Shailesh Vidyarthi, 9th Energy Efficiency Summit 2010 ... · © ABB Group September 4, 2010 | Slide...

© ABB Group September 4, 2010 | Slide 1

Optimization Solutions in Thermal Power Plants

Shailesh Vidyarthi, 9th Energy Efficiency Summit 2010, Chennai


“The need of the hour is to optimize the resources and rapidly adopt energy efficiency techniques and improvement mechanisms.”

- CII, 9th Energy Efficiency Summit 2010


Contents

Today’s energy challenges

ABB in Energy Efficiency

Optimax® Plant Optimization Solution

Introduction

Product Portfolio

Optimax Products

Typical Layout

Summary


Contents




Introduction

Product Portfolio

Optimax Products

Typical Layout

Summary


Today’s energy challengesRising demand

China

94% 177%

India

116% 261%

Europe and North America5.4% 26%

140%89%Growth in primary energy demandGrowth in electricity demand

IEA forecast 2007-30

M. East and Africa


Today’s energy challengesPresent Scenario in India

• Demand for energy has risen steadily in the past decade.

• Electricity consumption is rising even faster, and is set to increase about 76 percent between 2007 and 2030 under current policies and trends (IEA estimate).

• India has set an ambitious target of generating 78,700 MW by 2012.

• Need of the hour is maximum utilization of installed capacity( Average PLF in thermal power stations for power utilities has gone up by around 12% for the period 1999-2010)



1997-1998 2003-2004 2008-2009

64.7%

78.7% 84.98%

Central PLF

*Ministry of Power, India



Aim for overall improvement in efficiency of power plants in India.

*Ministry of Power, India


Today’s energy challengesCut link between growth, energy use and emissions

Meeting these challenges requires the world to:

Reduce the correlation between economic growth

and energy use

Reduce the correlation between energy use and

emissions

Energyefficiency

Renewable sourcesof energy


Contents




Introduction

Product Portfolio

Optimax Products

Typical Layout

Summary


Primary energy Transport Generation T&DIndustrial processes

Industrial production

80% of energyis lost

Avai

labl

e en

ergy

ABB in energy EfficiencyOnly 20% of primary energy generates economic value.The rest is lost to conversion processes, transportationand operational inefficiencies


Primary energy Transport Generation T&DIndustrial processes

Industrial production

Avai

labl

e en

ergy

ABB technology can double energy productivity

More efficient fuel combustion

Higher pipeline flows

Improved well efficiency Lower line losses,

higher substation efficiency

Improved productivity

More efficient motors & drives

Drives &motors

ProcessAutomation

Marine & pipelines

Power plantautomation

Gridoperation

Processautomation

ABB in energy EfficiencyReducing losses along the energy chainABB technology helping at every step


Contents




Introduction

Product Portfolio

Optimax Products

Typical Layout

Summary

© ABB GroupSeptember 4, 2010 | Slide 14

Environmental Systems Optimize your combustion process and reduce emissions

with Advanced Process Control solutions.

Asset Lifecycle Systems Schedule the most economical operation of different units

(unit commitment) and improve maintenance planningbased on lifetime consumption.

Operations Systems Monitor and predict plant performance, improve efficiency

and issue early warnings for equipment diagnosis andpreventive maintenance.

Maintenance Systems Reduce costs of maintenance activities and improve

maintenance work flow.

