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HELE - High Efficiency Low Emission
Yokogawa FGD Optimization System Flue Gas Desulfurization
1
27th Sep, 2016
Yokogawa Electric Corporation
Agenda
Introduction to Yokogawa
Flue Gas Desulphurization plant in Japan
Yokogawa optimization software system
2
3
Introduction to Yokogawa
Corporate Information
4
Established as an electric meter research institute in Tokyo.
1915 1917
Produced Japan’s first electric meter.
1924
Released Japan’s first portable magnetic
oscillograph.
1950
Developed Japan’s first electronic recorder.
1975
Released the world’s first distributed control system
(DCS).
1984
Entered the high-frequency measuring instrument
business with digital oscilloscope.
1988 2015
Released analog LSI test system
100th Anniversary
100 years of history for control and measurement business
Products & Solution portfolio
5
Corporate Management (ERP*) Integrated business operation systems
Production Management
(MES*) Systems for advanced control, simulation, production management, and scheduling
Plant Information management System
Asset Management
CAMS for HIS
Advanced Process Control & Operational Work Assistance
AXF
Magnetic Flowmeter
DYF
Digital Vortex Flowmeter
Field Instruments Field instruments, sensors, measuring instruments, analyzers and other equipment
EJA/ EJX
Differential Pressure Transmitter
US300
Ultrasonic Flowmeter
GC8000
Process Gas Chromatograph
YVP
Advanced Valve Positioner
YTA50/70 YTA100/300
Temperature Transmitter
Production Control Systems
Safety Instrumented System
Network Based Control System
* ERP = Enterprise Resource Planning
* MES = Manufacturing Execution System
Production & Operation Management System
Distributed
Control System (DCS)
TDLS
Tunable Diode Laser Analyzer
DCS Installation Map
6
NORTH AMERICA
Africa
Asia
Oceania
Middle East
South America
North America
Europe 970
712
422
20,775
426
660
2,610
EUROPE As of Jun. 2016
TOTAL
26,575 UNITS
AFRICA
MIDDLE EAST
OCEANIA AUSTRALIA (409) NEW ZEALAND (2)
NEW CALEDONIA (1) PAPUA NEW GUINEA (4)
FIJI (6)
ASIA SOUTH AMERICA
AUSTRIA (30) AZERBAIJAN (1) BELGIUM (222) BELARUS (17) BULGARIA (5) CROATIA (5) DENMARK (6) FINLAND (3)
FRANCE (251) GERMANY (283)
GREECE (21) HUNGARY (69) IRELAND (4) ITALY (153)
KAZAKHSTAN (17) LITHUANIA (1)
NETHERLANDS (193) NORWAY (10) POLAND (24)
PORTUGAL (8) ROMANIA (12) RUSSIA (799) SERBIA (12)
SLOVAKIA/CZECH (115) SLOVENIA (2) SPAIN (163) SWEDEN (2)
SWITZERLAND (18) TURKMENISTAN (12)
UK (106) UKRAINE (8) TURKEY (37)
SCOTTLAND (1)
ALGERIA (50) ANGOLA (16)
BOTSWANA (4) CONGO (14) EGYPT (64) GABON (10) GHANA (6) KENYA (3) LIBYA (5)
MOROCCO (24) MOZAMBIQUE (1)
NAMBIA (1) NIGERIA (50) SENEGAL (3)
SOUTH AFRICA (160) SUDAN (6)
SWAZILAND (2) TUNISIA (2) UGANDA (4) Tanzania (1)
BAHRAIN (37) DUBAI (1) IRAN (106) IRAQ (17)
JORDAN (5) KUWAIT (16) OMAN (61) QATAR (15)
SAUDI ARABIA (315) SYRIA (6) U.A.E (69)
YEMEN (11) Lebanon (1)
BANGLADESH (2) INDIA (1,579) MYANMAR (7) PAKISTAN (6) CHINA (2,921) KOREA (1,212) TAIWAN (525) JAPAN (12,794) MALAYSIA (311)
INDONESIA (380) PHILIPPINES (200) SINGAPORE (274) THAILAND (510) VIETNAM (47) BRUNEI (4)
SRILANKA (3)
ARGENTINE (12) BRAZIL (594) BOLIVIA (1) CHILE (4)
COSTA RICA (1) COLOMBIA (17)
CUBA (14) EL SALVADOR (1)
MEXICO (49) NICARAGUA (1)
PANAMA (2) PERU (1)
TRINIDAD TOBAGO (2) URUGUAY (2)
VENEZUELA (11)
