SPPA-P3000 Combustion Optimization

© Siemens AG 2016. All Rights Reserved.

Instrumentation, Controls & Electrical

September 28th 2016Max Starke, Product Manager for Process OptimizationArturo Montero, Sales Manager PG IE- Spain

NOx Reduction by Combustion OptimizationSPPA-P3000 Combustion Optimization Solutions

SPPA-P3000 Process Optimization Power Generation • Instrumentation, Controls & Electrical© Siemens AG 2016. All Rights Reserved.Page 2SPPA-P3000_siemens day 28th-v4a.ppt

“Spanish Generation Market Overview”Coal Fired Power Plants = 10.065 MW

1.- “La Directiva de Emisiones Industriales” • 1A.- Directiva 2010/75/UE del Parlamento Europeo y del Consejo, de 24 de noviembre de 2010. (GIC ; > 50 MWt)• 1B.- Directiva (UE) 2015/2193 sobre Limitación de Emisiones de Instalaciones de Combustión Medianas (MIC; 1-50 MWt)

2.- “Las Centrales Térmicas de Carbón en España”


1A.- “La Directiva de Emisiones Industriales 2010/75/UE ” *) Alternativas y Calendario de Aplicación



1B.- “Directiva (UE) 2015/2193 Emisiones (MIC; 1-50 MWt) ” :*) Alternativas y Calendario de Aplicación



2.- “Las Centrales Térmicas de Carbón en España”





Métodos chemicol(Chemical clearing of flue gas with Ammonia / Urea)

TÉCNICAS CLÁSICAS para Reducir los NOx SPPA-P3000 Combustion Optimization & SNCR/SCR

Medidas PrimariasAvoid NOx formation = “good” combustion

Métodos de Control(Optimum, low O2 + fuel distribution in boiler)

NOx Reduction: 15-35%+O2 Reduction: 0.2-1.0%

(Efficiency 0.1-0.5%)

Técnicas

Métodos mecánicos(Combustion with low temperature + low O2)

Name Method Potent.LEA Low excess air <10%Staged Staged air 10-40%- BOOS Burners out of service

- BBF Biased burner firing

- OFA Over-fire air

FGR Flue gas recirculation <20%LNB Low-NOx burners 20-30%AFLNB Air-staged & air/fuel-staged

LNB <40%

RIR Reburning/in-furnace NOx reduction <20%

Reducción Catalítica Selectiva

(SCR)

ReducciónSelectiva NO

Catalítica (SNCR)

ADDITIONAL Benefits: CAPEX (compared with SCR)

OPEXLife Time

Reducción Catalítica (Heterogénea)

Medidas SecundariasRemove NOx after combustion


Temperature distribution in the combustion zone

optimization

Calculation and evaluation of temperature-and concentration distribution through Computer-Aided Tomography (CAT)

before

Laser based Measurement of Temperature- and Concentrations- ( H2O, O2, CO, CO2, ...) values directly in the combustion zone

Unique direct measurement and optimization inside combustion zone

SPPA-P3000:2D-Measurent in combustion zone

Classical:Point measurement far downstream

afterwards

Measurement positions Measurement, Calculation, Optimization

Optimization through hybrid combustion control, using classical model based control structures and adaptive neural network

homogenous combustionincreased efficiencyreduced emissions


Approved Technology...designed for the harsh boiler environment

Boiler(top view) Sensor Head

(Transmitter)

Junctionbox

Junctionbox

No sensitive electronics near the boilerAutomatic cleaning (rodders + air)Online alignment (SensAlign™)Long service life time 100,000 h (use ofstandard telecommunication components)Standardised systems with 10-24 paths Modular variation of paths

Sensor Head(Receiver)

Boiler

Central installation of sensitive components, e.g. in electronic equipment room Measurements currently possible:- Temperature, O2, CO, CO2, H2O- Further development potential

Mux

12

403

Demux

12

403

Measurement cabinet

Transmitter Receiver

Electronic equipment room


Absorption Spectroscopy a renown and established measurement technique

Absorption spectroscopy measures the absorption of radiation (e.g. photons) at specific wavelengths. The absorption intensity varies as a function of frequency causing absorption spectrums.Absorption spectroscopy is employed as an analytical chemistry tool to determine the presence of a particular substance in a sample and to quantify the amount of the substance present. Infrared and ultraviolet-visible spectroscopy are common in analytical applications. Absorption spectroscopy is also employed in studies of molecular and atomic physics, astronomical spectroscopy and remote sensing.


