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© EUtech Scientific Engineering GmbH Dennewartstrasse 25-27, 52068 Aachen, Germany www.eutech-scientific.de Phone:+49/241/963-2380 Fax:+49/241/963-2389
Online Fineness Measurement System for Controlling a Biomass Fired Unit
Dr.-Ing. Francesco Turoni
POWER-GEN Europe Köln June 14th, 2012
© EUtech Scientific Engineering GmbH Dennewartstrasse 25-27, 52068 Aachen, Germany www.eutech-scientific.de Phone:+49/241/963-2380 Fax:+49/241/963-2389
Introduction
EUcoalsizer mobile - system details
Towards ‘best practices’
Application and results
Summary
Content
© EUtech Scientific Engineering GmbH Dennewartstrasse 25-27, 52068 Aachen, Germany www.eutech-scientific.de Phone:+49/241/963-2380 Fax:+49/241/963-2389
Introduction
© EUtech Scientific Engineering GmbH Dennewartstrasse 25-27, 52068 Aachen, Germany www.eutech-scientific.de Phone:+49/241/963-2380 Fax:+49/241/963-2389
Reduce process variability and shift operating point closer to the limits
The particle size is an essential parameter with a very strong impact on combustion properties
Identify and utilize the intricate interplay of combustion parameters
Air/fuel ratio and performance Strategy
Introduction
l
hth
NOx
COLoI
l = 1.0 l
hth
NOx
COLoI
l = 1.0
lgeslopt
Air/fuel ratio (l) - optimised combustion settings
Air/fuel ratio (l) - regular combustion settings
Continuous optimization
Instantaneous adaptation to load changes
© EUtech Scientific Engineering GmbH Dennewartstrasse 25-27, 52068 Aachen, Germany www.eutech-scientific.de Phone:+49/241/963-2380 Fax:+49/241/963-2389
Introduction
Fuel and air flow parameters determine the quality of combustion
Area in which the overall generation process is least perfect
Process not directly monitored and controlled
Increasing variability of coal quality (co-firing)
Renewable energies impose increasingly dynamic load adaptation (down-swing)
Boiler are usually not operated at their design point
Why is coal fineness so important?
© EUtech Scientific Engineering GmbH Dennewartstrasse 25-27, 52068 Aachen, Germany www.eutech-scientific.de Phone:+49/241/963-2380 Fax:+49/241/963-2389
Why is coal fineness so important?
Controllable O&M variable Dh th
Coal fineness 0.1 - 0.3%
Primary air-flow 0.1 - 0.2%
Fuel line balance 0.1 - 0.3%
Particulate-air ratio 0.1 - 0.3%
Carbon-in-ash (LoI) 0.1 - 0.3%
Excess oxygen 0.1 - 0.3%
Total* 0.6 – 1.7%
* These benefits do not add up synergistically. Typically, an overall improvement in net efficiency will be around 0.3 – 1.0%
© EUtech Scientific Engineering GmbH Dennewartstrasse 25-27, 52068 Aachen, Germany www.eutech-scientific.de Phone:+49/241/963-2380 Fax:+49/241/963-2389
EUcoalsizer mobile - System details
© EUtech Scientific Engineering GmbH Dennewartstrasse 25-27, 52068 Aachen, Germany www.eutech-scientific.de Phone:+49/241/963-2380 Fax:+49/241/963-2389
´Inline´ and ´online´ laser-based analysing system for coal particles in coal pipes
Simultaneous measurement of
- Particle size distribution
- Particle velocities
- Mass flow
- Air/Fuel Ratio
- Flow temperature
No mechanical interaction with the particles
Immediate results with integrated evaluation and online reporting
Portable system, easy to handle
Fast and reliable results during operation
Introduction
Features
© EUtech Scientific Engineering GmbH Dennewartstrasse 25-27, 52068 Aachen, Germany www.eutech-scientific.de Phone:+49/241/963-2380 Fax:+49/241/963-2389
Measuring range: 20 µm up to 4 mm
Operating temp.: up to 200 °C (air cooled)
Flow density up to 1000 g/m³
Lance length -1.5 m
Lance diameter 51/60 mm
Option: Continuous scanning by automatic traversing probe
Hardware
System specifications
Online determination of particle size distribution, velocities and load
Statistic functions
2D distributions
Software
System set-up on site
© EUtech Scientific Engineering GmbH Dennewartstrasse 25-27, 52068 Aachen, Germany www.eutech-scientific.de Phone:+49/241/963-2380 Fax:+49/241/963-2389
