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G ti S itGeneration Summit
February 7-8, 2012 San Antonio, TXSan Antonio, TX
John WeedaDirector, North Dakota Generation
Great River Energy
Great River Energygy
Generation & transmission cooperati e• Generation & transmission cooperative
• 28 member cooperatives in MN and WI
• Serving 645 000 homes & businesses• Serving 645,000 homes & businesses
• 850 employees
• $850 million revenue$850 million revenue
• $3.3 billion total assets
• Investment grade debt
• 2,800+ MW of generation
• 4,500+ miles of transmission lines
Background –Th "T i l B tt Li "The "Triple Bottom Line"
• Great River Energy has a• Great River Energy has a commitment to provide customers with:
Stable rates
ReliabilityReliabilityReliabilityReliabilityRatesRatesRatesRates
– Stable rates– Reliable electricity– Environmental stewardship EnvironmentEnvironmentEnvironmentEnvironment
• Members annually approve:– Rates– New projects– Environmental investments
A P i E l f thA A Premier Example of the Innovative Spirit
Coal Creek Station Units 1&2Coal Creek Station Units 1&2• 2 X 600 MW Tangentially Fired,
Dual Furnace
• 8 X 8 burners, plus SOFA
• Eight Pulverizers per Unit• Eight Pulverizers per Unit
• Mine Mouth, ND Lignite
o Contract thru 2045
o 6,200 BTU/lb (14.4 MJ/kg)
o 38% moisture
o Approximately 8M tons/yrpp y y
• Commissioned 1979, 1981
• Wet FGD’s from original design
Cl d L C li• Closed Loop Cooling
• DC transmission to Minnesota
Why should DryFine technology be f i t t t ?of interest to you?
Dual ReheatUltra-SuperCritical at 1120F/1120F (604C/604C)
Low-T Fuel DryingUltra-SuperCritical at 1256F/1292F (680C/700C)
Advanced Ultra-Supercritical at 1350F/1400F (732C/760C)
Low-T Feedwater Pre-heatingLow-T Air Pre-Pre-heating
Reduce cooling tower approach temperatureNatural Draft Cooling Tower
Dual Reheat
0% 5% 10% 15%
Reduce Air Heater Leakage (6% to 1%)
Heat Rate Improvement, % Baseline
Figure 2-24Comparison of Heat Rate Improvement Technologies Baseline is 1080°F/1080°F/3800 psi steam cycle (582°C/582°C/262 bar), 87.2% efficient boiler firing PRB coal with mechanical draft cooling towers. Baseline Unit Heat Rate is 8,982 Btu/kWh (9,497 kJ/kWh).From:CoalFleet Guideline for Advanced Pulverized Coal Power Plants: Version 5 EPRI Palo Alto CA: 2009 1015698CoalFleet Guideline for Advanced Pulverized Coal Power Plants: Version 5. EPRI, Palo Alto, CA: 2009. 1015698.
Problem Statement:The Friday Afternoon Brainstorm Question
• Plant performance is based on 6,800 BTU/lb (15.8 MJ/kg) fuel (with ( g) (normal margins), but delivered fuel HHV has rarely exceeded 6,200 BTU/lb (14.4 MJ/kg)
• As a result• As a result….
• Lost Boiler And Cycle Efficiency
– 9% Higher Coal Flow Rate Than Design
– 20 MW Of Station Service Power
– 20% Higher Flue Gas Flow Rate Than Design
High Exit Gas Temperature– High Exit Gas Temperature
• Lost Spare Mill Capability
• Increased Operating And Maintenance Costs
• Flue Gas Flow Limited Scrubbers!
Culture of InnovationCulture of Innovation
• Is a “Friday afternoon” brainstorm session allowed, encouraged or frowned upon?
• Do employees have the big picture of what improvements in their area of responsibility can do for the company?
• Is plant performance a “tracking” program or an “improvement” program?p g
Solution • Objective….
