St.

Peter’s College

College of Engineering

Department of Mechanical Engineering

32 MW Coal Fired Power Plant Design

Power Plant Engineering

In Partial fulfilment of the requirements for

ME 28.1

Submitted by:
Kit Bryan C. Barrato

Submitted to:
Prof. Bernabe Sanchez PhD.
Province Selection

The peak demand for the central part of Negros Occidental is about 38 MW.
Fitting this peak load onto the given load curve, a base load of 15MW is selected to be
powered by power plant having a maximum capacity of 32 MW. For the load curve,

Each box represents 10MW x 1hr = 10MWh

PEAK DEMAND = 38 MW

DESIGN = 32 MW
Base Load Selection Argument

The peak demand for the province of Lanao del Norte which is Iligan City is
about 38 MW. Fitting this peak load onto the given load curve, a base load of 15 MW is
selected to be powered by power plant having a maximum capacity of 32 MW for the
load curve.

Where:

A. Diesel Engine
B. Condesing Steam Turbine
C. Francis Type Hydraulic Turbine
 Based Load
Operating Range = x 100
Designed Load

15
Operating Range = x 100
32

Operating Range = 46.88%

32 MW
Thermal Effieciency =
2

1
Operating Range = 16 MW or
2

1
Then base load 15 MW, below
2
See Figure 2.9 = 23%

Loss Operating Range = 15 box x 10 = 150

Using Figure 2.9. For a condensing steam turbine at 46.88% operating range,
the thermal efficiency is 23% or at 15 MW. Assuming a coal value of 18
MJ/kg. The needed amount of coal to maintain 1 MWH is:

360 MS = 869.57 kg of coal

1 MWH =
(18 MS/kg) (0.23)
For a 24 hrs operation at 15 MW,

(15 MW) (24 hrs) (869.57 kg/mwh) = 313,045.2 kg of coal

The area above the load curve and below the base load line

(A = 16 box units) represents a loss for the operating range.

Loss = 15 box units x 10 MWH = 150 MWH

Thus,

(150 MWH) (869.57 kg of coal per MWH) = 130,435.5 kg of coal is considered

as waste. Assuming price of electricity 10,000 Php/MWH and coal price of 6
Php/kg. This means that the profit energy is:

Value of total coal burned = (313,045.2 kg of coal) (6 Php/kg)

= 1,878,271.2 Php

And hence, a profit of:

Profit case 1 = (24) (10 MWh) (10,000 php/MWh) – 1,878,271.2

= 521,728.8 php
VARIOUS BASE LOAD PLANT

Each box represents 5 mw x 2hr = 10mwh

Average Load Computation:

15,000 + 16,000
A1 = (2hrs) = 31,000 kwh
2

16,000 + 18,000
A2 = (2hrs) = 34,000 kwh
2

18,000 + 21,500
A3 = (2hrs) = 39,500 kwh
2

21,500 + 22,000
A4 = (2hrs) = 43,500 kwh
2

22,000 + 27,000
A5 = (2hrs) = 49,000 kwh
2

27,000 + 28,000
A6 = (2hrs) = 55,000 kwh
2

28,000 + 32,500
A7 = (2hrs) = 60,500 kwh
2

32,500 + 38,000
A8 = (2hrs) = 70,500 kwh
2

38,000 + 37,500
A9 = (2hrs) = 75,500 kwh
2

37,500 + 30,000
A10 = (2hrs) = 67,500 kwh
2

30,000 + 26,000
A11 = (2hrs) = 56,000 kwh
2

26,000 + 27,500
A12 = (2hrs) = 53,500 kwh
2

635,500
ATotal = kwh
 635,500 kwh
Average Load = = 26,479 KW
24 hrs
= 26.479 MW

Average Load 26,479 mw

Load Factor = =
Peak Load 38 mw
= 0.70

Since the base load plant has reserves above peak load and is continuous
use, its use and capacity factors are:

Annual Megawatt hours

Average Load = produced
Capacity hours of operation

(635,500) (365 days)

Average Load =
(24 hrs) (32) (365)

= 827.43 MW/hr

Actual Energy Produced Annually

Capacity Factor = Max Energy Produced for the same
period

(26.479) (365)
Average Load =
(32) (365)

= 0.83
DESIGN OF BASE LOAD POWER PLANT

The maximum output of the base plant is 38,000 KW. For this type of
capacity, Table 11.3 at Power Plant Engineering Book Moise, is consulted
regarding the preferred of condensing steam turbine was suggested.

