offering fluidized bed boilers as a standard package. This success is largely due to the Clean Coal Technology Program and the Energy Department's Fossil Energy and industry partners R&D.
5.3. Generator
In Göynük power plant AKSA Company preferred to choose Siemens SGen-100a-2p aır cooled generators. It is because outstanding design features of the Siemens air-cooled SGen-100A-2P series generators include:
For each customer project, a customized generator is developed according to the individual technological specifications, output and customer needs. Using a building-block system, the required generator type is designed by choosing from different diameters and by making adjustments to length. This enables us to supply our customers with generators specially tailored to their requirements. Ref no 5
Figure-8
5.4. Cooling System
The main purpose of the hybrid technology (dry) is the plume abatement in cold or humid ambient conditions in proximity of inhabited places, airports etc. The combination of wet and dry systems when required to avoid visible plume has the further advantage of water saving. Spig’s environmentally sound wet/dry technology avoids environmental impact coupling a wet Cooling Tower and a dry section (air-cooled heat exchangers) producing dry and hot air [5].
Figure-9
5.4.1. Flue gas treatment system
The purpose of a flue gas cleaning system is to reduce atmospheric emissions of substances hazardous to the environment and health. This includes e.g. heavy metals, dioxins and substances that cause acidification and eutrophication. Because many of the substances are toxic and carcinogenic, it is important to reduce their emissions. The acidification of forests and lakes has been reduced substantially by removing sulfur dioxide and oxides of nitrogen from flue gas. [9]
Figure-10
5.5. Coal Crusher
The Coalpactor’s popularity is the result of its ability to maintain top size and provide low cost-per-ton crushed while keeping fines at a minimum.
Advantages & Benefits:
5.6 Substation Control Panel
The substation control panel is designed to form automated control systems of the traction substations, using digital protection and programmable logic controllers. Substation control panel includes:
As a result in Göynük thermal power plant Aksa Energy used boiler
Ses-Tlmace- Slovakia (fluid bed, lignite combusted) ,steam turbınes from Skoda - Czech republıc,(mtd-50) generator Siemens - Germany (synchronized air cooled) ,coolıng system spıg-turkey / Italy (wet tower) ,coal thermal value 2450 kcal/kg ± 250 ,coal crusher Pennsylvania crusher-use ,swıtchyard Siemens - turkey ,flue gas treatment system effort machine - Turkey Hamon - Belgium , Hp-by-pass statıon: CCI valve - Austria as a main equipment in Göynük power plant. Power plant's capacity is 135 MW. They use coal in this power plant. Their coal mine is 2km far from their power plant. They use lignite as a coal fuel. Nominal temperature of feed water 240 °C. Nominal steam output: 373 (340.5) t/h from turbine. Pressure of superheated (reheated) steam: 14.9 (2.9.) MPa from boiler. In Göynük they use reheat. Temperature of superheated (reheated) steam: 540 (540) °C.
References:
Göynük placed in southwest of Bolu. Local toys, sweat beans, some of wraps are the popular products of Göynük.You can also run across Ottoman culture with todays Turkey culture in there.Farming and stock raising are the most common economical business of the district.Beside of them there is thermal power plant.
Thermal power plants are used for to generate electricity. They are also called as generation station,powerhouse,generating plant. Almost each of them contaions one or more generators and also rotating machines to convert mechanical power into electrical power. They have basic working principle.Power plants consist of alternator which is working with the help of steam.Steam comes from high prsessure boilers. Generally in India, bituminous coal, brown coal and peat are used as fuel of boiler. The bituminous coal is used as boiler fuel has volatile matter from 8 to 33 % and ash content 5 to 16 %. To increase the thermal efficiency, the coal is used in the boiler in powder form.