• Restore lost performance by removing moisture in the incoming fuel• Restore lost performance by removing moisture in the incoming fuel stream just prior to bunkering
• How….• Employ waste heat to reduce moisture content of the lignite conveyed to
the bunkersthe bunkers • Approach….
• Demonstrate and Select Basic Drying Process Concept• Develop “Proof Of Concept” Pilot Plant• Develop Dryer Design And Predictive Performance Modeling• Prototype Full Scale Dryer Design • Integrate Full Scale Commercial Demonstration Into Existing Plant
ProjectProject
Coal Pile Testing, Initial Fluidized Bed
Pilot Dryer2 Ton/hr
Phase 2Commercial Application
Phase 1Prototype
DryerFluidized Bed Dryer Design
2002
2 Ton/hr2003- Present
Application2009
Dryer 112Ton/hr2005-2009
Culture of InnovationCulture of Innovation
• Are employees free to try new things?
• Is failure acceptable?• Is failure acceptable?
• Is there some funding available for improvement development?
• Would you support a pilot study?
• Is a prototype a taboo thought?
DryFiningTM Process
NOx
Culture of InnovationCulture of Innovation
• Are integrated solutions encouraged?
• Is boiler efficiency equivalent to environmental controls?
Is reduced maintenance cost a valid factor in economic evaluation?• Is reduced maintenance cost a valid factor in economic evaluation?
• Can you take credit for reduced company staff time without a layoff?
Collaborative Development Effort
Prototype Coal Dryeryp y
M i it 112 5 t /h• Maximum capacity - 112.5 tons/hr
• Removed approx. ¼ of coal moisture.
– Dried lignite from 38.5% to 29.5% moisture
– Improved HHV from 6,200 BTU/lb (14.4 MJ/kg) to 7,045 BTU/lb (16 4 MJ/kg)(16.4 MJ/kg)
• Fully automated operation, integrated into the plant control system.
Six patent applications on dryer design and control filed by GRE• Six patent applications on dryer design and control filed by GRE (two awarded).
Culture of InnovationCulture of Innovation
• Will your operators support operation of a prototype?
• How will maintenance support the need to keep a prototype running?
• Is collaboration embraced as a way to leverage knowledge and innovation?
Boiler Efficiency Improvement from the Prototypefrom the Prototype
3.0
Theory
2 0
2.5
nt [%
Abs
]
Theory
Test Result
1.5
2.0
cy Im
prov
eme
ctio
n
0 5
1.0
oile
r Effi
cien
c
Moi
stur
e R
educ
0.0
0.5
0 1 2 3 4 5 6 7 8 9 10
Bo
Targ
et
Reduction inTotal Moisture in Coal [% Abs]
Segregation Stream from the PrototypePrototype
Sulfur and Hg in Segregation Stream
60.00%
50.00%
Mercury
30.00%
40.00%
%
%S in UC
%Hg in UC
20.00%
%Hg in UC
Sulfur
0.00%
10.00%
5/31/06 6/3/06 6/5/06 6/6/06 6/7/06 6/8/06 6/9/06 6/12/06 6/13/06 6/14/06
date
The Transition from Prototype to Commercial
• Pursue the one unit at a time original concept?
• Evaluating least cost options
DryFining – the clear choice
02007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018
nefit
sst
s N
et B
enm
ulat
ive
Cos
Present Value difference between the cases exceeds
$292 million in value
Cum
m
Confidential 19Alternative Case - No Coal Drying Base Case - Coal Drying
Culture of InnovationCulture of Innovation
• Is a least cost model vs. an ROI model acceptable?
• Does the board trust management enough to authorize a project like this?
• Will management and the board support the rough spots in the road as serial number one issues of budget, schedule, and startup issues need resolutionneed resolution.
Culture of InnovationCulture of Innovation
• Are you willing to make proactive environmental improvements?
• Do your employees have enough ownership of their equipment to make it thru serial number one issues?
