8. Thermal Power Plants
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THERMAL POWER PLANT
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TYPES OF THERMAL POWER PLANT
1. Boiler-Turbine Cycle
2. Diesel engine type
2. Gas turbine cycle
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BOILER-TURBINE CYCLE
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SURFACE CONDENSER
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WATER COOLED CONDENSER
Basically it condenses the low pressure/temp steam at the
exhaust of turbine to convert steam into water at the same
pressure and temp. In Indian condition, the pressure and temp.
of steam at condenser inlet is approx. 680 mmHg and 45 degC.
It consists of a shell and bundles of tubes inside. Water will be
passed through the tubes and steam falls directly on the tube
surface.
Water in circulation in the condenser of a 100 MW turbine will
be approx.20,000 cum/hr(20 million litres/hr).
A cooling tower will be necessary for cooling the hot water
leaving the condenser so that the same water can be circulated
to condenser through a set of pumps.
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AIRCOOLED CONDENSER
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It is a variation to the conventional water cooled condenser.
Instead of using water, here atmospheric air through a set of
fans will be impinged on the tube surface.
One major difference is that here steam will be passed through
the tubes and cooling medium, air will be passed over the tube
surface.
Here there is no necessity of cooling tower as in the case of
water cooled condenser.
This is most suitable for project sites where water availability is
scarce.
AIR COOLED CONDENSER
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STEAM JET EJECTOR
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STEAM JET EJECTOR
Steam jet ejectors are a reliable and economical means for
producing vacuum. The primary advantages of the ejector design are
its low initial cost, lack of moving parts, and simplicity of operation.
The conventional steam jet ejector has four basic parts; the steam
chest, the nozzle(s), the mixing chamber and the diffuser.
A high pressure motivating fluid (steam) enters and expands
through the converging-diverging nozzle.
The suction fluid enters and mixes with the motivating fluid in the
mixing chamber . Both are then recompressed through the diffuser .
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DEAERATOR SPRAY TYPE
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DEAERATOR PRINCIPLE
The removal of dissolved gases from boiler feedwater is an essential
process in a steam system. The presence of dissolved oxygen in
feedwater causes rapid localized corrosion in boiler tubes.
Carbon dioxide will dissolve in water, resulting in low pH levels and
the production of corrosive carbonic acid. Low pH levels in feedwater
causes severe acid attack throughout the boiler system.
While dissolved gases and low pH levels in the feedwater can be
controlled or removed by the addition of chemicals, it is more
economical and thermally efficient to remove these gases
mechanically.
This mechanical process is known as deaeration and will increase the
life of a steam system dramatically.
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DEAERATOR PRINCIPLE
The feedwater is sprayed in thin films into a steam atmosphere
allowing it to become quickly heated to saturation.
Spraying feedwater in thin films increases the surface area of the
liquid in contact with the steam, which, in turn, provides more rapid
oxygen removal and lower gas concentrations.
This process reduces the solubility of all dissolved gases and
removes it from the feedwater.
The liberated gases are then vented from the deaerator.
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AIR PREHEATER
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REGENERATIVE AIR PREHEATER
(TRI SECTOR)
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REGENERATIVE AIRHEATER
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REGENERATIVE AIRPREHEATER
In regenerative type the heating medium flows through a closely
packed matrix to raise its temperature and then air is passed
through the matrix to pick up the heat.
Either the matrix or the hoods are rotated to achieve this and hence
there is slight leakage through sealing arrangements at the moving
surfaces.
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ELECTROSTATIC PRECIPITATOR
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ELECTROSTATIC PRECIPITATOR WORKING
PRINCIPLE
An electrostatic precipitator is air pollution control device used toseparate solid particulate matter from a contaminated fluegas
stream.
Contaminated fluegas flows into an ESP chamber and is ionized by
electron emitting electrodes; also known as the corona chamber.
ESP essentially consists of a number of emitting electrodes and
collecting surfaces between which the gas carrying entrained solid
or liquid particles flows.
