PANKI THERMAL POWER STATION, KANPUR

COAL FIRED THERMAL POWER PLANTS,

INTRODUCTION
Heat engines were developed around two hundred years ago to convert low grade
thermal energy into high grade mechanical energy. With invention of better materials
and development of theories to explain the working and evaluate the performance of
heat engines, it could become possible to convert more and more thermal energy into
mechanical energy. Coal fired power generating station is a sort of external combustion
heat engine, which operates on Rankine cycle with water as a standard working fluid.
Reheating and regenerative feed heating arrangements improve the performance of
power plants.
Conventional power plants are evaluated for performance through various
performance evaluation criteria (PEC), like Plant Load Factor (PLF), Loading Factor,
Partial Loading, Forced Outages, Auxiliary Power Consumption, Specific Oil
Consumption, Specific Coal Consumption etc. Most common criterion used for
performance evaluation is PLF, however the most important parameter from the point of
view of energy conversion is thermal efficiency (Heat Rate), which is calculated
frequently for boiler, turbine and for the entire plant.
HEAT ENGINE
A heat engine, in broader sense can be defined as a device which converts low
grade thermal energy into high grade mechanical energy. Internal combustion engines,
gas turbines, thermo electric power generators, steam turbine power plants, steam
engines etc. are the examples of heat engines. However in more restricted sense and
most commonly a heat engine is defined as a device that operates on thermodynamic
cycle and produces a net positive mechanical work through heat absorption from a high
temperature reservoir and heat rejection to a low temperature reservoir. The device
uses a working fluid, which goes under change of thermodynamic state to complete the
thermodynamic cycle during heat absorption and heat rejection processes. The
thermodynamic cycle employed for producing mechanical work is called power cycle.
QA

Boiler
Turbine

Figure 1, simple steam power

plant or a heat engine.

Work
out-put

Work to
Pump
Condenser
Pump

System boundary
QR

A simple coal fired steam power plant, shown in Figure 1, is an example of heat
engine. It works with water (steam) as a working fluid. An amount of heat QA is
absorbed from the high temperature reservoir, which is produced in the furnace (boiler)
by means of combustion of coal. A portion of the turbine work is utilized to run the pump
1

and the remaining work is the net positive mechanical output produced by the engine.
The quantity of heat QR is rejected to the low temperature reservoir, which is normally
the cooling water in a condenser.
COAL FIRED POWER PLANT
Conventional coal fired power generating plants operate on Rankine cycle with water
as standard working fluid. The most common design of these power-generating units
are 100/110 MW, 200/210 MW or 500 MW with features of reheating and regeneration.
In general, one reheating at reduced pressure and up-to main steam temperature is
provided. There are five to seven regenerative feed water heaters. The main steam at
the inlet of turbine is kept at 535-540 oC temperature and 13.0-14.0 MPa pressure. The
plants are equipped with pulverized coal combustion system.
Designed thermal efficiency of the coal plants installed during last 20 years is 3638%. However in India the old units commissioned during 70s, are still in use, and
comprise a considerable percentage of total installed capacity. Designed thermal
efficiency of these units is 31-33 %.
Most of the power plants proposed to be installed in future are based on Super
Critical Technology. These plants operate on thermal efficiency of about 41-42%. The
first Supercritical power generating unit in India started recently by Adani Power. Other
units are likely to be installed at Sipat & Barh Thermal Power Plants of NTPC.
RANKINE CYCLE
Cycle of operation of heat engines may be plotted on different thermodynamic planes
by assuming ideal or hypothetical reversible processes which represent the basic
desired operations. A Rankine cycle as shown on enthalpy-entropy (h-s) and
temperature-entropy (T-s) planes in Figure 2 represents the operational cycle of a
simple steam power plant.
This Rankine cycle is an ideal reversible cycle consisting of reversible constant
pressure heating process in boiler (4-1) to convert water into steam, reversible adiabatic
expansion of steam in turbine (1-2) to convert thermal energy of steam into mechanical
work, reversible constant pressure heat rejection during condensation of steam in
condenser (2-3) and reversible adiabatic compression of feed water (saturated liquid) to
the boiler pressure by boiler feed pump (3-4).
h
T

4
2
4

Figure 2. Ideal Rankine cycle on h-s and T-s plane.

