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THERMAL POWER HOUSE
CHEMISTRY
AT
KODERMA THERMAL POWER STATION
DAMODAR VALLEY CORPORATION
VOCATIONAL TRAINING REPORT
WITH EFFECT FROM :- 11/10/2017 TO 30/10/2017
Submitted by:-
Yashwant Yadav
M.Sc. 3rd
semester
Chemistry
Session:- 2016-18
Vinoba Bhave University
(Hazaribagh) Submitted to:-
Dr. Sanjoy Kumar Sinha
Manager (Chemist)
DVC, KTPS Banjhedih
ACKNOWLEDGEMENT
HOW MUCH THIS TRAINING WAS HELPFUL TO ME
The training at the DVC KTPS Banjhedih was very much helpful to me.
It is a matter of great pleasure and privilege for me to present this report
of 20 days on the practical knowledge gained by me during practical
training at KTPS Banjhedih, Koderma during session 11 oct 2017 to 30
oct 2017.
I attribute heartiest thanks to Dr. Sanjoy Kumar Sinha along with
Chemist Mr. Arun Kumar Parmanik , Mr. Shashi Bhushan ,Mrs. Kumari
Priti and Mr. Bhutnath Rajwar, Mr. Chandresh Kumar, Mr. Shushil Tuddu
and greatly thanks to Dy. Manager (Chemist) Mr. Rasikan J. Bhengra. As
well as workers of the chemical lab. The project has been prepared
based on the vocational training undergone in a highly esteemed organi-
zation of Eastern region , a pioneer in Generation, Transmission & Distri-
bution of power , one of the most technically advanced & largest
thermal power station in Jharkhand, the KTPS Banjhedih under DVC.
Koderma Thermal Power Station providing me such opportunity to
undergo training in the DVC, KTPS. I would also like to thank the senior
chemists, highly experienced without whom such type of concept build-
ing in respect of thermal power station would not have been possible.
INDEX
Introduction
(a) Damodar Valley Corporation
(b) Necessity of the power plant
(c) Koderma thermal power station
Water chemistry & analysis
(a) Raw water
(b) Aerator
(c) Clarifier
(d) Filter house
(e) Demineralization plant {DM- plant}
(f) Boiler water chemistry
(g) Chlorination plant
Coal chemistry & analysis
(a) Introduction
(b) Sample preparation
(c) Proximate analysis
(d) GCV analysis
INTRODUCTION
Electricity generation is the process of generating electric power
from other source of energy. Generally in KTPS, thermal power plant
prime mover is steam. When water is heated turns into steam and
steam passes through the turbine moves and electric produced, this
process is repeated again and again. Coal is the energy & water is the
blood for the thermal power plant. Some prefer to use the term en-
ergy because such facilities converted forms of heat energy into
electrical energy.
DAMODAR VALLEY CORPORATION
Damodar Valley Corporation (DVC) is the first multipur-
pose river valley project of independent India formed in July 7,
1948.
DVC has its command area of approx 24,235 sq. kms. The
upper valley consists of two districts (Dhanbad & Bokaro) and
eight districts partly (Hazaribagh, koderma, Giridih, chhatra,
Palamu, Ranchi, Lohardaga & Dumka) in Jharkhand. The lower
valley consists of five districts partly (Burdwan, Hooghly,
Hawrah, Bankura & purulia) in West Bengal.
DVC was set up with the intent of promoting and operat-
ing schemes for social and economic upliftment in the valley
region and has been successfully doing the same for more than
six decades un perfect harmony. Effective water management
by the corporation has turned the devastating river Damodar
from ‘River of Sorrow’ to a ‘River of Prospects and Opportuni-
ties’. DVC facilitated irrigation, industrial and domestic water
supply, soil conservation and promotion of social integration in
the valley area.
DVC has been generating, transmitting and distributing
electrical energy since 1953 and has successfully met the ex-
pectation of the consumers to a great height. For a period of
more than 68 years. DVC has maintained a lead role in the
eastern region, meeting the challenges of time and new tech-
nologies.
KODERMA THERMAL POWER STATION
This site is located at Banjhedih, block-Jainagar, dist-
Koderma, Jharkhand. The site is 5 KM far from Barakar river.
The nearest railway stations are Herodih & koderma junction.
Line of eastern railways passes about 1.5 KM from site. The wa-
ter requirement of the thermal power plant including expan-
sion will be from Barkar river Telaiya Dam. A closed cycle circu-
lating water system is proposed. Make up water requirement
for present stage of the plant is estimated at 2800m3
/day.
NECESSITY OF THE POWER PLANT
“Power to progress”
Energy provides the powers to progress. The natural re-
sources of a country may be turned into wealth if they are de-
veloped, used and exchanged for other goods this cannot be
achieved without energy. Availability of sufficient energy and
its proper use in any country can result in this people using
from substaintial level to the highest standard of living. It has
been found that countries whose national output is mainly ag-
ricultural and whose population lives mostly in rural communi-
ties enjoy low per capita growth of energy consumption is
dependent is the extent to which industrial activity forms a part
of its energy usage a distinct changes. Once energy is made
suitable in excess of domestic needs it has been round that it is
not used solely as a consumer good but becomes factor of pro-
duction.
A growing proportion of energy is being met all over the
world the electricity. This trend will further be stimulated be-
cause of increasing availability of clean electricity. This applies
especially to developing countries because their industrial pro-
gress will be based on modern technologies, which gererally
use electricity intensively.
WATER CHEMISTRY & ANALYSIS
The purest available form is from water vapour in atmosphere, as
rain, snow or produced by melting of ice. Water on reaching the
ground absorbs different types of gases from atmosphere like nitro-
gen, oxygen and to a lesser extent carbon dioxide. Other gases like
ammonia, oxides of nitrogen and sulphur etc. , also dissolves during
rain depending upon the pollution level of the atmosphere. Apart
from this, the surface water travels to various places and catches or-
ganic matter, suspended solids etc.
