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The document summarizes opportunities to reduce heat rates in coal-fired power plants through various methods. It discusses optimizing combustion conditions, improving sootblowing practices, upgrading steam temperature controls, maintaining steam turbines, and reducing coal and flue gas moisture. Implementing these various techniques could potentially reduce heat rates by 1-4%, though the achievable amount depends on the specific plant and equipment. The document provides examples from research projects analyzing heat rate improvements through combustion optimization, sootblowing optimization, and upgrading steam temperature controls.
The document summarizes opportunities to reduce heat rates in coal-fired power plants through various methods. It discusses optimizing combustion conditions, improving sootblowing practices, upgrading steam temperature controls, maintaining steam turbines, and reducing coal and flue gas moisture. Implementing these various techniques could potentially reduce heat rates by 1-4%, though the achievable amount depends on the specific plant and equipment. The document provides examples from research projects analyzing heat rate improvements through combustion optimization, sootblowing optimization, and upgrading steam temperature controls.
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The document summarizes opportunities to reduce heat rates in coal-fired power plants through various methods. It discusses optimizing combustion conditions, improving sootblowing practices, upgrading steam temperature controls, maintaining steam turbines, and reducing coal and flue gas moisture. Implementing these various techniques could potentially reduce heat rates by 1-4%, though the achievable amount depends on the specific plant and equipment. The document provides examples from research projects analyzing heat rate improvements through combustion optimization, sootblowing optimization, and upgrading steam temperature controls.
Авторское право:
Attribution Non-Commercial (BY-NC)
Доступные форматы
Скачайте в формате PDF, TXT или читайте онлайн в Scribd
fired generating units has become a Examples of Heat Rate Improvement Opportunities: priority for many power generation Bituminous, Subbituminous and Lignite Coals companies. Sharp increases in the cost Potential Heat Rate Reductions (%) of coal has led many in the industry to Lignite and PRB Bituminous search for ways to reduce their annual BOILER AND FUEL MOISTURE fuel bills. In addition, some companies are placing increased emphasis on heat • Optimize Combustion and Sootblowing 1 to 2 1 to 2 rate reductions in preparation for • Upgrade Air Preheater Seals 0.5 0.5 possible future CO2 regulations. • (a) Pre-dry High Moisture Coals 2 to 4 (a) ----- Research projects at the ERC are and Reduce Stack Temperature to 140°F 1.5 (a) 1.5 (a) developing new techniques for reducing heat rate as well as developing an or information-base on heat rate reduction (b) Reduce Stack Temperature to 100°F 1.5 to 3.5 (b) 1.5 (b) options for existing coal-fired power plants. TURBINE CYCLE AND HEAT REJECTION Edward Levy explains, “Heat rate SYSTEM improvement opportunities for existing • Install Advanced Steam Turbine Blading 2 to 3 2 to 3 units include reductions in heat rate due and Seals to process optimization, more aggressive • Upgrade Steam Temperature Control maintenance practice and equipment Capabilities 1 1 design modifications. Opportunities exist in the boiler, turbine cycle and heat • Upgrade Cooling System Performance 1 to 3 1 to 3 rejection system. The overall level of Note: Use either (a) or (b) above, but not both heat rate improvement which can be achieved varies with unit design, maintenance condition, operating adjusting mixing patterns of coal and steam temperatures and unit heat rate. conditions, and type of coal.” combustion air and adjusting economizer Sootblowing optimization is used to The Energy Research Center has been O2 level. Changes to these parameters identify sootblowing strategies which working on research projects dealing affect quantities such as combustion prevent uncontrolled buildup of slag and with heat rate improvements in coal-fired efficiency, steam temperatures, slagging soot deposits and minimize heat rate. power plants since the 1980’s. These and fouling patterns and furnace heat The Center has developed test projects cover a wide range of heat rate- absorption, which in many boilers have procedures to determine optimal related topics extending from optimi- significant effects on unit heat rate. There sootblowing schedules and has also zation of combustion and sootblowing are systematic procedures which can be developed adaptive intelligent software practice to development of methods to used to identify the combinations of boiler to automate the sootblowing process. accurately measure changes in unit heat control settings which minimize unit heat The Center’s recent sootblowing projects rate. Center researchers who have been rate. Referred to as “Combustion indicate potential heat rate improvements involved in this area of research include Optimization” these procedures typically in the 0.25 to 1% range. Harun Bilirgen, Edward Levy, Carlos involve use of intelligent software to assist Steam Temperature Control. One of Romero and Nenad Sarunac. This article in the optimization process. The Energy the techniques used to prevent summarizes findings from some of these Research Center has optimized excessively high steam temperatures at projects. combustion at over 25 coal-fired units at the inlets to the HP and IP turbines is to Optimizing Combustion. The boiler is which achievable heat rate reductions in spray liquid H2O into the steam. often a good place to begin to look for the 0.5 to 1.5% range were identified. Referred to as attemperating spray, these heat rate improvements. The operating Sootblowing Optimization. Slagging liquid flows are taken from the turbine conditions of a typical pulverized coal and fouling deposits from coal ash cycle and result in increased