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ELECTROSTATIC PRECIPITATOR
WORKING PRINCIPLE
A unidirectional high potential field is set up between them through
the use of high voltage direct current. The emitting electrodes are at
high tension negative, while the collecting surfaces are at ground
potential. Ionisation of the gas takes place.
The ions formed attach themselves to the solid or liquid particles
entrained
Accumulate particulate matter is removed from the collection plates
at periodic intervals by rapping or hitting the plates with rappers
(mallets type hammers).
Heavy particles fall to the base of the ESP where hoppers hold the
removed particles for disposal.
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FUNCTION OF ESP
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FUNCTION OF ESP
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RAPPING OF THE COLLECTING ELECTRODES
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BOILERS
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BOILER TYPES AND CLASSIFICATIONS
WATER TUBE BOILER
Water flow through tubes
Water Tubes surrounded by hot
gas
Application
Used for Power Plants
Used for high pressure high
capacity steam boiler
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TRAVELLING GRATE BOILER
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BASIS OF FBC TECHNOLOGY BUBBLING BED TYPE
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FBC TECHNOLOGY
FLUIDIZED BED COMBUSTION (FBC) BOILER
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FLUIDIZED BED COMBUSTION (FBC) BOILER
Further, increase in velocity gives
rise to bubble formation, vigorous
turbulence and rapid mixing and
the bed is said to be fluidized.
Coal is fed continuously in to a hot
air agitated refractory sand bed, the
coal will burn rapidly and the bed
attains a uniform temperature
When an evenly distributed air or gas is passed upward through a finely
divided bed of solid particles such as sand supported on a fine mesh, the
particles are undisturbed at low velocity. As air velocity is graduallyincreased, a stage is reached when the individual particles are suspended in
the air stream
Fluidized Bed Combustion
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TYPES OF FLUIDIZED BED COMBUSTION SYSTEM
There are three basic types of fluidized bed combustion boilers:
1. Atmospheric Fluidized Bed Combustion System (AFBC)
2. Circulating Fluidized Bed Combustion system (CFBC)
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SCHEMATIC DIAGRAM OF AFBC
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FLUIDISED BED COMBUSTION
The 3 Ts as required for complete combustion which is satisfied byfluidised bed combustion boiler are as follows:
Time
Temperature
Turbulence
Turbulence is promoted by fluidisation making the entire mass of
solids behave much like a liquid
Improved mixing generates heat at a substantially lower and more
uniformly distributed temperature typically 800 to 9000
C
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ATMOSPHERIC FLUIDIZED BED COMBUSTION
(AFBC)
In AFBC, coal is crushed to a size of 110 mm depending on the
rank of coal, type of fuel feed and fed into the combustion chamber.
The atmospheric air, which acts as both the fluidization air and
combustion air, is delivered at a pressure and flows through the bed
after being preheated by the exhaust flue gases.
The velocity of fluidizing air is in the range of 1.2 to 3.7 m /sec.
The rate at which air is blown through the bed determines the
amount of fuel that can be reacted.
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ATMOSPHERIC FLUIDIZED BED COMBUSTION(AFBC)
Almost all AFBC/ bubbling bed boilers use in-bed evaporator tubes
in the bed of limestone, sand and fuel for extracting the heat from
the bed to maintain the bed temperature.
The bed depth is usually 0.9 m to 1.5 m deep and the pressure drop
averages about 1 inch of water per inch of bed depth.
Very little material leaves the bubbling bedonly about 2 to 4 kg of
solids are recycled per ton of fuel burned.
The combustion gases pass over the super heater sections of the
boiler, flow past the economizer, the dust collectors and the air
preheaters before being exhausted to atmosphere.
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CIRCULATING BED BOILER
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CIRCULATING FLUIDISED BED COMBUSTION
(CFBC)
Circulating Fluidised Bed Combustion (CFBC) technology has
evolved from conventional bubbling bed combustion as a means to
overcome some of the drawbacks associated with conventional
bubbling bed combustion .