SOURCES OF WATER
Following are water sources given below
1. Rivers, lakes and reservoirs (surface drainage water)
2. Underground water (shallow well, deep well, springs)
3. Rain water
4. Sea water
5. Snow melting
RAW WATER
Raw water is natural water found in the environment and has not
been treated, nor have any minerals, ions, particles or living organ-
isms been removed. Raw water includes rainwater, ground water,
water from infiltration wells, and water from bodies like lakes and
rivers. Without treatment, raw water can be used for farming, con-
struction or cleaning purposes, water in this form is considered raw
water.
COMPOSITION
The composition of raw water is naturally variable, but commonly
contains one or more of the following significant contaminants, in
the form of dissolved ions, particles and living organisms :-
 Minerals which make water hard. Most common are car-
bonates of calcium and magnesium.
 Particles of clay and silt.
 Microorganisms such as bacteria, viruses, protozoa and their
cysts . Vibrio cholera is an example of an infectious bacteria
found in contaminated water.
 Dissolved air molecules, especially oxygen.
 Salt, which makes water brackish, having more salinity than
fresh water, but not as much as seawater.
In KTPS DVC, raw water is coming from Telaiya Dam which is based
on the Barkar river. A big intake wall is constructed by KTPS DVC in
the Telaiya Dam for sucking water from Telaiya Dam
INTAKE WeLL IN TELAIYA DAM
Raw water pump through intake well into pipe with high pressure
and than raw water reach into reservoir of KTPS. Raw water stored
into the reservoirs, per requirement of plant PT area take raw water
from reservoir. Also some sediment settle down on the basin of the
reservoir.
AERATOR
When raw water is pumping into pipe with pressure for passing into
aerator, water molecules splits into tiny particles and trapped gase-
ous molecules removed. Aeration brings water air in close contact in
order to remove dissolved gases such as carbon dioxide and oxidizes
dissolved metals such as iron, hydrogen sulfide and volatile organic
chemicals. Aeration is often the first major process at the treatment
plant. During aeration, constituents are removed or modified before
they can interfere with the treatment processes. When water come
into the chanal then pre-Chlorination is done.
Aeration brings water and air in close contact by exposing
drops or thin sheets of water to the air or by introducing small bub-
bles of air and letting them rise through the water. The scrubbing
process caused by the turbulence of aeration physically removes dis-
solved gases from solution and allows them to escape into the sur-
rounding air.
Aeration also helps remove dissolved metals through oxidation,
the chemical combination of oxygen from the air with certain unde-
sirable metals in the water once oxidized, these chemicals fall out of
solution and become particles in the water and can be removed by
filtration or flotation,
The addition of oxygen is required for the oxidation of bivalent iron (
Fe2+
), manganese ( Mn2+
) and ammonium ( NH4
+
),these substances
are present in dissolved form in groundwater. Due to chemical and
biological oxidation, the substances can removed,
The efficiency of aeration depends on the amount of surface contact
between air and water which is controlled primarily by the size of the
water drop or air bubble.
Oxygen is added to water through aeration and can increase the pal-
pability of water by removing the flat taste. The amount of oxygen
the water can hold depends primarily on the temperature of the wa-
ter. ( The colder the water the more oxygen the water can hold).
Water that contains excessive amounts of oxygen can become very
corrosive. Excessive oxygen con also causes problems in the treat-
ment plant i.e. air binding of filters.
Chemicals removed or oxidized by aeration
Constituents commonly affected by aeration are:
 Volatile organic chemicals such as benzene (found in gasoline),
or trichloroethylene, dichloroethylene, and perchloroethylene
(used in dry-cleaning or industrial processes)
 Ammonia
 Chlorine
 Carbon dioxide
High solubility of carbon dioxide reduced the pH of water which causes
excessive consumption of lime or other neutralizing agents in coagula-
tion and softening process. The corrosiveness of water is also higher at
lower pH values.
 Hydrogen sulfide
It is highly soluble in water, poisoning is one of the lauding causes of ac-
cidents in the field.
 Methane
 Iron and manganese
removal of iron and manganese from water by aeration
 iron and manganese in excess of 0.30mg/L and 0.05 mg/L
should be removed.
 Aeration provides the dissolved oxygen needed to convert
the iron and manganese from their Fe2+
and Mn2+
forms
to their insoluble oxidized Fe3+
and Mn4+
forms. The pro-
duced precipitates of ferric hydroxide and manganic oxide
are then removed by sedimentation.
Oxidation reaction of iron is
4 Fe(HCO3)2 + 2H2O+ O2 4 Fe(OH)3 + 8CO2
Oxidation reaction of manganese is
2 MnSO4 + 2H2O + O2 2 MnO2 + 2H2SO4
2 Mn(HCO3)2 + O2 2MnO2 + 2H2O + 4CO2
Aerator
CLARIFIER
There are mainly three processes occurred in the clarifier, these are
coagulation, flocculation and clarification processes are used when a
water source contains a large amount of fine suspended matter, such
as silt or mud. If this type of water flows into a sand filter will soon
block and stop working. The three processes are used together to
make the water clean enough for filtering.
1. Coagulation is a chemical reaction which occurs when a chemi-
cal or coagulant, is added to the water. The coagulant encour-
ages colloidal material in the water to join together into flocks.
Further suspended matter in the water is then attracted to the
flocks. Rapid mixing of the water and coagulant is important to
ensure thorough and even distribution of the coagulant.
2. Flocculation is a slow gentle mixing of the water to encourage
the flocks to form and grow to a size which will easily settle out.
This mixing is often done in a chamber.
3. Clarification is the final part of the process and allows the large
flocks containing much of the suspended matter to sink to the
bottom of a tank or basin, while the clear water overflows and
is then further treated.
Clay or mud has negatively charge colloidal particle, that’s why
we used alum which is positively charge in nature. When oppo-
site charge come into contact to each other, they will be neu-
tral and settle down on the basin of the chamber. When excess
dozing occurs that time lime is needed for the requirement of
control the pH level of the water, because at a certain pH value
coagulation and flocculation occur. When water will be cleared,
then water out from the clarifier and come into the filter house
with the help of chanal.
Clarifier
FILTER HOUSE
Clarified water come into the filter house by the chanal, if any parti-
cles of clay or mud not completed the reaction, then they complete
their reaction in the chanal. Because some particles require more
time to complete their reaction and when coagulate they filtered out
from the filter bed.
