May 10, 2007
Optimization Pays Big Dividends for Coal-fired Plants - Conclusion from Hot Topic Hour on May 10
A number of experts provided clear evidence that optimizing coal-fired boilers will reduce emissions, increase efficiency, and most importantly produce more electricity.
The individual presentations are in two Decision Trees (Particulate and FGD). You can view the visuals in the Decision Tree through the links below.
PARTICULATE DECISION TREE
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Optimization |
Rob Mudry - Air Flow Sciences
The company has done many optimization projects involving the following:
F.D. Fans
PA/SA Ductwork
Mills
Coal Pipes
Windbox
Burners
Furnace
The goals are emissions reduction, efficiency improvement and maintenance saving.
Ø Combustion optimization to Reduce Emissions and Increase Efficiency
Steve Ostanek – Neundorfer
Steve provided details on big improvements in efficiency and reductions in power consumption by using an optimization system which controls power input to the precipitator.
Ø Precipitator Performance Optimization
FGD DECISION TREE
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Analysis |
James Mooney, Engineering Consultants
Monroe power plant is a 3,100 MW power plant which blends high percentages of PRB coal with Central Appalachian coals – mid sulfur eastern, low sulfur eastern. The objectives of blending have two purposes: minimizing fuel cost and lowering sulfur emissions. Several tools are used to manage blending issues. These are Digital Fuel Tracking Systems, online analyzers that determine fuel quality, burner modifications to swirl-stabilized burners, and extensive pulverizer testing and combustion modeling.
Ø Blending to minimize fuel cost and lower emissions. Analysis by James Mooney, Engineering Consultants Group.
William “Bill” Poe - Invensys Global Solutions
Invensys optimization benefits include:
Pre-Combustion
– Coal / Fuel Blending Optimization – 1-2% production increase
– Mill Optimization – lower LOI, heat rate improvement, pluggage detection
Combustion
– NOx Reduction – 10-30%
– Heat Rate Improvement – 0.25–1.5%
– Dynamic Steam Temperature Control – +/- 1%, reduce steam turbine cyclic life
expenditure
– Ramp Rate Improvement – up to 100%
– Intelligent Soot-blowing – up to 0.25% heat rate improvement, lower equivalent
forced
outage rate (EFOR)
– LOI Reduction – 10-30%
Post-Combustion
– SCR’s – Reduce NH3 slip; Lower capital equipment costs;
– 2% additional reduction in NOx
– FGD’s – Increase SO2 removal efficiency with less
limestone consumption.
Ø Power Plant Optimization Solutions presented by Bill Poe, Invensys Global Solutions
Neil Widmer - GE
GE’s zonal combustion optimization system.
· Optimizes … output, availability, emissions and heat rate
· Layered systems are applied in phases but work together
· Remote burner fuel and air flow hardware are reliable, as are low maintenance combustion monitors
· Relational display of combustion topology and burner controls are utilized along with centralized monitoring and control to manage combustion and burner operation
· Performance trending and archiving are also provided.
Ø Zonal Combustion Optimization presented by Neil Widmer, GE
Richard Vesel - ABB
Due to the many inputs, outputs and constraints, the control problem is well-suited to solution by a multi-variable model-predictive control (MPC) (ABB’s “Advanced Predict & Control – APC”).
· Multi-variable MPC models “know” the dynamic behavior and the interactions between process quantities, by learning from a short history of a range of boiler operations (steady state and ramping).
· MPC controls all variables simultaneously, which is different from traditional base controls (e.g. PID control), where each controller has one input and one output.
· MPC controller, when active, sends set points to the base controls and can be independently activated or deactivated.
· The advantages:
o Greatly simplified control structure
o Much easier tuning
o Smoother transition from one constraint to another
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Superior performance over base controls during load and fuel
quality changes.
Ø Combustion Optimization for the Coal / Oil-Fired Power Plant by Richard Vesel ABB
Andy Smolenack - ThermoFisher Scientific
Andy was in Europe this week and was not able to make the verbal presentation but the power points are in the Decision Tree. They cover the coal analyzer and other products.
