© 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”
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1A.- “La Directiva de Emisiones Industriales 2010/75/UE ” *) Alternativas y Calendario de Aplicación
“Spanish Generation Market Overview”Coal Fired Power Plants = 10.065 MW
SPPA-P3000 Process Optimization Power Generation • Instrumentation, Controls & Electrical© Siemens AG 2016. All Rights Reserved.Page 4SPPA-P3000_siemens day 28th-v4a.ppt
1B.- “Directiva (UE) 2015/2193 Emisiones (MIC; 1-50 MWt) ” :*) Alternativas y Calendario de Aplicación
“Spanish Generation Market Overview”Coal Fired Power Plants = 10.065 MW
SPPA-P3000 Process Optimization Power Generation • Instrumentation, Controls & Electrical© Siemens AG 2016. All Rights Reserved.Page 5SPPA-P3000_siemens day 28th-v4a.ppt
2.- “Las Centrales Térmicas de Carbón en España”
“Spanish Generation Market Overview”Coal Fired Power Plants = 10.065 MW
SPPA-P3000 Process Optimization Power Generation • Instrumentation, Controls & Electrical© Siemens AG 2016. All Rights Reserved.Page 6SPPA-P3000_siemens day 28th-v4a.ppt
“Spanish Generation Market Overview”Coal Fired Power Plants = 10.065 MW
SPPA-P3000 Process Optimization Power Generation • Instrumentation, Controls & Electrical© Siemens AG 2016. All Rights Reserved.Page 7SPPA-P3000_siemens day 28th-v4a.ppt
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
SPPA-P3000 Process Optimization Power Generation • Instrumentation, Controls & Electrical© Siemens AG 2016. All Rights Reserved.Page 8SPPA-P3000_siemens day 28th-v4a.ppt
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
SPPA-P3000 Process Optimization Power Generation • Instrumentation, Controls & Electrical© Siemens AG 2016. All Rights Reserved.Page 9SPPA-P3000_siemens day 28th-v4a.ppt
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
SPPA-P3000 Process Optimization Power Generation • Instrumentation, Controls & Electrical© Siemens AG 2016. All Rights Reserved.Page 10SPPA-P3000_siemens day 28th-v4a.ppt
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.
SPPA-P3000 Process Optimization Power Generation • Instrumentation, Controls & Electrical© Siemens AG 2016. All Rights Reserved.Page 11SPPA-P3000_siemens day 28th-v4a.ppt
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
SPPA-P3000 Process Optimization Power Generation • Instrumentation, Controls & Electrical© Siemens AG 2016. All Rights Reserved.Page 12SPPA-P3000_siemens day 28th-v4a.ppt
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
SPPA-P3000 Process Optimization Power Generation • Instrumentation, Controls & Electrical© Siemens AG 2016. All Rights Reserved.Page 13SPPA-P3000_siemens day 28th-v4a.ppt
Laser measurement system equipped with Automatic Cleaning and Laser Centering
Port rodder retracted Port rodder extended
Boiler wall
Slagging
SPPA-P3000 Process Optimization Power Generation • Instrumentation, Controls & Electrical© Siemens AG 2016. All Rights Reserved.Page 14SPPA-P3000_siemens day 28th-v4a.ppt
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
SPPA-P3000 Process Optimization Power Generation • Instrumentation, Controls & Electrical© Siemens AG 2016. All Rights Reserved.Page 15SPPA-P3000_siemens day 28th-v4a.ppt
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 Process Optimization Power Generation • Instrumentation, Controls & Electrical© Siemens AG 2016. All Rights Reserved.Page 16SPPA-P3000_siemens day 28th-v4a.ppt
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%
SPPA-P3000 Process Optimization Power Generation • Instrumentation, Controls & Electrical© Siemens AG 2016. All Rights Reserved.Page 17SPPA-P3000_siemens day 28th-v4a.ppt
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
SPPA-P3000 Process Optimization Power Generation • Instrumentation, Controls & Electrical© Siemens AG 2016. All Rights Reserved.Page 18SPPA-P3000_siemens day 28th-v4a.ppt
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%)
SPPA-P3000 Process Optimization Power Generation • Instrumentation, Controls & Electrical© Siemens AG 2016. All Rights Reserved.Page 19SPPA-P3000_siemens day 28th-v4a.ppt
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
SPPA-P3000 Process Optimization Power Generation • Instrumentation, Controls & Electrical© Siemens AG 2016. All Rights Reserved.Page 20SPPA-P3000_siemens day 28th-v4a.ppt
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
SPPA-P3000 Process Optimization Power Generation • Instrumentation, Controls & Electrical© Siemens AG 2016. All Rights Reserved.Page 21SPPA-P3000_siemens day 28th-v4a.ppt
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
SPPA-P3000 Process Optimization Power Generation • Instrumentation, Controls & Electrical© Siemens AG 2016. All Rights Reserved.Page 22SPPA-P3000_siemens day 28th-v4a.ppt
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 Process Optimization Power Generation • Instrumentation, Controls & Electrical© Siemens AG 2016. All Rights Reserved.Page 23SPPA-P3000_siemens day 28th-v4a.ppt
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 Process Optimization Power Generation • Instrumentation, Controls & Electrical© Siemens AG 2016. All Rights Reserved.Page 24SPPA-P3000_siemens day 28th-v4a.ppt
SPPA-P3000 Combustion Tª Measurement (Optimization)
Phase 1.- Mechanical works
VIDEO
SPPA-P3000 Process Optimization Power Generation • Instrumentation, Controls & Electrical© Siemens AG 2016. All Rights Reserved.Page 25SPPA-P3000_siemens day 28th-v4a.ppt
SPPA-P3000 Combustion Tª Measurement (Optimization)Phase 2.- Electrical Works
SPPA-P3000 Process Optimization Power Generation • Instrumentation, Controls & Electrical© Siemens AG 2016. All Rights Reserved.Page 26SPPA-P3000_siemens day 28th-v4a.ppt
SPPA-P3000 Combustion Tª Measurement (Optimization)Phase 3.- Commissioning
SPPA-P3000 Process Optimization Power Generation • Instrumentation, Controls & Electrical© Siemens AG 2016. All Rights Reserved.Page 27SPPA-P3000_siemens day 28th-v4a.ppt
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
SPPA-P3000 Process Optimization Power Generation • Instrumentation, Controls & Electrical© Siemens AG 2016. All Rights Reserved.Page 28SPPA-P3000_siemens day 28th-v4a.ppt
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
SPPA-P3000 Process Optimization Power Generation • Instrumentation, Controls & Electrical© Siemens AG 2016. All Rights Reserved.Page 29SPPA-P3000_siemens day 28th-v4a.ppt
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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SPPA-P3000 Process Optimization