Coal handling plant in a thermal power

generating station
Posted Mar 4 2012 by Bipul Raman in Energy and Power with 1 Comment
Coal Handeling Mine/Plant in a thermal power generating station
Introduction to Coal handling plant
n a !oal based thermal power plant" the initial pro!ess in the power generation is #Coal
Handling$% &o in this arti!le i will dis!uss the o'erall pro!esses !arried out at a Coal Handling
plant in a !oal based thermal power generating station%
(he huge amount o) coal is usually supplied through railways% * railway siding line is ta+en into
the power station and the !oal is deli'ered in the storage yard% (he !oal is unloaded )rom the
point o) deli'ery by means o) wagon tippler% t is ra!+ and pinion type% (he !oal is ta+en )rom
the unloading site to dead storage by belt conveyors% (he belt deli'er the !oal to 0m le'el to the
pent house and )urther mo'es to transfer point ,%
(he trans)er points are used to trans)er !oal to the ne-t belt% (he belt ele'ates the !oal to breaker
house% t !onsists o) a rotary ma!hine" whi!h rotates the !oal and separates the light dust )rom it
through the a!tion o) gra'ity and trans)er this dust to re.e!t bin house through belt%
(he belt )urther ele'ates the !oal to the transfer point / and it rea!hes the !rusher through belt%
n the crusher a high0speed 3-phase induction motor is used to !rush the !oal to a si1e o)
20mm so as to be suitable )or milling system% Coal rises )rom !rusher house and rea!hes the
dead storage by passing through transfer point ,%
&tages in !oal handeling power plant
Equipment used in a coal handling plant
1. ull chord switch
* series o) su!h swit!hes are arranged in series at a 1m distan!e on the side o) !on'eyor belt% (he
power supply to rotor o) the !on'eyor belt is established only i) all swit!hes in series are
!onne!ted%
!. "ibrating feeder
(he !oal stored in a huge hub is !olle!ted on the belt through 'ibrations !reated by the 'ibrating
)eeder%
3. #lap gates
(hese are used to !hanneli1e the route o) !oal through another belt in !ase the )ormer is bro+en
or unhealthy% (he )lap gates open let the !oal pass and i) !losed stop its mo'ement%
$. %agnetic separator
these are used to separate the )errous impurities )rom the !oal%
&. %etal detector
(hese are dete!t the presen!e o) any )errous and non0)errous metal in the !oal and sends a signal
to a relay whi!h !loses to sei1e the mo'ement o) belt until the metal is remo'ed% t basi!ally
!onsists o) a transmitter and a re!ei'er%
(he transmitter !onsists o) a high )re3uen!y os!illator" whi!h produ!es a os!illations o) 1200 H1
at 124% (he re!ei'er re!ei'es this )re3uen!y signal% ) there is any presen!e o) metal in the !oal%
(hen this )re3uen!y is disturbed and a tripping signal is send to relay to stop the !on'eyor belt%
'. (elt weightier
t is used to +eep an a!!ount o) the tension on the belt !arrying !oal and is mo'es a!!ordingly to
release tension on the belt%
). *eclaim hopper
Re!laimation is a pro!ess o) ta+ing !oal )rom the dead storage )or preparation or )urther )eeding
to re!laim hoppers% (his is a!!omplished by belt !on'eyors%
(op
+team generation from coal
1. ,ipplers
Coal )rom the !oal wagons is unloaded in the !oal handling plant% (his unloading is done by the
#(ipplers$% (his !oal is transported up to the raw !oal bun+ers with the help o) !on'eyor belts%
!. Crush -ouse
*)ter hand pi!+ing )oreign material" !oal is transported to the Crush house by !on'eyor belts
where it is !rushed to small pie!es o) about 20 mm diameter% (he !rushed !oal is then transported
to the store yard% Coal is transported to bowl mills by !oal )eeders%
3. (owl %ill
(he !oal is pul'eri1ed in the bowl mill" where it is grounded to a powder )orm% (he mill !onsists
o) a round metalli! table on whi!h !oal parti!les )all%
(his table is rotated with the help o) a motor% (here are three large steel rollers" whi!h are spa!ed
120$ apart% 5hen there is no !oal" these rollers do not rotate but when the !oal is )ed to the table
it pa!+s up between rollers and the table and this )or!es the rollers to rotate%
Coal is crushed by the crushing actions between the rollers and rotating tables.
$. #urnaces
(his !rushed !oal is ta+en away to the )urna!e through !oal pipes with the help o) hot and !old
air mi-ture )rom P%* 6an% P%* 6an ta+es atmospheri! air" a part o) whi!h is sent to *ir pre0heaters
)or heating while a part goes dire!tly to the mill )or temperature !ontrol%
Atmospheric air from F.D Fan is heated in the air heaters and sent to the furnace as
combustion air.
&. (oiler
(oiler used in the power plant is suspended type% (his pre'ents it )rom getting de)ormed" when a
sub.e!ted to 'ery high temperatures%
(he boiler is di'ided into two !ylindri!al parts namely the Primary and the &e!ondary boiler%
5ater )rom the boiler )eed pump passes through e!onomi1er and rea!hes the boiler drum% 5ater
)rom the drum passes through down !omers and goes to bottom ring header% 5ater )rom the ring
header is di'ided to all the )our side o) )urna!e%
Due to heat and density difference the water rises up in the water wall tubes.
