Bokaro Thermal Power Station (BTPS) is a coal-based power plant located in Jharkhand with an installed capacity of 630 MW, commissioned in 1986. The plant utilizes conventional thermal power generation methods, employing facilities like coal handling, water treatment, boilers, and turbines to convert coal into electricity. Key components include economizers, super heaters, condensers, cooling towers, and electrostatic precipitators for efficient operation and environmental compliance.

1. JIS COLLEGE OF ENGINEERING

2. Introduction
 Bokaro Thermal Power Station (BTPS ) is located at Bokaro district in Jharkhand 44 km from the
bokaro steel city and is about 55 km from Dhanbad city. The nearest railway station is Bokaro
Thermal. The power plant is one of the coal based power plants of DVC. Bokaro Thermal Power
Station has an installed capacity of 630 MW. The First unit was commissioned in March 1986. The
station is located on the banks of the Konar River near Bokaro Thermal Power Station. Entire power
generated by the plant is supplied to DVC network.

3. INTRODUCTION OF THERMAL POWER PLANT
 Thermal power generation plant or thermal power station is the most conventional
source of electric power. Thermal power plant is also referred as coal thermal power
plant and steam turbine power plant.
 In coal thermal power plant, the steam is produced in high pressure in the steam boiler
due to burning of fuel (pulverized coal) in boiler furnaces.
 This supper heated steam then enters into the turbine and rotates the turbine blades.
 In turbine this steam force rotates the turbine blades that means here in the turbine the
stored potential energy of the high pressured steam is converted into mechanical energy.

4. 1. Coal handling plant
2. Water Treatment Plant
3. Boiler
4. Steam Turbine
5. Economizer
6.Turbine
7. Generator
8. Super heater
9.Condenser
10. Ash handling plant
11. Electrostatic Precipitator
12.Cooling Tower
13. Chimney

5. COAL HANDLING PLANT(CHP)
 In a coal based thermal power
plant, the initial process in the
power generation is “Coal
Handling”.
 The huge amount of coal is
usually supplied through
railways. A railway siding line is
taken into the power station and
the coal is delivered in the
storage yard.
 The coal is unloaded from the
point of delivery by means of
wagon tippler.

6.  Conveyors convey coal from one point to another with the help of Belts,
Pulleys and idlers. Conveyor belts are made of Polyester or Nylon.

7. Action of coal as a fuel:-
 There are mainly three classifications of coal: Anthracite, Bituminous and
Lignite. Lignite has the lowest grade of coal whereas anthracite is the highest
one. Power plants generally use steam coal which is a grade between
anthracite and bituminous.
 Coal is first milled to a fine powder, which increases the surface area and
allows it to burn more quickly. In these pulverized coal combustion systems,
the powdered coal is blown into the combustion chamber of a boiler where it
is burnt at high temperature

The hot gases and heat energy produced converts water – in tubes lining the
boiler – into steam. The steam drives turbines which results in the generation
of electricity

8. Water treatment plant
 Raw water which is taken from intake contains a lot of impurities in the form
of dissolves gases and other micro-organic component, however the water
used in the power plant must be free from all types of impurities so water get
treated before it used in plants. For which water is first deaerated and then
by the help of a separator the micro-organic components and the other heavy
impurities settled down at a section of the tank and then blown off

9. Demineralized water also known as Deionized water, water that has had its
mineral ions removed. Mineral ions such as cations of sodium, calcium,
iron, copper, etc. and anions such as chloride, sulphate, nitrate, etc. are
common ions present in water. Deionization is a physical process which
uses specially-manufactured ion exchange resins which provides ion
exchange site for the replacement of the mineral salts in water with water
forming H+ and OH- ions. Because the majority of water impurities are
dissolved salts, deionization produces a high purity water that is generally
similar to distilled water, and this process is quick and without scale build
up.
PRINCIPLE: Raw water is passed via two small polystyrene bead filled (ion
exchange resins) beds. While the cations get exchanged with hydrogen
ions in first bed, the anions are exchanged with hydroxyl ions, in the
second one.

