Ccm Mega Presentation V3
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Ccm Mega Presentation V3

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Continuous Combustion Management (CCM)

Continuous Combustion Management (CCM)

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Ccm Mega Presentation V3 Ccm Mega Presentation V3 Presentation Transcript

  • J. Estrada, Progress Energy St. Petersburg, FLD. Earley, Combustion Technologies Apex, NC B. Kirkenir, Progress Energy Raleigh, NC
  • AcknowledgementsBob Sisson Crystal River Plant EngineerCrystal River Power Plant Crystal River, FL
  • Ideal Furnace Combustion Proper and even burner stoichiometry leads to consistent flames in furnace Fuel:Air ratio distribution Emissions reduction and improved efficiency Low hanging fruit Potential alternative to post combustion emission equipment
  • Crystal River Unit 4 B&W Opposed Fire Pulverized Coal 770 MW 6 MPS-89 Puvlerizers 9 Coal Outlets per Mill 54 B&W DRB-4Z Low NOx Burners 6 Compartmentalized Windboxes 3 x Front, 3 X Rear SCR, Cold Side ESP & Wet FGD
  • Continuous Combustion Management(CCM) Equipment Additions: Coal Flow Measurement & control valves Burner Secondary Air Flow Measurement & auto purge Burner Secondary Air Flow Adjustment Primary Air Measurement and Auto Purge CO measurement Equipment Modifications Relocation of O2 Probes New O2 equipment (probes and cabinets)
  • Coal Balancing Problem: Uneven Coal distribution Solution: Online coal measurement + adjustment Coal Out Adjustable Coal Valves Pulverizer Coal In Discharge
  • Coal Flow Measurement Air Monitor Corporation Santa Rosa, CA
  • Coal Flow Balancing
  • Coal Flow Balancing
  • Burner Air:Fuel Ratios
  • Secondary Air BalanceWindbox Air Windbox Air Dampers Dampers •Problem: Uneven Secondary Air (SA) distribution •Solution: Measure SA flow at Secondary Secondary each burner and adjust SA Air Air dampers
  • Secondary Air Measurement Wind Tunnel Testing at Air Monitor HQ
  • Why Automate SA Dampers? Dynamic windbox flow profiles Fluctuating windbox pressure Ash build-up Burner Burner Burner 1 2 3
  • Post-Combustion CO and O2 measurement accuracy is critical Grid configuration preferred Combustion Parameters Optimum Zone Boiler Efficiency CO Comfort Zone Slagging NOx Fireside Corrosion Tube Leaks O2 LOI Air Flow
  • O2 Probe Relocation Old location not representative of furnace O2 profile 40New location Economizer CASCADE ROOMproven to be more OLD O2accurate through LOCATIONtesting with B&W NEW O2 FLUE GAS 15 LOCATIONSignificantdistributionimprovement ECONOMIZER ASH HOPPERrealized due to newlocation
  • O2 Probe Standard Deviation CR4 O2 Probe Standard Deviation 8 7 6 5 (Probes 2 & 7 Omitted) Stanard Deviation 4 Pre-Outage Pre-Tuning Post Tuning 3 2 1 0 0 100 200 300 400 500 600 700 800 900 Gross Load (MW)
  • CRN O2 Distribution Comparisons CR4 O2 Profiles CR5 O2 ProfilesNote: Unit scales are different
  • CO Probe Augmentation CO is better diagnostic tool than O2 alone Air leakage impact on O2 probe
  • CCM Tuning
  • Remote Combustion Dashboard
  • New O2 Curve LOI benefit Unit 4 O2 Curve 10.0% 9.0% 8.0% 7.0% 6.0% Excess O2 (%) 5.0% Old Curve Manual Curve 4.0% New Curve 3.0% 2.0% 1.0% 0.0% 0 1000 2000 3000 4000 5000 6000 Steam Flow (kpph)
  • NOx Benefit
  • Project Results Boiler Efficiency Increase = 0.5% Annual fuel savings Combustion NOx Reduction 7% at full load, 15-25% at part load Annual Ammonia Reagent Usage Reduction SCR Catalyst Life Extension Fan Auxiliary Power Savings
  • Pre vs. Post CCM Boiler Efficiency Comparisons Base -- Original OEM Predicted Post CCM test w/ 2.5 lb Sulfur Coal &Operational Description Efficiency Pre CCM Test w/ 2.5 lb Sulfur Coal Post CCM Test w/ 2.5 lb Sulfur Coal optimized O2 Curve This test was run @ full load on 6/24/10 This test was run @ full load on 8/16/10 Original predicted performance This test was run @ full load on 5/30/10 after initial balancing of the coal burner w/ stable O2 & CO parameters. The assumes 0.013 lbs moisture / lb of air prior to placing the CCM project in lines and placing the secondary air O2 curve had been adjusted down toComments (80˚F & 60% Humidity). service. registers in automatic. optimize overall boiler efficiency.Adjustments / Variables Excess Air 20.0 16.0 15.0 11.0 Humidity 60% 80% 80% 80% Average Air Heater Exit Gas Temperature ˚F 262 317 319 315 Annual Capacity Factor 85% 71% 71% 71% % Dry Carbon in Refuse --- 4.00 2.70 3.20Boiler Efficiency Parameter Dry Gas Loss % 4.43 5.36 5.28 4.99 Water from Fuel Loss % 5.91 5.15 5.13 5.12 Moisture in Air Loss % 0.11 0.21 0.20 0.19 Unburned Combustible Loss % 0.30 0.51 0.34 0.41 Radiation Loss % 0.15 0.15 0.15 0.15 Unaccounted for Manuf Margin % 1.50 1.50 1.50 1.50 Total Losses % 12.40 12.88 12.61 12.36 Overall Boiler Efficiency % 87.60 87.12 87.39 87.64Input in Fuel (MKB/HR) 6581.00 6717.48 6690.00 6662.11Input in Fuel (MLB/HR) 639.80 584.13 581.74 579.31Wet Gas Wt (MLB/HR) 6579.00 6892.86 6821.53 6570.70Tot air to Burn Equip (MLB/HR) 5891.00 6324.39 6254.89 6008.25
  • Additional “Soft” Benefits1. Reduced emissions2. Reduced pulverizer wear3. Reduced wear on Coal Yard equipment.4. Reduced boiler tube & non-pressure part erosion due to lower flue gas velocities.5. Improved ESP performance due to lower flue gas velocities.6. Reduced potential for slagging and fouling events7. Improved Pressure part life due to improved temperature profile8. Reduced ash disposal costs9. Reduced boiler tube failures due to reducing atmospheres
  • Contact Joe Estrada – jose.estrada@pgnmail.com David Earley – dearley@combustiontc.com Bill Kirkenir – bill.kirkenir@pgnmail.com