5ater is partly !on'erted to steam as it rises up in the )urna!e% (his steam and water mi-ture is
again ta+en to the boiler drum where the steam is sent to super heaters )or superheating%
(he super heaters are lo!ated inside the )urna!e and the steam is superheated 72408C9 and )inally
it goes to turbine% 6lue gasses )rom the )urna!e are e-tra!ted by indu!ed dra)t )an" whi!h
maintains balan!e dra)t in the )urna!es with )or!ed dra)t )an% (hese )lue gasses emit their heat
energy to 'arious super heaters in the pant house and )inally pass through air pre0heaters and
goes to ele!trostati! pre!ipitator where the ash parti!les are e-tra!ted% Ele!trostati! pre!ipitator
!onsists o) metal plates" whi!h are ele!tri!ally !harged%
ossil fuel power plant
Published: May 1/" 2010" ;:42 pm
<pdated: *pril 4" 201=" 10:0= pm
*uthor: >anos Beer
(opi! Editor: Cutler >% Cle'eland
(opi!s: Energy
?ohle+ra)twer+ &!hol'en" a )ossil )uel power plant in @ermany% 7By &ebastian &!hlAter 0 Basan1B,0" 'ia 5i+imedia Commons9
A coal-fired power plant. Photo: DOE
* )ossil )uel power plant is a system o) de'i!es )or the !on'ersion o) )ossil )uel energy to
me!hani!al wor+ or ele!tri! energy% (he main systems are the steam !y!le and the gas turbine
!y!le% (he steam !y!le relies on the Ran+ine !y!le in whi!h high pressure and high temperature
steam raised in a boiler is e-panded through a steam turbine that dri'es an ele!tri! generator% (he
steam gi'es up its heat o) !ondensation in a !ondenser to a heat sin+ su!h as water )rom a ri'er or
a la+e" and the !ondensate !an then be pumped ba!+ into the boiler to repeat the !y!le% (he heat
ta+en up by the !ooling water in the !ondenser is dissipated mostly through !ooling towers into
the atmosphere%
(he gas turbine !y!le relies on the Brayton !y!le in whi!h air !ompressed to high pressure" and
heated to high temperature by the !ombustion o) natural gas or light )uel oil" is the wor+ing )luid
that e-pands in the turbine to pro'ide the tor3ue )or dri'ing both a !ompressor and the ele!tri!
generator% (he gas turbine demands !lean )uels su!h as natural gas or light )uel oil% Combustion
is the pre'ailing )uel utili1ation te!hnology in both the abo'e !y!les% Coal is the pre)erred )uel
)or the steam !y!le be!ause o) its low !ost and broad and se!ure a'ailability worldwide%
Combustion0generated pollutants" su!h as o-ides o) nitrogen 7CD"-9" o) sul)ur 7&D-9" and
parti!ulates" i) un!ontrolled and emitted into the atmosphere represent en'ironmental and health
ha1ards" su!h as a!id rain% En'ironmental regulations supported by intensi'e resear!h and
de'elopments ha'e redu!ed pollutant emissions signi)i!antly% mpro'ements in e))i!ien!y and
emissions !ome by in!reasing steam pressure and temperature in the steam !y!le" and by
in!reased turbine inlet temperature in the gas turbine !y!le% Coal gasi)i!ation produ!es a )uel gas
that is !apable o) being used in the gas turbine% By integrating !oal gasi)i!ation with gas turbine
and steam !y!les" ad'antage !an be ta+en o) high e))i!ien!y and low pollutant emission while
using !oal" an ine-pensi'e" se!ure and indigenous )uel in many !ountries throughout the world% *
potential additional ad'antage o) the ntegrated @asi)i!ation Combined Cy!le 7@CC9 is the
!apability o) !apturing !arbon dio-ide 7CD29 )rom the )uel gas and ma+ing it ready )or high0
pressure pipeline transportation to a !arbon se3uestration site% (his will be +ey to the !ommer!ial
and !lean !o0produ!tion o) ele!tri!ity and hydrogen )rom !oal%
#ossil-fuel power station
6rom 5i+ipedia" the )ree en!y!lopedia
<%&% 201= Ele!tri!ity @eneration By (ype%
E1F
EuropeGs largest !oal )ired power station" the BeH!hatIw Power &tation in Poland
(he &t% Clair Power Plant" a large !oal0)ired generating station in Mi!higan
* fossil fuel power station burns )ossil )uels su!h as !oal" natural gas or petroleum 7oil9 to
produ!e ele!tri!ity% Central station )ossil0)uel power plants are designed on a large s!ale )or
!ontinuous operation% n many !ountries" su!h plants pro'ide most o) the ele!tri!al energy used%
6ossil0)uel power stations ha'e rotating ma!hinery to !on'ert the heat energy o) !ombustion into
me!hani!al energy" whi!h then operates an ele!tri!al generator% (he prime mo'er may be a steam
turbine" a gas turbine or" in small plants" a re!ipro!ating internal !ombustion engine% *ll plants
use the energy e-tra!ted )rom e-panding gas 0 steam or !ombustion gases% 4ery )ew MHJ
generators ha'e been built whi!h dire!tly !on'ert the energy o) mo'ing hot gas into ele!tri!ity%
Byprodu!ts o) thermal power plant operation must be !onsidered in their design and operation%
5aste heat energy" whi!h remains due to the )inite e))i!ien!y o) the Carnot" Ran+ine" or Jiesel
power !y!le" is released dire!tly to the atmosphere" dire!tly to ri'er or la+e water" or indire!tly to
the atmosphere using a !ooling tower with ri'er or la+e water used as a !ooling medium% (he
)lue gas )rom !ombustion o) the )ossil )uels is dis!harged to the air% (his gas !ontains !arbon
dio-ide and water 'apor" as well as other substan!es su!h as nitrogen o-ides 7CD-9" sul)ur o-ides
7&D-9" mer!ury" tra!es o) other metals" and" )or !oal0)ired plants" )ly ash% &olid waste ash )rom
!oal0)ired boilers must also be remo'ed% &ome !oal ash !an be re!y!led )or building materials%
E2F
6ossil )ueled power stations are ma.or emitters o) CD2" a greenhouse gas 7@H@9 whi!h
a!!ording to a !onsensus opinion o) s!ienti)i! organisations is a !ontributor to global warming as
it has been obser'ed o'er the last 100 years% Per unit o) ele!tri! energy" brown !oal emits about =
times as mu!h CD2 as natural gas" and bla!+ !oal emits about twi!e as mu!h CD2%
Ecitation neededF

Carbon !apture and storage o) emissions is not e-pe!ted to be a'ailable until te!hnology is sa)e
and deployable%
Contents
1 Basi! !on!epts
o 1%1 Heat into me!hani!al energy
2 Coal
o 2%1 6uel transport and deli'ery
o 2%2 6uel pro!essing
= &team0ele!tri!
