SUMMER INTERNSHIP REPORT

NTPC Noida

Submitted by: Shivani Yadav

1700895

B.Tech 3rd Year

(Mechanical Engineering)
ABOUT NTPC
India‟s largest power company, NTPC was set up in 1975 to accelerate power
development in India. NTPC is emerging as a diversified power major with presence in the
entire value chain of the power generation business. Apart from power generation, which
is the mainstay of the company, NTPC has already ventured into consultancy, power

trading, ash utilization and coal mining. NTPC ranked 341st in the „2010, Forbes Global
2000‟ ranking of the World‟s biggest companies. NTPC became a Maharatna company in
May, 2010, one of the only four companies to be awarded this status.

The total installed capacity of the company is 39,174 MW (including JVs) with 16 coal
based and 7 gas based stations, located across the country. In addition under JVs, 7
stations are coal based & another station uses naptha/LNG as fuel. The company has set
a target to have an installed power generating capacity of 1,28,000 MW by the year
2032. The capacity will have a diversified fuel mix comprising 56% coal, 16% Gas, 11%
Nuclear and 17% Renewable Energy Sources(RES) including hydro. By 2032, non-fossil
fuel based generation capacity shall make up nearly 28% of NTPC‟s portfolio.

NTPC has been operating its plants at high efficiency levels. Although the company has
17.75% of the total national capacity, it contributes 27.40% of total power generation
due to its focus on high efficiency.
In October 2004, NTPC launched its Initial Public Offering (IPO) consisting of 5.25%
as fresh issue and 5.25% as offer for sale by Government of India. NTPC thus became a
listed company in November 2004 with the Government holding 89.5% of the equity
share capital. In February 2010, the Shareholding of Government of India was reduced
from 89.5% to 84.5% through Further Public Offer. The rest is held by Institutional
Investors and the Public.
Strategies of NTPC

Technological Initiatives

• Introduction of steam generators (boilers) of the size of 800 MW.

• Integrated Gasification Combined Cycle (IGCC) Technology.
• Launch of Energy Technology Centre -A new initiative for
development of technologies with focus on fundamental R&D.
• The company sets aside up to 0.5% of the profits for R&D.
• Roadmap developed for adopting µClean Development.
• Mechanism to help get / earn µCertified Emission Reduction.
Corporate Social Responsibility

• As a responsible corporate citizen NTPC has taken up number of CSR initiatives.

• NTPC Foundation formed to address Social issues at national level
• NTPC has framed Corporate Social Responsibility Guidelines committing up
to0.5% of net profit annually for Community Welfare.
• The welfare of project affected persons and the local population
around NTPC projects are taken care of through well drawn
Rehabilitation and Resettlement policies.
• The company has also taken up distributed generation for remote rural areas

Partnering government in various initiatives

• Consultant role to modernize and improvise several plants across the country.
• Disseminate technologies to other players in the sector.
• Consultant role ³Partnership in Excellence´ Programme for improvement of
PLF of 15 Power Stations of SEBs.
• Rural Electrification work under Rajiv Gandhi Garmin Vidyutikaran.

Environment management
• All stations of NTPC are ISO 14001 certified.
• Various groups to care of environmental issues.
• The Environment Management Group.
• Ash tilization Division.
• Afforestation Group.
• Centre for Power Efficiency & Environment Protection.
• Group on Clean Development Mechanism.
• NTPC is the second largest owner of trees in the country after the
Forest department
Vision

“To be the world‟s largest and best power producer, powering India‟s growth.”

Mission

“Develop and provide reliable power, related products and services at

competitive prices, integrating multiple energy sources with innovative and eco-
friendly technologies and contribute to society.”

