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8/8/2019 Unburned Carbon Versus CO2 Emission
1/23
we focus on your process
Unburned Carbon
In the fly ash
UBC versus COUBC versus CO22 EmissionEmission
8/8/2019 Unburned Carbon Versus CO2 Emission
2/23
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Coal bin
Mill
Precipitator
Air preheaterBurner
Air fan
Intermediate
storage tank
Pulverizedfuel
-
Air
Flue gas
Fly ash
Secondarya
ir
Primary
air
CoalUBC
AirSteam Generator
Heat Input:Coal
Losses:Flue gas heat lossGaseous LOI (CO)Unburned CarbonRadiationAsh Heat Loss
8/8/2019 Unburned Carbon Versus CO2 Emission
3/23
8/8/2019 Unburned Carbon Versus CO2 Emission
4/23
we focus on your process
Sources of Improvement
CO
Carbon
in ashFlue gas heat
loss improvement(0.43 % absolute)
Otherimprovements(0.13 % absolute)
Goals of good combustion practice:
Reduction of excess air 5 [%-points]
Reduction of fly ash carbon content 1 [%-points]
Reduction of CO 80 [ppmdv]
8/8/2019 Unburned Carbon Versus CO2 Emission
5/23
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Total boiler losses6 % (absolute)
reduction in flue gas heat loss
reduction in solid LOI (carbon in ash)
reduction in gaseous LOI (CO)
total fuel heat
savings = 0.57 %
Savings in CO2
emissions: 26 493 shtn/a CO2
emission credit
Assumed market price within intern. CO2 emission trading system:
5 $ per ton 132 000 $ per year
0.43%
0.04%
0.10%
reduced CO2 emission
Fuel savings: 10,000 shtn/yr at 30 US$ per shtn:300 000 US$ per year
8/8/2019 Unburned Carbon Versus CO2 Emission
6/23
we focus on your process
Coal bin
Mill
Precipitator
Air preheaterBurner
Air fan
Intermediate
storage tankPulverizedfuel
-
Air
Flue gas
Fly ash
Secondarya
ir
Primaryair
CoalUBC
AirSteam Generator
Heat Input:Coal mass flow & CV
Losses:Flue gas temperature & O2COUnburned Carbon in Fly AshCoal analysis (Ash Content)Ash Temperature
8/8/2019 Unburned Carbon Versus CO2 Emission
7/23
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MECONTROL
UBC Sensor
Screw MeasuringChamber
DriveShaft
8/8/2019 Unburned Carbon Versus CO2 Emission
8/23
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Dielectric constant of fly ash is a function of the carboncontent. Measuring the shift of frequency in aresonator ( f) the carbon content can be calculated.
MECONTROL UBC Measurement Principle
UBC = A + B f
A and B are thecalibration coefficients
we focus on your process
8/8/2019 Unburned Carbon Versus CO2 Emission
9/23
we focus on your process
Measurement Data of MECONTROL UBC
Wedel
0
100
200
300
400
500
600
700
800
900
1000
18.07.2001
00:00
20.07.2001
00:00
22.07.2001
00:00
24.07.2001
00:00
26.07.2001
00:00
28.07.2001
00:00
Rest-C[0,0
1%
]
0
100
200
300
400
500
600
700
800
900
1000
Kanal 2
Kanal 3
Temperatur Kanal 2
Temperatur Kanal 3
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8/8/2019 Unburned Carbon Versus CO2 Emission
10/23
we focus on your process
Trial run at BEWAG "Reuter West" power plant
170
165
160
155
150
145
140
135
130
125
06:00 07:00 08:00 09:00 10:00 11:00 12:00 13:00 14:00 15:00 16:00 17:00 18:00
Time
SecondaryAirx1000(in
verte
d)[m/h
]STP
1
2
3
4
5
6
7
8
9
10
UBC[%]
Secondary Air (MECONTROL Air)UBC ETG 17 (MECONTROL UBC)
UBC ETG 18 (MECONTROL UBC)
Remark: Listed values of secondary airamount are only for one burner plane.
1 % O2
Result of SA Reduction Trial Run
8/8/2019 Unburned Carbon Versus CO2 Emission
11/23
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Result of SA Reduction Trial Run
we focus on your process
Boiler Optimization Program
0
2
4
6
8
10
12
14
16
18
7:00 7:30 8:00 8:30 9:00 9:30 10:00 10:30 11:00 11:30 12:00 12:30 13:00 13:30 14:00 14:30 15:00 15:30 16:00 16:30 17:00
Time
UBC[%];
CO
x10
[mg/m]STP
0
0,5
1
1.5
2
2.5
3
3.5
4
4.5
O2
[%]
UBC Fly ash (MECONTROL UBC)
UBC Fly ash (Lab analysis)
CO Stack
O2 Boiler / DeNOx outlet
Trial run at BEWAG "Reuter West" power plant
8/8/2019 Unburned Carbon Versus CO2 Emission
12/23
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Parameters for Efficiency Improvement
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Boiler Optimization Program
UBC
at 7.2 % A
General calculation example with parameter variationBasis: 5 % UBC in fly ash; 4.3 % O2 in flue gas
0.00%
0.05%
0.10%
0.15%
0.20%
0.25%
0.30%
0.35%
0.40%
0.45%
0% 1% 2% 3% 4% 5% 6%
UBC in fly ash
Increasei n
efficien
cy
*
*) Without power savings of fans
at 3.6 % A
UBC
O2
Excess air reduction
most efficient !
