Transcript Zonal™ Combustion Optimization

Zonal™ Combustion Tuning
System
Central District's 13TH Annual Power
Generation Conference
Florida Department of Environmental Protection
July 30, 2009
© 2008 General Electric Company
All rights Reserved
Data in this presentation is for indication and
discussion purposes only and may not be
representative of results to be expected in
specific applications.
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Agenda
• Zonal Combustion Principles
• Zonal System
– Features
– Application
– Reliability
• Operating Experiences and Achievements
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Zonal™ Combustion Principles
Combustion Performance Issues
High LOI
Reduced
efficiency
High CO
/Opacity
High NOx
Excessive
attemperation
Local
corrosion
Coal
Crusher
Coal
Supply
Excessiv
e
FEGT
Air
Heater
Coal
Silos
Mill
Boiler
Local hot
spots
ID
Fan
Stack
FD
Turbine
Fan Generator
ZonalTM Combustion
Monitors in Boiler
Backpass
Poor
Combustion
~
Local
slagging
Increased O2
Poor Combustion = Increased Boiler Issues = Poor Plant Performance
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Good Combustion, Bad Combustion
The Principles of Zonal Combustion Tuning
Comfort
Zone
Performance Parameters
Fuel Savings & CO2
Output, Throughput
& Fan Power
Improved
Improved
A/F σ
A/F σ
Minimum local A/F
limits average O2
Credits & Compliance
FEGT
Initial A/F σ
Availability & Output
Ash Sales &
Efficiency
Availability & CO
compliance
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Approaches to NOx Control
Technique
Nat. Gas Fuel Oil
Operational Modifications
Low Excess Air
Reduced Air Preheat
Fuel Biasing
Burners Out of Service(BOOS)
Combustion Equipment Modifications
Flue Gas Recirculation (FGR)
Overfire Air (OFA)
Steam Inject ion
Low-NOx Burners (LNB)
Reburning
Post-Combustion Techniques
Selective Non-Catalytic Reduction (SNCR)
Selective Catalytic Reduction (SCR)
Coal
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
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Benefits of Combustion Tuning
Emissions
Peak power
Great Benefits and Returns
• Increase Availability
• Reduce Emissions
• Improve Heat Rate
• Maximized Output
• Further Upside
Heat Rate
Availability
3,000,000
Annual Benefits, $/yr
2,500,000
2,000,000
– Stable and Predictable Operation
– Integrated with Mercury Removal
– Reduce or avoid slag additives
1,500,000
Chart Based on Specific Improvement
of :
1,000,000
500,000
100
300
500
700
Plant Size (MW)
900
1100
•
•
•
•
•
Excess O2: 0.5% reduction
Emissions (NOx): 15% reduction
Heat Rate: 0.5% improvement
Peak Power: 2.3% increase
Availability: 3 outage days avoided
*Benefits and improvements are site-specific. Actual results may vary.
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The Zonal™ Combustion System
Zonal™ Combustion Modules
Zonal™ Grid
#1 Zonal™ Combustion Monitoring
System
• CO/O2 Combustion Sensors
• Central Operator Interface
• Intuitive Graphic HMI Displays*
#2 Zonal™ Combustion Tuning Advisor
• Library of Zonal Models
• Burner/OFA Influence Identification
• Fuel/Air Adjustment Advice
• Map Profile Correction Advice
Zonal™ Advisor
* Software Modules built on iFIX HMI/SCADA
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Combustion Monitoring
Application
Combustion completed.
Good tracing to burners.
Reduced air in-leakage.
Incomplete
combustion.
Recirculation
zones and non
uniform flow.
TDL
Air in-leakage,
non uniform flow
and poor tracing
to burners.