4 @as turbine plants
2 Re!ipro!ating engines
; En'ironmental impa!ts
o ;%1 Carbon dio-ide
o ;%2 Parti!ulate matter
o ;%= Radioa!ti'e tra!e elements
o ;%4 5ater and air !ontamination by !oal ash
;%4%1 Mer!ury !ontamination
/ @reening o) )ossil )uel power plants
o /%1 Kow CD- Burners
o /%2 Clean !oal
, Combined heat and power
B *lternati'es to )ossil )uel power plants
o B%1 Relati'e !ost by generation sour!e
10 &ee also
11 Re)eren!es
12 Bibliography
1= E-ternal lin+s
(asic concepts
n a )ossil )uel power plant the !hemi!al energy stored in )ossil )uels su!h as !oal" )uel oil"
natural gas or oil shale and o-ygen o) the air is !on'erted su!!essi'ely into thermal energy"
me!hani!al energy and" )inally" ele!tri!al energy% Ea!h )ossil )uel power plant is a !omple-"
!ustom0designed system% Constru!tion !osts" as o) 2004" run to <&L1"=00 per +ilowatt" or L;20
million )or a 200 M5e unit
Ecitation neededF
% Multiple generating units may be built at a single site )or
more e))i!ient use o) land" natural resour!es and labour% Most thermal power stations in the
world use )ossil )uel" outnumbering nu!lear" geothermal" biomass" or solar thermal plants%
-eat into mechanical energy
(he se!ond law o) thermodynami!s states that any !losed0loop !y!le !an only !on'ert a )ra!tion
o) the heat produ!ed during !ombustion into me!hani!al wor+% (he rest o) the heat" !alled waste
heat" must be released into a !ooler en'ironment during the return portion o) the !y!le% (he
)ra!tion o) heat released into a !ooler medium must be e3ual or larger than the ratio o) absolute
temperatures o) the !ooling system 7en'ironment9 and the heat sour!e 7!ombustion )urna!e9%
Raising the )urna!e temperature impro'es the e))i!ien!y but !ompli!ates the design" primarily by
the sele!tion o) alloys used )or !onstru!tion" ma+ing the )urna!e more e-pensi'e% (he waste heat
!annot be !on'erted into me!hani!al energy without an e'en !ooler !ooling system% Howe'er" it
may be used in !ogeneration plants to heat buildings" produ!e hot water" or to heat materials on
an industrial s!ale" su!h as in some oil re)ineries" plants" and !hemi!al synthesis plants%
(ypi!al thermal e))i!ien!y )or utility0s!ale ele!tri!al generators is around ==M )or !oal and oil0
)ired plants" and 2; N ;0M 7KH49 )or !ombined0!y!le gas0)ired plants% Plants designed to
a!hie'e pea+ e))i!ien!y while operating at !apa!ity will be less e))i!ient when operating o))0
design 7i%e% temperatures too low%9
E=F
Pra!ti!al )ossil0)uel stations operating as heat engines !annot e-!eed the Carnot !y!le limit )or
!on'ersion o) heat energy into use)ul wor+% 6uel !ells do not ha'e the same thermodynami!
limits as they are not heat engines%
Coal
Jiagram o) a typi!al steam0!y!le !oal power plant 7pro!eeding )rom le)t to right9
Coal is the most abundant )ossil )uel on the planet% t is a relati'ely !heap )uel" with some o) the
largest deposits in regions that are relati'ely stable politi!ally" su!h as China" ndia and the
<nited &tates% (his !ontrasts with natural gas and petroleum" the largest deposits o) whi!h are
lo!ated in the politi!ally 'olatile Persian @ul)% &olid !oal !annot dire!tly repla!e natural gas or
petroleum in most appli!ations" petroleum is mostly used )or transportation and the natural gas
not used )or ele!tri!ity generation is used )or spa!e" water and industrial heating% Coal !an be
!on'erted to gas or li3uid )uel" but the e))i!ien!ies and e!onomi!s o) su!h pro!esses !an ma+e
them un)easible%
Ecitation neededF
4ehi!les or heaters may re3uire modi)i!ation to use !oal0deri'ed
)uels% Coal !an produ!e more pollution than petroleum or natural gas%
*s o) 200B the largest !oal0)ired power station is (ai!hung Power Plant in (aiwan% (he worldGs
most energy0e))i!ient !oal0)ired power plant is the *'edOre Power &tation in Jenmar+%
E4F
#uel transport and delivery
Big Bend Coal Power &tation in *pollo Bea!h" 6lorida in the <nited &tates%
Coal0)ired power plants pro'ide about 4;M o) !onsumed ele!tri!ity in the <nited &tates% (his is
the Castle @ate Plant near Helper" <tah%
Coal is deli'ered by highway tru!+" rail" barge" !ollier ship or !oal slurry pipeline% &ome plants
are e'en built near !oal mines and !oal is deli'ered by !on'eyors% * large !oal train !alled a Punit
trainP may be two +ilometers 7o'er a mile9 long" !ontaining 1=00140 !ars with 100 short tons o)
!oal in ea!h one" )or a total load o) o'er 12"000 tons% * large plant under )ull load re3uires at
least one !oal deli'ery this si1e e'ery day% Plants may get as many as three to )i'e trains a day"
espe!ially in Ppea+ seasonP during the hottest summer or !oldest winter months 7depending on
lo!al !limate9 when power !onsumption is high% * large thermal power plant su!h as the one in
Canti!o+e" Dntario stores se'eral million metri! tons o) !oal )or winter use when the la+es are
)ro1en%
Modern unloaders use rotary dump de'i!es" whi!h eliminate problems with !oal )ree1ing in
bottom dump !ars% (he unloader in!ludes a train positioner arm that pulls the entire train to
position ea!h !ar o'er a !oal hopper% (he dumper !lamps an indi'idual !ar against a plat)orm that
swi'els the !ar upside down to dump the !oal% &wi'eling !ouplers enable the entire operation to
o!!ur while the !ars are still !oupled together% <nloading a unit train ta+es about three hours%
&horter trains may use rail!ars with an Pair0dumpP" whi!h relies on air pressure )rom the engine
