zonal combustion tuning system central district's 13th annual power generation conference...
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Zonal™ Combustion Tuning SystemCentral District's 13TH Annual Power Generation ConferenceFlorida Department of Environmental Protection
July 30, 2009
2 /GE /GE Confidential and Proprietary
© 2008 General Electric Company All rights Reserved
Data in this presentation is for indication and discussion purposes only
and may not be representative of results to be expected in specific
applications.
3 /GE /GE Confidential and Proprietary
Agenda
• Zonal Combustion Principles• Zonal System
–Features–Application–Reliability
• Operating Experiences and Achievements
Zonal™ Combustion Principles
5 /GE /GE Confidential and Proprietary
~CoalSupply
CoalCrusher
Mill
CoalSilos
AirHeater
Stack
IDFan
FDFanTurbine Generator
Poor Combustion
ZonalTM Combustion Monitors in Boiler
BackpassBoiler
Combustion Performance Issues
Excessiveattemperatio
n
High LOIHigh CO
/Opacity
Reduced
efficiency
High NOx
Local slaggin
g
Local corrosio
n
Excessive
FEGTLocal hot
spotsIncreased
O2
Poor Combustion = Increased Boiler Issues = Poor Plant Performance
6 /GE /GE Confidential and Proprietary
Good Combustion, Bad CombustionThe Principles of Zonal Combustion Tuning
Com
fort
Zon
e
Initial A/F σFEGT
Improved A/F σ
Perf
orm
an
ce
Para
mete
rs
Minimum local A/F limits average O2
Improved A/F σ
Fuel Savings & CO2
Credits & ComplianceAvailability & Output
Output, Throughput & Fan Power
Ash Sales & EfficiencyAvailability & CO compliance
7 /GE /GE Confidential and Proprietary
Approaches to NOx Control
Technique
Operational ModificationsLow Excess AirReduced Air PreheatFuel BiasingBurners Out of Service(BOOS)
Combustion Equipment ModificationsFlue Gas Recirculation (FGR)Overfire Air (OFA)Steam Inject ionLow-NOx Burners (LNB)Reburning
Post-Combustion TechniquesSelective Non-Catalytic Reduction (SNCR)Selective Catalytic Reduction (SCR)
Nat. Gas Fuel Oil Coal
X X XX XXX
X XX
XX X X
X X
X X XX X X
X
X
X X
8 /GE /GE Confidential and Proprietary
Benefits of Combustion Tuning
Great Benefits and Returns• Increase Availability• Reduce Emissions• Improve Heat Rate• Maximized Output• Further Upside
– Stable and Predictable Operation– Integrated with Mercury Removal– Reduce or avoid slag additives
Chart Based on Specific Improvement of :• Excess O2: 0.5% reduction• Emissions (NOx): 15% reduction• Heat Rate: 0.5% improvement• Peak Power: 2.3% increase• Availability: 3 outage days avoided
*Benefits and improvements are site-specific. Actual results may vary.
An
nu
al B
en
efi
ts, $
/yr
-
500,000
1,000,000
1,500,000
2,000,000
2,500,000
3,000,000
100 300 500 700 900 1100
Plant Size (MW)
Emissions Heat RatePeak power Availability
The Zonal™ Combustion System
10 /GE /GE Confidential and Proprietary
Zonal™ Combustion Modules
#1 Zonal™ Combustion Monitoring System• CO/O2 Combustion Sensors• Central Operator Interface • Intuitive Graphic HMI Displays*
#2 Zonal™ Combustion Tuning Advisor• Library of Zonal Models• Burner/OFA Influence Identification• Fuel/Air Adjustment Advice• Map Profile Correction Advice
Zonal™ Grid
Zonal™ Advisor
* Software Modules built on iFIX HMI/SCADA
11 /GE /GE Confidential and Proprietary
Combustion Monitoring Application
TDL
Combustion completed. Good tracing to burners. Reduced air in-leakage.
Air in-leakage, non uniform flow and poor tracing to burners.
Incomplete combustion.Recirculation
zones and non uniform
flow.