Number of Extractions = 5
Throttle Pressure = 8.5 MPa
Throttle Temperature = 535 °C
Exhaust Pressure = 10 kPa
Given:

Coal Fired Power Plant

Rated Power = 40 MW

Regenerative Rangine Cycle

5 Heaters  4 Close, 1 Open

 Throttle Condition : 8.5 MPa; 535 °C
Back Pressure : 10 kpa
Powered Required : 32 mw

GENERAL EFFICIENCY
Assumption: Full-load

0.98 - 0.055 Rating

[ Equation. 8-10, Morse, PPE ]
%Gen = 3 𝑅𝑎𝑡𝑖𝑛𝑔 x
√
1000 Load

0.98 - 0.055
Gen = 332,000 = 97.03%
√
1000

5
Normal [ Equation 8-8, Morse, PPE ]
Friction Loss = 𝑅𝑎𝑡𝑖𝑛𝑔 %
√ Rating
1000

Friction Lo ss = (0.7905%) (32,000) = 282.88 kw

TURBINE EFFICIENCY

%T = 0.94 x Rate Eff – 2% to 5% rotation and leakage allowance

[Equation 11-13, Morse, PPE]

Assumption:Reaction Turbine Blading with Velocity Ratio; R=0.75, then

Blade Efficiency = 95 % with 35% allowance

[Figure 11-19, Morse, PPE]

 nt = 0.94 x 0.95 – 0.035 = 85.8%

32,000
Wt = + 282.88 = 33,262.37 kW
0.9703

PRESSURE EXTRACTION

Pb = Pressure at Boiler = 8.5 mpa

PL = Condenser Pressure = 10 kpa

Tsat Pb – Tsat PL
= Topt.
n+1

Tsat Pb = 299.27 °C @ 8.5 mpa

Tsat PL = 45.81 °C @ 10 kpa

n = [number of healers] = 5

299.27 – 45.81
= 42.24 °C (Temp. Difference)
5+1

Extraction Boiler:

Tsat = 299.27 ° c  8.5 mpa [From Steam Table]

Extraction E:

TsatE = TsatPB - TD = 299.27 – 42.24

= 257.03 oC

PE = Pressure at TsatE on Steam Table

= 4.469 MPa
Extraction D:

TsatD = TsatE – TD = 257.03 – 42.24

= 214.79 oC

PD = Pressure at TsatD on Steam Table

= 2.096 MPa

Extraction C:

TsatC = TsatD – TD = 214.79 – 42.24

= 172.55 oC

PC = Pressure at TsatC on Steam Table

= 842.07 KPa

Extraction B:

TsatB = TsatC – TD = 172.55 oC

= 130.31 oC

PB = Pressure at TsatB on Steam Table

= 272.77 kPa

Extraction A:

TsatA = TsatB – TD = 130.31 – 42.24

= 88.07 oC

PA = Pressure at TsatA on Steam Table

= 65.1 oC
 Extraction Condenser:

TsatCon = TsatA – TD = 88.07 – 42.24

= 45.81 oC

PCon = Pressure at TsatCon

= 10 kPa

STATE 1: Boiler

P1 = 8.5 MPa

T1 = 535 °C

S1 = @ T1 & P1 (Steam Table)

= 6.8022 kj/kg. ° K

H1 = @ T1 & P1 (Steam Table)

= 3480.09 kj/kg

STATE E

s1 = sE’ = 6.8022 kj/kg.°K @ 4.469 MPa (PE) [Steam Table]

TE’ = s1 = sE’ = 6.8022 kj/kg.°K & PE @ Steam Table

TE’ = 426.33 oC

hE' = sE’ & PE

= 3,298.88 kJ/kg

n = assuming pump eff. 85.8%

ℎ1−ℎ𝐸 3,480.09 −ℎ𝐸

n = 0.858 = =
ℎ1−ℎ𝐸′ 3,480.09 − 3,268.89

hE’ = 3,298.88 kJ/kg

Therefore, Actual State E:

TE = 439.07 oC (@ hE & PE using Steam Table)