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Zonal Combustion Tuning Advisor
Built on Predominant Fluid Structure
Predominant
Burner Path
Lines
Zonal
Combustion
Monitoring
System
Burners/OFA
Burner-to-Sensor Models
Capture Fluid Structure
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T-Fired Fluid Stratification Suited to
Zonal Tuning
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Zonal™ Monitoring System
Designed for Reliability
Zonal base analyzer technology has;
• Decades in similar applications
• 1000s installed world wide
• High reliability
Zonal
Installations
Sites
A - U1
Zonal Analyzer ZCA-30 status
• Deployed January 2007
• Over 330,000 hrs of operation as of
Apr 28, 2009
• Mean time to maintenance event:
– > 19 months
– Low Spec Limit > 12 month @ 2
Sigma, 95% PI
B - U3
C - U1
D - U5
D - U6
E - U1
Location
Denmark
MN, USA
UT, USA
UK
UK
SC, USA
Trials
1-4/07
11/07 – 3/08
5 – 10/07
NA
NA
11/08 - 1/09
Systems
12 Pts 6/08
8 pts 1/09
10 Pts 10/07
8 Pts 7/08
8 Pts
7/08
Pending
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GE’s Zonal Combustion Monitoring
Application Experience
Sensors applicable to Coal, Oil and Gas
Coal Type – Bituminous or Subbituminous
• Ash < 30%
• Moisture < 30%
• Sulfur < 3% (up to 4%)
Biomass co-firing to < 30%
Gas Temperature: 900 °F to 1200 °F (1500 °F maximum)
Ambient environments
• Electronics rated 0 to 60 °C, avoid exposure to severe weather.
– Installations to –20 °C but not recommended.
• Sensor rated–18 to 93 °C.
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Zonal Combustion Monitoring
Benefits of Zonal Approach
• Post combustion
• Close to furnace
• Zonal data traces to
burners
• Low air in-leakage
• Ease of installation
• Robust technology
• Accurate measurements
• Accurate point data
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Operating Experience and
Achievements
Zonal Combustion System
Installation Zonal Combustion Topology
Zonal Sensor Grid
Plant
• Western US
• 460 MW T-fired boiler
• Western Bituminous Coal
Zonal Project
• Zonal Combustion Monitor Grid
– 2x5 sensor array
• Zonal Tuner Advisor
– CCOFA yaw
Issues
• Frequent Slagging Events
• New Corporate NOx and CO
Mandates
Burner-toSensor
Models
Burner
Adjustment
s
Boiler
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As-Found Conditions – Western US
Boiler
Normal Operation
• Typically High 3.6% Excess O2
• O2 Imbalanced +/- 1% (ie. 10% ex
air)
• Low average CO 37 ppm
• High NOx 0.4 lb/MMbt
Reduced O2 Operation
• O2 reduced to 3.0%
• Low average CO 150 ppm
• High peak 900 ppm, fuel-rich zone
• Slagging severe at reduced O2
Combustion Issues not be Detected by Stack CO
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Zonal Combustion Tuning Event
T-Fired, Western US Boiler
O2 average: 3.13%
O2 spatial variance: 0.32%
25.00
20.00
15.00
10.00
5.00
0.00
0.00
5.00
10.00
15.00
20.00
25.00
30.00
35.00
40.00
45.00
50.00
5.00
4.75
4.50
4.25
4.00
3.75
3.50
3.25
3.00
2.75
2.50
2.25
2.00
1.75
1.50
1.25
1.00
0.75
0.50
0.25
0.00
250
225
25.00
200
175
20.00
150
15.00
125
100
10.00
75
CO average: 14 ppm
CO spatial variance: 9 ppm
5.00
50
0.00
0.00
25
5.00
10.00
15.00
20.00
25.00
30.00
35.00
40.00
45.00
50.00
0
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Zonal Tuning Improvements
T-Fired, Western US Boiler
Zonal O2 Distribution
Realized Benefits
NOx
25% Reduction
O2
0.5% Reduction
CO, ppm <50 ppm
9-Mar-09
Slagging No events
12-Jun-08
Efficiency 0.5% Increase
After
Before
2
2.5
3
3.5
4
4.5
5
5.5
Zonal O2, %
Ave 3.6% O2
Ave 3.1% O2
Before
(6/12/08)
After (3/9/09)
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Zonal Identified Air Leak at Boiler
