This document summarizes the Continuous Combustion Management (CCM) project implemented at the Crystal River Unit 4 power plant. The project involved adding equipment to measure and control coal and air flows to improve combustion and reduce emissions. Key results included a 0.5% increase in boiler efficiency, 7-15% reduction in NOx, and annual fuel and reagent savings. The project demonstrates how automated balancing of coal and air flows can optimize combustion and improve plant performance.
The market for the supply of heat to buildings is changing constantly. Solar systems, heat systems and other technologies, integrated concepts for energy supply and electronic control systems have established themselves in this market. The objectives remain the same – demand controlled heat supply, low energy consumption and low emissions.
Testo supply superior measurement tools for all you engineering and servicing needs. It is impossible to find another product line with so many well-engineered mobile gas analysers as Testo have. Which ever flue gas analyser you decide, you can be assured that the gas paths are optimised i.e. are kept as short as possible. Using the instruments has never been so easy; this gives the user confidence to work efficiently, fast and professionally.
The market for the supply of heat to buildings is changing constantly. Solar systems, heat systems and other technologies, integrated concepts for energy supply and electronic control systems have established themselves in this market. The objectives remain the same – demand controlled heat supply, low energy consumption and low emissions.
Testo supply superior measurement tools for all you engineering and servicing needs. It is impossible to find another product line with so many well-engineered mobile gas analysers as Testo have. Which ever flue gas analyser you decide, you can be assured that the gas paths are optimised i.e. are kept as short as possible. Using the instruments has never been so easy; this gives the user confidence to work efficiently, fast and professionally.
NeuCo/DOE Clean Coal Power Initiative (CCPI) Round II Final Results NeuCo, Inc
The second round of the Clean Coal Initiative Project (CCPI) officially concluded in late November 2010 with the publishing of NeuCo’s final technical report by the DOE. This presentation summarizes the final analysis results and was presented at the 2011 Reinhold NOx conference.
Presentation given by Paul Fennell of Imperial College London on "The Integration of Power Generation, Cement Manufacture, Biomass Utilisation and Calcium Looping." at the Alternative CCS Pathways Workshop, Oxford Martin School, 27 June 2014
NeuCo/DOE Clean Coal Power Initiative (CCPI) Round II Final Results NeuCo, Inc
The second round of the Clean Coal Initiative Project (CCPI) officially concluded in late November 2010 with the publishing of NeuCo’s final technical report by the DOE. This presentation summarizes the final analysis results and was presented at the 2011 Reinhold NOx conference.
Presentation given by Paul Fennell of Imperial College London on "The Integration of Power Generation, Cement Manufacture, Biomass Utilisation and Calcium Looping." at the Alternative CCS Pathways Workshop, Oxford Martin School, 27 June 2014
Study of stationary combustion source fine particulate matterEnrique Posada
This is a study of partiulate matter emisions in small boilers in the Aburra Valley region of Colombia. It correlates emission data with efficiency values and chemical composition
Tunnel ventilation ppt tunnel asia 2013Hitesh Khanna
THis presentation deals with Tunnel Ventilation concepts, with special reference to T80, India's longest transportation tunnel across Pir Panjal range, connecting Jammu region to Kashmir valley
Presentation given by Hao Liu of the University of Nottingham on "Effective Adsorbents for Establishing Solids Looping as a Next Generation NG PCC Technology" at the UKCCSRC Gas CCS Meeting, University of Sussex, 25 June 2014
Takashi Kiga – IHI Corporation – Callide Oxyfuel Project: Demonstration and f...Global CCS Institute
Takashi Kiga, General Manager, Staff Group, Energy Operations, IHI Corporation, presented on the Callide Oxyfuel Project: Demonstration and for the Commercialisation at the Global CCS Institute's Japanese Members' Meeting held in Tokyo on 8 June 2012
Cokemaking in an Integrated Steel Works - Technology, Location and Greenhouse...Smithers Apex
- Impact of cokemaking technology on costs and greenhouse gas emissions for different steel works configurations
- Regional implications that drive cokemaking technology selection
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Author:
Ian Cameron, Senior Director - Iron & Steel, HATCH, Canada
The presentation discusses the various factors which affect the performance of Power Boilers including the quality of coal, airheater performance, air ingress etc.
Sampling methods using sorbent traps have been used extensively over the past 20 years for speciating mercury in flue gas. The Flue Gas Adsorbent Mercury Speciation (FAMS) method is an example. This method has gained widespread acceptance as the preferred alternative for mercury speciation due to its simplicity, sensitivity, and repeatability. However, FAMS and other sorbent trap methods were developed primarily for measurements made in the relatively clean, dry, and cool flue gas present downstream of the particulate control devices. Application of sorbent traps to measure mercury in the high temperatures and high particulate loadings that exist upstream of the APC system or the saturated drop-laden gas downstream of FGD requires modifications to the approach. This presentation addresses the use of sorbent traps to speciate mercury throughout the air pollution control system of a coal-fired utility. Specific sampling approaches to accommodate testing at high temperatures, high dust loadings, and saturated gas streams are discussed. Data are presented for measurements made from points ranging from near the exit of the boiler to the outlet of a wet scrubber. We discuss the interpretation of the results and examine metrics used to assess data quality.
Presentation given by Richard T. J. Porter from ETII, University of Leeds, on "CO2QUEST Typical Impurities in Captured CO2 Streams" at the EC FP7 Projects: Leading the way in CCS implementation event, London, 14-15 April 2014
Presentation given by Richard Marsh of Cardiff University on "Phase 1 Project: Methane Oxycombustion in a Swirl Stabilised A Gas Turbine Burner" at the UKCCSRC Gas CCS Meeting, University of Sussex, 25 June 2014
Eneractive Solutions - Power Plant Solutions for NAES Conference Eneractive Solutions
VP of Eneractive's Power Plant Solutions Division, Bill Gretta, delivered a presentation on CO and SCR System Evaluation Tools to key stakeholders at the NAES Plant Managers' Conference in Bellevue, WA.
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
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
14. 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
15. O2 Probe Relocation
Old location not representative of furnace O2
profile
40'
New location Economizer
CASCADE ROOM
proven to be more
OLD O2
accurate through LOCATION
testing with B&W
NEW O2
FLUE GAS
15'
LOCATION
Significant
distribution
improvement ECONOMIZER ASH
HOPPER
realized due to new
location
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