Removal of solid particle from water by passing it through a fil-
tering medium. Filtration is usually a mechanical process and does
not remove dissolved solids. Gravity filter is closed, rectangle shell of
concrete containers that are open at the top and function at atmos-
pheric pressure of the incoming water.
DM-PLANT
(Demineralization plant)
In DM-plant, filter water comes from filter house.
ACTIVATED CARBON FILTER:-
In ACF chamber, activated carbon filled which has lots of pour in
their surface. When water molecules passing through the activated
carbon, impurities are adsorbed on the surface of activated carbon
and only water molecules as well as dissolved minerals passes
through the activated carbon.
ACF remove the following particles present in the filter water, which
come from the filter house are
 Free residual chloride (FRC)
 Turbidity of 5 NTU (which reduce to 0.5 NTU)
 Odour of water
WEAK ACID CATION (WAC) & STRONG ACID CATION (SAC)
EXCHANGER
Both WAC & SAC resin exchanges the Na+
, Ca2+
, Mg2+
ect. cation
particles/ions are which are present in the water molecule ex-
changed by the resin H+
ion.
DEGASIFIER
Now water from SAC tank send into the degasifier tank for removal
of CO2 gas, because Na+
, Ca2+
and Mg2+
ions are exchanged by the
resin H+
ion which is present in the WAC and SAC chamber then car-
bonates and bicarbonates ions remaining in the water solution. It is
easily removed only by the air blowing.
Then water solution allowed passing into the weak base anion.
WEAK BASE ANION (WBA) & STRONG BASE ANION (SBA)
EXCHANGER
Degasifier water allowed passing through the WBA resin for remov-
ing the negatively charged Chloride ion ( Cl-
), SO4
2-
, NO3
-
, SiO4
4-
ect.
Anion particles/ions which are present in the water molecule is ex-
changed by the resin OH-
ion.
MIXED BED (MB)
In MB chamber both resins are filled that if any ion passes the posi-
tive and negative resin than in MB chamber, ion will be completely
exchanges and no any ion will be pass and then we get DM water
with parameter of SiO2
-
less than 0.02ppm; conductivity less than
0.1micron-siemon/cm; pH = 6.8 to 7.2 (online).
DEMINERALIZED WATER STORAGE TANK
It is an storage tank in which DM water is stored.
CATION RESIN REACTION
R---H+
+ Ca2+
/ Mg2+
/ Na+
ect.
R---Na + H+
R---Ca + 2H+
R---Mg + 3H+
exhausted resin
regeneration of resin
HCl(5%)
NaCl
R---H + MgCl2
CaCl2
DRAIN WTER
ANION RESIN REACTION
R---OH + Cl-
/ SO4
2-
etc
R---Cl + OH-
R2SO4 + 2OH-
Regeneration NaOH(5%)
R---OH + NaCl
Na2SO4
DRAIN WATER
BOILER WATER CHEMISTRY
In the boiler water, mainly three types of chemicals are used, be-
cause as the temperature of boiler is increases, pH of water decreas-
es then acidic nature of water increase. Due to degree of dissociation
of H2O, H+
also increases :-
1. Ammonia (NH3):- it maintainance only pH value at low pressure
as well as pH value increase.
2. Trisodium phosphate (Na3PO4):- it maintained pH value at high
pressure and also leakage of the cooling water is trapped. It is
in solid state.
Reaction of T.S.P
Na3PO4 + H2O N Na2HPO4 + NaOH
High pressure
Na2HPO4 + H2O NaH2PO4 + NaOH
Trapping of leakage
Na3PO4 + Ca2+
Ca3(PO4)2
Na3PO4 + Mg2+
Mg3(PO4)2
3. Hydrazine (N2H4):- it removes dissolved oxygen which reduces
the probability of corrosion.
By the following reaction:-
N2H4 + H2O + O2 3H2O + N2
Why boiler water treatment is important
Boiler water treatment is important due to the followings reasons:-
a. Water contains dissolved salts, which upon evaporation of
water forms scales on the heat transfer surfaces.
b. Low pH or dissolved oxygen in the water attacks the steel.
This causes lowering the thickness of the steel tubes, leading
to rupture the boiler tubes.
c. Flow assisted corrosion occurs in the carbon steel pipes due to
continuous removal of the protective oxide layer at high pres-
sure.
d. Impurities carry over in the steam, causing deposits on tur-
bine blades leading to reduced turbine efficiency and blade
failure. These contaminants can also causes erosion of turbine
blade. Silica at higher operating pressures volatilizes and car-
ries over to the turbine blades.
Chlorination
Chlorination is the process in which biological impurities are re-
moved, such as bacteria, algae, fungi ect. Chlorine is a powerful oxi-
dizing agent and reacts with the nitrogenous part of microbial sub-
stances to form chloramines.
 Cl2 + H2O HOCl +H+
+ Cl-
HOCl H+
+ OCl-
 NH3 + HOCl NH2Cl + H2O (Monochloramine)
 NH2Cl + HOCl NHCl2 + H2O (Dichloramine)
Chlorination is used in the PT-plant and also in cooling
tower. In cooling tower cl2 in used to prevent biofouling
deposition in condenser tube.
Two types of chlorination occurs in pre-treatment
plant:-
I. Pre-chlorination:- it occurs, after the aeration in the
chamber and then aerated water go into the clarifi-
er.
II. Post-chlorination:- it occurs in the filter house
sump, then supply in the DM plant or colony pur-
pose.
Some data is given below
pH
conductivity total hard-
ness
Ca hard-
ness
Mg hard-
ness MO turbidity Chloride
RW 8 570 256 190 66 114 4.74
CW coagulate 7.95 135.7 56 42 14 72 2.05 10
DM coagulate 7.62 135.7 56 42 14 168 1.82 10
FW 7.6 139 56 42 14 68 1.2 11
COAL SAMPLING AND ITS PROXIMATE
ANALYSIS
Coal
• Coal is compacted mass of fossilized plant debris mixed
with smaller amounts of inorganic matter and covered
by sedimentary rocks.
• Its chemical properties depend upon :
1.The proportion of different chemical
components present.
2. The nature of changes occur in
components.
