Energy Efficiency and

Intelligent Power PlantsRameshbabu R S

10th May, 2006The Center For Bits And Atoms

MIT

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Broad and Diverse Business, Technologies and Products Broad and Diverse Business, Technologies and Products

Aerospace

Specialty Materials

Automation and Control

SolutionsTransportation

and Power Systems

Honeywell International Inc

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Context for Industrial Energy Efficiency

Emission

DemandGeneration

Plant Performance Management

Dis

trib

uted

Dem

and

Man

agem

ent

Equipm

ent Perform

ance Optim

ization

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Key Components of Intelligent Power plant

• Process monitoring and optimization

• Plant and Unit performances analysis

• Economical analysis of plant for optimization

• Schedule optimization

• Advanced control technologies

• Equipment health management

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Process Monitoring, Optimization & Mgmt

• Real-time Process data collection

• Real-time process statistics

• Real-time process monitoring

• Schematics visualization & analysis

• Reports Generation

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Performance Calculation & Analysis

• Plant Performance• Unit Performance• Mass and Energy

Balance• Boiler• Turbine• Feedwater Heater• Condenser• Cooling Tower

• Air Preheater• Feedwater Pump• Condensing Pump• Circulating Pump• Induced Draft Fans• Force Draft Fans• Primary Air Fans• Combustion Turbine

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Economical analysis and optimal operation guidance

• Calculate and compare between the actually controllable parameters and expected parameters to obtaining the energy losses

• Analyze the reasons of deviation by expert system, and providing the operation direction

• Primary Controllable Losses

- Main Steam Pressure

- Main Steam Temperature

- Reheat Steam Temperature

- Carbon Content of Fly Ash

- More…• Primary uncontrollable Losses

- RH Pressure Loss- Fuel Thermal Value- HP Turbine Efficiency- More…

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Optimal Operational Schedule

• Receive the instruction from EMS (Energy Management System), then distribute the load to each unit, meanwhile reduce the gross coal consumption and ensure safe, steady and economical running.

• Integrate the equal Incremental Rate and Neural Network arithmetic to predict the load variation.

• Consider all restricted conditions and running steadily, to ensure running safely and economically.

• Flexible running modes, and satisfy various conditions.

• E.g. Sootblowing- How to measure & monitor the cleanliness or fouling?

- How to quantify the degree of contamination?

- How to measure the change in heat transfer efficiency of the surface?

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Advanced Control Technology

• E.g. Advanced Combustion Control- To optimize the excess air in the

combustion process to decrease CO emission

- Calculate the best relationship between oxygen, air flow, coal supply, main steam flow and so on

• Online Performance Test- Boiler Performance Test

- Turbine Performance Test

- Condenser Performance Test

- Air Preheater Leakage Test

- Vacuum Leakage Test

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Typical Sol: Industrial Power Plant

ACC

ACC

ACC

EL

A-B

TLC

ELA-TMPC

Several boilers operating to common steam header

Backpressure turbine(s) (w/extractions)

Condensing turbine(s)(w/extractions)Steam Let-down

Station(s)

ACC – Advanced Combustion ControlELA-B – Economic Load Allocation for BoilerELA-T – Economic Load Allocation for Turbine

TLC – Tie Line ControlMPC – Master Pressure Control

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Sample Optimization Benefits

• HPI/Chemical plant relying on steam delivery from in-house

boiler unit

Scenario for Industrial Power:

Item Original Optimized NotesSteam production capacity [t/h] 200 200Steam production costs [€/t] 6.75 6.65 1.5 % improvementPlant Daily Production [€/day] 1 000 000 1 000 000Lost production on off-spec steam [€/h] 20 833 20 833Trips due to off-spec steam [h/yr] 72 36 50 % trips eliminatedAnnual Revenue [€/yr] 363 500 000 364 250 000Steam production costs [€/yr] 11 824 598 11 647 229Profit (w/out fixed+input costs) [€/yr] 351 675 402 352 602 771Optimization Benefit [€/yr] 927 369

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Sample Optimization Benefits

• CHP selling heat, power, and power ancillary services

Scenario for District Heating:

Item Original Optimized NotesWinter average heat delivery [t/h] 300 300Summer average heat delivery [t/h] 85 85Winter average power delivery [MW] 80.0 81.6 2% improvementSummer average power delivery [MW] 40.0 40.4 1 % improvementAnnual Operations [h] 8 760 8 760Availability factor [%] 0.92 0.92 1 month offAncillary services regulatory range [MW] 8 12 enhanced flexibilityAncillary services contracted [months] 6 6Heat price [€/GJ] 12 12Power price [€/MWh] 32 32Ancillary service price [€/MW/h] 23 23Total annual revenue [€/yr] 71 368 734 72 028 654Optimization Benefit [€/yr] 659 920

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Summary

• Specific Benefits of the Industrial Energy Efficiency Sol- Improved stability of steam headers, responsiveness to steam

demand

- Increased power generation flexibility

- Minimized operations cost

- Overall efficiency increase

- Fuel cost savings

- CO2 Emission Reduction

• A comprehensive Intelligent Power Plan is aimed to improve the overall Energy Efficiency in following aspects- Improved Generation Efficiency

- Improved Energy Consumption Efficiency

- Reduced Emission

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We are building a world that’s…Safer and more secure

More comfortable and energy efficient

More innovative and productive

We are Honeywell.

Aerospace Automation Control Transportation SystemsSpecialty Materials

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www.honeywell.com