Operation and boiler performance enhancement using online ...€¦ · Operation and boiler performance enhancement using online monitoring instruments ... Steam temperatures at SH

© EUtech Scientific Engineering GmbH Dennewartstraße 25-27, 52068 Aachen, Germany www.eutech-scientific.de [email protected] Phone: +49/241/963-2380 Fax: +49/241/963-2389

NTPC Indian Power Stations 2020 - February 14, 2020 - Raipur (India)

Operation and boiler performance enhancement using online monitoring instruments

Cost-effective flexibilisation of fossil-fired power plants

Dr. Francesco Turoni

https://www.eutech-scientific.de/

mailto:[email protected]

© EUtech Scientific Engineering GmbH

Content

▪ Power generation in India

▪ Flexible operation

▪ Online monitoring instruments

- EUcoalflow

- EUcoalsizer

- EUsoft air

- EUflame 2D

▪ Best practices / Results

▪ Summary and outlook

2


Power generation in India

3


▪ Inherent intermittencies of wind and solar resources

▪ Dynamic, flexible and new minimal operation requirements for fossil fuels base-load plants

▪ Compliance of emission limits (NOx & CO), improvement of plant efficiency and plant reliability

Power generation in India

Challenges

▪ Steady economy growth requires more capacity

▪ NTPC plans doubling of coal-fired capacity to 85 GW by 20321

- Existing plants are designed for base-load

- Varying fuel types and blends

- Almost no online and reliable information of fuel, air flows, particle size distribution and FEGT available

▪ New record for renewable energy sources (wind, solar and hydro) in Q1&Q2, 20192

Status

41) NTPC Ltd.2) Central Electricity Authority (CEA)


Flexible operation

5


▪ Increase operational flexibility (fuel flexibilisation, min. load & load swing flexibilisation)▪ Increase flame stability and thus reduce SH & RH water spray injection and thermal stresses▪ Reduce unburned carbon (LoI, slagging and fouling minimization)▪ Improve overall plant efficiency and minimize flue gas losses▪ Comply with emissions legislation (NOx, Co, GHG, particulates)▪ Increase operational reliability

Flexible operation

...and why that matters!

▪ Pulverizer fineness and load range optimization with pipe specific dynamic mass flow measurement ▪ Robust measurement and control of primary, secondary and overfire air flow ▪ Balancing fuel and air distribution into the burner belt (AFR management)▪ Control of temperature and burnout distribution in vertical and horizontal domain▪ Control of SH and RH steam temperatures▪ Continuously utilizing available data with online analysis (e.g. condition-based maintenance)

How to achieve/enhance flexible operation?

6


Online monitoring instruments

7


Step by step to success

Motivation

8

MEASUREMENT CONTROL OPTIMIZATION

Coal mass flow

Coal fineness

Air mass flow

2D Temperature Distribution

Air Fuel Ratio

Advanced Control Strategies

Model Predictive Control

Efficiency

Emissions

Slagging

FEGT


▪ Absolute mass flow and velocity measurement▪ Stationary and mobile ECF System▪ Plug and play solution▪ Comfortable user interface (ECF Software)▪ Full integration to DCS

Online fuel mass flow measurement

EUcoalflow

9


▪ Online coal flow analysis with direct results

- Particle fineness

- Air flow

- Coal mass flow

- Air-fuel ratio▪ Immediate results & online reporting▪ Built for everyday use

Immediate coal flow readings

EUcoalsizer mobile

10


▪ Flow measurement with virtual sensors▪ Reliable and accurate mass flow values▪ All air flows (PA, SA, OFA)▪ No maintenance, auto-control▪ Easy to implement into DCS ▪ No footprint, windbox compatible

Complete air management

EUsoft air

11


▪ Online flame temperature and burnout measurement (2D/3D)▪ Sensor based on optical measuring technique▪ Single-point and net-measurements▪ Designed for different scales of combustion chambers▪ Precise measurement of FEGT distributions▪ Stationary or mobile system available

Flame temperature and burnout

EUflame 2D

12


Best practices / Results

13


12-Dec-2019 11:50:26 12-Dec-2019 16:03:50 12-Dec-2019 20:17:14 13-Dec-2019 00:30:38 13-Dec-2019 04:44:03 13-Dec-2019 08:57:270

10

20

30

40

50

60

70

80

Time

Mass f

low

[t/

h]

Coal mass flow mill H

H1ECF

H2ECF

H3ECF

H4ECF

Mill HECF

sum

Mill Hfeeder

H1 H2 H3

12-Dec-2019 20:06:30 12-Dec-2019 20:27:26 12-Dec-2019 20:48:22 12-Dec-2019 21:09:18 12-Dec-2019 21:30:15 12-Dec-2019 21:51:110