plus a Phot shoeP on ea!h !ar% (his Phot shoeP when it !omes into !onta!t with a Phot railP at the
unloading trestle" shoots an ele!tri! !harge through the air dump apparatus and !auses the doors
on the bottom o) the !ar to open" dumping the !oal through the opening in the trestle% <nloading
one o) these trains ta+es anywhere )rom an hour to an hour and a hal)% Dlder unloaders may still
use manually operated bottom0dump rail !ars and a Psha+erP atta!hed to dump the !oal%
@enerating stations ad.a!ent to a mine may re!ei'e !oal by !on'eyor belt or massi'e diesel0
ele!tri!0dri'e tru!+s%
* !ollier 7!argo ship !arrying !oal9 may hold 40"000 long tons o) !oal and ta+es se'eral days to
unload% &ome !olliers !arry their own !on'eying e3uipment to unload their own bun+ersQ others
depend on e3uipment at the plant% Colliers are large" seaworthy" sel)0powered ships% 6or
transporting !oal in !almer waters" su!h as ri'ers and la+es" )lat0bottomed 'essels !alled barges
are o)ten used% Barges are usually unpowered and must be mo'ed by tugboats or towboats%
6or start up or au-iliary purposes" the plant may use )uel oil as well% 6uel oil !an be deli'ered to
plants by pipeline" tan+er" tan+ !ar or tru!+% Dil is stored in 'erti!al !ylindri!al steel tan+s with
!apa!ities as high as B0"000 barrels 714"000 m
=
9G worth% (he hea'ier no% 2 Pbun+erP and no% ;
)uels are typi!ally steam0heated be)ore pumping in !old !limates%
#uel processing
Coal is prepared )or use by !rushing the rough !oal to pie!es less than 2 in!hes 72 !m9 in si1e%
(he !oal is then transported )rom the storage yard to in0plant storage silos by rubberi1ed
!on'eyor belts at rates up to 4"000 short tons per hour%
n plants that burn pul'eri1ed !oal" silos )eed !oal pul'eri1ers 7!oal mills9 that ta+e the larger 20
in!h 721 mm9 pie!es" grind them to the !onsisten!y o) tal!um powder" sort them" and mi- them
with primary !ombustion air whi!h transports the !oal to the boiler )urna!e and preheats the !oal
in order to dri'e o)) e-!ess moisture !ontent% * 200 M5e plant may ha'e si- su!h pul'eri1ers"
)i'e o) whi!h !an supply !oal to the )urna!e at 220 tons per hour under )ull load%
n plants that do not burn pul'eri1ed !oal" the larger 20in!h 721 mm9 pie!es may be dire!tly )ed
into the silos whi!h then )eed either me!hani!al distributors that drop the !oal on a tra'eling
grate or the !y!lone burners" a spe!i)i! +ind o) !ombustor that !an e))i!iently burn larger pie!es
o) )uel%
+team-electric
Main arti!le: (hermal power station
Most ele!tri! power made )rom )ossil )uel is produ!ed by thermal power stations% Re!ipro!ating
steam engines )ell out o) use rapidly a)ter the )irst steam turbines were introdu!ed around 1B0;%
.as turbine plants
4,0 megawatt @E H series power generation gas turbine
Currant Cree+ Power Plant near Mona" <tah is a natural gas )ired ele!tri!al plant%
Dne type o) )ossil )uel power plant uses a gas turbine in !on.un!tion with a heat re!o'ery steam
generator 7HR&@9% t is re)erred to as a !ombined !y!le power plant be!ause it !ombines the
Brayton !y!le o) the gas turbine with the Ran+ine !y!le o) the HR&@% (he thermal e))i!ien!y o)
these plants has rea!hed a re!ord heat rate o) 2;B0 Btu/7+5Rh9" or .ust under ;0M" at a )a!ility in
Baglan Bay" 5ales%
E2F
(he turbines are )ueled either with natural gas" syngas or )uel oil% 5hile more e))i!ient and )aster
to !onstru!t 7a 1"000 M5 plant may be !ompleted in as little as 1, months )rom start o)
!onstru!tion9" the e!onomi!s o) su!h plants is hea'ily in)luen!ed by the 'olatile !ost o) )uel"
normally natural gas% (he !ombined !y!le plants are designed in a 'ariety o) !on)igurations
!omposed o) the number o) gas turbines )ollowed by the steam turbine% 6or e-ample" a =01
!ombined !y!le )a!ility has three gas turbines tied to one steam turbine% (he !on)igurations range
)rom 71019" 72019" 7=019" 74019" 72019" to 7;019
Ecitation neededF
&imple0!y!le or open !y!le gas turbine plants" without a steam !y!le" are sometimes installed as
emergen!y or pea+ing !apa!ityQ their thermal e))i!ien!y is mu!h lower% (he high running !ost
per hour is o))set by the low !apital !ost and the intention to run su!h units only a )ew hundred
hours per year% Dther gas turbine plants are installed in stages" with an open !y!le gas turbine the
)irst stage and additional turbines or !on'ersion to a !losed !y!le part o) )uture pro.e!t plans%
*eciprocating engines
Jiesel engine generator sets are o)ten used )or prime power in !ommunities not !onne!ted to a
widespread power grid% Emergen!y 7standby9 power systems may use re!ipro!ating internal
!ombustion engines operated by )uel oil or natural gas% &tandby generators may ser'e as
emergen!y power )or a )a!tory or data !enter" or may also be operated in parallel with the lo!al
utility system to redu!e pea+ power demand !harge )rom the utility% Jiesel engines !an produ!e
strong tor3ue at relati'ely low rotational speeds" whi!h is generally desirable when dri'ing an
alternator" but diesel )uel in long0term storage !an be sub.e!t to problems resulting )rom water
a!!umulation and !hemi!al de!omposition% Rarely used generator sets may !orrespondingly be
installed as natural gas or KP@ to minimi1e the )uel system maintenan!e re3uirements%
&par+0ignition internal !ombustion engines operating on gasoline 7petrol9" propane" or KP@ are
!ommonly used as portable temporary power sour!es )or !onstru!tion wor+" emergen!y power"
