DR. B.C.

ROY ENGINEERING COLLEGE

TECHNICAL REPORT ON

ADVANCEMENT IN THERMAL POWER

PLANT -AN OVERVIEW

SUMITTED TO: DEPARTMENT OF

MECHANICAL ENGINEERING
SUBMITTED BY:
SANTOSH KUMAR 12000716077
SANDIP BAURI 12000716178
SAIF ALI KHAN 12000716079
SACHIN RAKSHIT 12000716080

DATE: - 9TH OCTOBER, 2018

 PREFACE

As a part of mechanical engineering curriculum and in order to gain practical knowledge in the
field of thermal engineering and thermal power plant , a project report on “Advancement in
thermal power plant” is prepared. The basic objective behind doing this project is to get
knowledge about thermal power plants and different type of advancement and their advantages.
In this report various concepts, implications and advantage regarding “Advancement in thermal
power plant” has been implemented.
Doing this project helped a lot to enhance our knowledge about thermal engineering and
different technology advancement in thermal power plant.
Sincere thanks to our mentor and all other for their unforgettable cooperation, advice, support
and help.
 LETTER OF CERTIFICATE

This is to certify that Santosh Kumar (12000716077), Sandip Bauri (12000716078), Saif Ali
Khan (12000716079),Sachin Rakshit (12000716080) belonging to Mechanical Engineering
Department have done this project in partial fulfilment of the requirements of ME 571 . They
have worked sincerely, dedicatedly and enthusiastically under my supervision.
To the best of my knowledge, this is an original and technically accurate work.

Prof. Partha Sarathi Bose

Department of Mechanical Engineering

Prof. Dr. Kanchan Chatterjee

HOD, Mechanical Engineering Department, BCREC
 ACKNOWLEDGEMENT

This project would not have been possible without the kind support and help of many
individuals. We would like to extend our sincere thanks to all of them.
We are highly indebted to Prof. Partha Sarathi Bose for his guidance and constant supervision as
well as for providing necessary information regarding the project and also for his support in
completing the project. Our thanks and appreciations also go to department of Mechanical
Engineering, DR. B.C. Roy Engineering College, Durgapur for their help to develop the project
and people who have willingly helped us out with their abilities.
TABLE OF CONTENTS
S.NO. TOPIC PAGE
NO.
1. INTRODUCTION 1-6
1.1 ABSTRACT 1
1 .2 HISTORY 2
1.3 OBJECTIVE 3-6
2. DISCUSSION 7-13
2.1 SUB-CRITICAL THERMAL POWER PLANT 7
2.2 NEED OF ADVANCEMENT 8-9
2.3 SUPER-CRITICAL POWER PLANT 10
2.4 ULTRA SUPER-CRITICAL POWER PLANT 11-13
2.5 INTEGRATED GASIFICATION COAL
COMBUSTION (IGCC)
3. ANALYSIS 14-19
3.1 PERFORMANCE OF THERMAL POWER PLANT 14-15
UNDER SUPER CRITICAL CONDITIONS
3.2 COMPARISION OF SUPER-CRITICAL UNIT WITH 17
ULTRA SUPER-CRITICAL UNIT
3.2.1 COMPARISION OF ULTRA SUPER-CRITICAL
WITH IGCC
3.3 THERMODYNAMIC ADVANTAGES 18-19
3.4 LIMITATIONS OF ADVANCEMENT 19
4. CONCLUSION 20
5. APPENDIX 21
 LIST OF ILLUSTRATIONS

S.NO. FIGURE FIGURE DISCRIPTION PAGE

NO. NO.
1. Fig: 1 Flow sheet of Sub- Critical Thermal 6
Power Plant

2. Fig: 2 Super-Critical Boiler Power Plant 7

3. Fig: 3 Ultra Super-Critical Boiler Power 9

Plant

4. Fig: 4 Flow Diagram Of Integrated 12

Gasification Coal Combustion Power
Plant

5. Fig: 5 Temperature – Entropy Diagram of 19

Rankine Cycle for Thermal Power
Plant
 METHODOLOGY

Methodology of the project is mainly based on the secondary resources; main reference goes to
various research paper and internet sites, as this is relatively new field of communication. Some
of the information are also gathered from journals. The project is based on thermal power plant .