12 /GE /GE Confidential and Proprietary
Zonal Combustion Tuning AdvisorBuilt on Predominant Fluid Structure
Predominant Burner Path
Lines Zonal Combustion Monitoring
System
Burners/OFA
Burner-to-Sensor Models
Capture Fluid Structure
13 /GE /GE Confidential and Proprietary
T-Fired Fluid Stratification Suited to Zonal Tuning
4
1
14 /GE /GE Confidential and Proprietary
Zonal™ Monitoring SystemDesigned for Reliability
Zonal base analyzer technology has;• Decades in similar applications• 1000s installed world wide• High reliability
Zonal Analyzer ZCA-30 status• Deployed January 2007• Over 330,000 hrs of operation as of Apr 28, 2009• Mean time to maintenance event:
– > 19 months– Low Spec Limit > 12 month @ 2 Sigma, 95% PI
Sites A - U1 B - U3 C - U1 D - U5 D - U6 E - U1
Location Denmark MN, USA UT, USA UK UK SC, USA
Trials 1-4/07 11/07 – 3/08 5 – 10/07 NA NA 11/08 -
1/09
Systems 12 Pts 6/08 8 pts 1/09 10 Pts 10/07 8 Pts
7/088 Pts 7/08 Pending
Zonal Installations
15 /GE /GE Confidential and Proprietary
GE’s Zonal Combustion Monitoring Application Experience
Sensors applicable to Coal, Oil and Gas
Coal Type – Bituminous or Subbituminous• Ash < 30%• Moisture < 30%• Sulfur < 3% (up to 4%)
Biomass co-firing to < 30%
Gas Temperature: 900 °F to 1200 °F (1500 °F maximum)
Ambient environments• Electronics rated 0 to 60 °C, avoid exposure to severe weather.
– Installations to –20 °C but not recommended. • Sensor rated–18 to 93 °C.
16 /GE /GE Confidential and Proprietary
Zonal Combustion Monitoring
Benefits of Zonal Approach• Post combustion• Close to furnace• Zonal data traces to
burners• Low air in-leakage• Ease of installation• Robust technology• Accurate measurements• Accurate point data
Operating Experience and Achievements
18 /GE /GE Confidential and Proprietary
Zonal Combustion System InstallationPlant• Western US• 460 MW T-fired boiler• Western Bituminous Coal
Zonal Project• Zonal Combustion Monitor
Grid– 2x5 sensor array
• Zonal Tuner Advisor– CCOFA yaw
Issues• Frequent Slagging Events• New Corporate NOx and CO
Mandates
Zonal Combustion Topology
Burner Adjustme
nts
Burner-to-Sensor Models
Boiler
Zonal Sensor Grid
19 /GE /GE Confidential and Proprietary
As-Found Conditions – Western US Boiler
Normal Operation• Typically High 3.6% Excess O2 • O2 Imbalanced +/- 1% (ie. 10%
ex air)• Low average CO 37 ppm• High NOx 0.4 lb/MMbt
Reduced O2 Operation • O2 reduced to 3.0%• Low average CO 150 ppm• High peak 900 ppm, fuel-rich
zone• Slagging severe at reduced O2
Combustion Issues not be Detected by Stack CO
20 /GE /GE Confidential and Proprietary
Zonal Combustion Tuning EventT-Fired, Western US Boiler
0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00 40.00 45.00 50.000.00
5.00
10.00
15.00
20.00
25.00
0.000.250.500.751.001.251.501.752.002.252.502.753.003.253.503.754.004.254.504.755.00
0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00 40.00 45.00 50.000.00
5.00
10.00
15.00
20.00
25.00
0.000.250.500.751.001.251.501.752.002.252.502.753.003.253.503.754.004.254.504.755.00
O2 average: 3.13%O2 spatial variance: 0.32%
0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00 40.00 45.00 50.000.00
5.00
10.00
15.00
20.00
25.00
0
25
50
75
100
125
150
175
200
225
250
CO average: 14 ppmCO spatial variance: 9 ppm
Zonal O2 - March 09, 2009
0
1
2
3
4
5
6
11:00 13:00 15:00 17:00 19:00 21:00 23:00
Time
O2,
%
Ox_1
Ox_2
Ox_3
Ox_4
Ox_5
Ox_6
Ox_7
Ox_8
Ox_9
Ox_10ZonalTuning
21 /GE /GE Confidential and Proprietary
Ave 3.1% O2
Ave 3.6% O2
After (3/9/09)
Zonal O2 Distribution
2 2.5 3 3.5 4 4.5 5 5.5
Zonal O2, %
9-Mar-09
12-Jun-08
Before (6/12/08)
Zonal Tuning ImprovementsT-Fired, Western US Boiler
Before