Computer Aided Tomography commonly used e.g. in medicine technique (CT)

Path-average values Temperature-, Distribution ofConcentration

Values of intersection points

Computer Aided Tomography (CAT)Measurement, Reconstruction und Interpolation


Mounting bolts

8-10 mm slot for boiler access

Installation of laser measurement equipment Requires only Minimum Effort and 1-2 Days of Outage

Mounting stem

Measurement head

Pneumaticcylinder Mechanic slag

rodder


Laser measurement system equipped with Automatic Cleaning and Laser Centering

Port rodder retracted Port rodder extended

Boiler wall

Slagging


SPPA-P3000 Combustion OptimizationSending Correction Signals into Exiting I&C Structures

Secondaryair & fuel

Boilerbefore optimization

(inhomogeneous combustion)

Existing I&C system

++

++

++

CorrectionSignals

OFA 2

OFA 1

after optimization(combustion homogenization)

Temp.

O2

CO

CombustionOptimisationControllers

2D-Measurement temp. & gas

concentrations

ControllerOFA 2.1

ControllerBurner 1

ControllerOFA 2.2


Combustion optimization strategiesMinimizing excess air increases efficiency + reduces NOx

Measuring and homogenizing the combustion process avoids local emission & temperature peaks. This gives room for the optimization of the excess air level - beneficial for both the NOx emissions and the efficiency!

Is the boiler operated in the comfort zone or in the optimum zone?

Com

fort

Zon

e

Optimization

Opt

imum

Zon

e

Com

bust

ion

and

proc

ess

para

met

ers

Excess air

CO

Optimum

NOx

2 Efficiency

1

4O23


SPPA-P3000 Combustion Optimization - Examples

EDF West Burton & Cottam,500 MW Hard Coal

NOx-Reduction

KCPL La Cygne,710 MW Hard Coal

NOx-Reduction

Huaneng Rizhao,680 MW Hard Coal

Efficiency Improvement

RWE Neurath & Niederaußem,300-1000 MW Lignite

Efficiency Improvement Mark-E Elverlingsen,310 MW Hard Coal & MBM Co-Firing

Improved Co-Firing & NOx Reductions

GenOn Keystone,850 MW Hard Coal

Efficiency Improvement Infracor Marl,125 MW Hard Coal & Petrochemicals

Efficiency Improvement & NOx Reductions

NOx reduction increasingly important - worldwide

> 22-34%

+ 0.5%O2 - 0.9%NOx - 14.4%

Coal - 1.8t/hCO2 - 4.4t/h

ReferencePlants

20%


EDF Cottam Unit 3 - Case StudySet-Up & Improvements of Combustion Optimization

OFA99ft

~110ft“Nose”

Laser measure-ment plain

SL

SL

SL

SL

Over fire air control

Secondary air control

Mill Bias

FD FanBias

Cttam Unit 3

S1 S2 S3 S4 S5 S6 S7 S8A1 A2 A3 A5

~10x24m

A4 A6

OFA

SALaser Path LayoutFor:

Single combustion chamber, Front & back wall access,Front firing, 3-sided OFA

0

100

200

300

400

500

2,5 3 3,5 4 4,5 5 5,5 6

O2 MW [%]

0

40

80

120

160

200

NOX h average mg\Nm3 Reg NOX mg/Nm3 CO Eco A ppm Reg CO ppm

O2

NOx

CO

Limit

Plant Assessment: NOx reduction Potential: > 30%Efficiency Improvement: ~ 0.25%

Process Data Evaluation – Process Optimization Potential Configuration: Front fired boiler