Books of thermal engineering were referred to for the completion of the project.
 ABSTRACT

Fossil fueled power plants have been supplying electricity for industrial use since the late 1880s.
At first, simple d.c. generators were coupled to coal-fired, reciprocating piston steam engines.
Electricity was delivered over relatively short distances, and was primarily used for district
lighting. The first central generating station was opened by Thomas Edison in September 1882 at
Pearl Street, Lower Manhattan, New York City. Lighting alone, however, could not provide an
economical market for successful commercial generation, so new applications for electricity
needed to be found. The popularity of urban electric tramways, and the adoption of electric
traction on subway systems, coincided with the widespread construction of generating equipment
in the late 1880s and 1890s. Initial power plant boiler designs generated steam in a simple water
tube boiler, from a coal or coal gas supply. They typically operated at 0.9 MPa (8.6 bar) and 150
°C (300 °F), and would have been connected to a 30 kW generator. Since then the topography of
the typical power plant has evolved into a highly complex system. Today, advanced turbine and
boiler designs, utilising new metal alloys, can operate at supercritical conditions of 28.5 MPa
(285 bar) and 600 °C (1112 °F), generating 1300 MW of electricity. In a search for reduced
operating costs, plant design has moved on from generating units based on the Rankine
whtypically achieved thermal efficiencies in the range 30--40 per cent. Now combined cycle gas
turbine (CCGT) units utilis-ing the latest heat recovery steam generator (HRSG) plant can
achieve efficiencies of 50-60 per cent. The removal of European Community restrictions on
burning gas for power generation, coupled with other factors, has resulted in increased
deployment of CCGT units. However different current plant may now appear, the underlying
principles of generation and distribution had been mastered by the end of the nineteenth century.
Since then the evolution of power plant design has been largely incremental, driven mainly by
new technology. The past three decades have witnessed the integration of microprocessor
equipment into every aspect of generation and distribution. The next 20 years should see this
technology develop further, bringing with it pseudo-intelligent applications which truly harness
the rapidly expanding computational power available. New computer-based systems will
increase plant automation, improve unit control and permit more flexible plant operation, while
at the same time maximising unit efficiency and reducing harmful emissions. New developments
in plant design are continually being sought and investigated to improve unit performance.
Currently integrated gasification combined cycle (IGCC) and advanced pressurised fluidised bed
1
combustion (PFBC) are emerging technolo-gies that are showing great potential for yielding high
efficiency and low emissions. The short-to-medium term targets that have been mapped out by
Vision 21 (US Department of Energy) for new plant designs are 60 per cent thermal efficiency
for coal/solid fuels and 75 per cent efficiency for natural gas units, combined with zero or very
low environmental emissions.

HISTORY THERMAL POWER PLANT

Coal power generation’s place in power’s history had already been firmly established. The first
coal-fired steam generators provided low-pressure saturated or slightly superheated steam for
steam engines driving direct current (DC) dynamos. Sir Charles Parsons, who built the first
steam turbine generator (with a thermal efficiency of just 1.6%) in 1884, improved its efficiency
two years later by introducing the first condensing turbine, which drove an AC generator. By the
early 1900s, coal-fired power units featured outputs in the 1 MW to 10 MW range, outfitted with
a steam generator, an economizer, evaporator, and a superheater section. By the 1910s, the coal-
fired power plant cycle was improved even more by the introduction of turbines with steam
extractions for feedwater heating and steam generators equipped with air preheaters—all which
boosted net efficiency to about 15%.

2
 OBJECTIVE

Technological advancement is the need of the hour in every field of industrialization for
improvement in efficiencies their by reduction in operating expenditure, judicious utilization of
natural resources and protection against damage to our natural environment. In present post, we
will discuss about the technological advancement in coal based thermal power plants in
improving efficiencies and reducing emissions of CO, SO, NOX and suspended particulate
matter.

