Professional Documents
Culture Documents
Introduction
Coal fleet has average 40 yrs
Investment to improve emissions
SCRs (Selective Catalytic Reactors)
FGD (Flue Gas Desulfurization)
Bag houses or ESPs
ID Fans
Mills
FD Fans
EFFICIENCY IMPROVEMENTS
TO THE EXISTING
COAL-FIRED FLEET
MINNEAPOLIS, MN 2011
Coal pulverizer
spillage from
pulverizer throats
that are too large
Bottom ash carbon
content
Non optimum primary airflow measurement
and control ; Excessive NOX levels
Reduce Spray-flows
Reduce furnace exit gas
temperature peaks to 150F
below ash softening temp.
Secondary air properly balanced
and stage 5%
Improve fuel
distribution to better
than 10%
Max. Airheater
leakage of 10%
Capability to use
lower cost fuels
Improve pulverizer and classifier performance for fineness >75%
passing 200 mesh and <0.1% remaining on 50 mesh
EFFICIENCY IMPROVEMENTS
TO THE EXISTING
COAL-FIRED FLEET
MINNEAPOLIS, MN 2011
Stealth Opportunities
Reheat De-Superheating
Spray Water Flows
Air In Leakage
10600
10500
10400
10300
10200
10100
10000
0
5
Years
EFFICIENCY IMPROVEMENTS
TO THE EXISTING
COAL-FIRED FLEET
MINNEAPOLIS, MN 2011
10
13.
Coal Quality
SO2
Fuel HGI
Fuel Moisture - HHV
Fixed Carbon: Volatile Ratio
Sulfur Content
Nitrogen Content
Ash Mineral Matter
NH4HSO4 formation
NOX
Erosion
Slag
&Fouling
ESP
Performance
LOI
Volatiles
WW Wastage
HGI
N
N N
N
N N
CO2
CO2
Oxidized Char Products
(Challenging upper furnace FEGT)
EFFICIENCY IMPROVEMENTS
TO THE EXISTING
COAL-FIRED FLEET
MINNEAPOLIS, MN 2011
Point at
which the
combustion
should be
completed
65%
Ignition
Major Devolatilization
Burning of Carbon
Residence time
0.000
0.200
0.400
0.600
0.800
1.00
84.3
%
of 1-2 seconds
Sensitive
First Generation
Low NOX Burner
2nd Generation
Low NOX Burner
Unforgiving
Challenging !
3rd Generation
Low NOX Burners w/ OFA / Staged Combustion
EFFICIENCY IMPROVEMENTS
TO THE EXISTING
COAL-FIRED FLEET
MINNEAPOLIS, MN 2011
40
Super Heater
Normal Operation
Water Walls
Slagged Furnace
30
Re Heater
20
10
Sections
Boiler Absorption Distribution
2400 psig Unit
EFFICIENCY IMPROVEMENTS
TO THE EXISTING
COAL-FIRED FLEET
MINNEAPOLIS, MN 2011
Economizer
Air In-Leakage
Penalties due to air in-leakage (up to
300 Btus/kWh
PTC-4 does not take into account.
Thus, we call them Stealth Losses
In addition to the thermal penalty,
artificially high oxygen readings can
have serious performance impacts
on good combustion
Leak path between penthouse and
air heater inlet gas
Bottom ash hopper seals
Air heater leakage and penalties
EFFICIENCY IMPROVEMENTS
TO THE EXISTING
COAL-FIRED FLEET
MINNEAPOLIS, MN 2011
0%
0%
0%
0%
0%
2
5
6-8%
0%
6
1
EFFICIENCY IMPROVEMENTS
TO THE EXISTING
COAL-FIRED FLEET
MINNEAPOLIS, MN 2011
5%
1-2%
5-10%
5-10%
0-3%
2
5
15-20+%
5-15+%
6
1
EFFICIENCY IMPROVEMENTS
TO THE EXISTING
COAL-FIRED FLEET
MINNEAPOLIS, MN 2011
Location
Leakage
19.37%
660
9.29%
21
19.51%
187
61.11%
432
EFFICIENCY IMPROVEMENTS
TO THE EXISTING
COAL-FIRED FLEET
MINNEAPOLIS, MN 2011
EFFICIENCY IMPROVEMENTS
TO THE EXISTING
COAL-FIRED FLEET
MINNEAPOLIS, MN 2011
Air
Outlet
Over-fire Air
(15%-20%)
Secondary Air
(55%-65%)
Primary Airflow
(15-20%)
Flue Gas
Outlet
Air
Inlet
EFFICIENCY IMPROVEMENTS
TO THE EXISTING
COAL-FIRED FLEET
MINNEAPOLIS, MN 2011
Horsepower/Ton
50