EUcoalsizer – Measurement principle
g
Direction of particle
movement
Measurement volume
Parallel laser beam
g Particle velocity :
vp= f0 * g
f0
Particle size:
xp = tp * vp
tp
fo = frequency analysis of signal tp = time of flight g = characteristic constant of the optical length
Legend
© EUtech Scientific Engineering GmbH Dennewartstrasse 25-27, 52068 Aachen, Germany www.eutech-scientific.de Phone:+49/241/963-2380 Fax:+49/241/963-2389
Particle velocity = function (particle and gas properties: Re, cw, …)
Smaller particles show good entrainment
The highest measured velocities are well correlated with the smallest particles
Air velocity
Air flow measurement & air/fuel ratio
Measurement TF, pF -> rF mF ~ (uF , rF)
Air mass flow
AFR = mF / mp
Air / fuel ratio
Fg
Fw
up
uF > up
Vp, rp
Ap
rF, nF
g
© EUtech Scientific Engineering GmbH Dennewartstrasse 25-27, 52068 Aachen, Germany www.eutech-scientific.de Phone:+49/241/963-2380 Fax:+49/241/963-2389
EUcoalsizer – System components
Head of measuring probe with laser emitter and detector
Specially protected probe head for hostile, abrasive environments
Lance Hybrid cable
Measuring volume
Harting connector
Outside protective/cooled shield
Purging air device
(impulse)
1 cm
© EUtech Scientific Engineering GmbH Dennewartstrasse 25-27, 52068 Aachen, Germany www.eutech-scientific.de Phone:+49/241/963-2380 Fax:+49/241/963-2389
EUcoalsizer – Portable control unit
Flash alarm
Pressure gauge
Air inlet
Toughbook with
EUcoalsizer Software
Connector to probe
Flow meter
Power supply
© EUtech Scientific Engineering GmbH Dennewartstrasse 25-27, 52068 Aachen, Germany www.eutech-scientific.de Phone:+49/241/963-2380 Fax:+49/241/963-2389
EUcoalsizer – User interface
Particle velocity
or
RRSB plot
Measurement modus
and
system control Particle size or
particle velocity
distribution
System status Overview
data
Sequential measurement
(time resolved mean values)
© EUtech Scientific Engineering GmbH Dennewartstrasse 25-27, 52068 Aachen, Germany www.eutech-scientific.de Phone:+49/241/963-2380 Fax:+49/241/963-2389
Measurements at coal-fired TPP
Application at coal pipe
Probe with measuring volume
Set-up with probe & media supply EUcoalsizer measuring probe
Instrumentation opening
© EUtech Scientific Engineering GmbH Dennewartstrasse 25-27, 52068 Aachen, Germany www.eutech-scientific.de Phone:+49/241/963-2380 Fax:+49/241/963-2389
Towards ‘best practices’
© EUtech Scientific Engineering GmbH Dennewartstrasse 25-27, 52068 Aachen, Germany www.eutech-scientific.de Phone:+49/241/963-2380 Fax:+49/241/963-2389
EUcoalsizer - Application at Power Station
Total time of measurement reduced to 20% of original time
Monthly rather than yearly measurements in each unit
Immediate analysis for improved performance management
Performance engineers available for other tasks
Access ports (overpressure)
Set-up at coal pipe
Lance with probe
Pipe
Air supply
System control box Port APort B
2‘‘
16‘‘
13‘‘
5‘‘
8‘‘
11‘‘
2‘‘
5‘‘
11‘‘
13‘‘
16‘‘
8‘‘
Port APort B
2‘‘
16‘‘
13‘‘
5‘‘
8‘‘
11‘‘
2‘‘
5‘‘
11‘‘
13‘‘
16‘‘
8‘‘
Port B Port A
Port B Port A
© EUtech Scientific Engineering GmbH Dennewartstrasse 25-27, 52068 Aachen, Germany www.eutech-scientific.de Phone:+49/241/963-2380 Fax:+49/241/963-2389
Carbon C (%) Ash Split (%) LOI (%)
Hydrogen H2(%)
Sulfur S (%)
Oxygen O2(%)
Nitrogen N2(%)
Moisture H2O (%)
Ash (%)
Other (%) (ppm)
Total: (%)
HHV (Btu/lbm)
(% by Vol)
(lb/lb dry air)
(lb/100lb
fuel)
(OF)
(OF)
(OF)
(OF)
(%)
(%)
(%)
excess air. Unaccounted for Losses Default = .50)
Manufacturers margin Default = 1.00)
assume values less than 10.0% are Boiler Efficiency Losses, Manual Input:
O2 and values greater than 10.0% are Radiation and convection (Default = .17)
4. Enter economizer exit O2 or excess air, To correct the efficiency for "Uncorrected AH Gas Outlet
whichever is known. Program will Temperature", enter "1" at right. If not, leave blank.