The technological advancements in coal based thermal power plants can be discussed under
following four categories-

Sub-critical power plants,

Super critical power plants,

Ultra super critical power plants and

Integrated gasification combined cycle power plants

First three categories of power plants uses either conventional pulverized coal combustion (PCC)
boilers or fluidized bed combustion (FBC) boilers. Both types of boilers have their own
advantages and disadvantages which we have already discussed in our previous post with
glimpse of sub-critical and super critical thermal power plants. We all know that fluidized bed
combustion system has the flexibility of utilizing even the poor quality of coal which is generally
not possible in pulverized coal combustion system.

The modified PCC systems with super critical and ultra super critical technology are operated at
comparatively higher pressure and temperature which results in improved overall thermal
efficiencies over 50% and substantial reduction in pollutants to atmosphere. Super critical power
plants have been commercially proven technology since last ten twelve years and thus has
become the right choice for new thermal power plants in many countries.

3
The development of ultra super critical power plants is in advanced stage of commercialization
in countries like Japan, Denmark and Germany with focus on development of special alloy steel
for boiler tubes to minimize rate of corrosion.

Integrated gasification combined cycle (IGCC) power plants are another advancement over PCC
and FCB boilers where in coal gasification technology are used. In IGCC power plants, the
sythetic gas (Syngas) is generated by combustion of coal in presence of oxygen and steam. The
syngas is an artificially prepared gas as a mixture of methane and water gas (CH+CO+H). It has
high pressure and calorific value but contains impurities like sulfur and suspended solids. The
cleaned syn gas at high pressure is passed through gas turbines for generation of electrical power.
The waste gas collected at the turbine exhaust is again burnt in gas fired boilers for generating
high pressure steam and thus electrical power in steam turbines. Capex for IGCC based thermal
power plants is much more compared to conventional coal fired power plants. The overall
thermal efficiency of IGCC power plants is in the range of 45% to 50% with improved
environmental control. This technology will bring revolutionary changes on commercialization
thus will be proved to be the right choice for our better tomorrow.

4
THERMAL POWER PLANTS
 SUB-CRITICAL POWER PLANTS

In a subcritical plant, steam pressure is below 3200 pounds per square inch and temperature is
below 1025 degrees Fahrenheit (550 degrees Celsius). Subcritical units have efficiencies of
between 33% and 37%; i.e. between 33% and 37% of the energy in the coal is converted into
electricity. In the late 1960s, supercritical combustion technology was commercialized, after
advances in materials technology made it possible to build boilers that could operate at higher
pressures. In supercritical units, the pressure of the boiler is about 3530 pounds per square inch
and temperatures are 1050 degrees Fahrenheit (565 degrees Celsius). At this higher pressure and
temperature, water can be maintained as a fluid despite being above the atmospheric boiling
plant, allowing greater efficiency. Efficiency ratings for supercritical coal plants range from 37%
to 40%. In ultra-supercritical units, pressures are at 4640 pounds per square inch and
temperatures of 1112-1130 degrees Fahrenheit (600-610 degrees Celsius), and current research
and development is targeting pressures of 5300-5600 pounds per square inch and temperatures of
1290-1330 degrees Fahrenheit (700-720 degrees Celsius), with the possibility of raising
generating efficiency to the 44-46% rangeal.

 FLOWSHEET OF SUB-CRITICAL THERMAL POWER PLANT

5
 Fig : 1
NEED OF ADVANCEMENT IN SUB-CRITICAL POWER PLANTS

Efficiency of sub-critical units in thermal power generating system are not matching with the
expected values as it was thought earlier. Improvement in this efficiency seems to be obtained
from the high capacity and high steam parameters of running units.