40
30
20
10
0
40
50
60
70
80
90
100
EFFICIENCY IMPROVEMENTS
TO THE EXISTING
COAL-FIRED FLEET
MINNEAPOLIS, MN 2011
EFFICIENCY IMPROVEMENTS
TO THE EXISTING
COAL-FIRED FLEET
MINNEAPOLIS, MN 2011
EFFICIENCY IMPROVEMENTS
TO THE EXISTING
COAL-FIRED FLEET
MINNEAPOLIS, MN 2011
SCR
Temperature
CO
NOX
EFFICIENCY IMPROVEMENTS
TO THE EXISTING
COAL-FIRED FLEET
MINNEAPOLIS, MN 2011
90
80
70
60
50
Ca/S
40
30
20
Normal Operating
10
Range
0
Increase Temperature
Bed Temperature, F
EFFICIENCY IMPROVEMENTS
TO THE EXISTING
COAL-FIRED FLEET
MINNEAPOLIS, MN 2011
Front Upper
Secondary Air
Front Lower
Secondary Air
Rear Secondary Air
Total Hot Secondary Air
Primary Air to Grid
Total Hot Primary Air
Startup Burner Primary Air
EFFICIENCY IMPROVEMENTS
TO THE EXISTING
COAL-FIRED FLEET
MINNEAPOLIS, MN 2011
EFFICIENCY IMPROVEMENTS
TO THE EXISTING
COAL-FIRED FLEET
MINNEAPOLIS, MN 2011
Microprocessor,
Gravimetric, Load Cell
STOCK Coal Feeder
Air/Fuel Ratio
Mechanical Condition
Throat Velocity Must
be Optimum to
prevent Coal Rejects
Primary Airflow
Measurement & Control
EFFICIENCY IMPROVEMENTS
TO THE EXISTING
COAL-FIRED FLEET
MINNEAPOLIS, MN 2011
30
100
90
80
70
60
50
40
30
20
10
0
25
20
15
10
5
0
1
10
EFFICIENCY IMPROVEMENTS
TO THE EXISTING
COAL-FIRED FLEET
MINNEAPOLIS, MN 2011
Note: Coal is 1,000 times more dense than air. The finer the product the better the distribution
(as finer coal acts more like a fluid or gas).
Air
Outlet
Over-fire Air
(15%-20%)
Secondary Air
(55%-65%)
Primary
Airflow
(15-20%)
Flue Gas
Outlet
Air
Inlet
EFFICIENCY IMPROVEMENTS
TO THE EXISTING
COAL-FIRED FLEET
MINNEAPOLIS, MN 2011
Primary Air,
16.40%
Secondary,
66.60%
OFA, 17%
EFFICIENCY IMPROVEMENTS
TO THE EXISTING
COAL-FIRED FLEET
MINNEAPOLIS, MN 2011
700
600
500
400
300
2 Pulverizers @
minimum 10,000
Lbs/Hr Coal Flow
Boosted Overfire
Air (BOFA)
200
100
Minimum Nozzle
Cooling Airflow
0
10
20
30
40
50
Load (MW)
60
70
80
90
Burner Zone
Stoichiometry < 1.00
EFFICIENCY IMPROVEMENTS
TO THE EXISTING
COAL-FIRED FLEET
MINNEAPOLIS, MN 2011
* Patent Pending
Maintain optimum
coal sizing at Yard
Crusher
Multipoint samplers at
Economizer Outlet
Gravimetric load cell
feeder for limestone
and coal feed
Secondary Airflow
measuring devices
Primary Airflow
measuring devices
Field calibrate airflow
monitoring devices
EFFICIENCY IMPROVEMENTS
TO THE EXISTING
COAL-FIRED FLEET
MINNEAPOLIS, MN 2011
Maintain optimum
coal sizing at Yard
Crusher
Multipoint samplers at
Economizer Outlet
Secondary Airflow
measuring devices
Primary Airflow
measuring devices
Field calibrate airflow
monitoring devices
EFFICIENCY IMPROVEMENTS
TO THE EXISTING
COAL-FIRED FLEET
MINNEAPOLIS, MN 2011
3.0%
3.60
2.5%
3.55
2.0%
3.50
1.5%
3.45
1.0%
3.40
0.5%
Note: 4 minute moving average of 1 second intervals
3.35
Leakage indication
remains relatively
constant despite a
reducing excess O2
Oxygen trim
pulls air out of
the unit to
return to the
set-point
0.0%
13:00
13:03
13:06
13:09
13:12
13:15
13:18
13:21
13:24
13:27
13:30
13:33
13:36
13:39
13:42
13:45
13:48
13:51
13:54
13:57
14:00
Observation
Doors Opened
3.65
EFFICIENCY IMPROVEMENTS
TO THE EXISTING
COAL-FIRED FLEET
MINNEAPOLIS, MN 2011
38.00
37.00
36.00
35.00
34.00
33.00
32.00
31.00
30.00
29.00
28.00
Boiler Opportunities
Turbine Opportunities