The Rankine cycle deviates from Carnot cycle due to heat addition in boiler across a
temperature difference. This temperature difference between the combustion gases and
the working fluid at high temperature reservoir, as shown in Figure 3, along with the
temperature difference between condensing working fluid and condenser cooling water
at low temperature reservoir, causes external irreversibilities which decrease the
thermal efficiency of Rankine cycle comparing with the efficiency of a Carnot cycle
operating between the same sources of heat absorption and heat rejection.
Flow rate through turbine and boiler feed pump is large and expansion &
compression processes in turbine and pump are rapid enough that heat loss per unit
mass may be neglected and processes may be assumed as adiabatic. However, due to
the presence of fluid friction the expansion processes in turbine and compression
processes in pump are not reversible and entropy of the fluid increases in both cases.
The actual process of expansion and compression in a Rankine cycle is shown in
Figure 4.
a
T

Combustion Gases
1
b

4
3

2
d
Cooling Water

c
s

Figure 3 External irreversibilities due to temp difference.

T

4
4
2
3

s
Figure 4, Rankine cycle with actual expansion & pumping processes.

REGENERATIVE FEED HEATING

To reduce the irreversibilities during heat addition in boiler, the feed water is supplied
in the boiler at elevated temperature. High feed water temperature at the inlet of the
boiler reduces the average temperature difference across which heat transfer takes
place in the boiler and thus reduces irreversibilities. In other sense there is an increase
in average temperature of heat addition, which results in higher thermal efficiency of
regenerative feed heating cycle. This improvement in thermal efficiency may also be
explained with the fact that heat rejection in condenser is reduced due to extraction of
steam from turbine for feed heating.
The feed water is heated in regenerative feed water heaters through steam extracted
from the turbine at one or more points after expansion through certain stages of turbine.
Feed water heaters may be an open type or a closed type heat exchanger. In an open
or direct contact type feed water heater, the extracted steam from turbine is mixed with
condensate (or feed water) to heat it up and condensate leave the heater at elevated
temperature. In a closed or surface type feed water heater, feed water flows through
the tubes and extracted steam is condensed in a shell outside the tubes.
This
condensate, usually at the saturation temperature of extracted steam pressure (also
called heater drip) then passes to the next lower pressure heater or added to the
condensate leaving heater by means of a drip pump. The drip of heater if passes to a
lower pressure heater, is finally discharged at the hot well of the condenser or added to
the condensate by means of a drip pump from the lowest pressure heater.
A typical feed heating arrangement with two feed water heaters is shown in Figure 5.
The feed water is heated from point 7 to 6 through extraction taken out at point 3 and
heated from point 6 to 5 through extraction bled off at point 4. Subsequently it is heated
in economizer (not shown in fig) and supplied to the boiler.

1
Boiler
Work
Output

Turbine
Fuel
Input

2
4
5
B

A - Feed heater;

3
A

8
Condenser

B - Drip pump;

C - Condensate pump

Figure 5, A typical regenerative feed heating cycle with two heaters.

REHEATING:
To avoid the erosion and corrosion problems due to wetting of steam in later stages
of expansion in a turbine, the steam is reheated at some intermediate pressure. It is
done by taking out entire quantity of steam from turbine at some suitable intermediate
pressure, where it tends to become wet and reheating it up to about same initial
temperature in the boiler through subsequent heat addition by means of flue gases or
4

live steam. Reheating of steam increases the final dryness fraction, nozzle and blade
efficiencies, turbine output power and also the thermal efficiency of the cycle over an
equivalent non reheat cycle. However, comparing with additional capital and
maintenance cost incurred in reheating, the improvement in efficiency (which is only 4-5
%) is marginal. A typical coal power plant with one reheating and three numbers of feed
heating is shown in Figure 6.
3
2
Boiler

Fuel
Input

HP
Turbine

8
9

B
A - Feed heater;

L P Turbine

6
A

Work
Output

B - Drip pump;