2. Yellow fields indicate user input data. Boiler Gas Exit Temp Corrected (Measured)
3. Data in white fields is auto-calculated.Fuel Temperature (Default
= Tref)
NOTES:
Calculation Reference
Temp
1. Calculation per ASME PTC 4.1 1964 FD Fan Inlet Air Temp
Moisture in Air O2 Measurement Basis: 1 = Wet, 0 = Dry
Additional Moisture
Air, Gas & Fuel
Temperatures:
O2 Measurement Basis: 1 = Wet, 0 = Dry
Air Heater Exit Gas Data:
Excess O2
Total Ash
Economizer Exit Gas Data:
Excess O2 (% by Vol) OR Excess Air (% by Weight)
Carbon Monoxide
Ash Location
Bottom Ash
Economizer AshPrecipitator or Baghouse
Ash
Fuel Data: Ash Data:
Boiler Efficiency Calculation via ASME PTC 4.1 Method
Data Input Sheet
Test Description:
32.40
2.50 80 3.00
1.50 5 5.00
8.20 15 5.00
0.40 100
50.00
5.00 3.00
0.00 0
100.00 1
11,200
4.00
0.0135 0
0.0000
80
80
392
80
0.17
0.50
1.00
Results and customised online report
F#1 F#2 F#3 F#4 A#4
% % % % %
50 mesh 99.2 98.3 98.4 98.8 97.1
100 mesh 86.6 80.0 81.2 89.2 79.0
200 mesh 47.7 47.4 42.1 51.0 45.2
Particle size
F#1 F#2 F#3 F#4 A#4
m/sec
(ft/sec)
m/sec
(ft/sec)
m/sec
(ft/sec)
m/sec
(ft/sec)
m/sec
(ft/sec)
Mean velocity 20.4
(66.9)
17.8
(58.4)
19.4
(63.6)
21.1
(69.2)
19.1
(62.7)
Std. deviation 4 % -10 % -1 % 7 % -
Velocity
F#1 F#2 F#3 F#4
% % % %
Mass flow dev. 6 - 13 19 - 12
Mass flow (rel.)
© EUtech Scientific Engineering GmbH Dennewartstrasse 25-27, 52068 Aachen, Germany www.eutech-scientific.de Phone:+49/241/963-2380 Fax:+49/241/963-2389
Applications and results ...
© EUtech Scientific Engineering GmbH Dennewartstrasse 25-27, 52068 Aachen, Germany www.eutech-scientific.de Phone:+49/241/963-2380 Fax:+49/241/963-2389
-35% -30% -25% -20% -15% -10% -5% 0% 5% 10% 15% 20% 25% 30% 35% 40% 45% 50%
Mean Velocity [m/s]
<75 µm [%]
75-150 µm [%]
150-300 µm [%]
>300 µm [%]
Mean Diameter [µm]
Mass Flow Air [kg/h]
Mass Flow Coal [kg/h]
Signal change during continuous measurement
0
10000
20000
30000
40000
50000
60000
70000
17:45 17:50 17:55 18:00 18:05 18:10 18:15 18:20 18:25 18:30 18:35 18:40
EUcoalsizer - continuous measurement - Mass Flow Coal [kg/h]
Test-#60
Test-#61
#REF!
Signal change during continuous measurement
Coal / Biomass – Change of Mixture
EUcoalsizer delivers quantitative readings.
Signal changes: - Sieve class >300µm strong increase - Velocity and Mass Flow Air minor increase - Mass Flow Coal strong increase
The signal fluctuation is increased significantly with biomass.
The timing and a periodic pulsing of the biomass addition can be monitored.
Result
Coal Coal + Biomass
© EUtech Scientific Engineering GmbH Dennewartstrasse 25-27, 52068 Aachen, Germany www.eutech-scientific.de Phone:+49/241/963-2380 Fax:+49/241/963-2389
0
5
10
15
20
25
30
17:45 17:50 17:55 18:00 18:05 18:10 18:15 18:20 18:25 18:30 18:35 18:40
EUcoalsizer - continuous measurement - Mean Velocity [m/s]
Test-#60
Test-#61
#REF!