EDF Cottam Unit 3 – Case Study Results: Reduced NOx with Efficiency Improvements

560 mg/Nm³551 mg/Nm³

416 mg/Nm³443 mg/Nm³

Combustion optimization control loops & set-point corrections(1) Balancing air/fuel-ratio at burner level Air Damper 32 x Secondary(2) Vertical air structuring with BOFA Flow 2 x BOFA Fan(3) Total O2 level optimization at ECO 1 x O2 Set-point(4) Stabilizing wind box pressure Air Damper 32 x Secondary(5) Balancing of FD-fan air supply biasing 1 x FD-Fan

Cottam Unit 3 - Optimsation Test Results at 530 MWel

Finally achieved

>30%

-112 mg/Nm³NOx reduction

( -20%)

-139 mg/Nm³maximum

NOx reduction( -25%)


1 x 500 MW, Steinkohle + Biomasse, BJ ~1968Cottam CUTLAS LT ModernisierungspotentialNOx Emissionen 400 – 550 mg/Nm³ ,

4 x 500 MW, hard coal + bio mass, erection 1965-70NOx emission levels before: 400 – 550 mg/Nm³Performance based optimization

NOx reduction: >30%Demand for boiler stress red. & flexibility increase

Underlying CUTLASS I&C System

EDF Cottam 3

0

100

200

300

400

500

2,5 3 3,5 4 4,5 5 5,5 6

O2 MW [%]

0

40

80

120

160

200

NOX h average mg\Nm3 Reg NOX mg/Nm3 CO Eco A ppm Reg CO ppm

O2

NOx

CO

Limit

Configuration: Front fired boiler

S1 S2 S3 S4 S5 S6 S7 S8A1 A2 A3 A5

~10x24m

A4 A6

OFA

SALaser Path LayoutFor:

Single combustion chamber, Front & back wall access,Front firing, 3-sided OFA

OFA99ft

~110ft“Nose”

Laser measure-mentplain

SL

SL

SL

SL

Over fire air control

Secondary air control

Mill control

Cottam Unit 3

Laser Arrangement at Boiler Walls

EDF Cottam Unit 3 - Case StudyCombustion Optimization for NOx Reduction


C&I Optimisation enhances the efficiency, flexibility, availability and decrease emissions of thermal power plants

Achieved CottamNOx reduction achieved: >30% O2 reduction: 0.5% (~0.25 efficiency)

Achieved West Burton

NOx reduction achieved: >22% O2 reduction: >0.7% (~0.35 efficiency)

Achieved NeurathLoad gradient tripledMinimum load reduced by 40%Efficiency increased


Windbox

BOFA

BOFAB

BOFAA

FDB

FDA

2 x BOFA Fan Flow

32 x Secondary Air Damper

Position

1 x FD-Fan Bias

I&C setpointsOptimisation

Process

A B C D

1 x O2at ECO

Balancing of localair/fuel-ratiobased on LM

Vertical air stucturing

by BOFA

Stabilizingwind box pressure

Balancing of FD-fan air supply

based on LM

Combustion Optimization

Control Modules

O2 leveloptimization

Laser Measurements (LM)

EDF Cottam Unit 3 – Case Study Results: Control Modules for Set-Point Corrections


Unit Average Power P G 350 MWOperation time t B 5000 h/aEfficiency of plant (gross) h l 38 %Specific price of electricity e 32,2105 55 EUR/MWhFuel - -Calorific value H u 25 MJ/kgAsh content of coal g A 10 %Disposal costs for ash k Asche 0 EUR/tSpecific price of fuel k Br 85 EUR/tPrice of ammonia k NH3 400 EUR/tPrice of NOx certificate e NOx 0 EUR/tSpecific price of CO2 e CO2 8 EUR/t

Unit

Benefit of SPPA-P3000 Process Optimization solutionsGNF La Robla 2 Combustion Optimization EXPECT

Description ValueFormula

General Plant Data

Hard coal

before afterNOx concentration (before SCR) NOx 800 680 mg/m3Lower CO2 emissionsO2 - content flue gas 02 5 4,5 %Flue gas temperature t RG 140 140 °C

