As a type of
thermal power station, a coal-fired power station converts chemical energy stored in coal successively into
thermal energy,
mechanical energy and, finally,
electrical energy. The coal is usually
pulverized and then burned in a
pulverized coal-fired boiler. The heat from the burning pulverized coal converts boiler water to
steam, which is then used to spin
turbines that turn
generators. Compared to a thermal power station burning other fuel types, coal specific fuel processing and ash disposal is required. For units over about 200
MW capacity, redundancy of key components is provided by installing duplicates of the forced and induced draft fans, air preheaters, and fly ash collectors. On some units of about 60 MW, two boilers per unit may instead be provided. The
hundred largest coal power stations range in size from 3,000 MW to 6,700 MW.
Coal processing Coal is prepared for use by crushing the rough coal to pieces less than in size. The coal is then transported from the storage yard to in-plant storage silos by
conveyor belts at rates up to 4,000 tonnes per hour. In plants that burn pulverized coal, silos feed coal to
pulverizers (coal mills) that take the larger 5 cm pieces, grind them to the consistency of
talcum powder, sort them, and mix them with primary combustion air, which transports the coal to the boiler furnace and preheats the coal in order to drive off excess moisture content. A 500 MWe plant may have six such pulverizers, five of which can supply coal to the furnace at 250 tonnes per hour under full load. In plants that do not burn pulverized coal, the larger 5 cm pieces may be directly fed into the silos which then feed either mechanical distributors that drop the coal on a traveling grate or the
cyclone burners, a specific kind of combustor that can efficiently burn larger pieces of fuel.
Boiler operation Plants designed for
lignite (brown coal) are used in locations as varied as Germany,
Victoria, Australia, and
North Dakota. Lignite is a much younger form of coal than black coal. It has a lower energy density than black coal and requires a much larger furnace for equivalent heat output. Such coals may contain up to 70% water and
ash, yielding lower furnace temperatures and requiring larger induced-draft fans. The firing systems also differ from black coal and typically draw hot gas from the furnace-exit level and mix it with the incoming coal in fan-type mills that inject the pulverized coal and hot gas mixture into the boiler.
Ash disposal The ash is often stored in
ash ponds. Although the use of ash ponds in combination with air pollution controls (such as
wet scrubbers) decreases the amount of airborne pollutants, the structures pose serious health risks for the surrounding environment. Power utility companies have often built the ponds without
liners, especially in the United States, and therefore chemicals in the ash can leach into
groundwater and surface waters. Since the 1990s, power utilities in the U.S. have designed many of their new plants with dry ash handling systems. The dry ash is disposed in landfills, which typically include liners and groundwater monitoring systems. Dry ash may also be recycled into products such as concrete, structural fills for road construction and grout.
Fly ash collection Fly ash is captured and removed from the flue gas by electrostatic precipitators or fabric bag filters (or sometimes both) located at the outlet of the furnace and before the induced draft fan. The fly ash is periodically removed from the collection hoppers below the precipitators or bag filters. Generally, the fly ash is pneumatically transported to storage silos and stored on site in
ash ponds, or transported by trucks or railroad cars to
landfills.
Bottom ash collection and disposal At the bottom of the furnace, there is a hopper for collection of
bottom ash. This hopper is kept filled with water to quench the ash and clinkers falling down from the furnace. Arrangements are included to crush the
clinkers and convey the crushed clinkers and bottom ash to on-site ash ponds, or off-site to landfills. Ash extractors are used to discharge ash from municipal solid waste–fired boilers.
Flexibility Effective
energy policy,
law and
electricity markets are essential for grid flexibility. While the flexibility of some coal-fired power stations can be enhanced, they generally offer less
dispatchable generation than most
gas-fired power plants. A key aspect of flexibility is low minimum load; however, certain flexibility upgrades for coal plants may be more costly than deploying
renewable energy sources with
battery storage. == Coal power generation ==