NeuCo/DOE Clean Coal Power Initiative (CCPI) Round II Final Results

CCPI II Project Results:

Mercury & Multi-PollutantControl

at NRG’s Limestone Plant

CCPI II Project Results:

Mercury & Multi-PollutantControl

at NRG’s Limestone Plantat NRG s Limestone Plantat NRG s Limestone Plant

Ray JohnsonNeuCo, IncCoal Gen 2010; Aug. 11, 2010

DOE Clean Coal Power Initiative (CCPI)

� Department of Energy CCPI Overview:� 10-year, $2 billion program� Demonstrate promising technologies - proven through R&D to

have commercial potential� Government provides up to 50% of the cost� Demonstrations at a commercial scale in operating

i tenvironments

� NeuCo and NRG Limestone Project Goal:� To demonstrate the ability to affect and optimize mercury

speciation and multi-pollutant control using non-intrusiveadvanced sensor and optimization technologies, with no impactto saleable products and an improvement in heat rate

NRG’s Limestone Electricgenerating Station Unit 2

Unit Overview:� T-fired boiler 913 MW fueled with

Lignite and PRB� Ten fuel elevations equipped with a

low-NOx burner/overfire air system� Cold side ESP and wet FGD� DCS control system is a Bailey Infi-90

Limestone Goals:� Reduce emissions (NOx, Hg, SO2)� Improve unit heat rate� Increase operating control & flexibility

Optimization Focal Points

ISB

OFuel

Management Combustion

Hg VOA

Hg VOA

Performance and Maintenance

NeuCo Optimizers at LimestoneUnit 2

MaintenanceOpt®

PerformanceOpt®

Alerts user to potential equipmenthealth issues and expedites

problem diagnosis

Monitors unit performance andalerts user to efficiency andcapacity deviations

Proprietary and Confidential

CombustionOpt®

SootOpt®Optimizes fuel & air mixingto reduce emissions and

improve efficiency Dynamically directs boiler cleaningactions toward achieving unit reliability,

efficiency & emissions goals

ProcessLink® Platform

Project Status

� Three project phases complete:� Phase I – Installation of advanced sensors� Phase II – Installation of optimizers & Hg model� Phase III – Demonstrate optimizer performance

� Final analysis & reporting nearing completion� Final analysis & reporting nearing completion� Final results to be presented this Fall

� Today’s Presentation Focus� Preliminary results� Closed-loop optimizer performance


BoilerOpt: CombustionOpt and SootOpt IntegrationMPCOptimizer

NeuralOptimizer

Aux Air Hot/Cold, F/R, A/B (5)

Aux Air Level Biases (10)

SSAS Level 13-14 Bias (2)

Tilts (2)

O2Trim (1)

SSAS Level 11-12, Hot Cold, F/R, A/B (5)

Fuel Air Hot/Cold, F/R, A/B

Mill Primary Air Biass, Feeder Biases

NOx (Down)

CO (Limit)

O2 (Limit)

Tilts (Down)

Temps (Range)

NOx (Down)

CO (Limit)

O2 (Limit)

Temps (Range)

• MPC attacks objectives using MVs it has• Neural attacks objectives using MVs it has, and tries to make it possible for the MPC to do more• SootOpt attacks objectives using MVs it has, helping MPC and Neural to do more

ExpertSystem

Clean or Reheat Zone (or don’t)

Clean orPlaten Zone (or don’t)

Clean Furnace Zone (or don’t)

Clean or Nose Zone (or don’t)

Clean or Shelf Zone (or don’t)

Clean or Econ 1,2 Zones (or don’t)

Clean or Econ 1,2 Zones (or don’t)

Tilts (Limit)

Temps (Range)

APH Dp (Limit)

Fouling (Limit)

APHGIT

Preliminary Results


Preliminary Results

Phase III Results:‘Generator Watts’ >880, i.e. Full Load

Avg OFF Avg ON Delta % DeltaNOx 0.214 0.181 -0.033 -15.4%CO 31.24 25.5 -5.74 -18.4%RHA 997.23 995.82 -1.41RHB 993.27 994.64 1.37


O2A 3.03 2.8 -0.23O2B 3.12 2.95 -0.17O2 3.07 2.86 -0.21Losses Eff (DCS) 78.82 78.9 0.08% COpt MV's Used 0 23

ON Data Selection: Last 30 Days, COpt Master ON, SootOpt Master ONOFF Data Selection: Last 30 Days, SootOpt Master OFF, COpt Master OFF

0.10%

Summary of KPI Means: SootOpt& CombustionOpt Off >880 MW

Summary of KPI Means: SootOpt& CombustionOpt On >880 MW


On vs. Off Percentage over Analysis Period at Full Load


CombustionOptOff

SootOpt Off SootOpt On

CombustionOptOn

NOx Distribution: CombustionOptand SootOpt Both Off

NOx Distribution: CombustionOptand SootOpt Both On

A 0 212 A 0 1


Average: 0.212 Average: 0.177

CO Distribution: Off CO Distribution: On


NOx & CO vs. MW: Off NOx & CO vs. MW: On


A vs. B RH Temps: Off A vs. B RH Temps: On



A & B Side RH Temps vs. MW: Off A & B Side RH Temps vs. MW: On

A & B Side O2: Off A & B Side O2: On



A & B Side Boiler O2 vs. MW: Off A & B Side Boiler O2 vs. MW : On

A & B APH Inlet Temp: Off A & B APH Inlet Temp: On



APH Inlet Temps vs. MW: Off APH Inlet Temps vs. MW: On

Heat Loss Efficiency: Off Heat Loss Efficiency: On


Heat Loss Boiler Efficiency vs. MW : Off Heat Loss Boiler Efficiency vs. MW: On


Percentage PRB: Off Percentage PRB: On



Percentage PRB vs. MW: Off Percentage PRB vs. MW : On

Summary of Results ‘GeneratorWatts’ >650 MW

Avg OFF Avg ON Delta % DeltaMW 914.86 907.35 -7.51NOx 0.212 0.177 -0.035 -16.5%CO 30.86 24.26 -6.6 -21.4%RHA 996.11 995.86 -0.25RHB 992.7 994.85 2.15O2A 3 03 2 79 0 24


O2A 3.03 2.79 -0.24O2B 3.12 2.95 -0.17O2 3.07 2.86 -0.21Losses Eff (DCS) 78.83 78.93 0.1% COpt MV's Used 0 23

ON Data Selection: Last 30 Days, COpt Master ON, SootOpt Master ONOFF Data Selection: Last 30 Days, SootOpt Master OFF, COpt Master OFF

0.13%

Summary of KPI Means: SootOpt& CombustionOpt Off >650 MW

Summary of KPI Means: SootOpt& CombustionOpt On >650 MW


Equipment Health & Efficiency Alerts

� Sample alerts that have been screened forescalation:� Econ Gas Outlet Temp stratification� DCA on 21B FWH� Main Turbine Bearing 3X VibrationMain Turbine Bearing 3X Vibration� Main Turbine Bearing 7X Vibration� Main Turbine Bearing 8X Vibration� 2A BFPT HP Bearing Temp� Low oil on primary air fan

� Alerts forwarded to NeuCo’s CustomerCenter in Ohio

Questions?


Date post:	07-Aug-2015
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NeuCo/DOE Clean Coal Power Initiative (CCPI) Round II Final Results

Technology