Core Values – BE COMMITTED

B Business Ethics

E Environmentally & Economically Sustainable

C Customer Focus

O Organizational & Professional Pride

M Mutual Respect & Trust

M Motivating Self & others

I Innovation & Speed

T Total Quality for Excellence

T Transparent & Respected Organization

E Enterprising

D Devoted

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JOURNEY OF NTPC

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NTPC Environment Policy

NTPC is committed to the environment, generating power at minimal environmental

cost and preserving the ecology in the vicinity of the plants. NTPC has undertaken
massive a forestation in the vicinity of its plants. Plantations have increased forest area
and reduced barren land. The massive a forestation by NTPC in and around its
Ramagundam Power station (2600 MW) have contributed reducing the temperature in
the areas by about 3°c. NTPC has also taken proactive steps for ash utilization. In 1991,
it set up Ash Utilization Division A

"Centre for Power Efficiency and Environment Protection- CENPEE" has been
established in NTPC with the assistance of United States Agency for International
Development- USAID. CENPEEP is efficiency oriented, eco-friendly and eco-nurturing
initiative - a symbol of NTPC's concern towards environmental protection and continued
commitment to sustainable power development in India. As a responsible corporate citizen,
NTPC is making constant efforts to improve the socio-economic status of
the people affected by its projects. Through its Rehabilitation and Resettlement
programmes, the company endeavors to improve the overall socio economic status
Project Affected Persons. NTPC was among the first Public Sector Enterprises to enter
into a Memorandum of Understanding-MOU with the Government in 1987-88. NTPC
has been placed under the 'Excellent category' (the best category) every year since the
MOU system became operative. Harmony between man and environment is the essence
of healthy life and growth. Therefore, maintenance of ecological balance and a pristine
environment has been of utmost importance to NTPC. It has been taking
various measures discussed below for mitigation of environment pollution due to
power generation.

NTPC is the second largest owner of trees in the country after the Forest department.

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As early as in November 1995, NTPC brought out a comprehensive document entitled
"NTPC Environment Policy and Environment Management System". Amongst the
guiding principles adopted in the document is company‟s proactive approach to
environment, optimum utilization of equipment, adoption of latest technologies and
continual environment improvement. The policy also envisages efficient utilization of
resources, thereby minimizing waste, maximizing ash utilization and providing green
belt all around the plant for maintaining ecological balance.

Environment Management, Occupational Health and Safety Systems:

NTPC has actively gone for adoption of best international practices on environment,
occupational health and safety areas. The organization has pursued the Environmental
Management System (EMS) ISO 14001 and the Occupational Health and Safety
Assessment System OHSAS 18001 at its different establishments. As a result of
pursuing these practices, all NTPC power stations have been certified for ISO 14001 &
OHSAS 18001 by reputed national and international Certifying Agencies.

Pollution Control systems:

While deciding the appropriate technology for its projects, NTPC integrates many
environmental provisions into the plant design. In order to ensure that NTPC complies
with all the stipulated environment norms, various state-of-the-art pollution control
systems / devices as discussed below have been installed to control air and water
pollution.

Electrostatic Precipitators:
The ash left behind after combustion of coal is arrested in high efficiency Electrostatic
Precipitators (ESPs) and particulate emission is controlled well within the stipulated
norms. The ash collected in the ESPs is disposed to Ash Ponds in slurry form.

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Flue Gas Stacks:
Tall Flue Gas Stacks have been provided for wide dispersion of the gaseous
emissions (SOX, NOX etc.) into the atmosphere.

Low-NOX Burners:
In gas based NTPC power stations, NOX emissions are controlled by provision of Low-
NOX Burners (Dry or wet type) and in coal fired stations, by adopting best combustion
practices.

Neutralization Pits:
Neutralization pits have been provided in the Water Treatment Plant (WTP) for pH
correction of the Effluents before discharge into Effluent Treatment Plant (ETP)
for further treatment and use.

Coal Settling Pits / Oil Settling Pits:

In these Pits, coal dust and oil are removed from the effluents emanating from the Coal
Handling Plant (CHP), coal yard and Fuel Oil Handling areas before discharge into ETP.

DE & DS Systems:
Dust Extraction (DE) and Dust Suppression (DS) systems have been installed in all coal
fired power stations in NTPC to contain and extract the fugitive dust released in the
Coal Handling Plant (CHP).

Cooling Towers:
Cooling Towers have been provided for cooling the hot Condenser cooling water in
closed cycle, Condenser Cooling Water (CCW) Systems. This helps in reduction in
thermal pollution and conservation of fresh water.