PE = 4.469 MPa

hE = 3,298.88 kJ/kg

sE = @ hE & PE

= 6.8447 kJ/kgoK

STATE D:

S1 = SD’ = 6.8022 kJ/kg @ 2.069 MPa (PD)

TD’ = @ sD’ & PD (Steam Table)

= 314.77 oC

hD' = @ sD’ & PD (Steam Table)

= 3,055.74 kJ/kg

n = assuming pump eff. 85.8%

ℎ1−ℎ𝐷 3,480.09 −ℎ𝐷

n = 0.858 = =
ℎ1−ℎ𝐷′ 3,480.09 − 3,055.74

hD = 3116 kJ/kg

Therefore, Actual State D:

TD = 341.27 oC (@ hD & PD using Steam Table)

PD = 2.096 MPa

hD = 3116 kJ/kg

sD = @ hE & PD (Steam Table)

= 6.9025 kJ/kg
STATE C:

s1 = sC’ = 6.8022 kJ/kgoK @ 842.07 kPa (PC)

TC’ = @ sC’ & PC (Steam Table)

= 172.56 oC

hc’ = @ sC’ & PC (Steam Table)

= 2,771.2 kJ/kg

n = assuming pump eff. 85.8%

ℎ1−ℎ𝐶 3,480.09 −ℎ𝐶

n = 0.858 = =
ℎ1−ℎ𝐶′ 3,480.09 − 2,771.2

hC = 2,871.86 kJ/kg

Therefore, Actual State C:

TC = @ hC & PC (Steam Table)

= 215.04 oC

PC = 842.07 kPa

hC = 2,871.86 kJ/kg

sC = @ hC & PC (Steam Table)

= 6.8617 kJ/kg

STATE B:

s1 = sB’ = 6.8022 kJ/kgoK @ 272.77 kPa (PB)

TB’ = @ sB & PB (Steam Table)

= 130.31 oC
 hB' = @ sB & PB (Steam Table)

= 2,631.3 kJ/kg

n = assuming pump eff. 85.8%

ℎ1−ℎ𝐵 3,480.09 −ℎ𝐵

n = 0.858 = =
ℎ1−ℎ𝐵′ 3,480.09 − 2,631.3

hB = 2,751.83 kJ/kg

Therefore, Actual State B:

TB = @ hB & PB (Steam Table)

= 144.61 oC

PB = 272.77 kPa

hB = 2,751.83 kJ/kg

sB = @ hB & PB (Steam Table)

= 7.0996 kJ/kgoK

STATE A:

s1 = sA’ = 6.8002 @ 65.1 kPa (PA)

TA’ = @ sA & PA (Steam Table)

= 88.03 oC

hA’ = @ sA & PA (Steam Table)

= 2,403.02 kJ/kg
 n = assuming pump eff. 85.8%

ℎ1−ℎ𝐴 3,480.09 −ℎ𝐴

n = 0.858 = =
ℎ1−ℎ𝐴′ 3,480.09 − 2,403.02

hA = 2,342.61 kJ/kg

Therefore, Actual State A:

TA = @ hA & PA (Steam Table)

= 88.03 oC

PA = 65.1 kPa

hA = 2,555.96 kJ/kg

sA = @ hA & PA (Steam Table)

= 7.2256 kJ/kgoK

STATE 2:

s1 = s2’ = 6.8022 kJ/kgoK @ 10kPa (PCon)

T2’ = @ s2’ & PCon (Steam Table)

= 45.8075 oC

h2’ = @ s2’ & PCon (Steam Table)

= 2,154.35 kJ/kg

n = assuming pump eff. 85.8%

ℎ1−ℎ2 3,480.09 −ℎ2

n = 0.858 = =
ℎ1−ℎ2′ 3,480.09 − 2,154.35

h2 = 2,342.61 kJ/kg
Therefore, Actual State 2:

T2 = @ h2 & PCon (Steam Table)

= 45.8075 oC

P2 = 10 kPa

h2 = 2,342.61 kPa

s2 = @ h2 & P2

= 7.3924 kJ/kgoK

STATE 3:

T3 = 45.81 oK

h3 = 191.81 kJ/kg (@ T3 using Steam Table)

v3 = 0.001010 m3/kg (@ T3 using Steam Table)

s3 = 6.4925 x 10-1 kJ/kgoK (T3 using Steam Table)