Optimax® Plant Optimization SolutionIntroduction

Solutions for improving economic performance and asset management


Contents




Introduction

Product Portfolio

Optimax Products

Typical Layout

Summary


Optimax® Plant Optimization SolutionProduct Portfolio


Contents




Introduction

Product Portfolio

Optimax Products

Typical Layout

Summary


Optimax Plant Performance Monitoring

Performance monitoring of power plants or water desalination plants

Calculates deviation between the expected and the measured data

Offers online thermodynamic models and what-if simulations

Reduces plant fuel costs

Improves predictive maintenance

Early detection of degradation possible

Provides the maximum flexibility in reconfiguring or dynamically modifying system parameters even during system operation



Optimax Plant Performance MonitoringOptimax® Plant Optimization Solution


Intermountain Power Service Corporation, Delta, Utah USA, Unit #1 & 2: 950 MW each, Coal Fired Power Plant

PPL, Montana,Colstrip Power Plant, USA, Unit 1 & 2 – 333MW, Unit 3 & 4 – 805 MW

CCPP Kirchlengern

Unit 2 of Roxboro plant(675 MW)


Project References



140k$ saved annually at Unit 2 of Roxboro plant(675 MW), North Carolina, USA. In addition, 100k$ annual saving achieved with performance testsreduction.

Using OPTIMAX, the detection of leakages at Astoria PP (Unit 30,360 MW), USA. result in cost saving equivalent of 150k$ per year.

50k$ can be saved annually by reducing the man power.

Information Management


Benefits



Model-based tool able to accurately simulate thermodynamic behavior of the plant under varying ambient conditions and different steady-state operating modes

Calculation options

Simulation

Data Validation

Optimization

Optimax® Plant Optimization SolutionPowerCycle


Advantages: Easy usage of existing

component characteristics Obtain not only “Expected”

power and efficiency, but all detailed process values (p, T, flows,…) Even non-measured failures

(e.g. leakage) are detected

Optimax® Plant Optimization SolutionPowerCycle-Simulation


Steady-State simulation of thermodynamic behavior of the plant and its equipment

Online Simulations

What-If Simulations

Deviations from the optimal efficiency can be recognized.

Optimax® Plant Optimization SolutionPowerCycle-Simulation


Measured values are integrated into the model

Alarm is generated if computed value deviates from the process value by more than a specified interval.

It is used for predictive maintenance and avoid unnecessary trips due to faulty alarms

Optimax® Plant Optimization SolutionPowerCycle-Data Validation


A parameter can be varied and its effect (resulting).

Effect can be cost.

This can be used for optimized set points during operation to provide decision support to the operator.

Optimax® Plant Optimization SolutionPowerCycle-Optimization


2 CCPP * 400 MW Middle-East desalination plant

Coal-fired PP in Germany Fujairah Water and Power Plant

(FWPP).

PowerCycle

Project References



What-if simulations and optimization result in 1% fuel savings for a plant consisting of 2 CCPP * 400 MW.

By determining the optimal load distribution over the 2 GT’s, nearly 100k$ saved per year.

In a Middle-East desalination plant, 1.8% water production costs saved by calculating optimal set points for the Multi-Stage Flash (MSF) process.

Determining a better sub-cooling at a coal-fired PP in Germany, resulted in 110k$ saving peryear.

PowerCycle

Benefits



Based on Model Predictive Control techniques (MPC) forclosed loop combustionoptimization of boilers fired with pulverized coal.

Models the multivariable nonlinear relationships of thecombustion process.

The relationships betweensignals/parameters are identified by analyzing theirhistorical data.

Optimax® Plant Optimization SolutionCombustion Optimizer


Improves boiler efficiency, reduces emissions, lowers operating costs

NOx reduction.

Heat rate improvement

Steam Temperature

O2 control ( Excess)

Burner Tilt





6x500 MW JaenschwaldePlant,Vattenfalls,Germany

PPL, Montana,Colstrip Power Plant, USA

Unit 1 & 2 – 333MW

Unit 3 & 4 – 805 MW


Project References


Reduce NOx by 8 - 40 % Heat rate improvements of:

0.5 - 1.5 % at base load

1.5 - 2.5 % at swing load Reduction of unburned carbon in

ash by 1 - 5 % Reduction of CO2 generation Maintenance of CO at desired

levels Improve availability

Environmental System


Benefits


It is based on a Neural net model.

It can initiate Soot-blowing sequences.