6
 TECHNOLOGICAL ADVANCEMENT

 SUPER-CRITICAL BOILER POWER PLANTS

Supercritical units are the standard for future power plants in many countries including China.
Water with pressure and heat first reach saturated temperature, then the steam is wet which
further gets dry and then superheat. With higher pressure latent heat gets lesser and lesser. At
about 225 kg/cm2 pressure latent heat become zero and water transform directly to superheated
steam.
So below this citical pressure it is subcritical and above 225 it is supercritical. Boilers generating
steam above 225 kg are supercritical boilers. Accordingly boilers are designed. Higher the steam
pressure lesser the volume which would save piping, turbine volume thereby saving equipment
weights and costs.
The main advantage and the reason for a higher pressure operation is the increase in the
thermodynamic efficiency of the Rankine cycle. Large subcritical thermal power plants with 170
bar and 540 / 540 ° C (SH / RH) operate at an efficiency of 38 %. Supercritical units operating at
250 bar and 600/615 ° C can have efficiencies in the range of 42 %.

Fig : 2

7
  BENEFITS

Supercritical boilers offer benefits in the three interrelated areas that mean the most to plant
owners and operators today: efficiency, emissions, and cost. While supercritical boilers cost
more than comparably sized subcritical boilers, the larger initial capital investment can be offset
by the lifecycle savings yielded by the technology’s improved efficiency, reduced emissions, and
lower operating costs —all due to its higher steam temperature and pressure parameters.
1. Improved Efficiency
Supercritical and ultra-supercritical boilers’ ability to operate at much higher pressures and
temperatures than subcritical boilers translates into noticeably better efficiency ratings.
Subcritical boilers typically run at 2400 psi/1000°F. By way of contrast, modern supercritical
units can go as high as 3900 psi/1100°F. The even more advance ultra-supercritical units reach
pressures and temperatures as high as 4600 psi/1120°F. Current research goals are set as high as
5300 psi/1300°F and seem to be on the horizon.
So how does all of this play out in terms of efficiency ratings. Well, the reports vary when it
comes to the exact percentages, but here is a chart that summarizes the ranges that are usually
cited. As a benchmark, the rating given by the 2007 MIT "THE FUTURE OF COAL" study is
also included.

2. Reduced Emissions
Improved plant efficiency also translates into reduced emissions, particularly of CO and
mercury, which are difficult to manage otherwise. The general rule of thumb is that each
percentage point of efficiency improvement yields 2–3% less CO.

3. Lower Operating Costs

For all fossil fuel–fired plants, fuel represents the largest operating cost. By reducing the amount
of fuel needed to yield the requisite energy, supercritical plants make a noticeable dent in bottom
lines when compared to subcritical plants.

8
  ULTRA- SUPER CRITICAL BOILER POWER PLANT
An ultra-super critical (USC) operates above super critical pressure and at advanced steam
temperature above 1100 degrees farhenhite (593degrees centigrade).Water with pressure and
heat first reach saturated temperature, then the steam is wet which further gets dry and then
superheat. With higher pressure latent heat gets lesser and lesser. At about 225 kg/cm2 pressure
latent heat become zero and water transform directly to superheated steam.Then it is again
heated above temperature of 593 degrees centigrade to reach to the ultra superheated steam.
So above 225 it is supercritical and above 350 it is ultra supercritical. Boilers generating steam
above 350 kg are ultra supercritical boilers. Accordingly boilers are designed. Higher the steam
pressure lesser the volume which would save piping, turbine volume thereby saving equipment
weights and costs.
Ultra supercritical units at 300 bar and 615 / 630 °C will still increase the efficiency up to 44 %.
Increase in efficiency directly leads to reductions in unit cost of power and CO2 emissions.

Fig : 3

9
 BENEFITS

1. With efficiencies in the 39-40 percent range(approximately 39-40 percent of the thermal
energy in the fuel comes out as electric power) is the most efficient steam cycle.
2. USC Technology requires less fuel than other processes to producethe same amount of
electricity.
3. Reduced emissions of sulphur dioxide (SO2), nitrogen oxide(NOX), mercury(Hg), carbon
dioxide(CO2) and particulate (PM-10).
4. Reduced production of solid waste products such as fly ash.
5. Reduced requirements for commodities used in environment control equipment such as
activated carbon and ammonia.