or re!reational uses%
Re!ipro!ating e-ternal !ombustion engines su!h as the &tirling engine !an be run on a 'ariety o)
)ossil )uels" as well as renewable )uels or industrial waste heat% nstallations o) &tirling engines
)or power produ!tion are relati'ely un!ommon%
Environmental impacts
(he Moha'e Power &tation" a 1"2,0 M5 !oal power station near Kaughlin" Ce'ada" out o)
ser'i!e sin!e 2002 due to en'ironmental restri!tions
E;F
&ee also: En'ironmental impa!t o) the !oal industry
(he worldGs power demands are e-pe!ted to rise ;0M by 20=0%
E/F
n 200/ there were o'er 20"000
a!ti'e !oal plants worldwide and this number is e-pe!ted to grow%
E,F
n 2004" the nternational
Energy *gen!y 7E*9 estimated that )ossil )uels will a!!ount )or ,2M o) the energy mar+et by
20=0%
E/F
5orld organi1ations and international agen!ies" li+e the E*" are !on!erned about the
en'ironmental impa!t o) burning )ossil )uels" and !oal in parti!ular% (he !ombustion o) !oal
!ontributes the most to a!id rain and air pollution" and has been !onne!ted with global warming%
Jue to the !hemi!al !omposition o) !oal there are di))i!ulties in remo'ing impurities )rom the
solid )uel prior to its !ombustion% Modern day !oal power plants pollute less than older designs
due to new Ps!rubberP te!hnologies that )ilter the e-haust air in smo+e sta!+sQ howe'er emission
le'els o) 'arious pollutants are still on a'erage se'eral times greater than natural gas power
plants% n these modern designs" pollution )rom !oal0)ired power plants !omes )rom the emission
o) gases su!h as !arbon dio-ide" nitrogen o-ides" and sul)ur dio-ide into the air%
*!id rain is !aused by the emission o) nitrogen o-ides and sul)ur dio-ide% (hese gases may be
only mildly a!idi! themsel'es" yet when they rea!t with the atmosphere" they !reate a!idi!
!ompounds su!h as sul)urous a!id" nitri! a!id and sul)uri! a!id whi!h )all as rain" hen!e the term
a!id rain% n Europe and the <%&%*%" stri!ter emission laws and de!line in hea'y industries ha'e
redu!ed the en'ironmental ha1ards asso!iated with this problem" leading to lower emissions a)ter
their pea+ in 1B;0s%
n 200," the European En'ironment *gen!y 7EE*9 do!umented )uel0dependent emission )a!tors
based on a!tual emissions )rom power plants in the European <nion%
EBF
ollutant -ard coal (rown coal #uel oil /ther oil .as
CD2 7g/@>9 B4";00 101"000 //"400 /4"100 2;"100
&D2 7g/@>9 /;2 1"=;1 1"=20 22, 0%;,
CD- 7g/@>9 2B2 1,= 1B2 12B B=%=
CD 7g/@>9 ,B%1 ,B%1 12%/ 12%/ 14%2
Con methane organi! !ompounds 7g/@>9 4%B2 /%/, =%/0 =%24 1%2,
Parti!ulate matter 7g/@>9 1"20= ="224 1; 1%B1 0%1
6lue gas 'olume total 7m
=
/@>9 =;0 444 2/B 2/; 2/2
Carbon dio0ide
Main arti!le: Carbon dio-ide
(ai!hung !oal0)ired power plant in (aiwan" the worldGs largest !arbon dio-ide emitter
E10F
Ele!tri!ity generation using !arbon based )uels is responsible )or a large )ra!tion o) !arbon
dio-ide 7CD29 emissions worldwide and )or =4M o) <%&% man0made !arbon dio-ide emissions in
2010% n the <%&%" /0M o) ele!tri!ity generation is produ!ed )rom !ombustion o) )ossil )uels%
E11F
D) the )ossil )uels" !oal is mu!h more !arbon intensi'e than oil or natural gas" resulting in greater
'olumes o) !arbon dio-ide emissions per unit o) ele!tri!ity generated% n 2010" !oal !ontributed
about ,1M o) CD2 emissions )rom generation and !ontributed about 42M o) the ele!tri!ity
generated in the <nited &tates%
E12F
n 2000" the !arbon intensity o) <%&% !oal thermal !ombustion
was 224B lbs/M5h 71"02B +g/M5h9%
E1=F
9 while the !arbon intensity o) <%&% oil thermal
generation was 1;/2 lb/M5h 7/2, +g/M5h or 211 +g/@>9
E14F
and the !arbon intensity o) <%&%
natural gas thermal produ!tion was 11=2 lb/M5h 7212 +g/M5h or 14= +g/@>9%
E12F
9
(he ntergo'ernmental Panel on Climate Change 7see PCC9 states that !arbon dio-ide is a
greenhouse gas and that in!reased 3uantities within the atmosphere will P'ery li+elyP lead to
higher a'erage temperatures on a global s!ale 7global warming9Q !on!erns regarding the potential
)or su!h warming to !hange the global !limate prompted PCC re!ommendations !alling )or
large !uts to CD2 emissions worldwide%
E1;F
Emissions may be redu!ed through more e))i!ient and higher !ombustion temperature and
through more e))i!ient produ!tion o) ele!tri!ity within the !y!le% Carbon !apture and storage
7CC&9 o) emissions )rom !oal0)ired power stations is another alternati'e but the te!hnology is
still being de'eloped and will in!rease the !ost o) )ossil )uel0based produ!tion o) ele!tri!ity% CC&
may not be e!onomi!ally 'iable" unless the pri!e o) emitting CD2 to the atmosphere rises%
articulate matter
*nother problem related to !oal !ombustion is the emission o) parti!ulates that ha'e a serious
impa!t on publi! health% Power plants remo'e parti!ulate )rom the )lue gas with the use o) a bag
house or ele!trostati! pre!ipitator% &e'eral newer plants that burn !oal use a di))erent pro!ess"
ntegrated @asi)i!ation Combined Cy!le in whi!h synthesis gas is made out o) a rea!tion
between !oal and water% (he synthesis gas is pro!essed to remo'e most pollutants and then used
initially to power gas turbines% (hen the hot e-haust gases )rom the gas turbines are used to
generate steam to power a steam turbine% (he pollution le'els o) su!h plants are drasti!ally lower
than those o) P!lassi!P !oal power plants%
E1/F
Parti!ulate matter )rom !oal0)ired plants !an be harm)ul and ha'e negati'e health impa!ts%