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Ash Dykes & Ash Disposal systems:
Ash ponds have been provided at all coal based stations except Dadri where Dry Ash
Disposal System has been provided. Ash Ponds have been divided into lagoons and
provided with garlanding arrangement for changeover of the ash slurry feed points
for even filling of the pond and for effective settlement of the ash particles.
Ash in slurry form is discharged into the lagoons where ash particles get settled from
the slurry and clear effluent water is discharged from the ash pond. The discharged
effluents conform to standards specified by CPCB and the same is regularly monitored.
At its Dadri Power Station, NTPC has set up a unique system for dry ash collection and
disposal facility with Ash Mound formation. This has been envisaged for the first time
in Asia which has resulted in progressive development of green belt besides far less
requirement of land and less water requirement as compared to the wet ash disposal
system.

Ash Water Recycling System:

Further, in a number of NTPC stations, as a proactive measure, Ash Water
Recycling System (AWRS) has been provided. In the AWRS, the effluent from ash
pond is circulated back to the station for further ash sluicing to the ash pond. This
helps in savings of fresh water requirements for transportation of ash from the plant.
The ash water recycling system has already been installed and is in operation at
Ramagundam, Simhadri, Rihand, Talcher Kaniha, Talcher Thermal, Kahalgaon,
Korba and Vindhyachal. The scheme has helped stations to save huge quantity of
fresh water required as make-up water for disposal of ash.

Dry Ash Extraction System (DAES):

Dry ash has much higher utilization potential in ash-based products (such as bricks,
aerated autoclaved concrete blocks, concrete, Portland pozzolana cement, etc.). DAES
has been installed at Unchahar, Dadri, Simhadri, Ramagundam, Singrauli, Kahalgaon,
Farakka, Talcher Thermal, Korba, Vindhyachal, Talcher Kaniha and BTPS.

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Liquid Waste Treatment Plants & Management System:
The objective of industrial liquid effluent treatment plant (ETP) is to discharge lesser
and cleaner effluent from the power plants to meet environmental regulations. After
primary treatment at the source of their generation, the effluents are sent to the ETP for
further treatment. The composite liquid effluent treatment plant has been designed to
treat all liquid effluents which originate within the power station e.g. Water Treatment
Plant (WTP), Condensate Polishing Unit (CPU) effluent, Coal Handling Plant (CHP)
effluent, floor washings, service water drains etc. The scheme involves collection of
various effluents and their appropriate treatment centrally and re-circulation of the
treated effluent for various plant uses.
NTPC has implemented such systems in a number of its power stations such as
Ramagundam, Simhadri, Kayamkulam, Singrauli, Rihand, Vindhyachal, Korba, Jhanor
Gandhar, Faridabad, Farakka, Kahalgaon and Talcher Kaniha. These plants have
helped to control quality and quantity of the effluents discharged from the stations.

Sewage Treatment Plants & Facilities:

Sewage Treatment Plants (STPs) sewage treatment facilities have been provided at all
NTPC stations to take care of Sewage Effluent from Plant and township areas. In a
number of NTPC projects modern type STPs with Clarifloculators, Mechanical
Agitators, sludge drying beds, Gas Collection Chambers etc. have been provided to
improve the effluent quality. The effluent quality is monitored regularly and treated
effluent conforming to the prescribed limit is discharged from the station. At several
stations treated effluents of STPs are being used for horticulture purpose.
OPERATION OF A POWER PLANT

Basic Principle

As per FARADAY‟s Law-“Whenever the amount of magnetic flux linked with a

circuit changes, an EMF is produced in the circuit. Generator works on the principle of
producing electricity. To change the flux in the generator turbine is moved in a great
speed with steam.” To produce steam, water is heated in the boilers by burning the coal.

In a Badarpur Thermal PowerStation, steam is produced and used to spin a turbine that
operates a generator. Water is heated, turns into steam and spins a steam turbine which
drives an electrical generator. After it passes through the turbine, the steam is condensed
in a condenser; this is known as a Rankine cycle.