This CFBC technology utilizes the fluidized bed principle in which
crushed (612 mm size) fuel and limestone are injected into the
furnace or combustor.
The particles are suspended in a stream of upwardly flowing air (60-
70% of the total air), which enters the bottom of the furnace through
air distribution nozzles.
The fluidising velocity in circulating beds ranges from 3.7 to 9
m/sec. The balance of combustion air is admitted above the bottom
of the furnace as secondary air.
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CIRCULATING FLUIDISED BED COMBUSTION
(CFBC)
Similar to Pulverized Coal (PC) firing, the controlling parameters in
the CFB combustion process are temperature, residence time and
turbulence.
For large units, the taller furnace characteristics of CFBC boiler
offers better space utilization, greater fuel particle and sorbent
residence time for efficient combustion and SO2 capture, and easier
application of staged combustion techniques for NOx control than
AFBC generators.
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POWER PLANT CYCLE WITH CFBC BOILER
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TECHNOLOGY
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Overview of Pressurized fluidized bed boiler
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Overview of Pressurized fluidized bed boiler
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PULVERISED FUEL FIRED BOILER
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PULVERISED FUEL FIRED BOILER
PULVERIZED FUEL BOILER
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PULVERIZED FUEL BOILER
Tangential firing
Coal is pulverised to a fine powder, so that less than 2% is +300 microns,
and 70-75% is below 75 microns.
Coal is blown with part of the combustion air into the boiler plant through
a series of burner nozzles.
Combustion takes place at
temperatures from 1300-1700C
Particle residence time in the boiler is
typically 2-5 seconds
One of the most popular system for
firing pulverized coal is the tangential
firing using four burners corner to
corner to create a fire ball at the
center of the furnace. See Figure
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TYPES OF PULVERISERS
Slow speed millsThese mills will be rotating between 15 to 25
rpm depending on the mill size. E.g. Drum mills or Tube mills or
Ball mills
Medium speed mills- These mills will be rotating between 50 to
100 rpm. E.g. Vertical shaft mills, Bowl mills, Ball & Race mills,
Roller mills etc.,
High Speed millsThese are directly coupled to the driving motor
and run at 750 to 1000 rpm. E.g., Hammer or Beater mill
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DRUM MILLS
The mill drum carrying the ball charge rotates on the antifriction
bearings.
Rawcoal is fed to the drum through the inlet elbow and gets crushed
to powder inside the mill drum.
The ball charge and the coal are carried to a certain height inside
the drum and allowed to fall down.
Due to the impact of balls on coal particles and due to attrition as
the particles slide over each other and also over the liners, the coal
get crushed.
Hot flue gases are used for drying and transporting the pulverisedcoal from the mill to the classifier.
The coarser particles are returned by the classifier for further
grinding.
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BALL MILLS
BALL & RACE MILL
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BALL MILLS
Coal fed from the top and fall in the center of the mill table and
passess through the grinding elements which consists of hollow
steel balls carried between two grinding rings.
Upper ring is stationary and applies pressure to the balls from
pneumatic loading cylinders containing pressurised inert gas.
The bottom ring rotates and inturn rotates the balls and in this
process coal trapped in between the grinding elements get
pulverised.
Hot primary air is fed to the mill which carries the finely ground coal
to the classifier.
The coarser particles are returned by the classifier for further
grinding
BOWL MILL
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BOWL MILL
Coal is fed from the bunkers by drag link feeder.
The coal falls on the mill grinding table and is carried under the
spring loaded, free running grinding rolls, which reduce the coal to
pulverised fuel of the required fineness.
Hot primary air is fed to the mill which carries the finely ground coal
to the classifier. These passages surround the lower part of the mill.
The coarser particles are returned by the classifier for further
grinding
HAMMER MILL
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HAMMER MILLS
Coal fed to the mill is crushed by the impact against the armour
plates and by attrition.
The hot air supplied dries the coal in the mill and transports the
coal powder to the classifier.
The coarser particles are returned by the classifier for further
grinding.
