Discussions on Auxiliary consumption in a 4 X 210 MW TPS, the common systems and individual unitwise Auxiliary consumption has been briefed in the presentation. Also savings in various aspects due to increase in Boiler Efficiency are also discussed in the presentation.

1. Auxiliary Consumption and Savings
due to Increase in Boiler Efficiency
Manohar Tatwawadi
total output power solutions
A2-806 PALLADION, Balewadi, Pune,411045
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2. Typical Auxiliary Consumption for
4X210 MW Power Station
Common Systems
S.N. Particulars
Energy Consumption
MWh/day
A Plant Common systems MWh=1000Kwh
1 Ash Handling Plant 45.41 MWh/d
2 Coal Handling Plant 24.53 MWh/d
3 Air Compressors 24.95 MWh/d
4 Cooling Water Systems 40.86 MWh/d
5 Water Treatment Plants 76.28 MWh/d
Total for common systems 212.03 MWh/d
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3. HT Auxiliary Consumption Unitwise
S.N. Particulars Energy Consumption MWh/day
B Unitwise Inhouse systems
1 Boiler Feed Pumps 558.58 MWh/d
2 Cond Extraction Pumps 95.83 MWh/d
3 Induced Draft Fans 155.5 MWh/d
4 Forced Draft Fans 40.22 MWh/d
5 Primary Air Fans 153.36 MWh/d
6 Cooling Water Pump 177.36 MWh/d
7 Mills 181.85 MWh/d
Total In House H.T. 1362.7 MWh/d
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4. Auxiliary Consumption Common
4 X 210 MW
S.N. Particulars Energy Consumption MWh/day
C Transformers and lighting Systems
1 Auxiliary Transformer Losses 25.98 MWh/d
2 Gen. Trans Losses 98.47 MWh/d
3 Unit & Station Trans Losses 15.737 MWh/d
4 Network Losses 20.82 MWh/d
5 Lighting and other Loads 28.46 MWh/d
Total of Trans and lighting loads 189.467 MWh/d
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5. Total Auxiliary Consumption for
4 X 210 MW TPS
D Total Aux Power 1764.197 MWh/d
E Total Generation 20340.96 MWh/d
F Aux Power Cons. % 8.67%
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6. SAVINGS DUE TO INCREASE IN
BOILER EFFICIENCY

7. BOILER EFFICIENCY INCREASE
For 1 Unit of 210 MW
Boiler Efficiency Increase from 80%
To 84.5% UNITS
80% 82% 83.0% 84.5% %
Generation per day 5040 5040 5040 5040 MWh/Day
Turbine Heat Rate 1940 1940 1940 1940 Kcal/KWh
Unit Heat Rate 2425.00 2365.85 2337.35 2295.86 Kcal/KWh
Reduction in Unit Heat Rate 59.15 28.50 41.49 Kcal/KWh
Fuel GCV 4500 4500 4500 4500 Kcal/Kg
Fuel Consumption Kg / Kwh 0.539 0.526 0.519 0.510 Kg/Kwh
Reduction in Fuel Cons 0.013 0.006 0.009 Kg/Kwh
Fuel consumption per day for
210 MW Load
2716 2649.76 2617.83 2571.36 Tonnes/day
Saving in daily fuel
consumption per unit
66.244 98.169 144.639 Tonnes/day
Fuel GCV, Generation and the Turbine Heat Rate is constant.
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8. Saving in Coal Handling Plant & Milling
Plant
Considering a plant of
4X210Mw units
Boiler Efficiency Increase from 80% To
84.5% UNITS
Coal Handling 80% 82% 83.0% 84.5% %
Reduction in Coal Handling 66.244 98.169 144.639 T/day
*Aux Power Required for handling coal per ton is 0.002044 Mwh/ton
Aux Power Reduction in Coal
Handling
0.135 0.201 0.296 MWh/day
#Aux Power required for milling coal per Ton = 181.85/2716= 0.066955Mwh/T
Aux Power Reduction in
Milling
4.435 6.573 9.684 MWh/day
Total Aux power reduction
due to coal reduction
4.571 6.774 9.980 MWh/day
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9. Savings in Ash Handling Plants
Considering a plant of
4X210Mw units
Boiler Efficiency Increase from
80% To 84.5%
UNITS
Ash Handling Plant 80% 82% 83.0% 84.5% %
*Aux. Consumption of Ash Handling per Ton Coal = 45.41/2716*4
= 0.00418MWh / T of coal (Assumption 40% Ash in Coal)
Reduction in Aux.
Consumption in ash
handling per day
-- 0.277 0.410 0.605 MWh/day
*The Total Ash Handling Plant consumption was booked to be 45.41MWh/day for total 4
units of 210 MW each.
*The consumption of coal is 2716 T/day for each unit of 210 MW.
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10. Reduction in Aux. Consumption
Air and Flue gas Handling
Considering a plant of
4X210Mw units Air and Flue
gas Handling
Boiler Efficiency Increase from 80% To
84.5%
UNITS
80% 82% 83.0% 84.5% %
Amount of air required Theoratical Air + Excess Air
= Approx 4.83 + 1.2 = 6.00 Kg/Kg of coal
Air required to be handled 16296.00 15898.54 15706.99 15428.17 T/day
Reduction in handling of air
per day
397.46 589.01 867.83 T/day
Aux Consumption of ID, FD and Primary Air = 155.5+40.22+153.36
= 349.08 MWh/day for handled air 16296 T/day
Aux power for air handling 349.08 340.57 336.46 330.49 MWh/day
Reduction in Aux power for
handling of air per day
8.51 12.62 18.59 MWh/day
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11. Total Savings in Rs. Per Day
Particulars
Boiler Efficiency Increase from 80% To
84.5%
UNITS
Efficiency 80% 82% 83.00% 84.50% %
Saving in daily fuel consumption
per unit --
66.244 98.169 144.639 Tonnes/day
Saving in Rs/day @ Fuel Cost Rs.
4500/- T --
298098 441760.5 650875.5 Rs./day
Total Aux power reduction due to
coal reduction --
4.571 6.774 9.98 MWh/day
Reduction in Aux. Consumption
in ash handling per day --
0.277 0.41 0.605 MWh/day
Reduction in Aux power for
handling of air per day
-- 8.51 12.62 18.59 MWh/day
Total Aux power reduction due to
increase in Efficiency --
13.358 19.804 29.175 MWh/day
Saving in Rs/day @ Elec. Cost Rs.
3000/-MWh --
40074 59412 87525 Rs./day
Total Saving in Rs/day -- 338172 501172.5 738400.5 Rs./day
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