LOI and Rejects
Aux. ID Fan HP Opportunities
Design vs. Actual
Opportunity
Overall Efficiency %
Typical (Design)
As Fired
35.83
0.75
1.79
1.04
0.09
31.85
Net Costs
$120,088
$240,177
$360,265
$480,353
$600,441
$120,088
$240,177
$360,265
$480,353
$0
$2,411,560
$4,823,120
$2,411,560
$4,823,120
Point at
which the
combustion
should be
completed
65%
Residence time
84.3
%
of 1-2 seconds
EFFICIENCY IMPROVEMENTS
TO THE EXISTING
COAL-FIRED FLEET
MINNEAPOLIS, MN 2011
EFFICIENCY IMPROVEMENTS
TO THE EXISTING
COAL-FIRED FLEET
MINNEAPOLIS, MN 2011
Fuel Type
Good
Average
Poor
Eastern
Bituminous
< 5%
8% - 12%
> 10%
< 0.2%
0.2 0.7%
> 1%
Western
(Lignite /
PRB)
High Primary Air Flows and What it Means for Heat Rate
Lower X-Ratios and gas side efficiencies are penalties of the
dry gas loss
Good
Average
Poor
Gas Side Efficiency
> 62%
52% - 58%
< 50%
EFFICIENCY IMPROVEMENTS
TO THE EXISTING
COAL-FIRED FLEET
MINNEAPOLIS, MN 2011
EFFICIENCY IMPROVEMENTS
TO THE EXISTING
COAL-FIRED FLEET
MINNEAPOLIS, MN 2011
EFFICIENCY IMPROVEMENTS
TO THE EXISTING
COAL-FIRED FLEET
MINNEAPOLIS, MN 2011
Cost/Benefit Summary
Summary calculations for a 500 Btu/kWhr heat rate
improvement on a 400 MW plant at $2/MMbtu Coal
cost, 70% capacity factor
Estimated Fuel Cost/Yr after Improvements:
$42,560,000 (70% Capacity)
$60, 800,000 (100% Capacity)
10,000 Btu/kWh
$2.00/MMBTU
$20.00/MW
7,000 Btu/kWh
$4.75/MMBTU
$33.25/MW
Hours
Lost hours
Difference in production cost
240 hrs
$13.25/MW
Note: In 2008 the consumption was over 100 Quadrillion BTUs (compared to 2009s
94.58) This decline shows the correlation of energy and economic prosperity
EFFICIENCY IMPROVEMENTS
TO THE EXISTING
COAL-FIRED FLEET
MINNEAPOLIS, MN 2011
US
Affluence
UK
Qatar
Mexico
10,000
Peru
South Africa
Congo
1,000
Bahrain
Bulgaria
Eritrea
Pove r t y
100
100
1,000
10,000
100,000
EFFICIENCY IMPROVEMENTS
TO THE EXISTING
COAL-FIRED FLEET
MINNEAPOLIS, MN 2011
EFFICIENCY IMPROVEMENTS
TO THE EXISTING
COAL-FIRED FLEET
MINNEAPOLIS, MN 2011
EFFICIENCY IMPROVEMENTS
TO THE EXISTING
COAL-FIRED FLEET
MINNEAPOLIS, MN 2011
Lbs CO2/MW
Natural Gas does emit less CO2, but it is not carbon free.
Depending on the efficiency of the end use, natural gas may result in a carbon
footprint that is 70% or more of an equivalent amount of energy from coal.
3,000
2,500
2,000
1,500
1,000
500
0
Old Coal
Ultra Supercritical
Coal
EFFICIENCY IMPROVEMENTS
TO THE EXISTING
COAL-FIRED FLEET
MINNEAPOLIS, MN 2011
Gas Turbine
27%
Fuels
Source: eia.gov
Coal
60%
Nuclear
13%
An estimated 21 GW
will be added during
this 25 yr period.
Coal will remain the
dominant energy
source.
Heavy reliance on
the existing coalfired fleet to meet
nations demand.
Electricity generation by fuel, 19902035. Data is shown as net electricity generation. Sources: Historical data
from EIA, Annual Energy Review 2009; projections from National Energy Modeling System, run REF 2011, D120810C
EFFICIENCY IMPROVEMENTS
TO THE EXISTING
COAL-FIRED FLEET
MINNEAPOLIS, MN 2011
Subcritical
80%
Ultrasupercritical
20%
Coal-Fired Generation Cost and Performance Trend. Sources: Power Magazine, May 2011. Article by Dale Probasco,
managing director with Navigants Energy Practice and Bob Ruhlman, associate director with Navigants Energy Practice.