In coal power plant systems steam comes from boiler again but this time steam generated by the burning of coal.This type of steam also called as ‘Super Heated Steam’.This steam enters the turbine and make the blades turn. After entering in turbine the steam pressure suddenly falls and corresponding volume of the steam increases. After this process steam passes turbine and goes to the condenser. In the condenser the cold water is circulated with the help of pump which condenses the low pressure wet steam. This condensed water is further supplied to low pressure water heater where the low pressure steam increases the temperature of this feed water, it is again heated in high pressure. [8]
Figure 1: Overview of TP
3.Types of Coals
3.1. Lignite
It is geologically younger than the other kinds.It is brown and can be both soft or fibrous.Contains discernible plant material.It has low energy such as 8-10 megajoule per kg. This coal is mined extensively in the Latrobe Valley south east of Melbourne, Australia. As the coal develops it loses its fibrous character and darkens in colour. Ref no:8
Figure 2:Lignite
3.2. Anthracite
It is a hard,black,shinny type of coal.There is no moisture and small amount of volatile inside of it.Because of this there will be no or less smoke while it is burning so thats why it is also called as smokless fuel. In Australia, coals only approach anthracite composition where bituminous coal seams have been compressed further by local crustal movements.It has 32 megajoules of energy per kg. Coal rank has little to do with quality as a coal matures its ash content actually increases as a proportion because of the loss of moisture and volatiles. Lower rank coals may have lower energy contents, but they tend to be more reactive because of their porosity and resultant higher surface area. Ref no :11
Figure 3:Anthracite
3.3.Bituminous Coal
Bituminous coal is an organic sedimentary rock formed by diagenetic and sub metamorphic compression of peat bog material. It has vitrinite, and liptinite inside of it. 60-80% of them is carbon the rest is composed of water, air, hydrogen, and sulphur, which have not been driven off from the macerals. Bank density is approximately 1346 kg/m³. Bulk density typically runs to 833 kg/m³ . The heat content of bituminous coal ranges from 24 to 35 MJ/kg on a moist, mineral-matter-free basis. Ref no 9
Figure 4: Bituminous Coal
3.4. Sub-Bitominous Coal
It is a type of coal whose properties range from those of lignite to those of bituminous coal and are used primarily as fuel for steam-electric power generation.It may be brown to black ,dull ,soft and crumble at lower end of the range.Contains %15-%30 moisture and they are non cocking. The heat content of sub-bituminous coals range from 8300 to 11,500 BTu/lb or 19,306 to 26,749 kJ/kg. A major source of sub-bituminous coal in the United States is the Powder River Basin in Wyoming.In USA typical types of sub-bitominous coal have a sulfur percantage of less than %1.So they are good for power plants to reduce SO2 emission.
Figure 5: Sub-Bitominous Coal
ref no 10
- Power Plant
The Bolu Göynük plant was designed with “fluidized bed combustion” technology that is an alternative to thermal plants which work with pulverized coal. Combustion is realized with the solid fuel that consists of coal and limestone on the air cushion formed with the air given under the combustion room due to fluidized bed boiler. This process ensures that coal remains in the boiler combustion room for longer, thereby enabling combustion reaction at lower temperatures. This technology reduces harmful Nitrous Oxide emissions, which are harmful to the environment, to a minimum. Ref no 1-3-4
4.1. Operation Values of Power Plant
- Equipment of Power Plant
In Göynük Power Plant AKSA Company choose turbine from SKODA. They choose thıs tribune because of materials and construction that ensure resilience to water drop erosion at high temperatures, when using moist steam applications at high pressures. Special construction techniques are also applied when moist steam is applied over the entire pressure range during expansion in the turbine. This model of turbines have been developed to handle the enormous steam flow parameters that are generated, which make extraordinary demands on the steam turbine structure. Ref no 6
Figure-6
5.2. HP Bypass Station
For matching of live steam and turbine metal temperatures for a quick start up, bypass stations have been provided, which dump the steam to the condenser through pressure reducing station and de-super heaters, during the period steam parameters at the boiler can be change. These stations, in addition to the quick start of turbine and low noise level, also economize the consumption of water. With the use of turbine by-pass station it is possible to build up the matching steam parameters at the boiler outlet during any regime of starting, independent of the steam flow through turbine. The steam generated by boiler, and not utilized by the turbine during start up or shut down, is conserved within the power cycle and losses of steam into the atmosphere is cut down to the barest minimum. By pass system enables to shorten the start-up time.