&tudies ha'e shown that e-posure to parti!ulate matter is related to an in!rease o) respiratory and
!ardia! mortality%
E1,F
Parti!ulate matter !an irritate small airways in the lungs" whi!h !an lead to
in!reased problems with asthma" !hroni! bron!hitis" airway obstru!tion" and gas e-!hange%
E1,F
(here are di))erent types o) parti!ulate matter" depending on the !hemi!al !omposition and si1e%
(he dominant )orm o) parti!ulate matter )rom !oal0)ired plants is !oal )ly ash" but se!ondary
sul)ate and nitrate also !omprise a ma.or portion o) the parti!ulate matter )rom !oal0)ired plants%
E1BF
Coal )ly ash is what remains a)ter the !oal has been !ombusted" so it !onsists o) the
in!ombustible materials that are )ound in the !oal%
E20F
(he si1e and !hemi!al !omposition o) these parti!les a))e!ts the impa!ts on human health%
E1,FE1BF

Currently !oarse 7diameter greater than 2%2 Sm9 and )ine 7diameter between 0%1 Sm and 2%2 Sm9
parti!les are regulated" but ultra)ine parti!les 7diameter less than 0%1 Sm9 are !urrently
unregulated" yet they pose many dangers%
E1,F
<n)ortunately mu!h is still un+nown as to whi!h
+inds o) parti!ulate matter pose the most harm" whi!h ma+es it di))i!ult to !ome up with
ade3uate legislation )or regulating parti!ulate matter%
E1BF
(here are se'eral methods o) helping to redu!e the parti!ulate matter emissions )rom !oal0)ired
plants% Roughly ,0M o) the ash )alls into an ash hopper" but the rest o) the ash then gets !arried
into the atmosphere to be!ome !oal0)ly ash%
E20F
Methods o) redu!ing these emissions o)
parti!ulate matter in!lude:
1. a baghouse
2. an ele!trostati! pre!ipitator 7E&P9
3. !y!lone !olle!tor
(he baghouse has a )ine )ilter that !olle!ts the ash parti!les" ele!trostati! pre!ipitators use an
ele!tri! )ield to trap ash parti!les on high0'oltage plates" and !y!lone !olle!tors use !entri)ugal
)or!e to trap parti!les to the walls%
E20F
* re!ent study indi!ates that sul)ur emissions )rom )ossil
)ueled power stations in China may ha'e !aused a 100year lull in global warming 71BB,0200,9
E21F
*adioactive trace elements
Coal is a sedimentary ro!+ )ormed primarily )rom a!!umulated plant matter" and it in!ludes
many inorgani! minerals and elements whi!h were deposited along with organi! material during
its )ormation% *s the rest o) the EarthGs !rust" !oal also !ontains low le'els o) uranium" thorium"
and other naturally o!!urring radioa!ti'e isotopes whose release into the en'ironment leads to
radioa!ti'e !ontamination% 5hile these substan!es are present as 'ery small tra!e impurities"
enough !oal is burned that signi)i!ant amounts o) these substan!es are released% * 1"000 M5
!oal0burning power plant !ould ha'e an un!ontrolled release o) as mu!h as 2%2 metri! tons per
year o) uranium 7!ontaining /4 pounds 7=4 +g9 o) uranium02=29 and 12%, metri! tons per year o)
thorium%
E22F
n !omparison" a 1"000 M5 nu!lear plant will generate about =0 metri! tons o) high0
le'el radioa!ti'e solid pa!+ed waste per year%
E2=F
t is estimated that during 1B,2" <& !oal burning
released 122 times as mu!h un!ontrolled radioa!ti'ity into the atmosphere as the (hree Mile
sland in!ident%
E24F
(he !olle!ti'e radioa!ti'ity resulting )rom all !oal burning worldwide between
1B=/ and 2040 is estimated to be 2"/00"000 !uries or 0%101 EB3%
E22F
t should also be noted that
during normal operation" the e))e!ti'e dose e3ui'alent )rom !oal plants is 100 times that )rom
nu!lear plants%
E22F
But it is also worth noting that normal operation is a de!ei'ing baseline )or
!omparison: .ust the Chernobyl nu!lear disaster released" in iodine01=1 alone" an estimated 1%/;
EB3 %
E22F
o) radioa!ti'ity" a 'alue one order o) magnitude abo'e this 'alue )or total emissions
)rom all !oal burned within a !entury% But at the same time" it shall also be understood that the
iodine01=1" the ma.or radioa!ti'e substan!e whi!h !omes out in a!!ident situations" has a hal)
li)e o) .ust , days%
1ater and air contamination by coal ash
* study released in *ugust 2010 that e-amined state pollution data in the <nited &tates by the
organi1ations En'ironmental ntegrity Pro.e!t" the &ierra Club and Earth.usti!e )ound that !oal
ash produ!ed by !oal0)ired power plants dumped at sites a!ross 21 <%&% states has !ontaminated
ground water with to-i! elements% (he !ontaminants in!luding the poisons arseni! and lead%
E2;F
*rseni! has been shown to !ause s+in !an!er" bladder !an!er and lung !an!er" and lead damages
the ner'ous system%
E2/F
Coal ash !ontaminants are also lin+ed to respiratory diseases and other
health and de'elopmental problems" and ha'e disrupted lo!al a3uati! li)e%
E2;F
Coal ash also
releases a 'ariety o) to-i! !ontaminants into nearby air" posing a health threat to those who
breath in )ugiti'e !oal dust%
E2/F
Currently" the EP* does not regulate the disposal o) !oal ashQ regulation is up to the states and
the ele!tri! power industry has been lobbying to maintain this status 3uo% Most states re3uire no
monitoring o) drin+ing water near !oal ash dump sites% (he study )ound an additional =B
!ontaminated <%&% sites and !on!luded that the problem o) !oal ash0!aused water !ontamination
is e'en more e-tensi'e in the <nited &tates than has been estimated% (he study brought to 1=/
the number o) ground water sites a!ross the <nited &tates that are !ontaminated by power plant0
produ!ed !oal ash%
E2;F
%ercury contamination