3. The nature and quantity of the inorganic
matter present.
TYPES OF COAL
According to the percentage of carbon coal is classified into
four groups
1. Anthracite : 80%-90% Carbon
2. Bituminous : 70%-80% Carbon
3. Lignite : 60%-70% Carbon
4. Pit : 50-60 % Carbon
Power coal is sub-bituminous.
SAMPLING OF COAL
General principles of sampling
• All the particles of coal in the lot to be sampled are ac-
cessible to the sampling equipments.
• Each individual particle shall have an equal probability of
being selected and included in the sample.
• The minimum mass of the gross sample should be suffi-
cient to enable particles to be preset in the same pro-
portions as in the lot of coal sample
• The ideal method of sampling is the stopped belt meth-
od which is free from bias.
General procedure for collection of sample
• Decide for which purpose the sample are taken for ex-
ample plant performance, process control or commer-
cial transaction.
• Identify the quality parameters to be determined i.e.
general analysis, total moisture, size analysis, wash abil-
ity etc.
• Define the lot.
General procedure for collection of sample
• Determine or estimate the nominal top size of the coal.
• Determine the minimum mass per increment and the
minimum mass of the total sample.
Manual Sampling
• Sampling from stopped belt
• Sampling from falling stream
• Sampling from moving belt
• Sampling from stock piles
• Sampling from bottom discharge
• Sampling from wagon
Sample mass reduction
• Mechanical Method :
1. Rotating disc type
2. Rotating cone type
3. Container type
• Manual Method :
1. Riffle method
2. Flattened heap method
3. Piling method
4.Coning and quartering method
PROXIMATE ANALYSIS
In the proximate analysis, following are test done:-
• MOISTURE CONTENT
• ASH CONTENT
• VOLATILE MATTER CONTENT
• FIXED CARBON
Moisture content
• We come across with different moisture terms
• Air dried(inherent moisture) is the moisture that coal
hold on equilibration with air.
• Coal analysis is done on air dried condition
• Surface moisture , the moisture coal losses on exposure
to air.
• Total moisture is the sum of air dried and total moisture
• It is the Total moisture of as fired coal that is used for ef-
ficiency calculation.
• All other parameters are converted to total moisture ba-
sis used for efficiency calculations.
• Free moisture- Surface moisture present on apparently
dry coals, which is dried off when coal is exposed to the
air without heating.
• Inherent moisture- The moisture retained in the process
of coal substance when free moisture has evaporated.
• Air-dry moisture- It is a term used to describe that part
of the total moisture retained in the 72-mesh analysis
sample after it has been exposed to the laboratory at-
mosphere and has attained approximately equilibrium
with it.
Moisture content
• Total moisture- It is the sum of free and inherent mois-
ture.
• Typical range of moisture is 0.5 – 20 %
Effect of Moisture content
• Increases heat loss due to evaporation and superheating
of vapor.
• It is an inert constituent of coal and it reduces the calo-
rific value; it costs as much as coal to transport and its
latent of evaporation.
• When the coal is burned, contributes to flue gas losses.
ASH CONTENT
• Ash is the residue remaining after the coal has been in-
cinerated to constant weight under standard conditions.
• Typical range of ash content is 5% - 40%
VOLATILE MATTER
• Volatile matters are methane, hydrocarbons, hydrogen
and carbon dioxide present in coal
• Volatile matter is an index of the gaseous fuels present
• A typical range of volatile matter is 20-35 %
EFFECT OF VOLATILE MATTER
• Proportionately increases flame length, and helps in eas-
ier ignition of coal
• Sets minimum limit on the furnace height and volume
• Influences secondary oil support.
Fixed carbon
• It is a calculated figure: Fixed carbon = 100 – (moisture +
volatile matter + ash), all expressed as per cent on the
same basis.
• Its purpose is to measure the coke residue from the vol-
atile matter determination
• Fixed carbon gives a rough idea of the heating value of
coal
Determination of Air Dried Moisture
• Weigh accurately 1 gm of sample in a silica dish (with
cover). Spread it thinly, keep it in electrically heated air
oven and temperature is controlled at 108 +/- 2o
c for 1
hour. Then take out the dish and keep it in a desiccators
to cool and weigh, from which calculate the percentage
loss as moisture.
% moisture Decrease in weight of coal * 100
= -------------------------------------------
Wt of sample taken
Determination of Ash content
• Weigh 1 gm of sample in a silica dish (with cover).
Spread it uniformly , keep it in an air electrically heated
muffle furnace and temperature is raised to815 +/- 10o
c
in 1 hour. Maintain it for 1 hour. Then take out the dish
and keep it in a desiccators to cool and weigh, from
which calculate the percentage of ash.
weight of ash * 100
% ash = -------------------------------------------
Wt of sample taken
Determination of Volatile matter
• Heat an empty, clean V.M crucible with lid at 900 +/-
10o
c for 07 minutes, remove and cool it for 10 mins in a
desiccators, then take empty weight (W1). Take 1 gm of
coal in it. Keep on a silica stand in an electrically heated
furnace maintained at 900 +/- 10o
c for 07 minutes. Take
out ,cool for 1 min on a metal plate ,then in a desicca-
tors for 10 min and weigh (W2).
Determination of Volatile matter
A = (W2-W1) / Wt of coal taken
V.M % = (A-Moisture %)*100
• Calorific value is the amount of heat per unit mass that
evolved on complete combustion and is expressed in
kJ/kg.
• This is normally determined at constant volume by burn-
ing a known weight of coal in a bomb calorimeter under
condition of excess oxygen and measuring the amount
of heat evolved.
• CV is two types : GCV and NCV.
GROSS CALORIFIC VALUE
• This is the total heat evolved in kJ/kg.
• All fuels contains hydrogen. This will combine with oxy-
gen and form steam during the process of combustion.
If the products formed are cooled to its initial tempera-
ture, the steam will be condensed. Thus maximum heat
is abstracted. This heat value is called GCV.
NET CALORIFIC VALUE
• NCV is the difference between the GCV and heat ab-
sorbed by water (due to combustion and surface mois-
ture.
• NCV= GCV--53 H Kcal/kg where H is the percentage of
hydrogen present including hydrogen of moisture and
water of constitution of the mineral matter.