Further efficiency increases l 38 38 %

Carbon in ash Asche 1 1 %

Disposed ash m Asche 0 0 t/a

Lower emissionsLower NOx emissions

Lower Carbon in Ash

Increased availability t h/a

Change of efficiency ges/ %

Benefit N EUR/a CO2-Reduction mCO2 t/a3.600

390.0000,28

0Results and Benefit

Combustion Optimization

Fuel Savings (0.28 efficiency), Power & CO2 Reduction = 223.000 Euro per YearAmmonia Savings = 168.000 Euro per Year

Benefit CalculationBasis of calculation:

Efficiency Increase (O2 / fuel, fan power red.)CO2 Reduction Ammonia reduction

Calculation dependent on estimations of market prices, cost, operating hours etc.More benefits that can be calculated with GNF internal information: Increased Life Time, Thermal Stress reduction, etc.

* Market boundary conditions adjusted according to GNF data from May 2015.

Example Economic Benefit CalculationExpected (NOx: -15%, O2: -0.5%)

Improvements

-15%

- 0.5%


SPPA-P3000 Combustion OptimizationSystem Features / Differentiation

1. Fast implementation time- Installation: 1-2 days during outage, 2 weeks commissioning- Optimization: 2-3 months during operation

2. No mechanical modification required,100 % adaptable to later process modifications

3. Reduced CAPEX- if installed in existing T3000- synergies for two Installations

4. Improved OPEX with Guaranteed Minimum Improvements- 10%-34% NOx reduction - 0.25%-0,25% O2 reduction (~0.15 to 0,5 % efficiency increase )

5. Improves Boiler Lifetime and Flexible Operation6. Laser Measurement enhances SNCR / other solutions


SPPA-P3000 Combustion Tª Measurement (Optimization)

Phase 1.- Mechanical works

VIDEO


SPPA-P3000 Combustion Tª Measurement (Optimization)Phase 2.- Electrical Works


SPPA-P3000 Combustion Tª Measurement (Optimization)Phase 3.- Commissioning


C&I optimisation to enhance the efficiency, flexibility, availability and decreases emissions of thermal power plants

Low Loss StartCombustion OptimiserSoot Blower Optimiser

Temperature OptimiserLow Throttling

Best Point

Fast StartFast Ramp

Frequency Control

Dispatch ControlMinimum Load Reduction

Maximum Load Plus

High flexibilityHigh efficiency

Runback PlusLife Time Plus

High availability

NOx MinimiserCO2 MinimiserLoI Minimiser

Low emissions

No changes to mechanical equipment

Laser Based Combustion OptimisationHybrid-Combustion Optimisation


RWE Neurath Unit D: Contractual targets reached and greatly exceeded

startingsituation

contract proven (trial run)

further possible potential

Load gradient 5 MW/min 12 MW/min 15 MW/min 20 MW/min

Minimum load (gross) 440 MW 290 MW270 MW

(w/o bypass operation)

250 MW (with risks, e.g. minimum

fire interlock)

Primary frequency control (PFC)

18 MW by throttling of inlet valves

18 MW bycondensate throttling 45 MW 50 MW

Secondary frequency control (SFC) n.a. 66 (75) MW 100 MW 110-115 MW

Simultaneous PFC and SFC n.a. 18 MW

66 (75) MW18 MW75 MW still under investigation

"Hot" commissioning - 10 days D: 9 daysE: 32 hours -

Optimsation phase - - D: 8 monthsE:1-2 months -

Source: PowerGen Europe Presentation 2013

x 3.0

40%

x 2.5

New

New


Published by and Copyright 2016:

Siemens AGPower Generation Instrumentation & Controls

Siemensallee 84D-76187 Karlsruhe

Phone: + 49 7 21 / 5 95 - 69 43Fax: + 49 7 21 / 5 95 - 67 21E-Mail: [email protected]/ic

Subject to change without prior notice.

The information in this document containsgeneral descriptions of the technical optionsavailable which do not always have to be present in individual cases. The required features should therefore be specified in each individual case at the time of closing the contact.

SPPA-P3000 Process optimization

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