Main arti!le: Mer!ury 7element9
<%&% go'ernment s!ientists tested )ish in 2B1 streams around the !ountry )or mer!ury
!ontamination% (hey )ound mer!ury in e'ery )ish tested" a!!ording to the study by the <%&%
Jepartment o) the nterior% (hey )ound mer!ury e'en in )ish o) isolated rural waterways% (wenty
)i'e per!ent o) the )ish tested had mer!ury le'els abo'e the sa)ety le'els determined by the <%&%
En'ironmental Prote!tion *gen!y )or people who eat the )ish regularly% (he largest sour!e o)
mer!ury !ontamination in the <nited &tates is !oal0)ueled power plant emissions%
E2,F
.reening of fossil fuel power plants
Main arti!les: Clean !oal and Kand)ill T Re!laiming materials
6urther in)ormation: Uero Emission 6ossil 6uel Power Plants
&e'eral methods e-ist to impro'e the e))i!ien!y o) )ossil )uel power plants% * )re3uently used
and !ost0e))i!ient method is to !on'ert a plant to run on a di))erent )uel% (his in!ludes
!on'ersions )or biomass and waste%
E2BFE=0FE=1F
Con'ersions to waste0)ired power plants ha'e the
bene)it o) redu!ing land)illing% n addition" waste0)ired power plants !an be e3uipped with
material re!o'ery" whi!h is also bene)i!ial to the en'ironment%
Regardless o) the !on'ersion" a truly green )ossil )uel power plant implements !arbon !apture
and storage 7CC&9% CC& means that the e-haust CD2 is not released into the en'ironment and the
)ossil )uel power plant be!omes an emissionless power plant% * 200; e-ample o) a CC& )ossil
)uel power plant is the pilot Elsam power station near Esb.erg" Jenmar+%
E=2F
2ow 3/0 (urners
* !ommon retro)it in )ossil )ueled power stations is the repla!ement o) original burners with
Kow CD- burners% Care)ul !onsideration o) )luid dynami!s and )lame thermodynami!s has
enabled substantial redu!tion in )lame temperature" leading to redu!ed )ormation o) Citrous
D-ides%
Clean coal
PClean !oalP is the name attributed to a pro!ess whereby !oal is !hemi!ally washed o) minerals
and impurities" sometimes gasi)ied" burned and the resulting )lue gases treated with steam" with
the purpose o) remo'ing sul)ur dio-ide" and reburned so as to ma+e the !arbon dio-ide in the
)lue gas e!onomi!ally re!o'erable% (he !oal industry uses the term P!lean !oalP to des!ribe
te!hnologies designed to enhan!e both the e))i!ien!y and the en'ironmental a!!eptability o) !oal
e-tra!tion" preparation and use"
E==F
but has pro'ided no spe!i)i! 3uantitati'e limits on any
emissions" parti!ularly !arbon dio-ide% 5hereas !ontaminants li+e sul)ur or mer!ury !an be
remo'ed )rom !oal" !arbon !annot be e))e!ti'ely remo'ed while still lea'ing a usable )uel" and
!lean !oal plants without !arbon se3uestration and storage do not signi)i!antly redu!e !arbon
dio-ide emissions% >ames Hansen in an open letter to <%&% President Bara!+ Dbama has
ad'o!ated a Pmoratorium and phase0out o) !oal plants that do not !apture and store CD2P% n his
boo+ Storms of My Grandchildren" similarly" Hansen dis!usses his Declaration of Stewardship
the )irst prin!iple o) whi!h re3uires Pa moratorium on !oal0)ired power plants that do not !apture
and se3uester !arbon dio-ideP%
E=4F
Combined heat and power
Combined heat and power 7CHP9" also +nown as !ogeneration" is the use o) a power station to
pro'ide both ele!tri! power and pro!ess heat or distri!t heating% 5hile re.e!ting heat at a higher
than normal temperature to enable building heating lowers o'erall plant ele!tri! power
e))i!ien!y" the e-tra )uel burnt is more than o))set by the redu!tion in )ossil )uel that would
otherwise be used )or heating buildings% (his te!hnology is widely pra!ti!ed in )or e-ample
Jenmar+" other &!andina'ian !ountries and parts o) @ermany% Cal!ulations show that CHPJH is
the !heapest method o) !arbon emissions redu!tions%
E=2F
4lternatives to fossil fuel power plants
*lternati'es to )ossil )uel power plants in!lude nu!lear power" solar power" geothermal power"
wind power" tidal power" hydroele!tri! power 7hydroele!tri!ity9 and other renewable energies
7see non0!arbon e!onomy9% &ome o) these are pro'en te!hnologies on an industrial s!ale 7i%e%
nu!lear" wind" tidal and hydroele!tri! power9 others are still in prototype )orm%
Cu!lear power" and geothermal power may be !lassed as heat pollutants as they add heat energy
to the biosphere that would not otherwise be released%
Ecitation neededF
(he net 3uantity o) energy
!on'ersion within the biosphere due to the utilisation o) wind power" solar power" tidal power"
hydroele!tri! power 7hydroele!tri!ity9 is stati! and is deri'ed )rom the e))e!ts o) sunlight and the
mo'ement o) the moon and planets%
@enerally" the !ost o) ele!tri!al energy produ!ed by non )ossil )uel burning power plants is
greater than that produ!ed by burning )ossil )uels% (his statement howe'er only in!ludes the !ost
to produ!e the ele!tri!al energy and does not ta+e into a!!ount indire!t !osts asso!iated with the
many pollutants !reated by burning )ossil )uels 7e%g% in!reased hospital admissions due
respiratory diseases !aused by )ine smo+e parti!les9%
*elative cost by generation source
See also Relative cost of electricity generated by different sources
5hen !omparing power plant !osts" it is !ustomary to start by !al!ulating the !ost o) power at
the generator terminals by !onsidering se'eral main )a!tors% E-ternal !osts su!h as !onne!tions
!osts" the e))e!t o) ea!h plant on the distribution grid are !onsidered separately as an additional