2

4

6

8

10

12

14

16

18

20

Time

Ma

ss f

low

[t/

h]

Coal mass flow mill H

H1ECF

H2ECF

H3ECF

H4ECF

H3

▪ Stable and reproducible signal correlates with mill load▪ Direct monitoring of dynamic effects allows active pipe-to-pipe mass flow & FEGT temperature balancing▪ Safety increase due to direct information of PF pipe choking (e.g. with wet coal)▪ Improve efficiency and emissions (CO, ƞ)

EUcoalflow (660 MW TPP)

Achievements

14

Online fuel mass flow distributionH2

H2-C4 H2-C2


▪ Active fineness management over whole mill lifetime▪ Ignition & combustion improvement (CO, η)▪ Reduction of unburned carbon (LoI)▪ Condition based mill maintenance▪ Availability improvement (slagging and fouling minimization)

EUcoalsizer mobile (660 MW TPP)

Achievements

15

Online fineness optimization

80,00

81,00

82,00

83,00

84,00

85,00

86,00

87,00

88,00

89,00

90,00

0,00

5,00

10,00

15,00

20,00

25,00

30,00

20:0

2:2

4

20:0

9:3

6

20:1

6:4

8

20:2

4:0

0

20:3

1:1

2

20:3

8:2

4

20:4

5:3

6

20:5

2:4

8

21:0

0:0

0

21:0

7:1

2

21:1

4:2

4

Fin

eness

[%

]

Fin

eness

[%

] /

Velo

city

[m

/s]

Classifier adj. Pos. 3 -> 5 -> 7 (Cont. meas. Dec. 13, 2019 - PF pipe F4)

Mean Velocity [m/s]

+ 50 mesh

- 200 mesh

86,5

87

87,7

26,3 26,225,6

Pos. 3 Pos. 5 Pos. 7


▪ Air-fuel ratio balancing and staging (key-driver of combustion)▪ Direct combustion and emissions improvement (CO, LoI, NOx, particulates)▪ Reduce spray-water injection requirements▪ Further reduction of excess O2, increases efficiency η

EUsoft air (600 MW TPP)

Achievements

16

AFR management with virtual sensors

AB

CD

EF

12

34

MillPipe AB

CD

EF

12

34

MillPipe

Air Fuel Ratio

09:36 10:48 12:00 13:12 14:24 15:36 16:48540

545

550

555

560

565

570

575

580

Tem

pera

ture

[°C

]

Steam temperatures at SH outlet [@ 600 MW, November 29th, 2012]

09:36 10:48 12:00 13:12 14:24 15:36 16:480

20

40

60

80

100

120

140

160

180

200

NO

x [

ppm

]

NOx [@ 600 MW, November 29th, 2012]


EUflame 2D (710 MW TPP)

17

Combustion homogenization

F1 F2 F3 F4

L1

Left

Front

L2

F1 F2 F3 F4

Left

Front

L2

R1

R2

R1

Right Right

L1

R2

▪ Higher combustion efficiency and higher flexibility▪ Active FEGT control / homogenization and emissions improvement (CO, LoI, NOx, particulates)▪ Identify and optimize optimal location for injecting NO reducing agents in SNCR▪ Reduce spray-water injection requirements▪ Less thermal stress

Achievements


Summary and outlook

18


▪ Robust and fully reliable solutions▪ Increase operational flexibility (fuel flex., load swing flex.)▪ Seamless integration into existing plant infrastructure ▪ Improve overall plant efficiency (O2 level & minimize flue gas losses)▪ Comply with emissions legislation (NOx, CO, GHG, particulates)▪ Avoid major, capital intensive retrofit▪ Reduce fatigue, wear and thermal stress▪ Leverage the best possible cost value option for plant upgradation

Summary and outlook

Opportunities for power generation in India

▪ Online and robust measurement of the coal flow and PA flow in each pipe▪ Adjust coal flow to acceptable reference limits (e.g. manual static adjustments)▪ Robust AFR management at burner levels▪ Use of optimisation tools rather than just measurement devices▪ Quality enhancement through frequent real-time measurement in less time▪ Real-time data enabling efficient and powerful control▪ Optimal efficient / cost ratio

Cost-effective flexibilisation

19


Thank you!www.eutech-scientific.de

© EUtech Scientific Engineering GmbH Dennewartstraße 25-27, 52068 Aachen, Germany www.eutech-scientific.de [email protected] Phone: +49/241/963-2380 Fax: +49/241/963-2389

https://www.eutech-scientific.de/

mailto:[email protected]

Documents

Operation and boiler performance enhancement using online ...€¦ · Operation and boiler performance enhancement using online monitoring instruments ... Steam temperatures at SH