Figure-7
5.2. Boiler:
İ
n Göynük they use SES Tlmace-SLOVAKIA (Fluid Bed, Lignite Combusted). [4]
| Project Data | |
| Customer: | AKSA Göynük Enerji Üretim A.S. |
| Site: | Bolu Göynük |
| Country: | Turkey |
| Contract: | 06/2009 |
| Performance of the contract: | K1: 05/2012; K2: 07/2012 |
| Handing over: | K1: 02/2016; K2: 05/2016 |
| Technical Parameters | |
| Nominal steam output: | 373 (340.5) t/h |
| Pressure of superheated (reheated) steam: | 14.9 (2.9.) MPa |
| Temperature of superheated (reheated) steam: | 540 (540) °C |
| Nominal temperature of feed water: | 240 °C |
| Fuel: | lignite |
| Design of Boiler: | Three-pass boiler with natural circulation, based on circulating fluidized bed (CFB), single drum, with reheater. |
5.3. Generator
In Göynük power plant AKSA Company preferred to choose Siemens SGen-100a-2p aır cooled generators. It is because outstanding design features of the Siemens air-cooled SGen-100A-2P series generators include:
- High efficiency,
- Low noise emissions,
- Low installation and commissioning costs,
- High serviceability and
- Long service life.
For each customer project, a customized generator is developed according to the individual technological specifications, output and customer needs. Using a building-block system, the required generator type is designed by choosing from different diameters and by making adjustments to length. This enables us to supply our customers with generators specially tailored to their requirements. Ref no 5
Figure-8
5.4. Cooling System
The main purpose of the hybrid technology (dry) is the plume abatement in cold or humid ambient conditions in proximity of inhabited places, airports etc. The combination of wet and dry systems when required to avoid visible plume has the further advantage of water saving. Spig’s environmentally sound wet/dry technology avoids environmental impact coupling a wet Cooling Tower and a dry section (air-cooled heat exchangers) producing dry and hot air [5].
Figure-9
5.4.1. Flue gas treatment system
The purpose of a flue gas cleaning system is to reduce atmospheric emissions of substances hazardous to the environment and health. This includes e.g. heavy metals, dioxins and substances that cause acidification and eutrophication. Because many of the substances are toxic and carcinogenic, it is important to reduce their emissions. The acidification of forests and lakes has been reduced substantially by removing sulfur dioxide and oxides of nitrogen from flue gas. [9]
Figure-10
5.5. Coal Crusher
The Coalpactor’s popularity is the result of its ability to maintain top size and provide low cost-per-ton crushed while keeping fines at a minimum.
Advantages & Benefits:
- Lower cost-per-ton-crushed than comparable crushers.
- Lower horsepower demand than comparable crushers.
- Control over product size, with minimum fines.
- Little or no loss of capacity or crushing efficiency when crushing high moisture content materials.
- Less chance of damage to the crusher from uncrushable.
- Hammers normally last longer than in crushers with grates.
- Doubles the amount of crushing surfaces, going from 8 to 16 surfaces on either side of the rotor.
- The wear plates have been improved with a higher hardness material.
- Decreased depth of grooves between crushing surfaces.
- Less maintenance when changing out plate segments.
- Cast segments are one quarter the length of the cage.
- Plate segments are interchangeable from top to bottom with any area on the cage.
5.6 Substation Control Panel
The substation control panel is designed to form automated control systems of the traction substations, using digital protection and programmable logic controllers. Substation control panel includes:
- An operation station for remote equipment control.
- A controller of the overall substation signaling.
- A controller for information control check network.
- An uninterruptible power system.
- Tele mechanical control of the substation (sending/receiving signals and orders).
- Remote control of the substation (using integrated controls and indicating devices)
- Collection and transmission of the telemetry and diagnosing data with digital channels of the data transmission network.
- With the substation control panel any traction substation may be reconstructed with gradual connection of the new smart controllers and bay terminals, while the unmodified equipment is still controlled with the existing telecommunications panel.
As a result in Göynük thermal power plant Aksa Energy used boiler
Ses-Tlmace- Slovakia (fluid bed, lignite combusted) ,steam turbınes from Skoda - Czech republıc,(mtd-50) generator Siemens - Germany (synchronized air cooled) ,coolıng system spıg-turkey / Italy (wet tower) ,coal thermal value 2450 kcal/kg ± 250 ,coal crusher Pennsylvania crusher-use ,swıtchyard Siemens - turkey ,flue gas treatment system effort machine - Turkey Hamon - Belgium , Hp-by-pass statıon: CCI valve - Austria as a main equipment in Göynük power plant. Power plant's capacity is 135 MW. They use coal in this power plant. Their coal mine is 2km far from their power plant. They use lignite as a coal fuel. Nominal temperature of feed water 240 °C. Nominal steam output: 373 (340.5) t/h from turbine. Pressure of superheated (reheated) steam: 14.9 (2.9.) MPa from boiler. In Göynük they use reheat. Temperature of superheated (reheated) steam: 540 (540) °C.
References:
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