EFFICIENCY IMPROVEMENTS
TO THE EXISTING
COAL-FIRED FLEET
MINNEAPOLIS, MN 2011
33.5
% Efficiency
33
34.7%
32.5
32.5%
32
33%
31.5
31
Small subcritical (<500 MW)
Coal-Fired Generation Cost and Performance Trend. Sources: Power Magazine, May 2011. Article by Dale Probasco,
managing director with Navigants Energy Practice and Bob Ruhlman, associate director with Navigants Energy Practice.
EFFICIENCY IMPROVEMENTS
TO THE EXISTING
COAL-FIRED FLEET
MINNEAPOLIS, MN 2011
39% Efficiency
Most efficient technology for producing
electricity fueled by pulverized coal.
14
12
10
8
PlantSupercritical
- Supercr.
Plant
Plant
PlantSubcritical
- Subcr.
SG
SG Supercritical
- Supercr.
SG Subcritical
- Subcr.
SG
6
4
2
0
1982-1984
1985-1987
1988-1990
1991-1999
1994-1996
1997
Years
EFFICIENCY IMPROVEMENTS
TO THE EXISTING
COAL-FIRED FLEET
MINNEAPOLIS, MN 2011
SUBCRITICAL
2400
1005F/1005F
SUPERCRITICAL
3600
1060F/1055F
SUPERCRITICAL
3800
1075F/1075F
ULTRASUPERCRITICAL
4200
1110F/1150F
T22
T91
TP347H
TP310HCbN
T12
T23
T91
T1a
T12
T23
SA192
SA210C
Waterwalls
SA210C
T1a
T12
T23
T12
Furnace Roof
T23
Rear Cage
T1a
T12
T23
EFFICIENCY IMPROVEMENTS
TO THE EXISTING
COAL-FIRED FLEET
MINNEAPOLIS, MN 2011
10,000
10000
8000
6000
4000
2000
48
44
26
400
0
US Coal
Power Plants*
US Forrest
Fires
Cremation of
Chinese
Volcanoes,
Human
Power Plants Subsea Vents,
Remains
Geysers &
other
sources**
Source: Wall Street Journal
EFFICIENCY IMPROVEMENTS
TO THE EXISTING
COAL-FIRED FLEET
MINNEAPOLIS, MN 2011
Coal-Fired Generation Cost and Performance Trend. Sources: Power Magazine, May 2011. Article by
Dale Probasco, managing director with Navigants Energy Practice and Bob Ruhlman, associate director
with Navigants Energy Practice.
EFFICIENCY IMPROVEMENTS
TO THE EXISTING
COAL-FIRED FLEET
MINNEAPOLIS, MN 2011
$3,000/kWh
installed cost
Coal-Fired Generation Cost and Performance Trend. Sources: Power Magazine, May 2011. Article by
Dale Probasco, managing director with Navigants Energy Practice and Bob Ruhlman, associate
director with Navigants Energy Practice.
EFFICIENCY IMPROVEMENTS
TO THE EXISTING
COAL-FIRED FLEET
MINNEAPOLIS, MN 2011
Coal-Fired Generation Cost and Performance Trend. Sources: Power Magazine, May 2011. Article by Dale
Probasco, managing director with Navigants Energy Practice and Bob Ruhlman, associate director with
Navigants Energy Practice.
EFFICIENCY IMPROVEMENTS
TO THE EXISTING
COAL-FIRED FLEET
MINNEAPOLIS, MN 2011
Stealth Opportunities
Potential Heat
Rate
Improvement
(Btu/kWh)
Potential
Annual
Fuel
Savings
300
$819,000
100
$273,000
Primary airflow
75a
$204,750
Steam temperature
75
$204,750
50
$136,500
Coal spillage
25
$68,250
25a
$68,250
25
$68,250
25a
$68,250
Cycle losses
25
$68,250
25
$68,250
750
$2,047,500
Variable
High Carbon In
Ash (LOI)
Total
Air In-Leakage
200 Btu/kWhr
50 Btu/kWhr
100 Btu/kWhr
40 Btu/kWhr
50 Btu/kWhr
50 Btu/kWhr
EFFICIENCY IMPROVEMENTS
TO THE EXISTING
COAL-FIRED FLEET
MINNEAPOLIS, MN 2011
Stack emissions since 1970 have been reduced over 77% for the six major pollutants
EFFICIENCY IMPROVEMENTS
TO THE EXISTING
COAL-FIRED FLEET
MINNEAPOLIS, MN 2011
Dick Storm
Storm Technologies, Inc.
Albemarle, NC
www.stormeng.com
704-983-2040
EFFICIENCY IMPROVEMENTS
TO THE EXISTING
COAL-FIRED FLEET
MINNEAPOLIS, MN 2011