USEFUL HEAT VALUE
• Power coals (non coking coal ) in India are presently
graded by UHV.
• UHV (Kcal/kg)= 8900-138(A+M) for V.M >19% , A and M
at 60% RH & 40O
C.
GRINDABIITY INDEX
Grind ability index of coal shows how easily the coal
can be pulverized.
Thank
you

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Thermal power house chemistry at DVC BANJHEDIH, KODERMA, JHARKHAND by Yashwant Yadav

  • 1. THERMAL POWER HOUSE CHEMISTRY AT KODERMA THERMAL POWER STATION DAMODAR VALLEY CORPORATION VOCATIONAL TRAINING REPORT WITH EFFECT FROM :- 11/10/2017 TO 30/10/2017 Submitted by:- Yashwant Yadav M.Sc. 3rd semester Chemistry Session:- 2016-18 Vinoba Bhave University (Hazaribagh) Submitted to:- Dr. Sanjoy Kumar Sinha Manager (Chemist) DVC, KTPS Banjhedih
  • 2. ACKNOWLEDGEMENT HOW MUCH THIS TRAINING WAS HELPFUL TO ME The training at the DVC KTPS Banjhedih was very much helpful to me. It is a matter of great pleasure and privilege for me to present this report of 20 days on the practical knowledge gained by me during practical training at KTPS Banjhedih, Koderma during session 11 oct 2017 to 30 oct 2017. I attribute heartiest thanks to Dr. Sanjoy Kumar Sinha along with Chemist Mr. Arun Kumar Parmanik , Mr. Shashi Bhushan ,Mrs. Kumari Priti and Mr. Bhutnath Rajwar, Mr. Chandresh Kumar, Mr. Shushil Tuddu and greatly thanks to Dy. Manager (Chemist) Mr. Rasikan J. Bhengra. As well as workers of the chemical lab. The project has been prepared based on the vocational training undergone in a highly esteemed organi- zation of Eastern region , a pioneer in Generation, Transmission & Distri- bution of power , one of the most technically advanced & largest thermal power station in Jharkhand, the KTPS Banjhedih under DVC. Koderma Thermal Power Station providing me such opportunity to undergo training in the DVC, KTPS. I would also like to thank the senior chemists, highly experienced without whom such type of concept build- ing in respect of thermal power station would not have been possible.
  • 3. INDEX Introduction (a) Damodar Valley Corporation (b) Necessity of the power plant (c) Koderma thermal power station Water chemistry & analysis (a) Raw water (b) Aerator (c) Clarifier (d) Filter house (e) Demineralization plant {DM- plant} (f) Boiler water chemistry (g) Chlorination plant Coal chemistry & analysis (a) Introduction (b) Sample preparation (c) Proximate analysis (d) GCV analysis
  • 4. INTRODUCTION Electricity generation is the process of generating electric power from other source of energy. Generally in KTPS, thermal power plant prime mover is steam. When water is heated turns into steam and steam passes through the turbine moves and electric produced, this process is repeated again and again. Coal is the energy & water is the blood for the thermal power plant. Some prefer to use the term en- ergy because such facilities converted forms of heat energy into electrical energy. DAMODAR VALLEY CORPORATION Damodar Valley Corporation (DVC) is the first multipur- pose river valley project of independent India formed in July 7, 1948. DVC has its command area of approx 24,235 sq. kms. The upper valley consists of two districts (Dhanbad & Bokaro) and eight districts partly (Hazaribagh, koderma, Giridih, chhatra, Palamu, Ranchi, Lohardaga & Dumka) in Jharkhand. The lower valley consists of five districts partly (Burdwan, Hooghly, Hawrah, Bankura & purulia) in West Bengal. DVC was set up with the intent of promoting and operat- ing schemes for social and economic upliftment in the valley region and has been successfully doing the same for more than six decades un perfect harmony. Effective water management by the corporation has turned the devastating river Damodar from ‘River of Sorrow’ to a ‘River of Prospects and Opportuni- ties’. DVC facilitated irrigation, industrial and domestic water
  • 5. supply, soil conservation and promotion of social integration in the valley area. DVC has been generating, transmitting and distributing electrical energy since 1953 and has successfully met the ex- pectation of the consumers to a great height. For a period of more than 68 years. DVC has maintained a lead role in the eastern region, meeting the challenges of time and new tech- nologies. KODERMA THERMAL POWER STATION This site is located at Banjhedih, block-Jainagar, dist- Koderma, Jharkhand. The site is 5 KM far from Barakar river. The nearest railway stations are Herodih & koderma junction. Line of eastern railways passes about 1.5 KM from site. The wa- ter requirement of the thermal power plant including expan- sion will be from Barkar river Telaiya Dam. A closed cycle circu- lating water system is proposed. Make up water requirement for present stage of the plant is estimated at 2800m3 /day. NECESSITY OF THE POWER PLANT “Power to progress” Energy provides the powers to progress. The natural re- sources of a country may be turned into wealth if they are de- veloped, used and exchanged for other goods this cannot be achieved without energy. Availability of sufficient energy and its proper use in any country can result in this people using from substaintial level to the highest standard of living. It has been found that countries whose national output is mainly ag- ricultural and whose population lives mostly in rural communi-
  • 6. ties enjoy low per capita growth of energy consumption is dependent is the extent to which industrial activity forms a part of its energy usage a distinct changes. Once energy is made suitable in excess of domestic needs it has been round that it is not used solely as a consumer good but becomes factor of pro- duction. A growing proportion of energy is being met all over the world the electricity. This trend will further be stimulated be- cause of increasing availability of clean electricity. This applies especially to developing countries because their industrial pro- gress will be based on modern technologies, which gererally use electricity intensively. WATER CHEMISTRY & ANALYSIS The purest available form is from water vapour in atmosphere, as rain, snow or produced by melting of ice. Water on reaching the ground absorbs different types of gases from atmosphere like nitro- gen, oxygen and to a lesser extent carbon dioxide. Other gases like ammonia, oxides of nitrogen and sulphur etc. , also dissolves during rain depending upon the pollution level of the atmosphere. Apart from this, the surface water travels to various places and catches or- ganic matter, suspended solids etc. SOURCES OF WATER Following are water sources given below 1. Rivers, lakes and reservoirs (surface drainage water) 2. Underground water (shallow well, deep well, springs) 3. Rain water 4. Sea water
  • 7. 5. Snow melting RAW WATER Raw water is natural water found in the environment and has not been treated, nor have any minerals, ions, particles or living organ- isms been removed. Raw water includes rainwater, ground water, water from infiltration wells, and water from bodies like lakes and rivers. Without treatment, raw water can be used for farming, con- struction or cleaning purposes, water in this form is considered raw water. COMPOSITION The composition of raw water is naturally variable, but commonly contains one or more of the following significant contaminants, in the form of dissolved ions, particles and living organisms :-  Minerals which make water hard. Most common are car- bonates of calcium and magnesium.  Particles of clay and silt.  Microorganisms such as bacteria, viruses, protozoa and their cysts . Vibrio cholera is an example of an infectious bacteria found in contaminated water.  Dissolved air molecules, especially oxygen.  Salt, which makes water brackish, having more salinity than fresh water, but not as much as seawater. In KTPS DVC, raw water is coming from Telaiya Dam which is based on the Barkar river. A big intake wall is constructed by KTPS DVC in the Telaiya Dam for sucking water from Telaiya Dam
  • 8. INTAKE WeLL IN TELAIYA DAM Raw water pump through intake well into pipe with high pressure and than raw water reach into reservoir of KTPS. Raw water stored into the reservoirs, per requirement of plant PT area take raw water from reservoir. Also some sediment settle down on the basin of the reservoir.