!ost to the !al!ulated power !ost at the terminals%
nitial )a!tors !onsidered are:
Capital !osts 7in!luding waste disposal and de!ommissioning !osts )or nu!lear energy9
Dperating and maintenan!e !osts
6uel !osts 7)or )ossil )uel and biomass sour!es" and whi!h may be negati'e )or wastes9
Ki+ely annual hours per year run or load )a!tor 7may be =0M )or wind energy" but B0M
)or nu!lear energy9
D))set sales o) heat 7)or e-ample in !ombined heat and power distri!t heating
7CHP/JH99%
(hese !osts o!!ur o'er the =0N20 year li)e o) the )ossil )uel power plants" using dis!ounted !ash
)lows% n general large )ossil plants are attra!ti'e due to their low initial !apital !ostsVtypi!ally
around W/20NW1000 per +ilowatt ele!tri!al !ompared to perhaps W1200 per +ilowatt )or onshore
wind%
Ecitation neededF
rocess and Instrumentation +ymbols - Equipment
Pumps and tan+s !ome in a 'ariety o) designs and shapes% Kearn the basi! +nowlegde about
piping and instrumentation diagram%
ump is a me!hani!al de'i!e using su!tion or pressure to raise or mo'e li3uids" !ompress gases"
or )or!e air into in)latable ob.e!ts su!h as tires% (he symbols )or pumps may !losely resemble
those )or !ompressors%
Centrifugal pump is rotodynami! pump that uses a re'ol'ing impeller to add to the )or!e and
pressure o) )luids%
.ear pump pro'ides !ontinuous" non0pulsing )low ma+ing it ideal in !hemi!al installations%
+ump pump is widely used to remo'e a!!umulated water )rom a sump pit or other lo!ation%
"acuum pump is applied to impro'e the e))i!ien!y o) steam heating systems in many ways% (he
most important !onsideration is the rapid and e))i!ient remo'al%
+crew pump is the *r!himedes s!rew pump that is still used in irrigation and agri!ultural
appli!ations%
,ank is )or storing pro!ess )luids o) 'arious types" under di))erent pro!ess !onditions%
/nion tank re)ers to an open top !ollapsible bladder designed )or use as a mobile storage
solution when re!o'ering !ontaminants%
Compressor is a me!hani!al de'i!e that ta+es in a medium and !ompresses it to a smaller
'olume% * me!hani!al or ele!tri!al dri'e is typi!ally !onne!ted to a pump that is used to
!ompress the medium%
40ial compressor is widely used in gas turbines" su!h as .et engines" high speed ship engines
and small s!ale power stations%
*eciprocation compressor is typi!ally used where high !ompression ratios are re3uired per
stage without high )low rates" and the pro!ess )luid is relati'ely dry%
*otary compressor is a type o) gas !ompressor whi!h uses a rotary type positi'e displa!ement
me!hanism%
%i0ing is a de'i!e that !ombine or put some materials together to )orm one substan!e or mass%
%i0ing vessel is a !ontainer that is used to blend se'eral !omponents together%
-eat e0changer is a de'i!e used to trans)er heat energy between two pro!ess )lows% Heat
e-!hangers trans)er heat energy through !ondu!ti'e and !on'e!ti'e heat trans)er%
Cooling towers trans)er heat energy to the outside air through the prin!iple o) e'aporation%
Cooler is a de'i!e" !ontainer or room that !ools air through the e'aporation o) water or +eeps air
!ool%
,urbine driver is used to dri'e pumps and )ans at petro!hemi!al plants%
#urnace is a de'i!e )or heating a !ontinuous !urrent o) air by means o) a )ire !ontained within
the apparatus and without mingling the )resh air with the produ!ts o) !ombustion%
(oiler is a !losed 'essel in whi!h water or other )luid is heated%
/il burner is engineered )rom the ground up e-!lusi'ely to burn waste oils%
4utomatic stoker is applied to supply hot water to !entral heating systems%
late tower is used e-tensi'ely in many pro!esses and industrial appli!ations%
acked tower is a type o) pa!+ed bed used to per)orm separation pro!esses%
Elevator is used to !ontrol the position o) the nose o) the air!ra)t and the angle o) atta!+ o) the
wing%
%i0ing reactor is widely used in the !hemi!al industry to promote mi-ing%
rocess and Instrumentation +ymbols - "alves
.ate valve is a de'i!e used to !ontrol the )low o) li3uids and gases%
Check valve" also +nown as one0way 'al'e" is to pre'ent the line o) medium ba!+%
.lobe valve is a me!hanism used to !ontrol or stop the )low o) li3uid or gas through a pipe%
(all valve is a 'al'e with a spheri!al dis!" the part o) the 'al'e whi!h !ontrols the )low through
it%
(utterfly valve is installed between two )langes using a separate set o) bolts )or ea!h )lange%
4ngle valve is oriented at an angle o) B0 deg o) gate 'al'e%
rocess and Instrumentation +ymbols - iping 2ines
Pro!ess )low diagrams use spe!ial piping lines to represent how signals are transmitted between
e3uipments% (hese symbols are used to identi)y how the instruments in the pro!ess !onne!t to
ea!h other% *nd what type o) signal is being used% 7ele!tri!al" pneumati!" data" et!9
*ll lines to be )ine in relation to pro!ess piping lines%
%a5or pipeline is used to !onne!t the e3uipment in any position%
%a5or straight line is sued to !onne!t the e3uipment in the same hori1ontal or 'erti!al position%
rocess connection help to !reate the pro!ess )low between e3uipments% Jouble !li!+ pro!ess
!onne!tion to edit des!ription%
rocess and Instrumentation +ymbols - Instruments
Pro!ess 6low Jiagram use symbols and !ir!les to represent ea!h instrument and how they are
inter0!onne!ted in the pro!ess%
(hese instrumentation symbols !an easily !hange in types by !li!+ing the 3ui!+ a!tion button
while designing%