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

 

Start

Particulate Removal

Physical

System Integration

Optimization

 

Rob  Mudry - Air Flow Sciences

 

The company has done many optimization projects involving the following:

 

 

The goals are emissions reduction, efficiency improvement and maintenance saving.

 

Ø      Combustion optimization to Reduce Emissions and Increase Efficiency

http://www.mcilvainecompany.com/Particulate_Decision_Tree/subscriber/Tree/DescriptionTextLinks/Airflow_Sciences_McIlvaine_10May2007.htm

 

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

http://www.mcilvainecompany.com/Particulate_Decision_Tree/subscriber/Tree/DescriptionTextLinks/Neundorfer Precipitator Performance Optimization - May 10, 2007.htm
 

 

FGD DECISION TREE

 

Start

Scrub

Physical

Component Specification

Optimization & Instrumentation

Optimization Systems

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.

http://www.mcilvainecompany.com/FGD_Decision_Tree/subscriber/Tree/DescriptionTextLinks/DTE KerryMclenon Monroe Power Plant.pdf

 

 

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

http://www.mcilvainecompany.com/FGD_Decision_Tree/subscriber/Tree/DescriptionTextLinks/Invensys Process Systems Power Plant Optimization Solutions by William Poe.htm

 

 

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

http://www.mcilvainecompany.com/FGD_Decision_Tree/subscriber/Tree/DescriptionTextLinks/ZonalCombOptimization by Neil Widmer GE_Mcilvaine-10May07_Final.pdf

 

 

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

o       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

http://www.mcilvainecompany.com/FGD_Decision_Tree/subscriber/Tree/DescriptionTextLinks/Combustion Optimization with APC.htm



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

http://www.mcilvainecompany.com/FGD_Decision_Tree/subscriber/Tree/DescriptionTextLinks/ThermoFisher Scientific Andy Smolenack McIlvaine Hot Topic Hour Presentation.pdf

 

 

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/

 

 

Jeff Williams, Manager, Westinghouse Process Control, Inc.

 

Eugene Thompson, Supervisor, Boiler Optimization, Diamond Power International Inc.

 

Sandeep Shah, Director of Technology, Clyde Bergemann Inc.

 

Joyce Dasch, Director, Power Marketing, Emerson Process Management

 

John Kang, Optimization Specialist, JEA, Northside Generating Station

 

Herbert Miller, Retired VP Technology & Standards, Control Components Inc.

 

Stephen Foster, Executive Vice-President, SABIA Inc.

 

Rick Anderson, Coal Handling Superintendent, Southern Company, Plant Scherer

 

Rich Munson, Pipe Conveyor Product Manager, Dearborn Mid-West Conveyor Co.

 

Rob Vermeulen, Product Manager Level Instrumentation, Endress+Hauser Inc.

 

Bob Beck, Director, Stream Turbine Mods and Upgrades, TurboCare

 

Pisi Lu, Product Development Manager, RMT Inc.

 

Amitabha Basak, Principal Engineer, WorleyParsons

 

Gary Bases, President, BRIL, Inc.

 

Lev Nelikl, P.E., APICS, President, Pumping Machinery LLC

 

Steven Daily, Sr. Project Manager, CC Technologies, Inc.

 

Rui Afonso, President, Energy and Environmental Strategies

 

Thomas Wright, Project Engineer, WorleyParsons

 

Steve Katzberger, Sargent Lundy

 

Constance Senior, PhD Manager, Engineering R&D, Reaction Engineering International

 

Yiu-Lam (Albert) Lau, Plant Engineer, AES Deepwater Inc.

 

Jorgen Jensen, DONG Energy

 

Kenneth Stuckmeyer Principal Performance Engineer, Ameren

 

Clay Erickson, Director, Environmental Engineering, Babcock Power Environmental Inc.

 

Pat Bartley, Manager, Engineering Studies, ALSTOM

 

Thorsten Dux, Operation Manager CTF, E.ON Engineering Corp.

 

Dr. Anupam Sanyal, President, International Environmental and Energy Consultants Inc.

 

Hardik Shah, Applications Engineer, Southern Environmental Inc.

 

Scott Evans, Vice President, Regulatory Affairs, Clean Air Engineering

 

Michael Jasinski, Process Engineer Babcock Power Inc.

 

Paul Farber, PE DEE Environmental Specialist, Environmental Consulting Group, Sargent & Lundy LLC

 

Donald Shattuck, AQCS Program Manager, Utility Engineering Corp.

 

Clay Erickson, Director, Environmental Engineer, Babcock Power Environmental Inc.

 

Michael Gregory, Air Quality Control Mgr., Bibb and Associates

 

Steve Derenne, Principal Engineer, We Energies

 

Shin Kang, Technology Manager, ALSTOM Power Plant Laboratories

 

Jeffrey Thompson, Research Scientist, Energy and Environmental Research Center

 

Lisa Cooper, Vice President, Progress Materials Inc.

 

Lawrence Bool, PhD, Senior Development Assoc., Praxair Inc.

 

Constance Senior, PhD Manager, Engineering R&D, Reaction Engineering International

 

Jens Madsen, Senior Consulting Engineer, Fluent Inc.

 

Stephen Niksa, President, Niksa Energy Associates

 

Daniel Connell, Engineer, CONSOL Energy Inc., Research & Development

 

Keith Day, Regional Marketing Director, O'Brien and Gere

 

Chris Ungate, Senior Principal Consultant, Sargent & Lundy LLC

 

Dr. Anupam Sanyal, President, International Environmental and Energy Consultants Inc.

 

Jussi Heikkinen, Sales & Marketing Director, Wärtsilä Corp.

 

Joseph Alan Beamon, Director, Coal and Electrical Power Division, U.S. Department of Energy Office of Integrated and Analysis Energy Information Administration