10. Boiler and accessories
A boiler is usually a closed vessels type device used to
create steam by applying heat energy to water. Boiler is
generally of two types water tube boiler and fire tube
boiler depending upon the requirement it often used.
Coal is burned inside the combustion chamber of boiler.
the products of combustion are nothing but gases.
these gases which are at high temperature
vaporize the water inside the boiler to steam.

11. Ash handling plant
 A large quantity of ash is, produced in steam power
plants using coal.
 Ash produced in about 10 to 20% of the total coal
burnt in the furnace.
 A modern 2000MW plant produces about 5000
tons of ash daily.
 Fly ash is collected with an electrostatic
precipitator(ESP).
 The stations use some conveyor arrangement to
carry ash to dump sites directly or for carrying
and loading it to trucks and wagons which
transport it to the site of disposal

12. Accessories of a boiler
Economizer :- An economizer is a device used to heat feed water by utilizing the
heat in the exhaust flue gases before leaving through the chimney. Economizer
improves the economy of the steam boiler
Air preheater :-An air preheater (APH) absorbs waste heat from flue gas and
transfers this heat to incoming cold air. APHs are typically used in Fired Heaters,
Reformers, Process Furnaces, Boilers and other similar equipment to achieve high
levels of thermal efficiency
Super heater :-A superheater is a device used to convert saturated steam or wet
steam into superheated steam or dry steam. Super heaters are used in steam
engines or in processes, such as steam reforming.
Re heater:- it is a type of super heater which is used to reheat the low pressure
steam.

13. Stem turbine
About 86% of all electric generation in the world
is by use of steam turbines.
In a thermal power plant generally 3 turbines are
used to increase the efficiency.
High Pressure Turbine(HPT):- The Superheated
steam is directly fed to this turbine to rotate it.
Intermediate Pressure Turbine(IPT):- The output
from the HPT is reheated in a reheater and used
to rotate IPT.
Low Pressure Turbine(LPT):- The exhausted steam
from IPT is directly fed to rotate the shaft of LPT.
All the turbines are connect to a single shaft
which is connected to the generator.

14. Cross section view of turbines

15. Converts mechanical energy into electrical energy. Turbine is coupled with the Turbo-generator
that normally spins at 3000 rpm in countries with 50 Hz supply frequency
The generated voltage is stepped up in Generator Transformer and the power is
evacuated through transmission line feeders.

16. condenser
Theses condensers are heat exchangers which
covert steam from its gaseous to its liquid
state, also known as phase transition.
It creates a very low pressure at the exhaust
of turbine, this helps in converting heat
energy of steam into mechanical energy in the
prime mover.
The condensed steam can be used as feed
water to the boiler.

17. Cooling tower
Remove heat from the water discharged
from the condenser so that the water can be
re circulated and reused.
Air can be circulated in the cooling towers
through natural draft and mechanical draft.
In BTPS each unit has one cooling tower
consisting of 10 independent cells, each
with its own induced draft fan, water supply
& distribution grid.
An eight blade constant speed fan revolving
at 114 rpm discharges warm saturated air
through a kinetic energy recovery stake
from each cell.

18. Electro static precipitator
 The principal components of an ESP are 2 sets of
electrodes insulated from each other.
 First set of rows are electrically grounded vertical
plates called collecting electrodes while the
second set consists of wires called discharge
electrodes.
 The negatively charged fly ash particles are driven
towards the collecting plate and the positive ions
travel to the negatively charged wire electrodes.
 Collected particulate matter is removed from the
collecting plates by a mechanical hammer
scrapping system

19.  A chimney may be considered as
a cylindrical hollow tower made
of bricks or steel. In BTPS the
chimneys of eight units are
made of bricks.
 Chimneys are used to release
the exhaust gases (coming from
the furnace of the boiler) high
up in the atmosphere. So, the
height of the chimneys are
made high.