10
  INTEGRATED GASIFICATION COMBINED CYCLE
(IGCC)POWER PLANTS

In IGCC power plants, the coal is not burnt in a conventional steam power
plant, but is initially dried and supplied to a Gasifier, in which high
temperatures prevail. Here, the dried coal is subjected to pressure and is
converted into combustible or reactive gas using air or pure oxygen.

IGCC uses a coal gasification system to convert coal into a synthesis gas
(syngas) and produce steam. The hot syngas is processed to remove sulfur
compounds, mercury and particulate matter before it is used to fuel
combustion turbine generator, which produces electricity. The heat in the
exhaust gases from the combustion turbine is recovered to generate
additional steam. This steam, along with that from the syngas process, then
drives a steam turbine generator to produce additional electricity.

The plant includes....

• Coal preparation
• Air separation
• Coal gasification
• Ash removal
• Syngas cooling
• Acid gas removal
• Sulphur gas recovery

11
  FLOW DIAGRAM OF IGCC

Fig : 4

BENEFITS

1. High combined cycle power plant efficiencies.

2. Modular IGCC concepts to enable phased construction.
3. Less use of water than conventional coal based power plant.
4. Easy separation of CO2.

12
 ANALYSIS OF TECHNOLOGICAL ADVANCEMENT

1) Turbine inlet temperature

The following conclusions have been drawn from SCRC cycle without reheat, with
single reheat, with double reheat on variation of turbine inlet temperature.
• The energy efficiency of the mentioned supercritical cycles increases with an increase of
steam turbine inlet temperature at a given pressure.
• Maximum energy efficiency occurred at a turbine inlet temperature of 8000C and at a
turbine inlet pressure of 425 bar for all the cycles and at a condenser pressure of 0.05 bar.
The maximum energy efficiency obtained for SCRC with double reheat was 51.52%,
SCRC with single reheat was 50.06%, and SCRC without reheat was 45.66%.
• The energy efficiency of the mentioned supercritical cycles increases with an increase of
steam turbine inlet temperature from 5000C to 8000C at a given pressure.
• Maximum energy efficiency occurred at higher turbine inlet temperature of 8000C and at
higher turbine inlet pressure of 425 bar for all three supercritical cycles. The maximum
energy efficiency obtained for a SCRC with DRH was 70.14%, SCRC with SRH was
68.70%, and SCRC without RH was 65.95%.
• Total energy loss of all the above supercritical cycles decreases with increase of turbine
inlet temperature at a given turbine inlet pressure.
• Minimum total energy loss is occurred at a temperature of 8000C and a at a turbine inlet
pressure of 425 bar. Minimum total energy loss of SCRC with DRH was 307.6276 MW
and SCRC with SRH was 314.2263 MW and SCRC without RH was 341.8306 MW for
the given 1000MW capacity.
• Fractional energy loss of boiler was found to be 59.28% in SCRC with DRH and FEL of
the turbine was found to be 29.57% in SCRC with DRH. FEL of the condenser was 6%
and FEL of the pump is less 1% in SCRC with DRH. FEL of the exhaust was 4.36% in
SCRC with DRH.

2) Turbine inlet pressure

The following conclusions have been drawn from supercritical /ultra supercritical/advanced ultra
supercritical cycles without reheat, with single reheat and with double reheat on variation of
turbine inlet pressure for the given 1000 MW capacity.

13
 • The energy efficiency of the mentioned supercritical cycles increases with an increase of
steam turbine inlet pressure in the range of 170 to 425 bar at a given turbine inlet
temperature.
• Maximum energy efficiency was obtained at higher turbine inlet pressure, 425 bar which
requires from 43.50% to 51.52% for a range of 5000C to 8000C of turbine inlet
temperature of SCRC with DRH.
• The rate of increase in the energy efficiency with turbine inlet pressure was found to be
less than the rate of increase in the energy efficiency with turbine inlet temperature.
• The energy efficiency of the supercritical cycles increases with an increase steam turbine
inlet pressure from 170bar to 425bar at a given pressure.
• Total energy loss of all the above supercritical cycles decreases with increase of turbine
inlet pressure at a given turbine inlet temperature.