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DRUM
EVAPORATOR
SUPER HEATERPANEL
GAS FLOW
RADIAT
ION
STEAM
ECONOMISER
AFTERBURNINGCHAMBER
TYPICAL CROSS SECTION OF WASTE HEAT RECOVERY BOILER
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LIST OF WHRB PROJECT REFERENCE EXECUTED BY DASTURCO
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Sl.
No.
Name of the Client Capacity Commissioned in
the year
1. Prakash Industries Ltd,
Champa, Chhattisgarh2 x 7.5MW TG set &
1 x 50 tph WHRB.
(150,000 Tons/annum Sponge Iron
production)
1991
2. Orissa Sponge Iron Ltd,
Palaspanga, Orissa
1 x 10MW TG set &
1 x 46 tph WHRB(120,000 Tons/annum Sponge Iron
production)
1997
3. Tata Sponge Iron Ltd,
Joda, Orissa
1 x 7.5MW TG set &
1 x 35 tph WHRB
(110,000 Tons/annum Sponge Iron
production)
2001
4. Bellary Steels and Alloys
Ltd, Bellary, Karnataka
1 x 12MW TG set,
2 x 12 tph WHRB &
1 x 40 tph FBC
(2 x 30,000 Tons/annum Sponge
Iron production)
1996 (Project
implementation
partly completed in
1996. Presentlyunder HOLD)
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LIST OF WHRB PROJECT REFERENCE EXECUTED BY DASTURCO
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Sl.
No.Name of the Client Capacity Commissioned in
the year
8. Vandana Global Ltd,
Raipur
1 x 33MW TG set
1 x 55 tph WHRB
2 x 90 tph AFBC boiler
(1 x 150,000 Tons/annum &
1 x 60,000 Tons/annum
Sponge Iron Kiln
Project
commissioned in
September 2007
9. Abhijeet Infrastructure
Ltd, Raipur (Jayaswals
NECO Group)
1 x 15MW CPP
1 x 39 tph WHRB
1 x 33 tph AFBC boiler
(1 x 1,15,500 tons/annum
Sponge Iron Kiln)
Commissioned in
April 2007
10. Corporate Ispat Alloys Ltd,
Raipur (Jayaswals NECO
Group)
1 x 15MW CPP
1 x 56 tph WHRB
(1 x 1,65,000 tons/annum
Sponge Iron Kiln)
Project
Commissioned in
August 2007.
LIST OF WHRB PROJECT REFERENCE EXECUTED BY DASTURCO
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Sl.
No.Name of the Client Capacity Commissioned in
the year
11. Surana Industries Ltd,
Chennai
1 x 35MW
4 x 10.5 tph WHRB
1 X 110 tph AFBC boiler
(4 x 100 tpd Sponge Iron Kiln)
Project activities in
progress. Scheduled
for commissioning in
December 2008.
12. Janki Corp Ltd, Bellary 1 x 15MW CPP
6 x 100 tpd;
6 x 10.5 tph WHRB
Project under
execution
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DIESEL GENERATOR POWER PLANT
Diesel Engine
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DIESEL ENGINE SYSTEMS
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DIESEL ENGINE SYSTEMS
This system provides
process heat or steam
from engine exhaust.
The engine jacket
cooling water heat
exchanger and lube oil
cooler may also be
used to provide hot
water or hot air.
RECIPROCATING ENGINE BASED COGENERATION SYSTEM WITH UNFIRED
WHRB
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WHRB
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GAS TURBINE CYCLE
1. Using conventional fuels like Natural Gas, Diesel oil& Naphtha
2. Integrated gasification combined cycle (IGCC)
GAS TURBINE COMBINED CYCLE
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GAS TURBINE
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GAS TURBINE
The fuel is burnt in a pressurized combustion chamber using
combustion air supplied by a compressor that is integral with thegas turbine.
Gases enter the turbine at a temperature range of 900 to 1000oC
and leave at 400 to 500 oC.