CANADA (24) USA (944)
CENTUM is Well-accepted Widely in the Market
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FGD Plant Flue Gas Desulfurization
FGD plant installation history
0
50
100
150
200
250
300
0
500
1000
1500
2000
2500
3000
Total capacity (10⁶m³ N/h)
No. of plant Installation of FGD Plant
The number of installation
Total processing capacity
The number of installation 102 183 323 543 768 994 1134 1192 1227 1266 1329 1362 1366 1405 1583 1741 1758 1789 1810 1843 1914 2014 2099 2173 2142 2249 2228 2257 2336 2094 1993 1908 2077
Total processing capacity 5.4 9.3 18 28.8 42.7 79.5 104 111 115 117 122 127 127 129 133 155 155 169 176 179 194 205 210 214 215 216 222 233 248 224 218 221 209
8
Installed for Oil fired Installed for Coal fired
1970 2010
No. of FGD plant
Yokogawa DCS references for FGD in Japan
Electric Utility Power Station UnitGeneration
Capacity
FGD Plant
Supplier
Operation
Date
Kansai Electric Maizuru 1 900MW CCEC Jul-04
Kyushu Electric Reihoku 1 700MW IHI Jun-03
2 700MW IHI Jul-95
Chubu Electric Hekinan 1 700MW MHI Oct-91
2 700MW KHI Jun-92
3 700MW MHI/CCEC Apr-93
4 1,000MW KHI/BHK Mar-01
5 1,000MW KHI/BHK Mar-02
Hokuriku Electric Nanao Ohta 1 500MW CCEC Mar-95
2 700MW CCEC Jul-98
Tsuruga 1 500MW IHI Jan-91
2 700MW IHI Oct-00
Shikoku Electric Tachibana-wan 1 700MW MHI Jul-00
Chugoku Electric Misumi 1 1,000MW MHI Jul-98
Hokkaido Electric Tomato Atsuma 2 600MW MHI Jan-85
4 700MW MHI Oct-02
Electric Power Development Tachibana-wan 1 1,050MW MHI Jul-00
2 1,050MW BHK Jan-01
Matsuura 1 1,000MW Hitachi Jan-91
2 1,000MW IHI Jul-97
Matsushima 1 500MW Sumitomo Machine Jan-81
2 500MW Hitachi Jun-81
Takehara 3 700MW IHI Mar-83
Yokogawa’s DCS share for FGD in Japan: 60%
Above is some reference projects only. The share is for utility companies.
10
Yokogawa FGD Optimization System Flue Gas Desulfurization
Yokogawa Advanced Solutions
11
Production Asset EnergySafety and
SecurityKnowledge
Sequence of event
Recorder
Terminal Management
(Truck,Train Ship)
Analyser Maintenance
Advanced Process
Control
Batch and Grade
Tracking Device Maintenance
Laboratory
Information
Management System
Production Accounting
Production Scheduling
Safety Functional
Monitoring
Safety Override
Advisor
Asset Performance
Dashboard
Alarm
Analysis
Alarm
Master Database
Blend Property
Control
Oil Movement
Plant Simulation
Production
Performance
Dashboard
Wireless (Infratructure
and applications)
Cyber Security
Process Control
Domain
Energy Real Time
Optimizer
Energy Performance
Monitoring
Combustion
Control and
Optimization
Procedure
Management
Task Management and
Shift Handover
Procedural
Automation
Operator
Training Simulator
Incident and MOC
Management
Advanced Operator
Graphic
Pipeline Management
Benefits of APC
Page.12
104
102
100
98
96
94
92
90
Specification or limit
BEFORE APC APC ONLINE SETPOINT MOVED
CLOSER TO LIMIT
PE
RC
EN
T O
F L
IMIT
Standard deviation
of controlled variable
Base Case Stabilise
Operator target
Benefits
Flue Gas Desulfurization
Boiler
Flue Gas Combustion Air
► For
Fossil Fired
Power
Furnace / Flue Gas Draft
Flue Gas Flow
- Furnace / Flue Gas Temp.
O2 Analysis
NOx Analysis
SO2 Analysis
Dust Monitoring
Induced Draft Fan
(Vibration)
- Induced Draft Fan
(Lub. Oil & Winding Temp)
- Gas Recirculation Fan
(Lub. Oil & Winding Temp)
Gas Recirculation Fan
(Vibration)
Air Press.
Air Flow
- Air Temp.
