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CCM Mega Presentation 2010

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  • 1. J. Estrada, Progress Energy St. Petersburg, FL D. Earley, Combustion Technologies Apex, NC B. Kirkenir, Progress Energy Raleigh, NC
  • 2. Acknowledgements Bob Sisson Crystal River Plant Engineer Crystal River Power Plant Crystal River, FL
  • 3. 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
  • 4. 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
  • 5. 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)
  • 6. Coal Balancing  Problem: Uneven Coal distribution  Solution: Online coal measurement + adjustment Coal Out Adjustable Coal Valves Pulverizer Coal In Discharge
  • 7. Coal Flow Measurement  Air Monitor Corporation  Santa Rosa, CA
  • 8. Coal Flow Balancing
  • 9. Coal Flow Balancing
  • 10. Burner Air:Fuel Ratios
  • 11. Secondary Air Balance Windbox 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
  • 12. Secondary Air Measurement  Wind Tunnel Testing at Air Monitor HQ
  • 13. Why Automate SA Dampers?  Dynamic windbox flow profiles  Fluctuating windbox pressure  Ash build-up Burner Burner Burner 1 2 3
  • 14. Post-Combustion  CO and O2 measurement accuracy is critical  Grid configuration preferred
  • 15. O2 Probe Relocation  Old location not representative of furnace O2 profile 40'  New location Economizer CASCADE ROOM proven to be more accurate through OLD O2 LOCATION testing with B&W NEW O2 FLUE GAS 15' LOCATION  Significant distribution improvement ECONOMIZER ASH realized due to new HOPPER location
  • 16. 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)
  • 17. CRN O2 Distribution Comparisons CR4 O2 Profiles CR5 O2 Profiles Note: Unit scales are different
  • 18. CO Probe Augmentation  CO is better diagnostic tool than O2 alone  Air leakage impact on O2 probe
  • 19. CCM Tuning 1000 CR4 Load > 700 MW 6 900 5 CCM Tuning 800 4 700 3 600 PPM Percent 500 2 400 1 300 0 200 North CO Avg -1 100 South CO Avg SCR In Nox North SCR In Nox South 0 -2 O2 ANALYZER (SEL) 06/09/10 06/15/10 06/19/10 06/25/10 06/29/10 06/11/10 06/13/10 06/17/10 06/21/10 06/23/10 06/27/10 Daily LOI
  • 20. Remote Combustion Dashboard
  • 21. 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)
  • 22. NOx Benefit
  • 23. 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
  • 24. 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 to Comments (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 3.20 Boiler 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 87.64 Input in Fuel (MKB/HR) 6581.00 6717.48 6690.00 6662.11 Input in Fuel (MLB/HR) 639.80 584.13 581.74 579.31 Wet Gas Wt (MLB/HR) 6579.00 6892.86 6821.53 6570.70 Tot air to Burn Equip (MLB/HR) 5891.00 6324.39 6254.89 6008.25
  • 25. Additional “Soft” Benefits 1. Reduced emissions 2. Reduced pulverizer wear 3. 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 events 7. Improved Pressure part life due to improved temperature profile 8. Reduced ash disposal costs 9. Reduced boiler tube failures due to reducing atmospheres
  • 26. Contact  Joe Estrada – jose.estrada@pgnmail.com  David Earley – dearley@combustiontc.com  Bill Kirkenir – bill.kirkenir@pgnmail.com