Hot pressurized gases are used to turn a series of turbine blades,
and the shaft on which they are mounted, to produce mechanical
energy.
The available mechanical energy can be applied in the following
ways:
to produce electricity with a generator (most applications);
to drive pumps, compressors, blowers, etc.
SOME GAS TURBINE BASED POWER PLANTS
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Power station Agency/Promoter StateInstalled
capacity (MW)
Faridabad CCGT NTPC Haryana 430
Anta GT NTPC Rajasthan 413
Auraiya GT NTPC Uttar pradesh 652
Dadri GT NTPC Uttarpradesh 817
Kawas GT NTPC Gujarat 644
Gandhar GT NTPC Gujarat 648
Kayakulam GT NTPC Kerala 350Urban GT MSEB Maharastra 672.0
Vijeswaram GTAndhra pradesh gas
power corporation
Andhraprades
h272.3
Valuthur GT TNEB TamilNadu 2 x 95.0
Jegurupadu GT GVK Industries Gujarat 235.4
Kondapalli GT Lanco KondapalliAndhraprades
h350
P.Nallur CCGTPPN power generating
companyTamilNadu 330.5
Jegurupadu GT Extn GVK IndustriesAndhraprades
h230
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INTEGRATED GASIFICATION
COMBINED CYCLE (IGCC)
INTEGRATED GASIFICATION
COMBINED CYCLE (IGCC)
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COMBINED CYCLE (IGCC)
GASIFIER
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GASIFIER
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LIST OF GE INSTALLATIONS
Project Power , MW Gas Turbine Main fuel - back
up fuel
Coal IGCC Experience
Coolwater 120 107E Coal
SUV Vresova 350 209E Coal
SVZ 70 1x106B Coal
Wabash 250 107FA Coal/Pet Coke
Tampa Polk 250 107FA Coal
Refinery IGCC Experience
Frontier 40 6B Pet Coke
Shell Pernis 120 206B Oil
Sarlux 550 3x109E Vis breaker tar
Motiva 180 2-6FA Pet Coke
Exxon Singapore 173 2-6FA Oil
Nexen/Opti 160 2-7EA Asphaltene
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LIST OF ANSALDO INSTALLATIONS
Project Power,MW GasTurbine Main fuel - backup fuel
Enil power
Ferrera
255 MW 1 x
V94.2K
77% Tar syngas +
13% Natural gas
Backup fuel -
natural gas
ISAB Priolo 2 x 250MW
2 xV94.2K
100% Tar syngasBackup fuel - fuel
oil
POWER PLANT BASIC VARIANT
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POWER PLANT BASIC VARIANT
Utility Power Plant : It will generate and supply only Electric power.
Mostly owned by SEBs, PSU, IPPs
Cogeneration Power Plant:
Simultaneous generation of Electric power and low/medium
pressure & temperature steam.
Most ideal for process industries wherein both electric
power (for driving electric motors) and steam for heating
process fluids will be required.
POWER PLANT BASIC VARIANT
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Captive Power Plant (CPP) : It refers to power plant set up by an
Industry for its own consumption.
Depending upon the type of Industry, CPP will be designed either as
an utility power plant or cogeneration plant.
The boilers will be designed for firing by-product fuels if anyavailable in the plant along with conventional fuels. (Eg.Blast
furnace gas and coke oven gas in steel plant; dolochar in sponge
iron plant; bagasse in sugar plant)
In some cases, the hot waste gases generated in the plant will be
used for producing steam (eg. waste gas from Sponge iron kiln, coke
oven)
BACKPRESSURE STEAM TURBINE BASED COGENERATION SYSTEM
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EXTRACTION-CUM-CONDENSING STEAM TURBINE BASEDCOGENERATION SYSTEM
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GAS TURBINE BASED COGENERATION SYSTEM WITH SUPPLEMENTARYFIRED WHRB
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RECIPROCATING ENGINE BASED COGENERATION SYSTEM WITH
UNFIRED WHRB
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UNFIRED WHRB