STATE 4:

4 3
3

Wp1

Assume pump eff. = 85%

 Energy Balance

𝑤𝑏
= h4’ – h3 = v3 (PC – P3)
𝑚6

h4’ = (0.001010) (842.07 – 10) + 191.81

h4’ = 192.65 kJ/kg

ℎ4′ − ℎ3 192.65−191.81
np1 = = 0.85 =
ℎ4−ℎ3 ℎ4−191.81

h4 = 192.8 kJ/kg

Therefore, Actual State 4:

T4 = 45.87 oC (@ h4 & PC using Steam Table)

P4 = 842.07 kPa

h4 = 192.8 kJ/kg

s4 = 6.4968 x 10-1 kJ/kgoK

STATE 5:

Closed Feed Water Heater 1

5 4

A’
 TTD = 2.25 oC (Assumed)

h5 = P4 & (TsatA – TTD)

= 842.07 kPa & (88.03 – 2.25)

= 842.07 kPa & 85.73 oC (Steam Table)

h5 = 359.84 kJ/kg

Thus, Actual State 5:

h5 = 359.84 kJ/kg

P5 = P4 = 842.07 kPa

T5 = TsatA – TTD

= 85.78 oC

s5 = 1.143 kJ/kgoK

STATE 6:

Closed Feed Water Heater 2

6 5

B’
 h6 = P5 & (TsatB – TTD)

= 842.07 kPa & (130.31 oC – 2.25 oC)

= 842.07 kPa & 128.06 oC (Steam Table)

h6 = 538.51 kJ/kg

Thus, Actual State 6:

h6 = 538.51 kJ/kg

P6 = 842.07 kPa

T6 = TsatB – TTD

= 128.06 oC

S6 = 1.6135 kJ/kgoK (@ h6 & P6 using Steam Table)

STATE 7:

Open Feed Water Heater 1

C
7 6

D” B”

h7 = @ PC & TsatC (Steam Table)

= 730.39 kJ/kg

S7 = 2.0670 kJ/kg
STATE 8:

B 7

Wp2

𝑤𝑝2
= h8 – h7 = v7 (P8 – P7)
𝑚𝑒

Where: v7 = vf @ P7 = 842.07 kPa

v7 = 1.1175x10-3 m3/kg

h8’ = v7 (P8 – P7) + h7 = (1.1175x10-3) (8500 – 842.07) + 730.39

h8’ = 738.95 kJ/kg

ℎ8′ − ℎ7 738.95−730.39
np2 = = 0.85 =
ℎ8−ℎ7 ℎ8−730.39

h8 = 740.37 kJ/kg

Thus, Actual State 8:

h8 = 740.37 kJ/kg

P8 = 8500 kPa

T8 = 173.89 oC

s8 = 2.0702 kJ/kgoK
STATE 9:

Closed Feed Water Heater 3

9
B

E’’ D’

h9 = P8 & (TsatD + TTD)

= 8500 kPa & (214.79 + 2.25)

= 8500 kPa & 217.04 oC (Steam Table)

h9 = 931.9303 kJ/kg

Thus, Actual State 9:

h9 = 931.9303 kJ/kg

P9 = 8500 kPa

T9 = 217.04 oC

s9 = 2.4791 kJ/kgoK
STATE 10:

Closed Feed Water Heater 4

10 9

E’

h10 = P9 & (PsatE + TTD)

= 8500 kPa & (257.03 + 2.25)

= 8500 kPa & 259.28 oC

h10 = 1130.74 kJ/kg

Thus, Actual State 10:

h10 = 1130.74 kJ/kg

P10 = 8.5 MPa

T10 = 259.28 oC

s10 = 2.8680 kJ/kgoK

PROPERTIES TABLE

State Temperature Pressure Ethalpy Entropy Quality

oC kPa kJ/kg kJ/kgoK
1 535 8500 3480.09 6.8022 -
E 439.07 4469 3298.88 6.8447 -
D 341.27 2096 3116 6.9025 -
C 215.04 842.07 2871.86 6.8617 -
B 144.61 272.22 2751.83 7.0996 -
A 88.03 65.1 2555.96 7.2256 -
2 45.8075 10 2342.61 7.3624 0.8991
3 45.81 10 191.81 6.4925x10-1 -
4 48.87 842.07 192.8 6.4925x10-1 -
5 85.78 842.07 359.84 1.143 -
A’ 88.03 65.1 368.6951 1.1698 0
A” 45.8075 10 368.6951 1.2038 0.0739
6 128.06 842.07 538.51 1.6135 -
B’ 130.309 272.77 547.709 1.6379 0
B” 130.309 275.041 547.709 1.6379 -
7 172.55 842.07 730.37 2.0670 0
8 173.89 8500 740.37 2.0702 -
D’ 214.7676 2.096 925.5573 2.4816 -
D” 172.55 842.07 925.5573 2.5049 0.0956
9 217.04 8500 931.9303 2.4791 -
10 259.28 8500 1130.74 2.8680 -
E’ 257.01 4469 1120.064 2.8575 0
E” 214.7676 2096 1120.064 2.8802 0.1066
T-s DIAGRAM
The extraction flow per kg throttle flow are designated m A, mB, mC, mD, mE.

Heat balance for the heaters are written. Thus:

Heater E:

mE(3298.88) + (1)(931.93) = mE(1120.06) + (1)(1130.74)

mE(3298.88) + 931.93 = mE (1120.06) + 1130.74

mE(3298.88) – mE(1120.06) = 1130.74 – 931.93

mE(2178.82) = 198.81

mE = 0.091247 kg

Heater D:

mD(3116) + mE(1120.06) + (1)(740.37) = (1)(931.93) + mD(925.56)

mD(3116) – mD (925.56) + (0.091247)(1120.06) = (931.93 – 740.37)

mD = 0.040795

Heater C:

mC(2871.86) + (mD + mE)(925.56) + (1-mE – mD – mC – mB)(538.51

mB(547.71) = (1)(730.39)

mC(2871.86) + (0.040795 + 0.091247)(925.56) + (1 – 0.091247 –

0.040795 – mC – mB)(538.51) + mB (547.71) = 730.39

mC(2333.35) + 589.61 + mB(9.2) = 730.39

140.78−𝑚𝐵 (9.2)
mC = (1)
2333.35
Heater B:

mB(2751.83) + (1 – mE – mD – mC – mB)(359.84)

= (1 – mE – mD – mC – mB)(538.51) + mB(547.71)

mB(2751.83) + (0.867958 – mC – mB)(359.84)

= (0.867958 – mC – mB)(538.51) + mB(547.71)

mB(2382.79) + mC(178.67) = 155.07

155.07−𝑚𝑐(178.67)
mB = (2)
2382.79

Subs. (1) to (2) to get mB:

140.78−𝑚𝐵 (9.2)
155.07−[ ](178.67)
2333.35
mB =
2382.79
mB(2382.79) = 144.51 – mB(0.68985)

mB = 0.06063

Subs. MB to (1) to get mC:

140.78−(0.06063)(9.2)
mC =
2335.35

mC = 0.06009

Heater A:

mA(2555.96) + (1 – mE – mD – mC – mB)(192.8)

= mA(368.695) + (1 – mE – mD – mC – mB)(359.84)

mA(2555.96) + 144.07 = mA(368.695)(268.89)

mA(2187.27) = 124.82

mA = 0.0571
 Next, the mechanical work done per g of steam flow to the throttle is calculated.

W = (1) (3480.09 – 3298.88) + (1 – mE) (3298.88 – 3116)

+ (1 – mE – mD) (3116 – 2871.86)

+ (1 – mE – mD – mC) (2871.86 – 2751.83)

+ (1 – mE – mD – mC – mB) (2751.83 – 2555.96)

+ (1 – mE – mD – mC – mB – mA) (2555.96 – 2342.61)

W = 949.87 J per g throttle flow

5.0%
Friction Loss = x 949.87 = 8.4 J/g
32,000
√
1000

Input to generator per g steam flow at throttle = 949.87 – 8.4 = 941.47 J/g

The expansion line for a 1800-rpm unit, from Figure A-15 the generator eff. Is found to
be 98.2% for an air cooled generator, which type will be assumed here.

Energy in electrical output per g flow =

(32,000 kJ/s) (1000J/1kJ) (3600s/1hr) = 1.152x1011 J per hr

The Full throttle flow is 1.152x1011 J/hr