0
10
20
30
40
50
60
70
80
17:45 17:50 17:55 18:00 18:05 18:10 18:15 18:20 18:25 18:30 18:35 18:40
EUcoalsizer - continuous measurement - <75 µm
Test-#60
Test-#61
#REF!
0
5
10
15
20
25
30
35
17:45 17:50 17:55 18:00 18:05 18:10 18:15 18:20 18:25 18:30 18:35 18:40
EUcoalsizer - continuous measurement - <75-150 µm
Test-#60
Test-#61
#REF!
0
2
4
6
8
10
12
17:45 17:50 17:55 18:00 18:05 18:10 18:15 18:20 18:25 18:30 18:35 18:40
EUcoalsizer - continuous measurement - 150-300 µm
Test-#60
Test-#61
#REF!
0
10
20
30
40
50
60
17:45 17:50 17:55 18:00 18:05 18:10 18:15 18:20 18:25 18:30 18:35 18:40
EUcoalsizer - continuous measurement - >300 µm
Test-#60
Test-#61
#REF!
0
10
20
30
40
50
60
70
17:45 17:50 17:55 18:00 18:05 18:10 18:15 18:20 18:25 18:30 18:35 18:40
EUcoalsizer - continuous measurement - Mean Diameter [µm]
Test-#60
Test-#61
#REF!
0
5000
10000
15000
20000
25000
30000
35000
40000
17:45 17:50 17:55 18:00 18:05 18:10 18:15 18:20 18:25 18:30 18:35 18:40
EUcoalsizer - continuous measurement - Mass Flow Air [kg/h]
Test-#60
Test-#61
#REF!
0
10000
20000
30000
40000
50000
60000
70000
17:45 17:50 17:55 18:00 18:05 18:10 18:15 18:20 18:25 18:30 18:35 18:40
EUcoalsizer - continuous measurement - Mass Flow Coal [kg/h]
Test-#60
Test-#61
#REF!
Coal / Biomass – Change of Mixture
Test 3C50 – continuous measurements
Coal Coal + Biomass Coal Coal + Biomass
© EUtech Scientific Engineering GmbH Dennewartstrasse 25-27, 52068 Aachen, Germany www.eutech-scientific.de Phone:+49/241/963-2380 Fax:+49/241/963-2389
EUcoalsizer reduces test time by more than 50%.
EUcoalsizer delivers online results and online reports. Essential for the online mill and burner optimisation.
Further data processing can be fully automated and requires no additional time.
All measurements are very reproducible <2-3% and mostly independent from human influences.
The exact timing of the biomass addition and a periodical pulsing can be monitored with the continuous measurement.
Observations
Coal / Biomass – Change of Mixture
© EUtech Scientific Engineering GmbH Dennewartstrasse 25-27, 52068 Aachen, Germany www.eutech-scientific.de Phone:+49/241/963-2380 Fax:+49/241/963-2389
Summary ...
© EUtech Scientific Engineering GmbH Dennewartstrasse 25-27, 52068 Aachen, Germany www.eutech-scientific.de Phone:+49/241/963-2380 Fax:+49/241/963-2389
Benefits summarised
The coal particle size distribution strongly affects operating conditions e.g.
Combustion process and efficiency
Unit efficiency and LoI
Emissions NOx, CO
Tube erosion
Slagging
Benefits ….
Though particle size distribution may not appear to be an obvious “manipulated variable” which is in the prime focus of the operator, it can be influenced significantly (voluntarily or involuntarily) by
Mill condition (wear and tear)
Mill settings
Mill speed
Coal type
… by manipulating
© EUtech Scientific Engineering GmbH Dennewartstrasse 25-27, 52068 Aachen, Germany www.eutech-scientific.de Phone:+49/241/963-2380 Fax:+49/241/963-2389
Snapshot – Camera inside the boiler
Classifier setting Mill speed
Coal blending
Online control with
camera system
Optimisation Before … … and after
© EUtech Scientific Engineering GmbH Dennewartstrasse 25-27, 52068 Aachen, Germany www.eutech-scientific.de Phone:+49/241/963-2380 Fax:+49/241/963-2389
For more information, please visit us at booth 7A3
Thank you for your attention!