cleaner air for india with x solutions - fortum · cleaner air for india with fortum enext low-no x...

Cleaner air for India withFortum eNext low-NOx solutions

1

Fortum eNext provides a time saving,

low CAPEX & low OPEX solution to

help you comply with the new

NOx emission regulation in India

Seminars on NOx reduction in thermal power plants through primary means

9th & 11th April 2019New Delhi & Mumbai

This is Fortum

Fortum Group in briefWe are an active playeralong the Power Value Chain Our core

Energy from

Hydro, Nuclear,

Bio, Waste,

Solar and Wind

Circular economy

Driving

the changein energy market

transformation

Largest electricity

retailer in the

Nordics with

2.4 million customers

Pioneer in electric

vehicle charging

61% of all power

generation is

CO2 free,

96% in Europe

4

Forerunner in

Clean energy

Decades of

experience in

providing expert

services for

power plant

performance

Key figures 2018

Sales

EUR 5.2 bn

Comparable

operating profit

EUR 1.0 bnBalance

sheet

EUR 22 bn

8,300professionals

in the Nordics,

the Baltics, Russia,

Poland and India

Revising plant processes and technology, making

them fit for the coming years

> Best-In-Class usability and availability

Enabling energy companies to meet tightening

environmental regulations and safety standards

> Sustainability and safety always in the

forefront

Maintaining shareholder value

> Economical asset life cycle management

Helping traditional power plants

to Improve their operations and

Reduce emissions

6

Support and expertise along the whole life cycleof a thermal power plant

O&M as a service

Technical, commercial

and operational

advisory

Turnaround for full scope

performance improvement

Economical asset

life cycle management

Combustion solutions for emission reductions,

fuel conversions and performance optimization

Operations development and

improving plant efficiency

Overhauls, modernizations

Condition monitoring Optimized

last years

Decommissioning

Feasibility

& Design

Construction &

CommissioningOperations End-of-Life

Fortum in India

8

Currently Fortum operates185 MW of solar in India – and growing

We continue to develop our solar business

to secure our longer-term competitiveness.

Our immediate focus is in India.

The country offers one of the best solar

resources and sound government support

for the development of the solar sector.

We are pioneers in electric vehicle charging

9

Fortum Charge & Drive is a pioneer in

electric vehicle charging.

Our network consists of 1,200affiliated smart chargers in the Nordic

countries, with nearly 40,000 end

customers

India: the journey begins

450+ APP downloads (iOS + Android)

280Registered users

40 Operational, DC Fast & Semi Fast AC

charging points

4Cities Hyderabad, Mumbai & Delhi with

Fortum C&D chargers; Battery

Swapping at Noida

Bio2X: Acceleration towardsnatural resource efficiency

10

We are setting up the first Bio Refinery in India

Bio2X mission is to produce high-value products

from agro-residues and woody biomass to replace

fossil and other environmentally detrimental raw

materials

• You would be able to focus on running your daily

operations in the most efficient way, without

regulatory concerns

• You would secure the value of your assets and

continuous income

• You could show environmental compliance and

image on international markets

• We would all be able to breathe clean air and

provide a brighter future for our children

You can make a difference!

11

What if you could easily comply with the new NOx emission limits?

• New emission norms for thermal plants can be

fulfilled with Fortum eNext low-NOx solutions

• Your investment is secure – We give our

deliveries a guarantee of success

• Invest wisely – Only necessary capex, no

increase in opex

• Efficient turnkey project with short down time

12

Fortum eNext can help you achieve your goals

Installed up to

Dec 31, 2003

Installed Jan 1, 2004 –

Dec 31, 2016

Installed from

Jan 1, 2017 onwards

Oxides of Nitrogen

(NOx)600 mg/ Nm3 300 mg/ Nm3 100 mg/ Nm3

Emissions norms for coal-based thermal power plants

Emission Norms For Indian and European Thermal Power Plants

Category of Thermal Power

Plant (Units)

Particulate

MatterSulphur Dioxide (SO2)

Oxides

Nitrogen (NOx)

INDIA

TPPs (units) installed before

December 31, 2003100

600 (units smaller than 500 MW Capacity)

200 (units with capacity of 500 MW and above)

600

TPPs (units)installed after

January 1, 2004 to December

31, 2016

50 200 (units with capacity of 500 MW and above)

300

TPPs (units) to be installed from

January 1, 2017 onwards

30 100 100

EUROPE

IED 2016, old units 20 200 200

IED 2016, new units 10 150 150

BAT 2021, old units 2-11 10-130 65-165

BAT 2021, new units 2-10 10-110 65-125

All units in mg/Nm3

14

1990 1995 2000 2005 2010 2015 2020

200

400

600

800

1000

Limit for

NOx

mg/Nm3

IPPC 1996

650 mg/Nm3

LCP 2008

500mg/Nm3

IED

2016

200 mg/Nm3

BAT

2021

65-165 mg/Nm3

IPPC = International Plant Protection Convention

LCP = Large Combustion Plants

IED = Industrial Emission Directive

BAT / LCP BREF = Best Available technology / Reference Document on BAT techniques for LCP

Conventional

Burner

1st generation

low-NOx

eNext

solution today

Primary

Methods

300 mg/Nm3

eNext

solution today

Primary + SNCR

200 mg/Nm3

NOx Emission regulation for coal fired power plants in EU

Vs. Development of NOx reduction technologies

• Similar path in emission reduction regulation

to be expected in India as we have seen in

Europe

• Investment in the latest technology ensures

low CAPEX and low OPEX in the long run

• Invest wisely and be prepared for the

future

Fortum eNext can help you leap over several inevitable development steps

• Fortum eNext solution is based on State-of-

the-art Primary Methods

• What we deliver is always tailored to fit your

plant and any OEM’s technology

– Achieving best possible results for your plant

– Only the necessary investments – no more, no

less

• Remote monitoring and technical support for

the warranty period are always included

15

Achieving required NOx reductions in a cost efficient way

16

Comparison of alternative NOx reduction technologiesand solutions to reach 300 mg/Nm3 at all time

