Coal Power Plant Fundamentals The Steam Turbine

When I was a kid I didnt have video games or cable TV to help me occupy my time. Back then parents tended to be frugal, and the few games I had were cheap to buy and simple in operation, like the plastic toy windmill Id play with for hours on end. All I had to do to make it spin was take a deep breath, pucker my lips together, fill my cheeks with breath, then blow hard into the windmill blades. Its spin was fascinating to watch. Little did I know that as an adult I would come to work with a much larger and complex version of it, in the form of a power plants steam turbine. You see, when you trap breath within bulging cheeks and then squeeze your cheek muscles together, you actually create a pressurized environment. This air pressure buildup transfers energy from your mouth muscles into the trapped breath within your mouth, so that when you open your lips to release the breath through your puckered lips, the pressurized energy is converted into kinetic energy, a/k/a the energy of movement. The breath molecules flow at high speed from your lips to the toy windmills blades, and as they come into contact with the blades their energy is transferred to them, causing the blades to move. A similar process takes place in the coal power plant, where steam from a boiler takes the place of pressurized breath and a steam turbine takes the place of the toy windmill. If you recall from my previous article, the heat energy released by burning coal is transferred to water in the boiler, turning it to steam. This steam leaves the boiler under great pressure, causing it to travel through pipe to the steam turbine, as shown in Figure 1.

Figure 1 A Basic Steam Turbine and Generator In A Coal Fired Power Plant At its most basic level the inside of a steam turbine looks much like our toy windmill, of course on a much larger scale, and it is very appropriately called a wheel. See Figure 2.

Figure 2 A Very Basic Steam Turbine Wheel The wheel is mounted on a shaft and has numerous blades. It makes use of the pressurized steam that has made its way to it from the boiler. This steam has ultimately passed through a nozzle in the turbine that is directed towards the blades on the wheel. This is the point at which heat energy in the steam is converted into kinetic energy. The steam shoots out of the nozzle at high speed, coming into contact with the blades and transferring energy to them, which causes the turbine shaft to spin. The turbine shaft is connected to a generator, so the generator spins as well. Finally, the spinning generator converts the mechanical energy from the turbine into electrical energy. In actuality, most coal power plant steam turbines have more than one wheel and there are many nozzles. The blades are also more numerous and complex in shape in order to maximize the energy transfer from the steam to the wheels. MyCoal Power Plant Fundamentals seminar goes into far greater detail on this and other aspects of steam turbines, but what I have shared with you above will give you a basic understanding of how they operate. So to sum it all up, the steam turbines job is to convert the heat energy of steam into mechanical energy capable of spinning the electrical generator. Next time well see how the generator works to complete the last step in the energy conversion process, that is, conversion of mechanical energy into electrical energy.

oal Power Plant Fundamentals Coal Handling

If youve ever read a book to a small child on the subject of food or digestion, youve probably come across the analogy that our stomachs are like a furnace and our digestive system much like an engine. We explain to the youngster that what we eat is important, because our body needs the right fuel in order to operate properly. If little Susie or Danny insisted on eating only candy day after day, their bodies would become weak and sick. In much the same way a coal power plant is like a living organism, eating fuel in order to function. But instead of meats and vegetables, it eats coal, and the coal handling department of a power plant acts as a dinner table. Its where the food is placed and prepared before it enters the diners mouth. The coal our power plants consume comes from one of two places, underground mines or strip mines. It all depends on the particular geology of the area from which the coal is harvested. According to the US Energy Information Administration, underground mines are more common in the eastern United States, while strip mines are more common in the western states. The coal from underground mines is excavated by means of shafts and tunnels which are dug deep beneath the earths surface in order to provide access to the buried coal deposits. In strip mines the deposits are just below the surface, so the topsoil is merely stripped away with heavy earthmoving machinery, like bulldozers, to reveal the coal. In both types of mining activity excavating machines and conveyors are required to remove the coal from the mine so it can be loaded for shipment to its ultimate destination. Once harvested, coal is shipped to power plants primarily by train, river barge, or ship. Its journey can cover thousands of miles. It culminates in delivery to a power plant, where it is unloaded by means of a huge piece of machinery called a rotary dumper. This machine is capable of grabbing onto 100 ton railcars and turning them upside down. The coal spills into a large collection hopper positioned next to the railroad track. If the coal has found its way to a plant located near a waterway, that means of transport was most likely have been made by flat barge or ship. In this case a large crane with a clamshell bucket is used for unloading. The crane drops its bucket into a pile of coal located within the ships hold, takes out a large bite, then hoists and dumps its contents into a large collection hopper next to the crane. To get an idea of how coal flows within the coal handling system of a power

plant, lets refer to the flow chart in Figure 1.