Nose
Western US Boiler February 12,
•2009
Unusual Zone
of High O &
Zonal O2 Time Series - Feb 12, 2009
12
Sensor 5
10
2
O2, %
6
4
2
0
0:01
2:01
4:01
6:01
8:01
10:01
12:01
14:01
16:01
18:01
20:01
22:01
Time
Zonal CO Time Series - Feb 12, 2009
1200
CO_1
CO_2
CO_3
CO_4
CO_5
CO_6
CO_7
CO_8
CO_9
CO_10
1000
Sensor 5
800
CO, ppm
High CO
• Pinpointed likely
leakage area
• Boiler taken of
line for repair
• Repair verified
by O2 and CO
return to normal
8
Ox_1
Ox_2
Ox_3
Ox_4
Ox_5
Ox_6
Ox_7
Ox_8
Ox_9
Ox_10
600
400
200
0
0:01
2:01
4:01
6:01
8:01
10:01
12:01
14:01
16:01
18:01
20:01
22:01
Time
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Zonal versus Plant O2
Wall-Fired, Mid-West Boiler
Zonal O2 (true) reads 3.8%
Plant O2 (biased low) read
3.0%
X
Excess O2,
%
X
Plant O2 probes located in
these Zones @ 3% O2
CO, ppm
Existing Plant Sensors Biased Low and Not Suitable for
Tuning
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As-Found Zonal Combustion Conditions
Wall-Fired, Mid-West Boiler
Reduced Excess O2 Operation
Zonal Excess O2
• Average 3.2% O2
• Imbalance 1.3% to 5.1% O2
Zonal Combustibles (~CO)
• Average 133 ppm
• Imbalance 0 to 1000 ppm
Excess O2,
%
CO, ppm
Reducing Excess O2 Results in Poor Local Combustion
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Zonal™ Combustion Tuning
Wall-Fired, Mid-West Boiler
Zonal CO Profiles
As Found
Normal O2
700
As Found
@ Reduced O2
Zonal Tuned
@ Reduced
O2
CO Concentration, ppm
600
Normal O2
Reduced O2
Zonal Tuned
500
504
400
300
200
69
55
100
0
Sensor
Zonal monitoring provides ability to tune-out Poor Combustion
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Zonal Combustion Tuning System
Customer Reported Benefits
• Performance Engr expertise
captured in Tuning Advisor
• With topographical mapping of
both CO and O2, plant is able to
identify in-furnace problems.
• Plant is able to adjust the key
handles, to avoid split O2 and
problematic O2 distributions
• The unit is able to burn poorest
coals without slag outages or
significant slag buildup.
• 25% reduction in NOx levels
• Continuous operation within
corporate CO limits without
dropping load is possible
• Minimal variation in Oxygen
levels allowing O2 reduction in a
0.5% efficiency improvement
• A reduction of hot spots, fuel-rich
combustion resulting in reduced
forced outages.
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Conclusions
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Compelling Reasons to Optimize
• Combustion systems are more complex
• Retiring operator pool – new operators
benefit from improved tools
• Changing fuel sources – compliance coal,
low cost coals, biomass co-firing future
• Aging fleet and increasing electricity demand
• Stricter CO and NOx regulations ... and Hg
!!!
• Stiff penalties for emissions violations
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Zonal Combustion Tuning System
Summary
Provide operators Useful Information
Monitor End-Products of Combustion
Monitor Local Combustion Conditions
Capture Operator Expertise in Tuning and Operations
Strive for Predictable Performance in:
• Emissions – CO, NOx, Opacity
• Availability – slagging, water wall wastage
• Output – Pressure drop, fan limits
• Heat Rate – Steam Gen, Attemperation, Heat Losses
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Contact Information
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Contact Information
Product Manager, Combustion Optimization
- Neil Widmer
- 949-794-2630 (Work)
- 949-485-9543 (Mobile)
- [email protected]
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