  • 9. AERATOR When raw water is pumping into pipe with pressure for passing into aerator, water molecules splits into tiny particles and trapped gase- ous molecules removed. Aeration brings water air in close contact in order to remove dissolved gases such as carbon dioxide and oxidizes dissolved metals such as iron, hydrogen sulfide and volatile organic chemicals. Aeration is often the first major process at the treatment plant. During aeration, constituents are removed or modified before they can interfere with the treatment processes. When water come into the chanal then pre-Chlorination is done. Aeration brings water and air in close contact by exposing drops or thin sheets of water to the air or by introducing small bub- bles of air and letting them rise through the water. The scrubbing process caused by the turbulence of aeration physically removes dis- solved gases from solution and allows them to escape into the sur- rounding air. Aeration also helps remove dissolved metals through oxidation, the chemical combination of oxygen from the air with certain unde- sirable metals in the water once oxidized, these chemicals fall out of solution and become particles in the water and can be removed by filtration or flotation, The addition of oxygen is required for the oxidation of bivalent iron ( Fe2+ ), manganese ( Mn2+ ) and ammonium ( NH4 + ),these substances are present in dissolved form in groundwater. Due to chemical and biological oxidation, the substances can removed, The efficiency of aeration depends on the amount of surface contact between air and water which is controlled primarily by the size of the water drop or air bubble.
  • 10. Oxygen is added to water through aeration and can increase the pal- pability of water by removing the flat taste. The amount of oxygen the water can hold depends primarily on the temperature of the wa- ter. ( The colder the water the more oxygen the water can hold). Water that contains excessive amounts of oxygen can become very corrosive. Excessive oxygen con also causes problems in the treat- ment plant i.e. air binding of filters. Chemicals removed or oxidized by aeration Constituents commonly affected by aeration are:  Volatile organic chemicals such as benzene (found in gasoline), or trichloroethylene, dichloroethylene, and perchloroethylene (used in dry-cleaning or industrial processes)  Ammonia  Chlorine  Carbon dioxide High solubility of carbon dioxide reduced the pH of water which causes excessive consumption of lime or other neutralizing agents in coagula- tion and softening process. The corrosiveness of water is also higher at lower pH values.  Hydrogen sulfide It is highly soluble in water, poisoning is one of the lauding causes of ac- cidents in the field.  Methane  Iron and manganese removal of iron and manganese from water by aeration  iron and manganese in excess of 0.30mg/L and 0.05 mg/L should be removed.
  • 11.  Aeration provides the dissolved oxygen needed to convert the iron and manganese from their Fe2+ and Mn2+ forms to their insoluble oxidized Fe3+ and Mn4+ forms. The pro- duced precipitates of ferric hydroxide and manganic oxide are then removed by sedimentation. Oxidation reaction of iron is 4 Fe(HCO3)2 + 2H2O+ O2 4 Fe(OH)3 + 8CO2 Oxidation reaction of manganese is 2 MnSO4 + 2H2O + O2 2 MnO2 + 2H2SO4 2 Mn(HCO3)2 + O2 2MnO2 + 2H2O + 4CO2 Aerator
  • 12. CLARIFIER There are mainly three processes occurred in the clarifier, these are coagulation, flocculation and clarification processes are used when a water source contains a large amount of fine suspended matter, such as silt or mud. If this type of water flows into a sand filter will soon block and stop working. The three processes are used together to make the water clean enough for filtering. 1. Coagulation is a chemical reaction which occurs when a chemi- cal or coagulant, is added to the water. The coagulant encour- ages colloidal material in the water to join together into flocks. Further suspended matter in the water is then attracted to the flocks. Rapid mixing of the water and coagulant is important to ensure thorough and even distribution of the coagulant. 2. Flocculation is a slow gentle mixing of the water to encourage the flocks to form and grow to a size which will easily settle out. This mixing is often done in a chamber. 3. Clarification is the final part of the process and allows the large flocks containing much of the suspended matter to sink to the bottom of a tank or basin, while the clear water overflows and is then further treated.
  • 13. Clay or mud has negatively charge colloidal particle, that’s why we used alum which is positively charge in nature. When oppo- site charge come into contact to each other, they will be neu- tral and settle down on the basin of the chamber. When excess dozing occurs that time lime is needed for the requirement of control the pH level of the water, because at a certain pH value coagulation and flocculation occur. When water will be cleared, then water out from the clarifier and come into the filter house with the help of chanal.