3) Reheat pressure ratio

The performance of SCRC with SRH and SCRC with DRH was found to vary with reheat
pressure ratio. In view of this the present investigation carried out thermodynamic analysis of
this cycles in order to find the optimum value of reheat pressure ratio for (i) SCRC with single
RH and (ii) SCRC with second reheat.
• Optimum value of reheat pressure ratio for SCRC with SRH was found to be 0.25.
• Optimum value of second reheat pressure ratio for SCRC with DRH was found to be
0.25.
• The energy efficiency of SCRC with SRH at optimum value of reheat pressure ratio was
found to be 50.06% at maximum turbine inlet temperature of 8000C and maximum
turbine inlet pressure of 425 bar. Further, the maximum variation in the energy efficiency
185 with reheat pressure ratio was found to be 2.54% at maximum turbine inlet
temperature of 8000C and maximum turbine inlet pressure of 425 bar.
• The energy efficiency of SCRC with DRH at optimum value of reheat pressure ratio was
found to be 51.22% at maximum turbine inlet temperature of 8000C and maximum
turbine inlet pressure of 425 bar. Further, the maximum variation in the energy efficiency
with reheat pressure ratio was found to be 2.82% at maximum turbine inlet temperature
of 8000C and maximum turbine inlet pressure of 425 bar.
• The energy efficiency of SCRC with SRH at optimum value of reheat pressure ratio was
found to be 68.7% at maximum turbine inlet temperature of 8000C and maximum turbine
inlet pressure of 425bar. Further, the maximum variation in the energy efficiency with
reheat pressure ratio was found to be 2.31% at maximum turbine inlet temperature of
8000C and maximum turbine inlet pressure of 425 bar.

14
 • The energy efficiency of SCRC with DRH at optimum value of reheat pressure ratio was
found to be 70.14% at maximum turbine inlet temperature of 8000C and maximum
turbine inlet pressure of 425bar. Further, the maximum variation in the energy efficiency
with reheat pressure ratio was found to be 2.89% at maximum turbine inlet temperature
of 8000C and maximum turbine inlet pressure of 425 bar.
• FEL of components of the cycle is not a strong function of reheat pressure ratio.

• FEL of the SCRC with SRH of boiler, turbine, condenser, pump and exhaust are at a
reheat pressure ratio of 0.25 are 61.19%, 28.31%, 6.1% ,0.68% and 3.72% respectively.
• FEL of the SCRC with DRH of boiler, turbine, condenser, pump and exhaust are at a
reheat pressure ratio of 0.25 are 63.03%, 26.89%, 5.6%, 0.59% and 3.89% respectively at
maximum turbine inlet temperature of 8000C and maximum turbine inlet pressure of 425
bar.

4) Condenser pressure
The following conclusions have been drawn from supercritical/ultra supercritical/advanced ultra
supercritical cycle without reheat, with single reheat, with double reheat on the performance of
the cycles with variation of condenser pressure between 0.03 bar to 0.1 bar.
• Energy efficiency decreases with an increase of condenser pressure for all the cycles.
• The energy efficiency of SCRC with DRH was found to be high compared to other
cycles at all the values of condenser pressure. Further, the maximum energy efficiency
was obtained at a condenser pressure of 0.03bar for all the cycles.
• The energy efficiency of SCRC with DRH was found to give maximum efficiency at a
turbine inlet temperature of 8000C and a turbine inlet pressure of 425bar at all values of
condenser pressure.
• It is further inferred that the maximum energy efficiency of the cycle was found to be
52.64% for a turbine inlet temperature of 8000C and a turbine inlet pressure of 425 bar at
a condenser pressure of 0.03 bar for SCRC with DRH.
• Energy efficiency decreases with an increase of condenser pressure for all the cycles.
• The energy efficiency of SCRC with DRH was found to be high compared to other
cycles at all the values of condenser pressure. Further, the maximum energy efficiency
was obtained at a condenser pressure of 0.03bar for all the cycles.
• The energy efficiency of SCRC with DRH was found to give maximum efficiency at a
turbine inlet temperature of 8000C and a turbine inlet pressure of 425 bar at all values of
condenser pressure.

