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NTPC Indian Power Stations 2020 - February 14, 2020 - Raipur (India)
Operation and boiler performance enhancement using online monitoring instruments
Cost-effective flexibilisation of fossil-fired power plants
Dr. Francesco Turoni
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Content
▪ Power generation in India
▪ Flexible operation
▪ Online monitoring instruments
- EUcoalflow
- EUcoalsizer
- EUsoft air
- EUflame 2D
▪ Best practices / Results
▪ Summary and outlook
2
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Power generation in India
3
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▪ Inherent intermittencies of wind and solar resources
▪ Dynamic, flexible and new minimal operation requirements for fossil fuels base-load plants
▪ Compliance of emission limits (NOx & CO), improvement of plant efficiency and plant reliability
Power generation in India
Challenges
▪ Steady economy growth requires more capacity
▪ NTPC plans doubling of coal-fired capacity to 85 GW by 20321
- Existing plants are designed for base-load
- Varying fuel types and blends
- Almost no online and reliable information of fuel, air flows, particle size distribution and FEGT available
▪ New record for renewable energy sources (wind, solar and hydro) in Q1&Q2, 20192
Status
41) NTPC Ltd.2) Central Electricity Authority (CEA)
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Flexible operation
5
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▪ Increase operational flexibility (fuel flexibilisation, min. load & load swing flexibilisation)▪ Increase flame stability and thus reduce SH & RH water spray injection and thermal stresses▪ Reduce unburned carbon (LoI, slagging and fouling minimization)▪ Improve overall plant efficiency and minimize flue gas losses▪ Comply with emissions legislation (NOx, Co, GHG, particulates)▪ Increase operational reliability
Flexible operation
...and why that matters!
▪ Pulverizer fineness and load range optimization with pipe specific dynamic mass flow measurement ▪ Robust measurement and control of primary, secondary and overfire air flow ▪ Balancing fuel and air distribution into the burner belt (AFR management)▪ Control of temperature and burnout distribution in vertical and horizontal domain▪ Control of SH and RH steam temperatures▪ Continuously utilizing available data with online analysis (e.g. condition-based maintenance)
How to achieve/enhance flexible operation?
6
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Online monitoring instruments
7
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Step by step to success
Motivation
8
MEASUREMENT CONTROL OPTIMIZATION
Coal mass flow
Coal fineness
Air mass flow
2D Temperature Distribution
Air Fuel Ratio
Advanced Control Strategies
Model Predictive Control
Efficiency
Emissions
Slagging
FEGT
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▪ Absolute mass flow and velocity measurement▪ Stationary and mobile ECF System▪ Plug and play solution▪ Comfortable user interface (ECF Software)▪ Full integration to DCS
Online fuel mass flow measurement
EUcoalflow
9
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▪ Online coal flow analysis with direct results
- Particle fineness
- Air flow
- Coal mass flow
- Air-fuel ratio▪ Immediate results & online reporting▪ Built for everyday use
Immediate coal flow readings
EUcoalsizer mobile
10
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▪ Flow measurement with virtual sensors▪ Reliable and accurate mass flow values▪ All air flows (PA, SA, OFA)▪ No maintenance, auto-control▪ Easy to implement into DCS ▪ No footprint, windbox compatible
Complete air management
EUsoft air
11
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▪ Online flame temperature and burnout measurement (2D/3D)▪ Sensor based on optical measuring technique▪ Single-point and net-measurements▪ Designed for different scales of combustion chambers▪ Precise measurement of FEGT distributions▪ Stationary or mobile system available
Flame temperature and burnout
EUflame 2D
12
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Best practices / Results
13