C - Condensate pump

Condenser

Figure 6, Power plant cycle with one reheat and three feed water heaters.
Supercritical & Ultra Supercritical Technology of Power Generation:
Taken from source: http://www.thermalpowerplantsindia.com/super-critical-thermal-power-plants
(may not be exact y correct)
Supercritical thermal power plants have greater power output and higher efficiency levels.
These plants also have the best pollution control technology.
Supercritical thermal power plants function at a very high temperature of 580 degree centigrade
and pressure of 23 MPa. This results in a heat efficiency of 45% as compared to the 38 - 40%
generated by sub - critical coal fire plants. Supercritical thermal power plants have many
advantages like:
Improved efficiency in plant functioning
Reduced fuel costs
Less environmental pollution due to less CO2 emission
Low NO x, SO x and emission of other particles
Can be integrated with CO2 capture technology.
As more and more plants adopt supercritical thermal power plant technology, they benefit
tremendously by improving the lower heating value from 38-40% to more than 45% and also by
reducing the emissions of CO2, NO x, SO x and particulate matters.
Supercritical is a thermodynamic term that explains the state of a substance where there is no
distinction between the liquid and gaseous state. When water is heated beyond boiling point,
the temperature remains constant at 100 degree C until all the water is converted to steam.
Further heating will increase the temperature of the steam. Increase in pressure increases the
boiling temperature and the latent heat of vaporisation decreases. As we keep on increasing the
temperature and pressure, it leads to a stage where the latent heat of vaporisation is zero and
the boiling stops. Water directly becomes steam. This point is Critical Pressure and Critical

Temperature.
Supercritical thermal power plants operate at pressures much higher than critical pressure. The
operating pressures are in the range of 230 to 265 bar. Supercritical thermal power plants can
use various turbine designs, which can give more output due to its elevated temperature and
pressure. However, special care has to be taken while selecting materials for the high-pressure
turbine section and the wall of the turbine.
Supercritical thermal power plants perform better with good steam conditions. Steel with 12%
chromium content gives up to 30 MPa / 600C / 620C steam conditions. Austenite, an
expensive material gives up to 31.5 MPa / 620C / 620C. Nickel based alloys give 35 MPa /
700C / 720C providing a power efficiency of up to 48%.
The pressure and temperature can be increased further more in Ultra Supercritical Steam
Condition. Raising the temperature to 760C and pressure to 42 MPa, the thermal efficiency
can be increased up-to 52%.
Now, supercritical thermal power plants are set up as integrated plants with CO2 capture
facilities. CO2 had been tried and tested by many countries to increase oil production in the oil
fields.

Indian Power Sector at a Glance, as on 31-03-2013, Pl collect information from

net
Total Installed Capacity Sector wise:
Sector Wise
State Sector
Central Sector
Private Sector
Total

MW

Fuel Wise
Total Thermal

MW

%age

100
%age

Coal
Gas
Oil
Hydro (Renewable)
Nuclear
RES** (MNRE)
Total

100

Renewable Energy Sources (RES) include SHP, BG, BP, U&I and Wind Energy. SHP= Small
Hydro Project , BG= Biomass Gasifier ,BP= Biomass Power, U & I=Urban & Industrial Waste
Power, RES=Renewable Energy Sources
INTRODUCTION OF PANKI THERMAL POWER STATION
(A) BRIEF HISTORY OF THE PLANT
Panki Thermal Power Station (PTPS) located about 16 kilometers away from Kanpur
railway station, between Kalpi road and Grant Trunk road, was started in 1967-68 with two units
of 32 MW each (unit no. I & unit no. II). Subsequently two more units of 110 MW each (unit no.
III & unit no. IV) were added in 1976-77 as Panki extension stage. Unit No. I & II (2X32 MW

units) had become old and obsolete. Those units are now closed and permanently deleted from
the installed capacity. Unit No. III & IV (2X110 MW) are running with annual average PLF of
about 65-70 %, contributing to around 1100 1200 million units of electricity generation per
year to the nation.
PTPS is uniquely located at the geographical centre of the state in between generation and load
blocks of the state. Its reliable operation is very important for stability of the northern grid.
(B) DETAILS OF GENERATING UNITS
Unit No. I (32 MW)
The first unit of Panki Thermal Power Station commissioned on 4th Oct 1967 for commercial
loading was consist of Wagnner Biro, Austria make boiler and T.G. Jugoturbina, Yugoslavia
make turbo-generating set. The unit was closed on 30th November 1995 due to damage of its
turbine and permanently deleted from installed capacity of the station by the Central Electricity
Authority (CEA) w.e.f. 31st Aug 1999.
Unit No. II (32 MW)
The second unit of Panki Thermal Power Station commissioned on 14th July 1968 for
commercial loading was similar to that of unit I. The unit was closed on 18th April 1997 and
permanently deleted from installed capacity of the station w.e.f. 10th June 2005.
Unit No. III & IV (2X110 MW units)
2X110 MW units of Panki Thermal Power Station were manufactured, supplied, installed and
commissioned by M/S BHEL, India during 1976-77. The units are exactly identical. These units
have been de rated to 105 MW each by the Central Electricity Authority (CEA) w.e.f. 11th Jan
1990 resulting in present installed capacity of station as 210 MW.
With increasing global awareness for environmental impacts of coal fired power generation and
stringent pollution norms fixed by the Govt. of India, the units were equipped with modern
Electro Static Precipitators (ESPs) in Jan 1993 (unit III) and July 1996 (unit IV).

