coal fired boilers efficiency
DESCRIPTION
Increasing Coal-fired Plants EfficiencyTRANSCRIPT
INCREASING ENERGY EFFICIENCY AND REDUCING GHGS EMISSIONS AND FUEL INPUT BY COAL-FIRED
PLANTSAdam J. Szladow
REDUCT & Lobbe Technologies and
Bruce ClementsCANMET, Natural Resources Canada
Power Plants Efficiency
Issues in CFCC Efficiency
Plant Location Elevation, Ambient Temperatures and Pressure
Environmental Regulations Sulfur, Nitrogen Oxide, Particulates Control
Plant Design Steam Cycle, Cooling System, Pollution Control
Major Equipment Boiler, Generator, Condenser, Electrostatic Precipitators
Operational Practices Maintenance, Optimization,
Boiler Efficiency
Efficiency of Coal-Fired Boilers
0 200 400 600 800 1000 120075
80
85
90
95
100
Boiler Efficiency (Primary Fuel) at 100% Load (%)
Boilers
Bo
iler
Effi
cie
ncy
Efficiency of Coal-Fired Plants
0 200 400 600 800 1000 120075
80
85
90
95
100
Boiler Efficiency (Primary Fuel) at 100% Load (%)
What Does It Mean?
±10% approach incorrect:
Plants behavior (efficiencies) described by many patterns (groups)
The patterns are non-linear and defined by plant design and operations
Each pattern describes a bench-mark for possible improvement
BOILER EFFICIENCY ATTRIBUTES DEPENDENCIES
ATTRIBUTE DEPENDENCY
Particulate Regulation Compliance Year 0.305
SO2 Regulation Compliance Year 0.301
Primary NOx Control Process 0.298
Design Fuel Specifications for Coal Sulfur 0.248
NOx Control Process 1 0.231
Primary Alternative Fuel 0.225
Boiler Firing Type (Primary Fuel) 0.223
Primary Fuel 0.215
Boiler Manufacturer 0.205
Coal Origin State 0.194
etc.
Boiler Efficiency Distribution
75
80
85
90
95
100
0 200 400 600 800 1000 1200
BOILER
BOIL
ER E
FFIC
IENC
Y, %
Boiler Efficiency (Primary Fuel) at 100% Load (%) Opposed Stoker
Group_1 A&B Efficiency Distribution
83.00 84.00 85.00 86.00 87.00 88.00 89.00 90.00 91.00 92.000
5
10
15
20
25
30
Boiler Efficiency
# P
lan
ts
2σ = 1.8
2σ = 2.5
Group_1 A&B Efficiency Distribution
83.00 84.00 85.00 86.00 87.00 88.00 89.00 90.00 91.00 92.000
5
10
15
20
25
30
Boiler Efficiency
Fre
qu
en
cy ?
Your plant
Group_1 A&B Efficiency Distribution
83 84 85 86 87 88 89 90 91 920
5
10
15
20
25
30
Boiler Efficiency
# P
lan
ts
1.70.8
Boiler Efficiency Improvement
Combustion Optimizationexcess air, coal drying
Slagging and Fouling ControlISB, target in-furnace injection
Boiler Tube Failure Control (availability)steam leaks, tube maintenance
Boiler Analysis G_1A
Variable Low Efficiency High Efficiency
Boiler Efficiency 87.4 89.0
Boiler Type Tangential Dry Tangential Dry
Age 40.0 43.7
Manufacturer CE CE
Location Vernon York
Firing Fuel Bit. Illinois Bit. Pennsylvania
Average Heat Content 12,756 12,674
Average Sulfur Content 1.2 1.6
NOx Control Low NOx Burner Low NOx/OFA
SO2 Emissions 1.1 1.9
CW Maximum Intake Temp. 81 87
Boiler Design Coal Firing Rate 140 150
Boiler Max. Continuous Steam Flow 2354 2500
Plant Efficiency 33.9 34.9
Boiler Analysis G_1B
Variable Low Efficiency High Efficiency
Boiler Efficiency 84.5 87.1
Boiler Type Spreader Stoker Spreader Stoker
Age 62.1 48.1
Manufacturer Babcock CE
Location Tennessee Tennessee
Firing Fuel Bit, Virginia Bit. Virginia
Average Ash Content 6.8 6.9
NOx Control None None
SO2 Regulation Compliance 1974 1973
FGP Electrostatic Electrostatic
Allowance PM Emissions Factor 0.0917 0.0917
Design Coal Firing Rate 113 440
Max. Steam Flow 150 400
Discovered Patterns of Boilers
Boiler Type σ % # Boilers$ Savings ≈ σ
450 MW Boiler1
Group_1A 1.25 81 550,000
Group_1B 0.89 23 400,000
Group_2 1.56 55 700,000
Group_3
Group_R(emaining) To be determined
1 Productivity Improvement for Fossil Power Plants: One Hundred Case Studies, EPRI 2005
Boiler Efficiency Summary
There are strong non-linear relationships between boiler/plant performance and variables in DOE/NETL database
A number of clear patterns could be identified
The patterns show possible efficiency improvements of up to 2-3 percent, valued at ½ to 1.5 million dollars in operational savings
Additional efficiency improvements are possible for the plant generator and should be investigated
A Research Proposal is presented by REDUCT to CEARI for utility funding (bellow)
Identifying different boiler/plant clusters based on client database including their critical factors and performance/emissions patterns
Determining, for each cluster, possible improvements in performance and emissions given the limiting factors and operating procedures.
Establishing important factors for the design of future generation plants including potential benefits to utilities from
Work Statement: Analysis of Performance Patterns in Clients Coal-Fired
Power Plants Database
Work Statement
Task 1. Analysis of Key Performance Factors Influencing Efficiency
Task 2. Analysis of Plants Design and Performance Characteristics
Task 3. Analysis of Efficiency Improvements and GHGs Reductions
Task 4. Analysis of Possible Improvements to Sponsors' Plants
Task 5. Monthly Progress Reports and a Final Report
Client utility will get
A benchmark for individual generating companies providing information on the potential for further unit efficiency improvement
The max efficiency to be expected for their boilers/plants based on the US boilers/plants database.
A list of possible specific measures for increasing boiler/plant efficiencies
Comprehensive report summarizing project findings and conclusions
Project Organization and Schedule
Organization: Dr. Adam J Szladow, REDUCT & Lobe
Technologies
Schedule: 4 to 5 months
Cost: $8,000 to $12,000
.
Summary
“The way to success is no longer knowledge and information only, it is experience and insight into information.”