15
 • It is further inferred that the maximum energy efficiency of the cycle was found to be
70.94% for a turbine inlet temperature of 8000C and a turbine inlet pressure of 425bar at
a condenser pressure of 0.03bar for SCRC with DRH.
• Total energy loss increases with increase of condenser pressure for all the cycles.

• 5) Flue gas temperature at boiler entry

The following conclusions have been drawn from supercritical cycle without reheat, with single
reheat and with double reheat by varying the boiler flue gas inlet temperature from 9000C to
14000C and by keeping boiler flue gas outlet temperature as 1000C.
• Energy efficiency of all the cycles was found to be independent of boiler flue gas inlet
temperatures.
• Energy efficiency increases with an increase of boiler flue gas inlet temperature of all
three mentioned supercritical cycles.
• The maximum energy efficiency of all supercritical cycles occurred at a boiler flue gas
inlet temperature of 14000C.
• The maximum energy efficiency of supercritical cycle without reheat was found to be
71.93%, for supercritical cycle with single reheat was 77.67%, and that of supercritical
cycle with double reheat was 79.61%.
• Total energy loss increases with an increase of boiler flue gas inlet temperature from
9000C to 14000C of all the mentioned supercritical cycles for the given capacity.
• Minimum total energy loss is occurred in SCRC with DRH at a boiler flue gas inlet
temperature of 14000C over all cycles. Minimum total energy loss of supercritical cycle
with DRH is 300.4138 MW, SCRC with SRH is 313.7313MW and SCRC without RH is
380.0716 MW for the given capacity.

6) Flue gas temperature at boiler exit temperature

The following conclusions have been drawn from supercritical cycle without reheat, supercritical
cycle with single reheat, supercritical cycle with double reheat on their performance by varying
the boiler flue gas outlet temperature from 800C to 3000C and by keeping boiler flue gas inlet
temperature is 10000C.
• Boiler flue gas outlet temperature does not affect the energy efficiency of any cycle
considered.
• Energy efficiency decreases with an increase of boiler flue gas outlet temperature for all
the cycles considered.
• The maximum energy efficiency of all supercritical cycles occurred at a boiler flue gas
outlet temperature of 800C.

16
 • The maximum energy efficiency of SCRC without DRH was found to be 71.32%, for
SCRC without SRH was 70.44%, and that of SCRC without RH was 64.76% at a boiler
flue gas outlet temperature of 800C.
• Total energy loss increases with an increase of boiler flue gas outlet temperature of
supercritical cycles.

COMPARISON OF SUPER-CRITICAL UNIT WITH ULTRA

SUPER-CRITICAL UNIT

1. In supercritical units, the pressure of the boiler is about 3530 pounds per square inch and
temperatures are 1050 degrees Fahrenheit (565 degrees Celsius).
In ultra-supercritical units, pressures are at 4640 pounds per square inch
temperatures of 1112-1130 degrees Fahrenheit (600-610 degrees Celsius).

2. Efficiency ratings for supercritical coal plants range from 37% to 40%.
Efficiency ratings for ultra- supercritical coal plants range from 44% to 46%.

3. Emissions of SO2, NOX and CO2 is much less in ultra-supercritical unit than supercritical
unit.

4. Fuel consumption in ultra-supercritical unit is less than supercritical unit.

COMPARISION BETWEEN ULTRA- SUPERCRITICAL UNIT

AND IGCC UNIT

1. Efficiency ratings for ultra- supercritical coal plants range from 44% to 46%.
Efficiency ratings for IGCC coal plants range from 51% to 53%.

2. IGCC mainly requires low grade coal as afuel than ultra-supercritical unit.

17
 3. Cost of production is much less than the ultra-supercritical coal power plant.