Not just the engineers- how about your Mechanics, Electrical j g y ,and Instrument Technicians, Operators, Fuel Handlers and others?Do they work collaboratively or throw problems back and forth?y y p
Looking at the result in January 20102010
SO2 Reduction2
0.800
0.900
0.600
0.700
N btu
0.500
lB/m
ILLION
0.300
0.400GREAT RIVER ENERGYCoal Creek Station
DryFining Full Load SOx ImpactJCKennedy ‐5/14/2010
8-Sep-11230.200
10/14/09 11/3/09 11/23/09 12/13/09 1/2/10 1/22/10 2/11/10 3/3/10 3/23/10 4/12/10
NOx ReductionNOx Reduction0.300
0.250
GREAT RIVER ENERGYCoal Creek Station - Unit #2
Hourly Full Load NOx Readings - Oct 2009 to April 20105/25/2010 - JCKennedy
106BTU)
0.200
NOx (lb/1
0.150
0.100
10/14/09 11/3/09 11/23/09 12/13/09 1/2/10 1/22/10 2/11/10 3/3/10 3/23/10 4/12/10
Summary: HgT
Coal Creek Unit 1: sCEM: Total Mercury
y g
Coal Creek Unit 1: sCEM: Total Mercury
16
18
20
g/dN
m3 ] Wet Coal Baseline
Dried Coal
12
14
16
n in
Flu
e G
as [ μ
g
6
8
10
y C
once
ntra
tion
2
4
6
Tota
l Mer
cury
0APH Inlet FGD Inlet FGD Bypass FGD Outlet Stack
Measurement Location
DryFining Results
25% less H2O - dry lignite from 38 to 29% moisture, improving HHV from 6,100 to 6,800 BTU/lb
54% less SO2 - Segregation of ash minerals, plus improved collection efficiency
40% less Hg - Segregation of ash minerals, plus improved collection efficiency
32% less NO Reduced volumetric release rate improved32% less NOX - Reduced volumetric release rate, improved fineness and air & fuel distribution to furnace
4% less CO2 - 4% improved cycle efficiency4% less CO2 - 4% improved cycle efficiency
Meeting the Challenge of Marketing the Technology
• DOE requirement that the technology be made commercially available to others
• Repayment to DOE based in part on sale of technology
• Developing commercialization partners
• GRE not DryFine IncGRE not DryFine, Inc.
Process integrations (completed)g ( p )
Gasifiers• Gasifiers– Integrated Gasification Combined Cycle– Coal to Liquids
• Super Critical Pulverized Coal
• Activated Carbon
• Oxy-fuel firing
• Confidentiality agreements in place
• 50% Global reserves would benefit
Other GRE Successes from a B i I t C ltBusiness Improvement Culture
Efficiency ImprovementsEfficiency Improvements
Turbine bladesCooling TowersSimulator
DryFiningbeneficiation
4% 800 000 tons totalSimulatorVentilationVariable packingFans/VFD’s
4%, 800,000 tons total
Over $316,000,000 invested inOver $316,000,000 invested inFans/VFD sControlsLeak detectionCompressed air
Over $316,000,000 invested in Over $316,000,000 invested in environmental and efficiency environmental and efficiency improvements since 1979improvements since 1979
Compressed air605,771 tons total
Precision Maintenance Successes
C li T F f 2 f il / t $36 000 h t 12• Cooling Tower Fans-from 2 failures/yr at $36,000 each to 12 years with no failures
• Heater Drains Pump- annual rebuild to 8+ year life saving $5000/year
• Condensate pumps- 7 year life to 15+ years saving $49,000/pump X 6 pumps
• Valve maintenance- saving $14,000 to $100,000/year
• Boiler Feed pumps increase life between overhauls avoided• Boiler Feed pumps- increase life between overhauls avoided purchase of new pump for $550,000
Concluding Point of ViewConcluding Point of View
Whatever you call your drive for excellence a host of opportunities awaitexcellence, a host of opportunities await
you which, like DryFine, will improve your bottom line when you fosteryour bottom line when you foster
innovation.
Any questions???Any questions???