O2 Analysis
Forced Draft Fan
(Vibration)
- Forced Draft Fan
(Lub. Oil & Winding Temp)
Flue gas desulphurization types
14
Seawater
Scrubbing
Wet
* With humidification, ** With product recycling
Process Absorbent Byproduct Efficiency
Lime/Limestone
scrubbing
Spray
absorption
Fluid bed CFB/
GSA process
Dry injection
LIFAC
Ca(OH)2 / gypsum max. 98%
CaCO3 (saleable)
Ca(OH)2 useable for max. 95%
landfill
CaCo3 useable for max. 95%
landfill
CaCO3 useable for max. 40%
landfill max. 60%*
max. 80%**
Semi-
dry
Dry
Seawater
ScrubbingSeawater dissolved max. 97%
in seawater
Target
Limestone Scrubbing – Flow Diagram
Inlet SO2
Outlet SO2
To control outlet SO2
within regulation limit
Recirculation
pump x 4-6
Flue gas flow
Result
pH
Inlet SO2
No. of Pumps
MW load
Slurry flow
Outlet SO2
Optimization OFF: 8 hours Optimization ON: 8 hours
Actual data of 700MW coal fired unit in Japan
8 hours 8 hours
No. of Pump reduced from 5 to 3
Outlet SO2 is below target
Coal type changed to high sulfur coal
負荷(MW)
OutletSO2(ppm)
Slurry flow(m3/h)
PUMP
Flue gas flow(km3N/h)
Boiler Load (MW)
2days
InletSO2(ppm)
APC ON
Actual data of Boiler load 0 to 700MW
700MW coal fired unit in Japan
700MW 630MW 420MW
Outlet SO2 set point: 19
ppm
Outlet SO2 regulation: 25 ppm
Optimization Control Scheme
MPC: Model based Prediction
by Exasmoc
Process value prediction By Exarqe
ERC: Enhanced Regulatory Control
FGD normal control by DCS
- SO2 value prediction
- CaCO3 value
prediction
- pH bias prediction
- Optimized Slurry
flow calculation
- Optimized pH
calculation
- No. of Pump control
- Slurry flow set point calculation
- pH set point calculation
- FF control for abnormal cases
- Slurry flow control
- pH control
Advanced control: Optimization
Optimization can be added to existing system
Optimization and DCS control scheme
Lime stone slurry flow
Conventional Control by DCS
pH Control
Optimization Function
Outlet SO2 PV
pH value
Slurry flow
Outlet SO2 set point
Recirculation pump selection
MWD
Inlet SO2 PV
Flue gas flow pH set point
Pump inc/dec
Slurry flow bias
Slurry flow bias
SO2/ CaCO3 Prediction
pH- Total SOx F(x)
Total SOx Bias
Total SOx
Optimize lime stone slurry flow
Model
Predictive Control
Recirculation Pump Control
- FGD Perform - pH control
Slurry flow
Recirculation Pump Operation
2 Pumps
3 Pumps
4 Pumps
5 Pumps
pH Value
MW Load
Total SO2 value
pH - Pump curve
pH value of outlet SO2 Limit
Pump operation and pH set point
Normal operation pH high limit value
Normal operation pH low limit value
Recirculation pump start/ stop
pH value control
1. Control SO2 lower than regulation limit
• Primary objective of FGD plant
2. Optimize number of operating recirculation pumps
• Conventional: No. of pumps are not controlled well
• To reduce house load
3. Optimize lime stone slurry flow control
• By advanced and predictive control
4. Adjusted to various types of coal (Mixed)
• Even if coal changed, mixed, automatically optimized
FGD Optimization Key Features
FGD Optimization Key Features
5. Adjusted to plant aging
• Adjusted to spray nozzle plugging, pump performance deterioration
6. Predict CaCO3 value
• Prevent over-injection of limestone
• Once over-injected, plant must be stopped for clean-up
7.Adjusted to load change
• Optimization range: 15% to 100%
8. Automatic pump start/ stop
• Operators do not need to start/ stop manually
System Configuration
APC server can connect to variety of OPC compliant DCS platforms and control
systems. APC Client can be run on DCS consoles as rich or thin client.
.
Benefits of FGD Optimization System
Operation cost savings for FGD pump load
• 600k -800k Euro/ unit/ year cost saving
700MW, Base load, 300 days/ year, 7 cent Euro/kW (cost)
Operation cost savings for limestone
Optimization for various types of coal
Actual data of power plant in Japan References of 2x 700MW coal fired (in operation) To be used for 2x 1000MW coal fired plants (next year)
Benefits
Thank you for your attention.
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