The electricity generated at the plant is sent to consumers through high-voltage power
lines The Badarpur Thermal Power Plant has Steam Turbine-Driven Generators which
has a collective capacity of 705MW. The fuel being used is Coal which is supplied from
the Jharia Coal Field in Jharkhand. Water supply is given from the Agra Canal.
Basic Steps of Electricity Generation

The basic steps in the generation of electricity from coal involves following steps:

• Coal to steam
• Steam to mechanical power
• Mechanical power to electrical power

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Coal to Electricity : Basics

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PARTS OF A POWER PLANT

The various parts are listed below:-

1. Cooling tower
2. Cooling water pump
3. Transmission line (3-phase)
4. Unit transformer (3-phase)
5. Electric generator (3-phase)
6. Low pressure turbine
7. Condensate extraction pump
8. Condenser
9. Intermediate pressure turbine
10. Steam governor valve
11. High pressure turbine

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12. Deaerator
13. Feed heater
14. Coal conveyor
15. Coal hopper
16. Pulverised fuel mill
17. Boiler drum
18. Ash hopper
19. Super heater
20. Forced draught fan
21. Reheater
22. Air intake
23. Economiser
24. Air preheater
25. Precipitator
26. Induced draught fan
27. Flue Gas

1. Cooling Tower
Cooling towers are heat removal devices used to transfer process waste heat to the
atmosphere. Cooling towers may either use the evaporation of water to remove process
heat and cool the working fluid to near the wet-bulb air temperature or in the case of
closed circuit dry cooling towers rely solely on air to cool the working fluid to near the
dry-bulb air temperature. Common applications include cooling the circulating water used
in oil refineries, chemical plants, power stations and building cooling.
The towers vary in size from small roof-top units to very large hyperboloid structures
that can be up to 200 meters tall and 100 meters in diameter, or rectangular structures that
can be over 40 meters tall and 80 meters long. Smaller towers are normally factory-built,
while larger ones are constructed on site. The absorbed heat is rejected to the atmosphere
by the evaporation of some of the cooling water in mechanical forced-draft or induced

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Draft towers or in natural draft hyperbolic shaped cooling towers as seen at most nuclear
power plants.

2. Cooling Water Pump

it pumps the water from the cooling tower which goes to the condenser.

3. Three phase transmission line

Three phase electric power is a common method of electric power transmission. It is a type
of polyphase system mainly used to power motors and many other devices. A three phase
system uses less conductive material to transmit electric power than equivalent single
phase, two phase, or direct current system at the same voltage. In a three phase system,
three circuits reach their instantaneous peak values at different times.
Taking current in one conductor as the reference, the currents in the other two are delayed
in time by one-third and two-third of one cycle .This delay between “phases” has the
effect of giving constant power transfer over each cycle of the current and also makes it
possible to produce a rotating magnetic field in an electric motor. At the power station, an
electric generator converts mechanical power into a set of electric currents, one from each
electromagnetic coil or winding of the generator.
The current are sinusoidal functions of time, all at the same frequency but offset in
time to give different phases. In a three phase system the phases are spaced equally,
giving a phase separation of one-third of one cycle. Generators output at a voltage that
ranges from hundreds of volts to 30,000 volts.

4. Unit transformer (3-phase)

At the power station, transformers step-up this voltage to one more suitable for
transmission. After numerous further conversions in the transmission and distribution
network the power is finally transformed to the standard mains voltage (i.e. the
“household” voltage). The power may already have been split into single phase at this
point or it may still be three phase. Where the step-down is 3 phase, the output of this
transformer is usually star connected with the standard mains voltage being the phase-

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neutral voltage. Another system commonly seen in North America is to have a delta
connected secondary with a center tap on one of the windings supplying the ground
and neutral.
This allows for 240 V three phase as well as three different single phase voltages( 120
V between two of the phases and neutral , 208 V between the third phase ( or wild leg)
and neutral and 240 V between any two phase) to be available from the same supply.