  • 14. Clarifier FILTER HOUSE Clarified water come into the filter house by the chanal, if any parti- cles of clay or mud not completed the reaction, then they complete their reaction in the chanal. Because some particles require more time to complete their reaction and when coagulate they filtered out from the filter bed. Removal of solid particle from water by passing it through a fil- tering medium. Filtration is usually a mechanical process and does not remove dissolved solids. Gravity filter is closed, rectangle shell of concrete containers that are open at the top and function at atmos- pheric pressure of the incoming water.
  • 15. DM-PLANT (Demineralization plant) In DM-plant, filter water comes from filter house.
  • 16. ACTIVATED CARBON FILTER:- In ACF chamber, activated carbon filled which has lots of pour in their surface. When water molecules passing through the activated carbon, impurities are adsorbed on the surface of activated carbon and only water molecules as well as dissolved minerals passes through the activated carbon. ACF remove the following particles present in the filter water, which come from the filter house are  Free residual chloride (FRC)  Turbidity of 5 NTU (which reduce to 0.5 NTU)  Odour of water
  • 17. WEAK ACID CATION (WAC) & STRONG ACID CATION (SAC) EXCHANGER Both WAC & SAC resin exchanges the Na+ , Ca2+ , Mg2+ ect. cation particles/ions are which are present in the water molecule ex- changed by the resin H+ ion. DEGASIFIER Now water from SAC tank send into the degasifier tank for removal of CO2 gas, because Na+ , Ca2+ and Mg2+ ions are exchanged by the resin H+ ion which is present in the WAC and SAC chamber then car- bonates and bicarbonates ions remaining in the water solution. It is easily removed only by the air blowing. Then water solution allowed passing into the weak base anion. WEAK BASE ANION (WBA) & STRONG BASE ANION (SBA) EXCHANGER Degasifier water allowed passing through the WBA resin for remov- ing the negatively charged Chloride ion ( Cl- ), SO4 2- , NO3 - , SiO4 4- ect. Anion particles/ions which are present in the water molecule is ex- changed by the resin OH- ion. MIXED BED (MB) In MB chamber both resins are filled that if any ion passes the posi- tive and negative resin than in MB chamber, ion will be completely exchanges and no any ion will be pass and then we get DM water with parameter of SiO2 - less than 0.02ppm; conductivity less than 0.1micron-siemon/cm; pH = 6.8 to 7.2 (online). DEMINERALIZED WATER STORAGE TANK It is an storage tank in which DM water is stored.
  • 18. CATION RESIN REACTION R---H+ + Ca2+ / Mg2+ / Na+ ect. R---Na + H+ R---Ca + 2H+ R---Mg + 3H+ exhausted resin regeneration of resin HCl(5%) NaCl R---H + MgCl2 CaCl2 DRAIN WTER
  • 19. ANION RESIN REACTION R---OH + Cl- / SO4 2- etc R---Cl + OH- R2SO4 + 2OH- Regeneration NaOH(5%) R---OH + NaCl Na2SO4 DRAIN WATER
  • 20. BOILER WATER CHEMISTRY In the boiler water, mainly three types of chemicals are used, be- cause as the temperature of boiler is increases, pH of water decreas- es then acidic nature of water increase. Due to degree of dissociation of H2O, H+ also increases :- 1. Ammonia (NH3):- it maintainance only pH value at low pressure as well as pH value increase. 2. Trisodium phosphate (Na3PO4):- it maintained pH value at high pressure and also leakage of the cooling water is trapped. It is in solid state.
  • 21. Reaction of T.S.P Na3PO4 + H2O N Na2HPO4 + NaOH High pressure Na2HPO4 + H2O NaH2PO4 + NaOH Trapping of leakage Na3PO4 + Ca2+ Ca3(PO4)2 Na3PO4 + Mg2+ Mg3(PO4)2 3. Hydrazine (N2H4):- it removes dissolved oxygen which reduces the probability of corrosion. By the following reaction:- N2H4 + H2O + O2 3H2O + N2 Why boiler water treatment is important Boiler water treatment is important due to the followings reasons:- a. Water contains dissolved salts, which upon evaporation of water forms scales on the heat transfer surfaces. b. Low pH or dissolved oxygen in the water attacks the steel. This causes lowering the thickness of the steel tubes, leading to rupture the boiler tubes. c. Flow assisted corrosion occurs in the carbon steel pipes due to continuous removal of the protective oxide layer at high pres- sure.
  • 22. d. Impurities carry over in the steam, causing deposits on tur- bine blades leading to reduced turbine efficiency and blade failure. These contaminants can also causes erosion of turbine blade. Silica at higher operating pressures volatilizes and car- ries over to the turbine blades. Chlorination Chlorination is the process in which biological impurities are re- moved, such as bacteria, algae, fungi ect. Chlorine is a powerful oxi- dizing agent and reacts with the nitrogenous part of microbial sub- stances to form chloramines.  Cl2 + H2O HOCl +H+ + Cl- HOCl H+ + OCl-  NH3 + HOCl NH2Cl + H2O (Monochloramine)  NH2Cl + HOCl NHCl2 + H2O (Dichloramine) Chlorination is used in the PT-plant and also in cooling tower. In cooling tower cl2 in used to prevent biofouling deposition in condenser tube. Two types of chlorination occurs in pre-treatment plant:-
  • 23. I. Pre-chlorination:- it occurs, after the aeration in the chamber and then aerated water go into the clarifi- er. II. Post-chlorination:- it occurs in the filter house sump, then supply in the DM plant or colony pur- pose. Some data is given below pH conductivity total hard- ness Ca hard- ness Mg hard- ness MO turbidity Chloride RW 8 570 256 190 66 114 4.74 CW coagulate 7.95 135.7 56 42 14 72 2.05 10 DM coagulate 7.62 135.7 56 42 14 168 1.82 10 FW 7.6 139 56 42 14 68 1.2 11
  • 24. COAL SAMPLING AND ITS PROXIMATE ANALYSIS Coal • Coal is compacted mass of fossilized plant debris mixed with smaller amounts of inorganic matter and covered by sedimentary rocks. • Its chemical properties depend upon : 1.The proportion of different chemical components present. 2. The nature of changes occur in components. 3. The nature and quantity of the inorganic matter present. TYPES OF COAL According to the percentage of carbon coal is classified into four groups 1. Anthracite : 80%-90% Carbon 2. Bituminous : 70%-80% Carbon 3. Lignite : 60%-70% Carbon 4. Pit : 50-60 % Carbon Power coal is sub-bituminous.