heat rate. boiler can be controlled by adjusting fuel accumulation on heat exchanger tubes Consequently, attemperating spray flow and air flow rates among burners, affect boiler heat absorption patterns, rates should be the lowest flow rates needed to control steam temperatures to Example of Steam Temperature Control Impacts on Unit Heat Rate design levels. The table below shows data from a unit in which the steam Design Actual ΔHR (Btu/kWh) temperatures were lower than desired, TMS°F 1005 996 8 while both main steam and hot reheat TRHT°F 1000 985 20 steam attemperating sprays were in m& MS,spray (lb / h) 0 20,000 5 operation. This resulted in heat rate penalties due to low steam temperatures & RHT,spray (lb / h) m 0 22,500 56 and the use of attemperation when it was TOTAL 89 not needed. The total heat rate penalty was 89 Btu/kWhr or approximately 0.8%. An upgrade to the steam unit, for they can result in fuel handling temperature controls and perhaps repair problems and they affect heat rate, stack RESEARCHERS’ PROFILES of leaking flow control valves would be emissions and maintenance costs. ERC • Dr. Harun Bilirgen is a Senior needed to prevent this type of loss. research has shown that use of power Research Scientist in the Energy Steam Turbine Maintenance. The plant waste heat to reduce coal moisture Research Center and his research performance of HP, IP and LP turbine before pulverizing the coal can provide focuses on emissions control and stages deteriorates over time due to heat rate and emissions benefits. The performance improvement of coal- factors such as nozzle and blade erosion degree to which performance improves fired power plants. and seal leakage and periodic turbine depends strongly on the degree of drying, with heat rate gains expected to be in the 2 • Dr. Edward Levy is Professor of outages are used to restore degraded to 4% range. Mechanical Engineering and turbine components to as-new condition. Opportunities also exist to condense Mechanics and Director of the However, a new generation of aero- moisture from flue gas by reducing flue Energy Research Center. His dynamically improved turbine stage gas exit temperature. Captured sensible research deals with emissions designs with nozzles and blades made and latent heat can be used to improve control and performance from more erosion resistant materials unit heat rate through efficiency improvement in coal-fired power have been made available by steam improvements both in the boiler and plants. turbine vendors. For older units, these designs make it possible to produce 2 to turbine cycle. • Dr. Carlos Romero is an Associate 3% more gross power than can be Summary. The potential for improve- Director of the Energy Research produced by the original steam turbines. ment in unit heat rate for a given unit will Center. He is a specialist in Condenser Back Pressure. LP steam depend on fuel type because of the added combustion kinetics and emissions turbines are designed to operate with flexibility to reduce heat rate for units control. specific values of turbine back pressure. firing high moisture low-rank coals. The • Dr. Nenad Sarunac is Associate The turbine back pressure increases table on page 4 lists examples of Director of the Energy Research above the design value as the steam opportunities to improve heat rate for Center. His research focuses on temperature in the condenser increases units fired with bituminous, subbitumi- power plant heat rate improvement, above the design value, which results in nous and lignite coals. If improvements emissions control and process a reduction in MW produced and leads to could be made in all possible areas, the net optimization. increases in turbine cycle and unit heat improvement in heat rate would approach rates. For units which reject heat to river 10% for bituminous and 15% for PRB and • Dr. Eugenio Schuster is an lignite coals. While it would not be Assistant Professor of Mechanical water, increases in condenser pressure possible to take full advantage of all Engineering and Mechanics. His can occur due to factors such as an possible improvements on every coal-fired research focuses on dynamic increase in river water temperature unit, the table nevertheless shows there is modeling and control of electric and/or condenser fouling. For units potential for making significant heat rate power generation systems. equipped with cooling towers, factors such as condenser fouling, maintenance improvements to the fleet of coal-fired • Mr. Zheng Yao is a Research related cooling tower performance units. Scientist in the Energy Research deterioration, and increases in ambient Levy adds, “Center researchers are Center. His research deals with temperature and humidity can all cause working on analyses of the heat rate- optimization of power plant increases in back pressure. For full-load related factors which would affect the cost operations. operation, increases in turbine cycle heat and performance of CO2 capture systems rate of more than 2% are typical for an for controlling CO2 emissions from increase in exhaust pressure of 2 inches pulverized coal power plants. The initial Hg above design. It is not uncommon to results are quantifying the impacts of unit For more information on optimizing find units operating with turbine back heat rate improvements on the physical combined boiler-SCR operations, pressures approaching 5 inches Hg, size of back-end CO2 scrubbers and on the please contact Carlos Romero at which results in even larger heat rate thermal efficiency penalties which would cerj@lehigh.edu or (610) 758-4092. penalties. result from adding CO2 capture capabilities. We plan to estimate the For more information on heat rates of Pre-dry High Moisture Coal and/or impacts of heat rate improvements on the coal-fired power plants, please contact Reduce Stack Temperature. High fuel Edward Levy at ekl0@lehigh.edu or moisture levels found in low rank coals cost of carbon capture, once these (610) 758-4090. have several adverse impacts on the analyses are complete.” ■ operation of a pulverized coal generating