5. Electrical generator
An Electrical generator is a device that converts kinetic energy to electrical energy,
generally using electromagnetic induction. The task of converting the electrical energy
into mechanical energy is accomplished by using a motor. The source of mechanical
energy maybe water falling through the turbine or steam turning a turbine (as is the case
with thermal power plants). There are several classifications for modern steam turbines.
Steam turbines are used in our entire major coal fired power stations to drive the
generators or alternators, which produce electricity. The turbines themselves are driven
by steam generated in "boilers “or "steam generators" as they are sometimes called.
Electrical power stations use large steam turbines driving electric generators to produce
most (about 86%) of the world‟s electricity. These centralized stations are of two types:
fossil fuel power plants and nuclear power plants. The turbines used for electric power
generation are most often directly coupled to their-generators .As the generators must
rotate at constant synchronous speeds according to the frequency of the electric power
system, the most common speeds are 3000 r/min for 50 Hz systems, and 3600 r/min for
60 Hz systems. Most large nuclear sets rotate at half those speeds, and have a 4-pole
generator rather than the more common 2-pole one.

6. Low Pressure Turbine

Energy in the steam after it leaves the boiler is converted into rotational energy as it passes
through the turbine. The turbine normally consists of several stages with each stages
consisting of a stationary blade (or nozzle) and a rotating blade. Stationary blades convert
the potential energy of the steam into kinetic energy and direct the flow onto the

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rotating blades. The rotating blades convert the kinetic energy into impulse and reaction
forces, caused by pressure drop, which results in the rotation of the turbine shaft. The
turbine shaft is connected to a generator, which produces the electrical energy.
Low Pressure Turbine (LPT) consists of 4x2 stages. After passing through Intermediate
Pressure Turbine steam is passed through LPT which is made up of two parts- LPC
REAR & LPC FRONT. As water gets cooler here it gathers into a HOTWELL placed
in lower parts of turbine.

7. Condensation Extraction Pump

A Boiler feed water pump is a specific type of pump used to pump water into a steam
boiler. The water may be freshly supplied or returning condensation of the steam
produced by the boiler. These pumps are normally high pressure units that use
suction from a condensate return system and can be of the centrifugal pump type or
positive displacement type.

Construction and operation:

Feed water pumps range in size up to many horsepower and the electric motor is usually
separated from the pump body by some form of mechanical coupling. Large industrial
condensate pumps may also serve as the feed water pump. In either case, to force the
water into the boiler, the pump must generate sufficient pressure to overcome the steam
pressure developed by the boiler. This is usually accomplished through the use of a
centrifugal pump. Feed water pumps usually run intermittently and are controlled by a
float switch or other similar level-sensing device energizing the pump when it detects a
lowered liquid level in the boiler. Some pumps contain a two-stage switch. As liquid
lowers to the trigger point of the first stage, the pump is activated. If the liquid continues
to drop, (perhaps because the pump has failed, its supply has been cut off or exhausted,
or its discharge is blocked) the second stage will be triggered. This stage may switch off
the boiler equipment (preventing the boiler from running dry and overheating), trigger an
alarm, or both.

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8. Condenser
The steam coming out from the Low Pressure Turbine (a little above its boiling pump)
is brought into thermal contact with cold water (pumped in from the cooling tower) in
the condenser, where it condenses rapidly back into water, creating near Vacuum-like
conditions inside the condenser chest.

9. Intermediate Pressure Turbine

Intermediate Pressure Turbine (IPT) consists of 11 stages. When the steam has been
passed through HPT it enters into IPT. IPT has two ends named as FRONT &
REAR. Steam enters through front end and leaves from Rear end.

10. Steam Governor Valve

Steam locomotives and the steam engines used on ships and stationary applications such as
power plants also required feed water pumps. In this situation, though, the pump was often
powered using a small steam engine that ran using the steam produced by the boiler a means
had to be provided, of course, to put the initial charge of water into the boiler (before steam
power was available to operate the steam-powered feed water pump).The pump was often a
positive displacement pump that had steam valves and cylinders at one end and feed water
cylinders at the other end; no crankshaft was required. In thermal plants, the primary purpose
of surface condenser is to condense the exhaust steam from a steam turbine to obtain
maximum efficiency and also to convert the turbine exhaust steam into pure water so that it
may be reused in the steam generator or boiler as boiler feed water. By condensing the
exhaust steam of a turbine at a pressure below atmospheric pressure, the steam pressure drop
between the inlet and exhaust of the turbine is increased, which increases the amount heat
available for conversion to mechanical power. Most of the heat liberated due to condensation
of the exhaust steam is carried away by the cooling medium (water or air) used by the surface
condenser. Control valves are valves used within industrial plants and elsewhere to control
operating conditions such as temperature, pressure, flow and liquid level by fully or partially
opening or closing in response to signals received from controllers that compares a “set
point” to a

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“process variable” whose value is provided by sensors that monitor changes in such
conditions. The opening or closing of control valves is done by means of electrical,
hydraulic or pneumatic systems.