Ø Optimization through Coal Analysis by Andy Smolenack ThermoFisher Scientific
Good Technical Program Combines with Extensive Exhibits to Make Electric Power a Winner
Last week we provided 32 audio interviews and pictures from the Electric Power exhibition floor. These are available at http://www.mcilvainecompany.com/ElectricPower07/EP07.htm
The following papers will be of interest to our subscribers. They are available from the TradeFair group as part of access to the archives for $395. You can contact them at
http://www.tradefairgroup.com/
Software-Based Intelligent Sootblowing Utilizing an Expert System Combined with Model-Based Calculations
Jeff Williams, Manager, Westinghouse Process Control, Inc.
A Global Approach to Sootblower Optimization
Eugene Thompson, Supervisor, Boiler Optimization, Diamond Power International Inc.
Experience of DCS Integration for Intelligent Sootblowing
Sandeep Shah, Director of Technology, Clyde Bergemann Inc.
Building the Digital Power Plant of the Future
Joyce Dasch, Director, Power Marketing, Emerson Process Management
Using Optimization Technology to Minimize Emissions and Increase Efficiency and Productivity at JEA Northside
John Kang, Optimization Specialist, JEA, Northside Generating Station
Upgrade of Coal-Fired Plant Start-up Values
Herbert Miller, Retired VP Technology & Standards, Control Components Inc.
Using On-Line Nuclear Element Analyzers to Optimize Boiler Operation at Choctaw Generation Station in Northeast Mississippi
Stephen Foster, Executive Vice-President, SABIA Inc.
Improvements to Coal-Handling Systems at Plant Scherer
Rick Anderson, Coal Handling Superintendent, Southern Company, Plant Scherer
Pipe Conveyor Usage in FGD Industry
Rich Munson, Pipe Conveyor Product Manager, Dearborn Mid-West Conveyor Co.
New Techniques for Level Measurement of Flyash in Storage Silos
Rob Vermeulen, Product Manager Level Instrumentation, Endress+Hauser Inc.
Feedwater Pump Turbines: Your Plant's Most Under Appreciated Piece of Critical Equipment - An Overview of Options Available for Continued Reliability and Extended Service Life
Bob Beck, Director, Stream Turbine Mods and Upgrades, TurboCare
CFD Application in SmartBurn® Combustion Improvement
Pisi Lu, Product Development Manager, RMT Inc.
Boiler Draft System Optimization by Transient Analysis
Amitabha Basak, Principal Engineer, WorleyParsons
Water Gauge, Stiffeners, and Insulation on Air Pollution Equipment
Gary Bases, President, BRIL, Inc.
Engineered Upgrade of a 1,000-hp Ash Sluice Pump at a Power Station
Lev Nelikl, P.E., APICS, President, Pumping Machinery LLC
Corrosion Control Considerations for Power Generation Stations
Steven Daily, Sr. Project Manager, CC Technologies, Inc.
Regulatory and Technical Challenges in Achieving Environmental Compliance
Rui Afonso, President, Energy and Environmental Strategies
Impact of Future Air Pollution Control on PRB Use
Thomas Wright, Project Engineer, WorleyParsons
Impact of a Resource-Constrained FGD Market
Steve Katzberger, Sargent Lundy
Case Study of Fleetwide Hg Control Strategy: Technology, Schedule, and Cost Considerations
Constance Senior, PhD Manager, Engineering R&D, Reaction Engineering International
NOx Control Technologies at a 100% Petroleum Coke Pulverized Fuel Boiler
Yiu-Lam (Albert) Lau, Plant Engineer, AES Deepwater Inc.