Figure 1 Schematic Diagram of the Coal Handling System Collection hoppers and have slanted bottoms which allow coal to easily spill out onto a conveyor belt. Within the plant coal is transported by means of conveyors into whats known as a breaker building. This building lives up to its name because it contains a very large machine whose job it is to break the chunks of raw coal that have been harvested from mines into smaller chunks which the boiler can work with. Once broken down, the coal will go to one of two places, either directly into silos or coal bunkers in the power plant building for short term storage, or into an outside storage pile, usually a prominent feature of a power plant due to its formidable size. The coal pile can be several stories tall and much larger than a football field. It acts as a reserve supply should the regular delivery of coal be interrupted by labor strike, natural disaster, or equipment failure. When necessary,

the coal is removed from the pile and sent into the plant to fill the coal silos. Coal from the silos is used to feed the power plant boilers. Next week well continue to follow coals journey, on its way to arguably one of the most important pieces of equipment in a power plant, the boiler. _____________________________________________

Coal Power Plant Fundamentals Feeding The Furnace

Today well continue our discussion of coals journey through a power plant. Keep in mind that the material presented in this series of blogs is meant to be a primer. It is a simplification of what actually goes on. My training seminars go into much more depth. Now imagine a five course meal spread out on the table before you. You load up your plate and pack a forkful of food into your mouth. You instinctively chew, getting the digestive process underway and making it easier to swallow. Power plants approach their consumption of coal in much the same way. Last time we talked about handling the coal and filling up silos for short term storage within the power plant building. The coal silo is analogous to a dinner plate, and the furnace, which heats up the boiler water to make steam for the turbine, acts very much like a diners stomach. As for the fork and your teeth, there are a couple of machines within power plants which mimic their behavior. Theyre called the coal feeder and coal mill. The coal feeder does as its name implies, it systematically feeds a measured amount of coal to the coal mill. The coal mill, also known as a pulverizer, then grinds the coal to make it easier for the furnace to burn it. Lets take a look at Figure 1 below. At the top of the configuration is the coal silo, which is fully open at the bottom. Gravity draws the coal within the silo downward, facilitating the coals dropping through the opening into a chute, on its way to the coal feeder. The coal from the silo spills into little buckets on a wheel within the feeder, and as the wheel turns, the coal spills out and falls down into another chute leading to the mill.

Figure 1 Feeding Coal To A Power Plant Furnace Now you could have the coal spill down a chute directly from the silo into the mill, bypassing the coal feeder entirely, but thats really not a good idea. Just think how difficult it would be to chew if you tried to stuff an entire plate of food into your mouth at once. Just as your mouth requires to be fed in mouth-sized amounts, the coal mill must be fed coal in a size that it can handle. Its the job of the spinning wheel inside the coal feeder to keep coal flowing in measured amounts to the mill. You see, the wheel is attached to a variable speed motor, and depending on how quickly the furnace needs to be fed, the wheel will either turn faster or slower. Once inside the mill, the coal is ground up before moving on to the furnace. The coal mill contains massive steel parts capable of pulverizing chunks of coal into a fine black powder. This pulverized coal is then propelled by means of an exhauster towards the burners. The exhauster sits next to the coal mill and both are often driven by the same electric motor. The exhauster is connected to the top of the mill by a pipe, and another pipe connects the exhauster to burners on the furnace. The exhauster acts like a big vacuum cleaner, sucking coal powder out of the mill, then blowing it through pipes leading to the burners. Finally, the powder ignites within the furnace, heating the water inside the boiler.

Next time well learn about the combustion process in the power plant furnace.

Coal Power Plant Fundamentals The Steam Turbine

When I was a kid I didnt have video games or cable TV to help me occupy my time. Back then parents tended to be frugal, and the few games I had were cheap to buy and simple in operation, like the plastic toy windmill Id play with for hours on end. All I had to do to make it spin was take a deep breath, pucker my lips together, fill my cheeks with breath, then blow hard into the windmill blades. Its spin was fascinating to watch. Little did I know that as an adult I would come to work with a much larger and complex version of it, in the form of a power plants steam turbine. You see, when you trap breath within bulging cheeks and then squeeze your cheek muscles together, you actually create a pressurized environment. This air pressure buildup transfers energy from your mouth muscles into the trapped breath within your mouth, so that when you open your lips to release the breath through your puckered lips, the pressurized energy is converted into kinetic energy, a/k/a the energy of movement. The breath molecules flow at high speed from your lips to the toy windmills blades, and as they come into contact with the blades their energy is transferred to them, causing the blades to move. A similar process takes place in the coal power plant, where steam from a boiler takes the place of pressurized breath and a steam turbine takes the place of the toy windmill. If you recall from my previous article, the heat energy released by burning coal is transferred to water in the boiler, turning it to steam. This steam leaves the boiler under great pressure, causing it to travel through pipe to the steam turbine, as shown in Figure 1.

Figure 1 A Basic Steam Turbine and Generator In A Coal Fired Power Plant At its most basic level the inside of a steam turbine looks much like our toy windmill, of course on a much larger scale, and it is very appropriately called a wheel. See Figure 2.

