CCM Mega Presentation


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  • 135 test points9 4th orderequationsPressure andtemperature compensated
  • CCM Mega Presentation

    1. 1. Combustion Optimization for Decreased Emissions and Improved Efficiency<br />J. Estrada, Progress Energy<br />St. Petersburg, FL<br />D. Earley, Combustion Technologies<br />Apex, NC<br />B. Kirkenir, Progress Energy<br />Raleigh, NC<br />
    2. 2. Acknowledgements<br />Bob Sisson<br />Crystal River Plant Engineer<br />Crystal River Power Plant<br />Crystal River, FL<br />
    3. 3. Ideal Furnace Combustion<br />Proper and even burner stoichiometry leads to consistent flames in furnace<br />Fuel:Air ratio distribution<br />Emissions reduction and improved efficiency <br />Low hanging fruit<br />Potential alternative to post combustion emission equipment<br />
    4. 4. Crystal River Unit 4<br />B&W Opposed Fire Pulverized Coal 770 MW<br />6 MPS-89 Puvlerizers<br />9 Coal Outlets per Mill<br />54 B&W DRB-4Z Low NOx Burners<br /><ul><li>6 Compartmentalized Windboxes
    5. 5. 3 x Front, 3 X Rear
    6. 6. SCR, Cold Side ESP& Wet FGD</li></li></ul><li>Continuous Combustion Management (CCM)<br />Equipment Additions:<br />Coal Flow Measurement & control valves<br />Burner Secondary Air Flow Measurement & auto purge<br />Burner Secondary Air Flow Adjustment<br />Primary Air Measurement and Auto Purge<br />CO measurement<br />Equipment Modifications<br />Relocation of O2 Probes<br />New O2 equipment (probes and cabinets)<br />
    7. 7. Coal Balancing<br />Problem: Uneven Coal distribution<br />Solution: Online coal measurement + adjustment<br />Coal Out<br />Adjustable Coal Valves<br />Pulverizer Discharge<br />Coal In<br />
    8. 8. Coal Flow Measurement<br />Air Monitor Corporation<br />Santa Rosa, CA<br />
    9. 9. Coal Flow Balancing<br />
    10. 10. Coal Flow Balancing<br />
    11. 11. Burner Air:Fuel Ratios<br />
    12. 12. Secondary Air Balance<br />Windbox Air Dampers<br />Windbox Air Dampers<br /><ul><li>Problem: Uneven Secondary Air (SA) distribution
    13. 13. Solution: Measure SA flow at each burner and adjust SA dampers</li></ul>Secondary Air<br />Secondary Air<br />
    14. 14. Secondary Air Measurement<br />Wind Tunnel Testing at Air Monitor HQ<br />
    15. 15. Why Automate SA Dampers?<br />Dynamic windbox flow profiles<br />Fluctuating windbox pressure<br />Ash build-up<br />Burner<br />3<br />Burner<br />2<br />Burner<br />1<br />
    16. 16. Post-Combustion<br />CO and O2 measurement accuracy is critical<br />Grid configuration preferred<br />
    17. 17. O2 Probe Relocation<br />Old location not representative of furnace O2 profile<br /><ul><li>New location proven to be more accurate through testing with B&W
    18. 18. Significant distribution improvement realized due to new location</li></li></ul><li>O2 Probe Standard Deviation<br />
    19. 19. CRN O2 Distribution Comparisons<br />CR4 O2 Profiles<br />CR5 O2 Profiles<br />Note: Unit scales are different<br />
    20. 20. CO Probe Augmentation<br />CO is better diagnostic tool than O2 alone<br />Air leakage impact on O2 probe<br />
    21. 21. CCM Tuning<br />
    22. 22. Remote Combustion Dashboard<br />
    23. 23. New O2 Curve<br />LOI benefit<br />
    24. 24. NOx Benefit<br />
    25. 25. Project Results<br />Boiler Efficiency Increase = 0.5%<br />Annual fuel savings<br />Combustion NOx Reduction<br />7% at full load, 15-25% at part load<br />Annual Ammonia Reagent Usage Reduction<br />SCR Catalyst Life Extension<br />Fan Auxiliary Power Savings<br />
    26. 26.
    27. 27. Additional “Soft” Benefits<br />Reduced emissions <br />Reduced pulverizer wear <br />Reduced wear on Coal Yard equipment. <br />Reduced boiler tube & non-pressure part erosion due to lower flue gas velocities. <br />Improved ESP performance due to lower flue gas velocities. <br />Reduced potential for slagging and fouling events<br />Improved Pressure part life due to improved temperature profile<br />Reduced ash disposal costs<br />Reduced boiler tube failures due to reducing atmospheres<br />
    28. 28. Contact<br />Joe Estrada –<br />David Earley –<br />Bill Kirkenir –<br />