O2-content of flue gas; UBC in fly ash
8/8/2019 Unburned Carbon Versus CO2 Emission
13/23
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Parameters for Efficiency Improvement
UBC
at 7.2 % ash in fuel
Efficiency Calculation Example with Parameter VariationBasisline: 5 % UBC in fly ash; 4.3 % O2 in flue gas
0.00%
0.05%
0.10%
0.15%
0.20%
0.25%
0.30%
0.35%
0.40%
0.45%
0% 1% 2% 3% 4% 5% 6%
UBC in fly ash
Increaseinfueleffi c
iency
*
*) Without power savings of fans
at 3.6 % ash in fuel UBC
O2
Excess air reduction
most efficient !
O2-content of flue gas; UBC in fly ash
8/8/2019 Unburned Carbon Versus CO2 Emission
14/23
we focus on your processwe focus on your process
Boiler / Mill Optimization by UBC Monitoring
Excess air: nabs = 7.6 %-pts
= 0.5 %-pts
2
3
4
5
6
7
8
Time
U
BC
[wt.-%];
O2
[v
ol.-%]
200
220
240
260
280
300
320
340
360
380
400
Sec
onda
ryairx1000[m/h
r]STP
O2 right duct
UBC Basis: ash = 3.6%
Secondary airBasis: n = 1.259
O2 left duct
Trial run at Wedel power plant
UBC: Cabs = -2 %-pts
= -0.08 %-pts
Resulting efficiency increase:0.42 %-pts !
Excess Air Reduction
8/8/2019 Unburned Carbon Versus CO2 Emission
15/23
we focus on your processwe focus on your process
Boiler / Mill Optimization by UBC Monitoring
Datteln
0
2
4
6
8
10
12
14
16
18
20
09.08.00:00
11.08.00:00
13.08.00:00
15.08.00:00
17.08.00:00
19.08.00:00
21.08.00:00
23.08.00:00
25.08.00:00
27.08.00:00
29.0800:00
Rest-C[%]
Kanal 0 geglttet
Mittelwert Kanal 0
Coal type change
8/8/2019 Unburned Carbon Versus CO2 Emission
16/23
we focus on your process
Parameter Test at an E.ON Power Plant
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Boiler Optimization Program
2
2,5
3
3,5
4
4,5
5
10:00 11:12 12:24 13:36 14:48 16:00 17:12
O2
[Vol.-%]
240
245
250
255
260
265
270
275
280
Airflowrate
[kg/s
]
O2 downstream Eco
Sum SA-flow rate
SA2 TASA1+PA
PA
SA1
SA2
TL
TA
6 Burners x 4 levels
8/8/2019 Unburned Carbon Versus CO2 Emission
17/23
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Parameter Test at an E.ON Power Plant
we focus on your process
1
1.5
2
2.5
3
3.5
4
4.5
5
10:00 11:12 12:24 13:36 14:48 16:00 17:12
O2
[Vol.-%]
2
3
4
5
6
7
8
9
10
UBC[%
]
O2 Eco UBC Channel 0 UBC Channel 1 UBC Lab
SA2 TASA1+PA
= -0.18 %
UB
C=
+1.5
%
= +0.51 %
O2
=
-0.8%
total = +0.33 % efficiency increase !
8/8/2019 Unburned Carbon Versus CO2 Emission
18/23
we focus on your processwe focus on your processPower Station Farge, Power Utility E-on
2
2,5
3
3,5
4
4,5
5
10:00 11:12 12:24 13:36 14:48 16:00 17:12
O2
[Vol.-%
]
500
520
540
560
580
600
620
NOx[mg
/m]
O2 boiler out NOx before Kat.
SA2 TASA1+CA
8/8/2019 Unburned Carbon Versus CO2 Emission
19/23
we focus on your processwe focus on your process
Boiler Optimization Program
1,50
1,75
2,00
2,25
2,50
2,75
3,00
3,25
3,50
3,75
4,00
4,25
1,50 1,75 2,00 2,25 2,50 2,75 3,00 3,25 3,50 3,75 4,00 4,25
UBC in the fly ash with secondary air control [%]
UBC
inth
eflyash
withou
tSAcontr
ol[%]
Coal type change during test phase
worse
better
stack fan failure
Results with O2 leveling
UBC reduction at an E.ON boiler (for constant O2 in flue gas)
Results of Boiler Optimization
8/8/2019 Unburned Carbon Versus CO2 Emission
20/23
we focus on your processwe focus on your process
Boiler Optimization Program
750 MW units Germa
Amonia saving
15%
Fuel Saving
36%CO2 sales
27%
Ash
benefication
22%
savings potential
8/8/2019 Unburned Carbon Versus CO2 Emission
21/23
we focus on your processwe focus on your process
savings potential
Boiler Optimization Program
750 MW units USA
NOx credits
55%
Fuel Savings
22%
CO2 sales
17%
Ash
benefication ?
6%
8/8/2019 Unburned Carbon Versus CO2 Emission
22/23
we focus on your processwe focus on your process
savings potential
Boiler Optimization Program
$0,000
$50,000
$100,000
$150,000
$200,000
$250,000
$300,000
$350,000
$400,000
$450,000
$500,000
Nox credits /Amonia Fuel Savings CO2 sales Ash benefication ?
Savings pa 750 MW unit
USGermany
8/8/2019 Unburned Carbon Versus CO2 Emission
23/23
we focus on your processwe focus on your process
Determine the O2/ UBC, O2/ CO and
O2/ NOx impact due to different air admission
(Secondary air, Tertiary air, Overfire air, etc.)
Change overall O2-level on the back pass with
favorable excess air supply
Run boiler with optimized O2-settings
Action Items for UBC Control
Boiler Optimization Program