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Coal Fired Boilers Efficiency

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Increasing Coal-fired Plants Efficiency

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Coal Fired Boilers Efficiency

  1. 1. Increasing Energy Efficiency and Reducing GHGs Emissions and Fuel input by Coal-Fired Plants<br />Adam J. Szladow<br />REDUCT & Lobbe Technologies <br />and <br />Bruce Clements<br />CANMET, Natural Resources Canada<br />
  2. 2. Background<br />Szladow, A.J., “Performance and Emission Improvement in Thermal Generation Plants Using Optim/RT and DecisionExpert Systems”, The 28th International Technical Conference on Coal Utilization and Fuel Systems, Clearwater, Florida, March 10 – 13, 2003.<br />Szladow, A.J., “Automated Fault Detection and Diagnosis Systems (AFDDS) for Industrial Process Energy and Performance Improvement, NRCan, Canadian Energy Technology Center, 2008.<br />Szladow, A.J., “Data Analytics and Data Visualization”, DevTeach International Developers Conference, Vancouver, November 26-30, 2007.<br />Szladow, A.J. and Clemants, B., “Increasing Energy Efficiency and Reducing GHGs Emissions and Fuel input by Coal-Fired Plants,” CEATI, Washington, DC, October 28, 2009.<br />
  3. 3. Power Plants Efficiency<br />
  4. 4. Issues in CFCC Efficiency<br />Plant Location<br />Elevation, Ambient Temperatures and Pressure<br />Environmental Regulations<br />Sulfur, Nitrogen Oxide, Particulates Control<br />Plant Design<br />Steam Cycle, Cooling System, Pollution Control <br />Major Equipment<br />Boiler, Generator, Condenser, Electrostatic Precipitators<br />Operational Practices<br />Maintenance, Optimization, <br />
  5. 5. Boiler Efficiency<br />
  6. 6. Efficiency of Coal-Fired Boilers<br />
  7. 7. Efficiency of Coal-Fired Plants<br />
  8. 8. What Does It Mean?<br />±10% approach incorrect:<br />Plants behavior (efficiencies) described by many patterns (groups)<br />The patterns are non-linear and defined by plant design and operations<br />Each pattern describes a bench-mark for possible improvement<br />
  10. 10. Boiler Efficiency Distribution<br />
  11. 11. Group_1 A&B Efficiency Distribution<br />
  12. 12. Group_1 A&B Efficiency Distribution<br />Your plant<br />
  13. 13. Group_1 A&B Efficiency Distribution<br />0.8<br />
  14. 14. Boiler Efficiency Improvement<br />Combustion Optimization<br />excess air, coal drying<br />Slagging and Fouling Control<br />ISB, target in-furnace injection<br />Boiler Tube Failure Control (availability)<br />steam leaks, tube maintenance<br />
  15. 15. Boiler Analysis G_1A <br />
  16. 16. Boiler Analysis G_1B<br />
  17. 17. Discovered Patterns of Boilers<br />1Productivity Improvement for Fossil Power Plants: One Hundred Case Studies, EPRI 2005 <br />
  18. 18. Boiler Efficiency Summary<br />There are strong non-linear relationships between boiler/plant performance and variables in DOE/NETL database<br />A number of clear patterns could be identified<br />The patterns show possible efficiency improvements of up to 2-3 percent, valued at ½ to 1.5 million dollars in operational savings<br />Additional efficiency improvements are possible for the plant generator and should be investigated<br />A Research Proposal is presented by REDUCT to CEARI for utility funding (bellow)<br />
  19. 19. Work Statement: Analysis of Performance Patterns in Clients Coal-Fired Power Plants Database<br />Identifying different boiler/plant clusters based on client database including their critical factors and performance/emissions patterns <br />Determining, for each cluster, possible improvements in performance and emissions given the limiting factors and operating procedures. <br />Establishing important factors for the design of future generation plants including potential benefits to utilities from <br />
  20. 20. Work Statement<br />Task 1. Analysis of Key Performance Factors Influencing Efficiency<br />Task 2. Analysis of Plants Design and Performance Characteristics<br />Task 3. Analysis of Efficiency Improvements and GHGs Reductions<br />Task 4. Analysis of Possible Improvements to Sponsors' Plants<br />Task 5. Monthly Progress Reports and a Final Report<br />
  21. 21. Client utility will get<br /><ul><li>A benchmark for individual generating companies providing information on the potential for further unit efficiency improvement
  22. 22. The max efficiency to be expected for their boilers/plants based on the US boilers/plants database.
  23. 23. A list of possible specific measures for increasing boiler/plant efficiencies
  24. 24. Comprehensive report summarizing project findings and conclusions</li></li></ul><li>Project Organization and Schedule<br />Organization:<br /><ul><li>Dr. Adam J Szladow, REDUCT & Lobe Technologies </li></ul>Schedule:<br /><ul><li>4 to 5 months </li></ul>Cost:<br /><ul><li>$8,000 to $12,000</li></ul>.<br />
  25. 25. Summary<br />“The way to success is no longer knowledge and information only, it is experience and insight into information.” <br />