11.High Pressure Turbine

Steam coming from Boiler directly feeds into HPT at a temperature of 540°C and at a
pressure of 136 kg/cm2. Here it passes through 12 different stages due to which its
temperature goes down to 329°C and pressure as 27 kg/cm2. This line is also called as
CRH – COLD REHEAT LINE. It is now passed to a REHEATER where its
temperature rises to 540°C and called as HRH-HOT REHEATED LINE.

12. Deaerator
A Deaerator is a device for air removal and used to remove dissolved gases (an alternate
would be the use of water treatment chemicals) from boiler feed water to make it non-
corrosive. A dearator typically includes a vertical domed deaeration section as the
deaeration boiler feed water tank. A Steam generating boiler requires that the circulating
steam, condensate, and feed water should be devoid of dissolved gases, particularly
corrosive ones and dissolved or suspended solids. The gases will give rise to corrosion
of the metal. The solids will deposit on the heating surfaces giving rise to localized
heating and tube ruptures due to overheating. Under some conditions it may give rise to
stress corrosion cracking. Deaerator level and pressure must be controlled by adjusting
control valves the level by regulating condensate flow and the pressure by regulating
steam flow. If operated properly, most deaerator vendors will guarantee that oxygen in
the deaerated water will not exceed 7 ppb by weight (0.005 cm3/L)

13. Feed water heater

A Feed water heater is a power plant component used to pre-heat water delivered to a steam
generating boiler. Preheating the feed water reduces the irreversibility involved in steam
generation and therefore improves the thermodynamic efficiency of the system. This
reduces plant operating costs and also helps to avoid thermal shock to the boiler

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metal when the feed water is introduced back into the steam cycle. In a steam power
(usually modelled as a modified Rankine cycle), feed water heaters allow the feed
water to be brought up to the saturation temperature very gradually. This minimizes the
inevitable irreversibility associated with heat transfer to the working fluid (water).

14. Coal conveyor

Coal conveyors are belts which are used to transfer coal from its storage place to Coal
Hopper. A belt conveyor consists of two pulleys, with a continuous loop of material- the
conveyor Belt – that rotates about them. The pulleys are powered, moving the belt and
the material on the belt forward.
Conveyor belts are extensively used to transport industrial and agricultural material,
such as grain, coal, ores etc.

15. Coal Hopper

Coal Hoppers are the places which are used to feed coal to Fuel Mill. It also has the
arrangement of entering Hot Air at 200°C inside it which solves our two purposes:-
1. If our Coal has moisture content then it dries it so that a proper combustion takes place.
2. It raises the temperature of coal so that its temperature is more near to its Ignite
Temperature so that combustion is easy.

16. Pulverized Fuel Mill

A pulveriser is a device for grinding coal for combustion in a furnace in a fossil
fuel power plant.

17. Boiler drum

Steam Drums are a regular feature of water tube boilers. It is reservoir of water/steam at
the top end of the water tubes in the water-tube boiler. They store the steam generated in
the water tubes and act as a phase separator for the steam/water mixture. The difference
in densities between hot and cold water helps in the accumulation of the “hotter”-
water/and saturated –steam into steam drum. Made from high-grade steel (probably

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stainless) and its working involve temperature of 390°C and pressure well above 350psi
(2.4MPa). The separated steam is drawn out from the top section of the drum. Saturated
steam is drawn off the top of the drum. The steam will re-enter the furnace in through a
super heater, while the saturated water at the bottom of steam drum flows down to the
mud-drum /feed water drum by down comer tubes accessories include a safety valve,
water level indicator and fuse plug.

18. Ash Hopper

A steam drum is used in the company of a mud-drum/feed water drum which is located
at a lower level.
So that it acts as a sump for the sludge or sediments which have a tendency to accumulate
at the bottom.