AfterRealized BenefitsNOx 25% ReductionO2 0.5% ReductionCO, ppm <50 ppmSlagging No eventsEfficiency 0.5% Increase
22 /GE /GE Confidential and Proprietary
Zonal Identified Air Leak at Boiler NoseWestern US Boiler February 12, 2009 Zonal O2 Time Series - Feb 12, 2009
0
2
4
6
8
10
12
0:01 2:01 4:01 6:01 8:01 10:01 12:01 14:01 16:01 18:01 20:01 22:01
Time
O2,
%Ox_1
Ox_2
Ox_3
Ox_4
Ox_5
Ox_6
Ox_7
Ox_8
Ox_9
Ox_10
Zonal CO Time Series - Feb 12, 2009
0
200
400
600
800
1000
1200
0:01 2:01 4:01 6:01 8:01 10:01 12:01 14:01 16:01 18:01 20:01 22:01
Time
CO
, p
pm
CO_1
CO_2
CO_3
CO_4
CO_5
CO_6
CO_7
CO_8
CO_9
CO_10
• Unusual Zone of High O2 & High CO
• Pinpointed likely leakage area
• Boiler taken of line for repair
• Repair verified by O2 and CO return to normal
Sensor 5
Sensor 5
23 /GE /GE Confidential and Proprietary
Zonal versus Plant O2 Wall-Fired, Mid-West Boiler
Excess O2, %
CO, ppm
Existing Plant Sensors Biased Low and Not Suitable for Tuning
X X
Plant O2 probes located in these Zones @ 3% O2
Zonal O2 (true) reads 3.8%Plant O2 (biased low) read 3.0%
24 /GE /GE Confidential and Proprietary
As-Found Zonal Combustion ConditionsWall-Fired, Mid-West BoilerReduced Excess O2 Operation
Zonal Excess O2• Average 3.2% O2• Imbalance 1.3% to 5.1% O2
Zonal Combustibles (~CO)• Average 133 ppm• Imbalance 0 to 1000 ppm
Excess O2, %
CO, ppm
Reducing Excess O2 Results in Poor Local Combustion
25 /GE /GE Confidential and Proprietary
Zonal™ Combustion TuningWall-Fired, Mid-West Boiler
As FoundNormal O2
As Found@ Reduced
O2
Zonal Tuned@ Reduced
O2
55
504
69
0
100
200
300
400
500
600
700
CO C
once
ntra
tion
, ppm
Sensor
Normal O2Reduced O2Zonal Tuned
Zonal monitoring provides ability to tune-out Poor Combustion
Zonal CO Profiles
26 /GE /GE Confidential and Proprietary
Zonal Combustion Tuning System Customer Reported Benefits• Performance Engr expertise captured in Tuning Advisor• With topographical mapping of both CO and O2, plant is able to
identify in-furnace problems.• Plant is able to adjust the key handles, to avoid split O2 and
problematic O2 distributions • The unit is able to burn poorest coals without slag outages or
significant slag buildup.• 25% reduction in NOx levels
• Continuous operation within corporate CO limits without dropping load is possible
• Minimal variation in Oxygen levels allowing O2 reduction in a 0.5% efficiency improvement
• A reduction of hot spots, fuel-rich combustion resulting in reduced forced outages.
27 /GE /GE Confidential and Proprietary
Conclusions
28 /GE /GE Confidential and Proprietary
Compelling Reasons to Optimize
• Combustion systems are more complex• Retiring operator pool – new operators
benefit from improved tools• Changing fuel sources – compliance
coal, low cost coals, biomass co-firing future
• Aging fleet and increasing electricity demand
• Stricter CO and NOx regulations ... and Hg !!!
• Stiff penalties for emissions violations
29 /GE /GE Confidential and Proprietary
Zonal Combustion Tuning System SummaryProvide operators Useful Information
Monitor End-Products of Combustion
Monitor Local Combustion Conditions
Capture Operator Expertise in Tuning and Operations
Strive for Predictable Performance in:• Emissions – CO, NOx, Opacity• Availability – slagging, water wall wastage• Output – Pressure drop, fan limits• Heat Rate – Steam Gen, Attemperation, Heat Losses
30 /GE /GE Confidential and Proprietary
Contact Information
31 /GE /GE Confidential and Proprietary
Product Manager, Combustion Optimization- Neil Widmer - 949-794-2630 (Work) - 949-485-9543 (Mobile)- neil.widmer@ge.com
Contact Information
32 /GE /GE Confidential and Proprietary
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