  • 25. SAMPLING OF COAL General principles of sampling • All the particles of coal in the lot to be sampled are ac- cessible to the sampling equipments. • Each individual particle shall have an equal probability of being selected and included in the sample. • The minimum mass of the gross sample should be suffi- cient to enable particles to be preset in the same pro- portions as in the lot of coal sample • The ideal method of sampling is the stopped belt meth- od which is free from bias. General procedure for collection of sample • Decide for which purpose the sample are taken for ex- ample plant performance, process control or commer- cial transaction. • Identify the quality parameters to be determined i.e. general analysis, total moisture, size analysis, wash abil- ity etc. • Define the lot. General procedure for collection of sample • Determine or estimate the nominal top size of the coal.
  • 26. • Determine the minimum mass per increment and the minimum mass of the total sample. Manual Sampling • Sampling from stopped belt • Sampling from falling stream • Sampling from moving belt • Sampling from stock piles • Sampling from bottom discharge • Sampling from wagon Sample mass reduction • Mechanical Method : 1. Rotating disc type 2. Rotating cone type 3. Container type • Manual Method : 1. Riffle method 2. Flattened heap method 3. Piling method 4.Coning and quartering method
  • 27. PROXIMATE ANALYSIS In the proximate analysis, following are test done:- • MOISTURE CONTENT • ASH CONTENT • VOLATILE MATTER CONTENT • FIXED CARBON Moisture content • We come across with different moisture terms • Air dried(inherent moisture) is the moisture that coal hold on equilibration with air. • Coal analysis is done on air dried condition • Surface moisture , the moisture coal losses on exposure to air. • Total moisture is the sum of air dried and total moisture • It is the Total moisture of as fired coal that is used for ef- ficiency calculation. • All other parameters are converted to total moisture ba- sis used for efficiency calculations. • Free moisture- Surface moisture present on apparently dry coals, which is dried off when coal is exposed to the air without heating. • Inherent moisture- The moisture retained in the process of coal substance when free moisture has evaporated.
  • 28. • Air-dry moisture- It is a term used to describe that part of the total moisture retained in the 72-mesh analysis sample after it has been exposed to the laboratory at- mosphere and has attained approximately equilibrium with it. Moisture content • Total moisture- It is the sum of free and inherent mois- ture. • Typical range of moisture is 0.5 – 20 % Effect of Moisture content • Increases heat loss due to evaporation and superheating of vapor. • It is an inert constituent of coal and it reduces the calo- rific value; it costs as much as coal to transport and its latent of evaporation. • When the coal is burned, contributes to flue gas losses. ASH CONTENT • Ash is the residue remaining after the coal has been in- cinerated to constant weight under standard conditions. • Typical range of ash content is 5% - 40%
  • 29. VOLATILE MATTER • Volatile matters are methane, hydrocarbons, hydrogen and carbon dioxide present in coal • Volatile matter is an index of the gaseous fuels present • A typical range of volatile matter is 20-35 % EFFECT OF VOLATILE MATTER • Proportionately increases flame length, and helps in eas- ier ignition of coal • Sets minimum limit on the furnace height and volume • Influences secondary oil support. Fixed carbon • It is a calculated figure: Fixed carbon = 100 – (moisture + volatile matter + ash), all expressed as per cent on the same basis. • Its purpose is to measure the coke residue from the vol- atile matter determination • Fixed carbon gives a rough idea of the heating value of coal Determination of Air Dried Moisture • Weigh accurately 1 gm of sample in a silica dish (with cover). Spread it thinly, keep it in electrically heated air oven and temperature is controlled at 108 +/- 2o c for 1
  • 30. hour. Then take out the dish and keep it in a desiccators to cool and weigh, from which calculate the percentage loss as moisture. % moisture Decrease in weight of coal * 100 = ------------------------------------------- Wt of sample taken Determination of Ash content • Weigh 1 gm of sample in a silica dish (with cover). Spread it uniformly , keep it in an air electrically heated muffle furnace and temperature is raised to815 +/- 10o c in 1 hour. Maintain it for 1 hour. Then take out the dish and keep it in a desiccators to cool and weigh, from which calculate the percentage of ash. weight of ash * 100 % ash = ------------------------------------------- Wt of sample taken Determination of Volatile matter • Heat an empty, clean V.M crucible with lid at 900 +/- 10o c for 07 minutes, remove and cool it for 10 mins in a desiccators, then take empty weight (W1). Take 1 gm of coal in it. Keep on a silica stand in an electrically heated furnace maintained at 900 +/- 10o c for 07 minutes. Take out ,cool for 1 min on a metal plate ,then in a desicca- tors for 10 min and weigh (W2).
  • 31. Determination of Volatile matter A = (W2-W1) / Wt of coal taken V.M % = (A-Moisture %)*100 • Calorific value is the amount of heat per unit mass that evolved on complete combustion and is expressed in kJ/kg. • This is normally determined at constant volume by burn- ing a known weight of coal in a bomb calorimeter under condition of excess oxygen and measuring the amount of heat evolved. • CV is two types : GCV and NCV. GROSS CALORIFIC VALUE • This is the total heat evolved in kJ/kg. • All fuels contains hydrogen. This will combine with oxy- gen and form steam during the process of combustion. If the products formed are cooled to its initial tempera- ture, the steam will be condensed. Thus maximum heat is abstracted. This heat value is called GCV. NET CALORIFIC VALUE • NCV is the difference between the GCV and heat ab- sorbed by water (due to combustion and surface mois- ture.
  • 32. • NCV= GCV--53 H Kcal/kg where H is the percentage of hydrogen present including hydrogen of moisture and water of constitution of the mineral matter. USEFUL HEAT VALUE • Power coals (non coking coal ) in India are presently graded by UHV. • UHV (Kcal/kg)= 8900-138(A+M) for V.M >19% , A and M at 60% RH & 40O C. GRINDABIITY INDEX Grind ability index of coal shows how easily the coal can be pulverized.