Vivek Asthana
Executive Engineer
viana29@rediffmail.com
May 2013

Ceiling S/H inside at the top roof of Boiler

Boiler Drum
Platen

Exit S/H

Re heater

S/H

Down
Comers

Furnace Exit

Primary Super
heater

Primary Air
(PA) Fan

P C Bunker
Tri Flux

Air
Heater
Air Heater III

Chamber
(Furnace)

III
Platen SH

(PC) Feeder

Secondary wind box

Pulverized Coal

PC+Primary Air

Combustion

Mixing
P A Wind

Secondary
Air

Economizer

Air Heater

II

Air Heater

Air from
FD Fan

Nozzle

Box

Flue Gases to
Chimney through ESP

Locations for various heat exchangers inside the boiler

Reheated steam from boiler

Main steam from boiler

Steam from IP to LP Turbine

Steam to boiler
for reheating
HP Turbine

IP Turbine

HP- High pressure

IP- Intermediate pressure
LP- Low pressure

Generator

LP Turbine

Exhaust steam to
condenser

Exhaust steam to
condenser

Figure Arrangement for HP, IP and LP Turbines

HPH- High pressure heater

LPH- Low pressure heater
BFP- Boiler feed pump
GSC- Gland steam condenser
CSC- Chimney steam condenser
PRS- Pressure reducing station
CEP- Condensate extraction pump

HRH
CRH
Re-heater
Main

HP

IP Turbine

LP Turbine

Drip

Drip
Drip

10

Drip

Drip from
Expander

Generator

Condenser
Cooling
Water

LPH I

Drip Hot well

Steam from PRS

CEP
Ejector

Drip

Drip

2nd
Extraction

LPH II

Steam from PRS

CSC
Drip

Steam from PRS

LPH

LPH

LPH V

HPH I

GSC

5th Extraction

8th Extraction
HPH II

Deaerator

BFP

Exhaust steam

3rd Extraction

Drip

1st Extraction

Exhaust steam

7th Extraction

4th Extraction

6th Extraction

Economize
r

Boiler

Drips to Expander

Drip to Expander

Raw Coal
Vapor Fan
HPT

IPT

Boiler

RCB

LPT

Boiler
Drum

Generator

Exit SH
Re heater

Down
Comers
(Water)

Cyclone
Pulverizer

Water to
Drum

Primary Air

Conv SH

Steam from
Drum

Economizer
Primary Air
Fan

PCB

PCF
Hot Flue
Gases

Condenser

Deaerator

Combustion
Chamber
(Furnace)

HPHs

LPHs

BFP

CEP

Air from atmosphere

Secondary
Air

Air Heater
Forced Draft Fan
To Stack

Cold Air

Wind
Box

Flue Gases to
Chimney through
ESP & ID Fan

Mixing
Nozzle

Induced Draft Fan

ESP

Legends:
RCB- Raw coal bunker
PCB- Pulverized coal bunker
PCF- Pulverized coal feeder
HPT- High pressure turbine
IPT- Intermediate pressure turbine
LPT- Low pressure turbine

Legends:
HPH- High pressure heater
LPH- Low pressure heater
BFP- Boiler feed pump
CEP- Condensate extraction pump
ESP- Electro static precipitator

Figure Schematic for conventional coal power plant

11

Boiler Drum

Ceiling SH

Primary SH

Exit SH

Platen SH

Main Steam
Attemperation-I

Attemperation-II

Re heater
Economizer

Triflux
Main steam to turbine

Water for

L P Turbine

Attemperation

HP Turbine
Water from

I P Turbine

Arrangement for super heating and reheating of steam

HPH-II
12

To Condenser