Figure 2 A Very Basic Steam Turbine Wheel The wheel is mounted on a shaft and has numerous blades. It makes use of the pressurized steam that has made its way to it from the boiler. This steam has ultimately passed through a nozzle in the turbine that is directed towards the blades on the wheel. This is the point at which heat energy in the steam is converted into kinetic energy. The steam shoots out of the nozzle at high speed, coming into contact with the blades and transferring energy to them, which causes the turbine shaft to spin. The turbine shaft is connected to a generator, so the generator spins as well. Finally, the spinning generator converts the mechanical energy from the turbine into electrical energy. In actuality, most coal power plant steam turbines have more than one wheel and there are many nozzles. The blades are also more numerous and complex in shape in order to maximize the energy transfer from the steam to the wheels. MyCoal Power Plant Fundamentals seminar goes into far greater detail on this and other aspects of steam turbines, but what I have shared with you above will give you a basic understanding of how they operate. So to sum it all up, the steam turbines job is to convert the heat energy of steam into mechanical energy capable of spinning the electrical generator. Next time well see how the generator works to complete the last step in the energy conversion process, that is, conversion of mechanical energy into electrical energy. _____________________________________________

Coal Power Plant Fundamentals Big Coal

Weve been talking about coal fired power plants for some time now, and its always good to introduce third party information on subject matter in order to gain the most from the discussion. What follows is an excerpt of an interesting book review on the subject of coal consumption which appeared in the New York Times: There is perhaps no greater act of denial in modern life than sticking a plug into an electric outlet. No thinking person can eat a hamburger without knowing it was once a cow, or drink water from the tap without recognizing, at least dimly, that its journey began in some distant reservoir. Electricity is different. Fully sanitized of any hint of its origins, it pours out of the socket almost like magic. In his new book, Jeff Goodell breaks the spell with a single number: 20. Thats how many pounds of coal each person in the United States consumes, on average, every day to keep the electricity flowing. Despite its outdated image, coal generates half of our electricity, far more than any other source. Demand keeps rising, thanks in part to our appetite for new electronic gadgets and appliances; with nuclear power on hold and natural gas supplies tightening, coals importance is only going to increase. As Goodell puts it, our shiny white iPod economy is propped up by dirty black rocks. To read the entire article, follow this link: http://www.nytimes.com/2006/06/25/books/review/25powell.html?_r=2

A locomotive crane unloading coal from railcars at a power plant in the late

1930s. Next week well continue our regular series, following energys journey through the power plant. _____________________________________________

Coal Power Generator

Plant

Fundamentals

The

When I was a kid I remember how cool it was to have a headlight on my bike. Unlike the headlights that the other kids had, mine was not powered with flashlight batteries. The power came from a little gadget with a small wheel that rode on the front tire. As I pedaled along, the tires spinning caused the small wheel to spin, and voila, the headlight bulb came to life. Little did I know that this gadget was a simple form of electrical generator, and of course I was oblivious to the fact that a similar device, albeit on a much larger scale, was being used at a nearby power plant to send electricity to my home. Over the last few weeks we learned how a coal fired power plant transforms chemical energy stored in coal into heat energy and then into mechanical energy which enables a steam turbine shaft to spin. Well now turn our attention to the electrical generator. Its responsible for performing the last step in the energy conversion process, that is, it converts mechanical energy from the steam turbine into the desired end product, electrical energy for our use. It represents the culmination in energys journey through the power plant, the process by which energy contained in a lump of coal is transformed into electricity. To show how this final energy conversion process works, lets look at Figure 1, a simplified illustration of an electrical generator.

Figure 1 A Basic Electrical Generator Youll note that the generator in our illustration has a shaft with a loop of wire attached to it. When the shaft spins, so does the loop. The shaft and wire loop are placed between the north (N) and south (S) poles of a horseshoe magnet. Its a permanent magnet, so it always has invisible lines of magnetic flux traveling between its two poles. These magnetic lines of flux are the same type as the ones created by kids magnets, when they play with watching paperclips jump up to meet the magnet. The properties of magnets are not completely understood, even to adults who work with them every day. And what could be more mysterious than the fact that as the shaft and wire loop spin through the lines of magnetic flux in the generator, an electric current is produced in the wire loop. Now, this current thats flowing through the spinning wire loop is of no use if we cant channel it out of the generator. The wire loop is spinning vigorously, so you cant directly connect the ends of the loop to stationary wires. A special treatment is required. Each end of the loop is connected to a slip ring. A part called a brush presses against each slip ring to make electrical contact. The electrical current then flows from the loop through the spinning slip rings, through the brushes, and into the stationary wires. So, if, for example, a light bulb is

connected to the other end of the stationary wires, this completes an electric circuit through which current can flow. The light bulb will glow as long as the generator shaft keeps spinning and the wire loop keeps passing through the magnetic lines of flux from the magnet. So we see that the key to the whole energy conversion process is to have movement between magnetic lines of flux and a loop of wire. As long as this movement occurs, the electricity will flow. This basic principle is the same in a coal fired power plant, but the electrical generator is far more complicated in construction and operation than shown here. My Coal Power Plant Fundamentals seminar goes into far greater detail on this and other aspects of electricity generation, but what I have shared with you above will give you a basic understanding of how they operate. That concludes our journal with coal through the power plant. This series of blogs has, you will remember, presented a simplified version of the complex material presented in my teaching seminars. Next week well branch off, taking a look at why electrical wires come in different thicknesses. _____________________________________________