4. Greatly reduces greenhouse gases than ultra- supercritical coal power plant.

THERMODYNAMIC ADVANTAGES
When temperature and pressure of live steam are increased beyond the critical point of water, the
properties of steam will change dramatically. The critical point of water is at 374 °C and 221.2
bars, it is defined to be the point where gaseous component cannot be liquefied by increasing the
pressure applied to it. Beyond this critical point water does not experience a phase change to
vapor, but it becomes a supercritical fluid. Supercritical fluid is not a gas or liquid. It is best
described to be a thermodynamic expression describing the state of a substance where there is no
clear distinction between the liquid and the gaseous phase (i.e. they are a homogenous fluid). It
has similar solvent power as liquid, but its transport properties are similar to gases.

The T-S diagram for a supercritical cycle can be seen in Figure 1.2. With the use of reheat and
regeneration techniques, point 3 in Figure 1.2, which corresponds to the T-S vapor state of the
coolant after it has expanded through a turbine, can be pushed to the right such that the coolant
remains in the gas phase. This simplifies the system by eliminating the need for steam separators,
dryers, and turbines specially designed for low quality steam.

18
 Fig : 5

LIMITATIONS

• The only disadvantage of these boilers are tightness of high pressure gas passage is
essential.

19
 SCOPE OF THE FUTURE WORK
• Earlier researchers have established that regeneration of steam in between
expansion of the steam in turbine enhances the performance of cycle with the use
of steam in the subcritical conditions. Similar studies are required to be carried
out for the steam in supercritical condition.

• Thermodynamic analysis and optimization of Supercritical Rankine cycle with

feed water heaters in supercritical conditions to be carried out.

• Research work on development of new material, nickel based alloys which can
sustain supercritical conditions. Hence, there is huge scope for the research in the
newer advanced materials.

• Emission analysis of flue gas for coal based thermal power plant may be carried
out.

• Analysis of multi stage steam turbine can be done for various supercritical/ultra
supercritical cycles
.
• Economic analysis of supercritical power plants can be carried out to reduce the
unit cost of electric power.

• Advanced coal combustion technologies could be used in Supercritical and ultra

supercritical power plants.

• Analysis of once through boiler technology CFB (Circulating Fluidized Bed)

boilers can be done for the higher efficiency of supercritical technology.
•
• Analysis of Once through HRSG (Heat Recovery Steam Generator) with
supercritical and ultra supercritical parameters could be done.

• Effect of different fossil fuels can be used for the supercritical cycles.

20
 CONCLUSION

Analysis shows that higher output can be obtained with high temperature steam at supercritical
pressure comparing with the output of subcritical units operating with same steam flow rates.
Thermal efficiency of supercritical plant is high as well as emission is also reduced due to higher
efficiency. Performance of supercritical boiler is calculated by different graphical representation
and it is compared to subcritical boilers curves. The increased pressure also increases cycle
efficiency and, although this effect is a second-order effect compared with the effect of
temperature, it can still make an important contribution to increasing overall plant efficiency.
However Supercritical boilers operate in a higher pressure and temperature zone as compared to
subcritical boilers leading to increased thermal efficiencies.

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 APPENDIX

• USC- Ultra Super-Critical

• IGCC- Integrated Gasification Coal Combustion

• Critical Temperature-The temperature of a gas in its critical state, above which it cannot
be liquefied by pressure alone.

• Superheater – increases the steam temperature above the saturation temperature.

• Reheater – removes the moisture and increases steam temperature after a partial
expansion.

• T-S Diagram- Temperature -Entropy Diagram

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 REFERENCES

• Malik A.R.: Practical Boiler Operation Engineering and Power Plant, 2nd edition,

2012,

• www.brighthubengineering.com/power plants.

• Super critical power generation - experience, issues and future challenges by Ashok

sarkar, N.T.P.C. –kahalgaon,

• www.worldcoal.org/improving efficiencies.

• “Recent Trends in Supercritical Power Generation Technology”.

• Engineering Thermodynamics by P K Nag.

• 660MW Supercritical unit operation by Jordan Hanania and Jason Donev.

• Singh, Onkar. Applied Thermodynamics. New Delhi: New Age Publishers, 2003,

Print.

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