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12-Dec-2019 11:50:26 12-Dec-2019 16:03:50 12-Dec-2019 20:17:14 13-Dec-2019 00:30:38 13-Dec-2019 04:44:03 13-Dec-2019 08:57:270
10
20
30
40
50
60
70
80
Time
Mass f
low
[t/
h]
Coal mass flow mill H
H1ECF
H2ECF
H3ECF
H4ECF
Mill HECF
sum
Mill Hfeeder
H1 H2 H3
12-Dec-2019 20:06:30 12-Dec-2019 20:27:26 12-Dec-2019 20:48:22 12-Dec-2019 21:09:18 12-Dec-2019 21:30:15 12-Dec-2019 21:51:110
2
4
6
8
10
12
14
16
18
20
Time
Ma
ss f
low
[t/
h]
Coal mass flow mill H
H1ECF
H2ECF
H3ECF
H4ECF
H3
▪ Stable and reproducible signal correlates with mill load▪ Direct monitoring of dynamic effects allows active pipe-to-pipe mass flow & FEGT temperature balancing▪ Safety increase due to direct information of PF pipe choking (e.g. with wet coal)▪ Improve efficiency and emissions (CO, ƞ)
EUcoalflow (660 MW TPP)
Achievements
14
Online fuel mass flow distributionH2
H2-C4 H2-C2
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▪ Active fineness management over whole mill lifetime▪ Ignition & combustion improvement (CO, η)▪ Reduction of unburned carbon (LoI)▪ Condition based mill maintenance▪ Availability improvement (slagging and fouling minimization)
EUcoalsizer mobile (660 MW TPP)
Achievements
15
Online fineness optimization
80,00
81,00
82,00
83,00
84,00
85,00
86,00
87,00
88,00
89,00
90,00
0,00
5,00
10,00
15,00
20,00
25,00
30,00
20:0
2:2
4
20:0
9:3
6
20:1
6:4
8
20:2
4:0
0
20:3
1:1
2
20:3
8:2
4
20:4
5:3
6
20:5
2:4
8
21:0
0:0
0
21:0
7:1
2
21:1
4:2
4
Fin
eness
[%
]
Fin
eness
[%
] /
Velo
city
[m
/s]
Classifier adj. Pos. 3 -> 5 -> 7 (Cont. meas. Dec. 13, 2019 - PF pipe F4)
Mean Velocity [m/s]
+ 50 mesh
- 200 mesh
86,5
87
87,7
26,3 26,225,6
Pos. 3 Pos. 5 Pos. 7
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▪ Air-fuel ratio balancing and staging (key-driver of combustion)▪ Direct combustion and emissions improvement (CO, LoI, NOx, particulates)▪ Reduce spray-water injection requirements▪ Further reduction of excess O2, increases efficiency η
EUsoft air (600 MW TPP)
Achievements
16
AFR management with virtual sensors
AB
CD
EF
12
34
MillPipe AB
CD
EF
12
34
MillPipe
Air Fuel Ratio
09:36 10:48 12:00 13:12 14:24 15:36 16:48540
545
550
555
560
565
570
575
580
Tem
pera
ture
[°C
]
Steam temperatures at SH outlet [@ 600 MW, November 29th, 2012]
09:36 10:48 12:00 13:12 14:24 15:36 16:480
20
40
60
80
100
120
140
160
180
200
NO
x [
ppm
]
NOx [@ 600 MW, November 29th, 2012]
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EUflame 2D (710 MW TPP)
17
Combustion homogenization
F1 F2 F3 F4
L1
Left
Front
L2
F1 F2 F3 F4
Left
Front
L2
R1
R2
R1
Right Right
L1
R2
▪ Higher combustion efficiency and higher flexibility▪ Active FEGT control / homogenization and emissions improvement (CO, LoI, NOx, particulates)▪ Identify and optimize optimal location for injecting NO reducing agents in SNCR▪ Reduce spray-water injection requirements▪ Less thermal stress
Achievements
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Summary and outlook
18
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▪ Robust and fully reliable solutions▪ Increase operational flexibility (fuel flex., load swing flex.)▪ Seamless integration into existing plant infrastructure ▪ Improve overall plant efficiency (O2 level & minimize flue gas losses)▪ Comply with emissions legislation (NOx, CO, GHG, particulates)▪ Avoid major, capital intensive retrofit▪ Reduce fatigue, wear and thermal stress▪ Leverage the best possible cost value option for plant upgradation
Summary and outlook
Opportunities for power generation in India
▪ Online and robust measurement of the coal flow and PA flow in each pipe▪ Adjust coal flow to acceptable reference limits (e.g. manual static adjustments)▪ Robust AFR management at burner levels▪ Use of optimisation tools rather than just measurement devices▪ Quality enhancement through frequent real-time measurement in less time▪ Real-time data enabling efficient and powerful control▪ Optimal efficient / cost ratio
Cost-effective flexibilisation
19
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Thank you!www.eutech-scientific.de
© EUtech Scientific Engineering GmbH Dennewartstraße 25-27, 52068 Aachen, Germany www.eutech-scientific.de [email protected] Phone: +49/241/963-2380 Fax: +49/241/963-2389