Deactivation of High-Dust de-NOx: A Catalyst When Co-Combustion Heavy Fuel Oil and Biomass Initiatives Maximize Removal of NOx
Jorgen Jensen, DONG Energy
Operational Experience from the Power Industry's First Commercial Installation of Alta at Ameren's Sioux Plant
Kenneth Stuckmeyer Principal Performance Engineer, Ameren
Enhanced Automated Controls for Improved SCR Performance
Clay Erickson, Director, Environmental Engineering, Babcock Power Environmental Inc.
Exit Gas Outlet Temperature Control for SCR Applications: An Overview of Available Options for SCR Operators
Pat Bartley, Manager, Engineering Studies, ALSTOM
Long-Term Experience with Bench Scale Reactor Catalyst Testing, Possibilities, and Limitations
Thorsten Dux, Operation Manager CTF, E.ON Engineering Corp.
Finding Lowest-Cost ESP Performance Enhancement for Particulate and Multipollutant Control Systems
Dr. Anupam Sanyal, President, International Environmental and Energy Consultants Inc.
Membrane WESP: A Lower-Cost Technology for Multi-pollutant Control
Hardik Shah, Applications Engineer, Southern Environmental Inc.
Low-Level Sulfuric Acid Measurement with EPA Method 8
Scott Evans, Vice President, Regulatory Affairs, Clean Air Engineering
Wet Flue Gas Desulfurization (WFGD) Upgrade at the Trimble County Generating Station Unit 1
Michael Jasinski, Process Engineer Babcock Power Inc.
Results of FGD Upgrade Projects on Low-Rank Coals
Paul Farber, PE DEE Environmental Specialist, Environmental Consulting Group, Sargent & Lundy LLC
A History of FGD: The Early Years
Donald Shattuck, AQCS Program Manager, Utility Engineering Corp.
The Design, Installation, Start-up, and Commissioning of a Modern WFGD System
Clay Erickson, Director, Environmental Engineer, Babcock Power Environmental Inc.
Design, Benefits, and Project Execution of a Vertically Integrated FGD System
Michael Gregory, Air Quality Control Mgr., Bibb and Associates
TOXECOM™ Clean Coal Demonstration for Mercury and Multi-pollutant Control at We Energies Presque Isle Power Plant
Steve Derenne, Principal Engineer, We Energies
Enhanced Mercury Capture via ALSTOM's Mer-Cure™ Technology
Shin Kang, Technology Manager, ALSTOM Power Plant Laboratories
Enhanced Sorbent Injection for Mercury Control at TXU Power's Big Brown Station
Jeffrey Thompson, Research Scientist, Energy and Environmental Research Center
Carbon Burn-Out as a Mercury Control Technology
Lisa Cooper, Vice President, Progress Materials Inc.
A Novel Process for On-Site Production of Mercury Sorbents
Lawrence Bool, PhD, Senior Development Assoc., Praxair Inc.
Hg Reduction via Co-Benefits at a PRB-Fired SDA/FF Boiler
Constance Senior, PhD Manager, Engineering R&D, Reaction Engineering International
Optimizing the TOXECON™ Mercury Removal System at Presque Isle with Flow Modeling
Jens Madsen, Senior Consulting Engineer, Fluent Inc.
Predicting Mercury Emissions Rates from Utility Gas Cleaning Systems
Stephen Niksa, President, Niksa Energy Associates
Initial Cost and Performance Results from the Greenidge Multipollutant Control Project
Daniel Connell, Engineer, CONSOL Energy Inc., Research & Development
SO3, SO2, and Mercury Control through "Duct Injection"
Keith Day, Regional Marketing Director, O'Brien and Gere
Baseload Generation Capital Cost Trends
Chris Ungate, Senior Principal Consultant, Sargent & Lundy LLC
Fuel Trends
Dr. Anupam Sanyal, President, International Environmental and Energy Consultants Inc.
Global Trends
Jussi Heikkinen, Sales & Marketing Director, Wärtsilä Corp.
Power Industry Outlook
Joseph Alan Beamon, Director, Coal and Electrical Power Division, U.S. Department of Energy Office of Integrated and Analysis Energy Information Administration