It monitors cleanliness and performance of the various boiler sections.

Calculated Heat Transfer

Factors Sootblowing signals

86400kWh 8.64E+10 kJ 1 Heat Loss [MJ/d] 383 9000 kJ/kWh Heat for Sootblowing [MJ/d] 0.5 Total Heat Loss [MJ/d] 383.5 1350

203.6

5.55555556

Heatloss vs. Sootblowing

0

50

100

150

200

250

300

350

400

450

1 2 4 8 16

# Sootblowing/day

Hea

t Los

s [M

J/d]

Heat Loss [MJ/d]

Heat for Sootblow ing [MJ/d]

Total Heat Loss [MJ/d]

Optimax® Plant Optimization SolutionSoot-Blowing Advisor


Tells the operator when and where to soot blow and for how much time.

Minimizes the overall cost for soot blowing.

Stops reduction of heat transfer efficiency and hence reduces loss of fuel.

Avoids high rates of tube wastage in the vicinity of soot blowers due to excessive wall blowing.

0

20

40

60

80

100

120

140

160

180

200

1.0 0.9 0.8 0.7Surface Effectiveness

ReheaterSuperheaterEconomizerFurnace

Base line heat Rate9734.6 BTU/kwhr

0.0 33 67 100Furnace Dirtiness %



265 MW Rawhide Energy Station Unit #1, Colorado,USA.


Project References


At the 265 MW Rawhide Energy Station Unit #1

60k$ saved with extended cleaning schedule

Operation cost reductions of 180k$ achieved by minimizing the reheat spray flow


Benefits


It is used for Boiler Start-up Optimization for large utility to meet base load to have shorter startup time. Similarly shorter shutdown time.

Based on nonlinear dynamic model.

It reduces startup costs for having plants of higher capacities having frequent startups.

Traditional vs. BoilerMax

unused potential

Savings with BoilerMax

design limits

Fuel flow

HP-Bypass position

LS-Temperature

dT thickwalled component

Optimax® Plant Optimization SolutionBoilerMax


Walsum Unit 10, 750 MW, Duisburg, Germany

KW Staudinger, 622 mW, Germany

KW Ingolstadt, 420 mW , Germany

KW Zolling, 450 mW, Germany

KW Heyden, 900 mW – 5units, Germany

Ingolstadt unit 420 MW, Germany, 4 oil-fired unit


Project References


For a coal-fired unit of 700 MW, BoilerMax may reduce startupcosts by 10 to 15%, resulting in savings of 130k$ per year


Benefits


Contents




Introduction

Product Portfolio

Optimax Products

Typical Layout

Summary


© ABB Group PSP-PRU / ma Slide 42

Unit 2ABB DCS 2

Unit 1ABB DCS 1

Unit …Other DCS

System Server

Internet

Office Engineering Maintenance Accounting

Monitoring Diagnostics Simulation Optimization

Information Mgmt Calculation Server Maintenance Mgmt

MeteringSystem

Billing & Settlement Fuel Demand Process Quality Balances Reporting

OPTIMAX® ClientOPTIMAX® Client OPTIMAX® ClientOPTIMAX® Client

DCS Interfaces

Firewall

Optimax® Plant Optimization SolutionTypical Layout


Contents




Introduction

Product Portfolio

Optimax Products

Typical Layout

Summary


Energy Efficiency, Fuel Conservation, Low Emissions

Power Plant Performance Reporting and Improvement under the Provision of the Indian Energy Conservation Act; Evonik,VGB are working under Indo German Program .

There were talk on regulations for the efficiency of Power Generation in European Union*

Different Power plants in India under the above banner have a Energy Management Policy which talks about efficiency and cost-effectiveness*.

Power and Productivity for a Better world

Summary

Optimization


Summary

Thank you for your patience…………….Any questions please.

For any clarifications please write to [email protected]

mailto:[email protected]�

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