19. Super Heater

A Super heater is a device in a steam engine that heats the steam generated by the boiler
again increasing its thermal energy. Super heaters increase the efficiency of the steam
engine, and were widely adopted. Steam which has been superheated is logically known as
superheated steam; non- superheated steam is called saturated steam or wet steam. Super
heaters were applied to steam locomotives in quantity from the early 20th century, to most
steam vehicles, and also stationary steam engines including power stations.

20. Force Draught Fan

External fans are provided to give sufficient air for combustion. The forced draught
fan takes air from the atmosphere and, warms it in the air preheater for better
combustion, injects it via the air nozzles on the furnace wall.

21. Reheater
Reheater is a heater which is used to raise the temperature of steam which has fallen
from the intermediate pressure turbine.

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22. Air Intake
Air is taken from the environment by an air intake tower which is fed to the fuel.

23. Economizers
Economizer, or in the UK economizer, are mechanical devices intended to reduce energy
consumption, or to perform another useful function like preheating a fluid. The term
economizer is used for other purposes as well-Boiler, power plant, heating, ventilating
and air-conditioning. In boilers, economizer are heat exchange devices that heat fluids ,
usually water, up to but not normally beyond the boiling point of the fluid. Economizers
are so named because they can make use of the enthalpy and improving the boiler‟s
efficiency. They are devices fitted to a boiler which save energy by using the exhaust
gases from the boiler to preheat the cold water used to fill it (the feed water). Modern day
boilers, such as those in cold fired power stations, are still fitted with economizer which
is decedents of Green‟s original design. In this context there are turbines before it is
pumped to the boilers. A common application of economizer in steam power plants is to
capture the waste heat from boiler stack gases (flue gas) and transfer thus it to the boiler
feed water thus lowering the needed energy input , in turn reducing the firing rates to
accomplish the rated boiler output . Economizer lower stack temperatures which may
cause condensation of acidic combustion gases and serious equipment corrosion damage
if care is not taken in their design and material selection.

24. Air Preheater

Air preheater is a general term to describe any device designed to heat air before another
process (for example, combustion in a boiler). The purpose of the air preheater is to
recover the heat from the boiler flue gas which increases the thermal efficiency of the
boiler by reducing the useful heat lost in the flue gas. As a consequence, the flue gases
are also sent to the flue gas stack (or chimney) at a lower temperature allowing
simplified design of the ducting and the flue gas stack. It also allows control over the
temperature of gases leaving the stack.

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25. Precipitator
An Electrostatic precipitator (ESP) or electrostatic air cleaner is a particulate device that
removes particles from a flowing gas (such as air) using the force of an induced
electrostatic charge. Electrostatic precipitators are highly efficient filtration devices, and
can easily remove fine particulate matter such as dust and smoke from the air steam.
ESPs continue to be excellent devices for control of many industrial particulate
emissions, including smoke from electricity-generating utilities (coal and oil fired), salt
cake collection from black liquor boilers in pump mills, and catalyst collection from
fluidized bed catalytic crackers from several hundred thousand ACFM in the largest coal-
fired boiler applications. The original parallel plate-Weighted wire design (described
above) has evolved as more efficient (and robust) discharge electrode designs, today
focus is on rigid discharge electrodes to which many sharpened spikes are attached ,
maximizing corona production. Transformer –rectifier systems apply voltages of
50-100 Kilovolts at relatively high current densities. Modern controls minimize sparking
and prevent arcing, avoiding damage to the components. Automatic rapping systems and
hopper evacuation systems remove the collected particulate matter while on line
allowing ESPs to stay in operation for years at a time.

26. Induced Draught Fan

The induced draft fan assists the FD fan by drawing out combustible gases from the
furnace, maintaining a slightly negative pressure in the furnace to avoid backfiring
through any opening. At the furnace outlet and before the furnace gases are handled
by the ID fan, fine dust carried by the outlet gases is removed to avoid atmospheric
pollution. This is an environmental limitation prescribed by law, which additionally
minimizes erosion of the ID fan.

27. Flue gas stack

A Flue gas stack is a type of chimney, a vertical pipe, channel or similar structure through
which combustion product gases called flue gases are exhausted to the outside air. Flue gases
are produced when coal, oil, natural gas, wood or any other large combustion