*Setup:

• 500MWe coal fired power plant

• Full load, 8000 h/a

• Excluding coals with extremely high FR and fuel N when achievable NOx level by any primary method is reduced

State-of-the art Primary

Method by Fortum

Simple Primary Method +

SNCRSCR

Total cost after 5 y < 3.0 MEUR ~28.5 – 30.0 MEUR >> 45 MEUR

Initial investment < 3.0 MEUR* ~3.5 – 5.0 MEUR* ~20 MEUR*

Increase in annual

operational costsNone

~5.0 MEUR

due to urea injection

>> 5.0 MEUR

Due to ammonium water

injection

Reduction with the

primary method

Reduction up to 60-70% of the

initial level 300 mg/Nm3 can

be achieved without changing

boiler performance*

Simple primary methods

enable reduction until

400 mg/Nm3N/A

Reduction with the

secondary methodN/A

SNCR needed to bring the

emissions further down to

required 300 mg/Nm3

300 mg/Nm3

can be reached with SCR

Further No additional maintenanceHigh risk of excessive LOI/UBC

Risk of NH3 slip

Frequent regeneration and

catalyst replacement required

17

State-of-the-art Primary Methods clearly most cost efficient over time

• Fortum State-of-art Primary methods

have a slightly higher initial investment

cost, but a significantly lower

cumulative cost over time

• Break-even within six months even

if CAPEX of Simple Primary is

assumed to be 0 EUR!

• When starting level is at 900-650 mg/Nm3,

SNCR technology alone will not be enough

to reach 300 mg/Nm3

• Simple primary methods required first to come

down to ~425 mg/Nm3

• SNCR with urea injection required in addition

to reduce further down to <300 mg/Nm3

*Calculation based on 8,000 operating hours per year

Pulverized coal boiler and steam turbine

Primary methods for cost efficientNOx reduction Case Fortum Suomenoja, Finland

Manufacturers Ahlström & Láng

Commercial use 1977

Steam amount 108 kg/s

Steam pressure 140 bar

Steam temperature 540 ºC

Electricity 90 MW

District heat 150 MW

Flue gas cleaning

Low-NOx burners

Two stage over-fired air

Semi-dry desulphurization plant

Electrostatic precipitators

19

Primary methods for cost efficient NOx reduction –Case Fortum Suomenoja

• Achieved OPEX savings from installing

primary methods instead of SNCR

• In 2012 Fortum decided to implement advanced

primary method only to reduce NOx down to 300

mg/Nm3.

• Cumulative savings from 2012 until the end of

2017 were approx. 5,5 MEUR.

• In 2018 Fortum decided to reduce NOx further

from

300 mg/Nm3 down to 250 mg/Nm3 – again with

advanced primary method and without SNCR

• Savings from 2018 until today have been approx.

1 MEUR.

20

Primary methods for cost efficientNOx reduction – Case Fortum Suomenoja

Guarantee

of

success

21

Fortum eNext as your partnerLow-NOx combustion technology for the past 30 years

Utility solution

• We operate and serve

our own fleet

• We are familiar with the

needs and priorities of a

utility

OEM independent

• Tailored solutions for any

OEM’s equipment

• Proven and patented

technologies

• Continuous R&D due to

tightening emission limits in

the EU

EHSQ in the forefront

of our operations

• Safety is a top priority in

everything we do

• Quality Assurance:

ISO 9001, ISO 14001

and OHSAS 18001

Long history and wide

experience

• Projects and presence in India

for last two decades

• First projects at Fortum’s own

power plants in early 1990’s

• First international project for

ČEZ in Czech in 1994

Introducing Fortum eNext Low-NOx delivery

From Concept to Delivery and Technical Support and Warranty

Fortum eNext Low-NOx solution guarantees the needed outcome regardless of the current set up at your site

23

> 50 references

for various types of PC plants

from 15 different OEMs

> 50 boilers

with reduced NOx levels

to Customer requirements

e.g. NOx 300 mg/Nm3

NOx 1200 mg/Nm3

NOx 800 mg/Nm3

NOx 600 mg/Nm3

STARTING POINT IS

ALWAYS DIFFERENT

OUTCOME ACCORDING TO

THE GIVEN LIMIT

Coal Quality

Burner Design

Air Distribution

OFA location

Boiler Performance• Superh & reheater metal temps within

design limits

• FEGT (furnace exit gas temp) within

design limits

• total air flow to boiler within design

limits

• Fuel flow within design limits

• Steam temperatures within design

limits

Water circulation / evaporator • Minor pipeline modifications to

accommodate new opening (OFA)

Fortum eNext low-NOx deliveryReferences

24

Firing Both Corner firing and wall

firing

MWe Rating 60 MW to 650 MW (supercritical)

Makes More than 10 OEMs

Age of boilers at the time of

implementation of primary means

Ranging from 10 to 30 years

> 50 boilers

with reduced NOx levels

to Customer requirements

25

Fortum eNext low-NOx delivery in IndiaTypical technical concept

Top of

Windbox

No OFA

Current

burners

Only COFA

CURRENT MODIFIED

New OFA

system, typically

2-stage

Modified

burners in all

corners:

burner tips

and new

secondary air

nozzles

No

changes

KEYS TO SUCCESSFULL

IMPLEMENTATION

New and carefully designed

OFA system

Modified burner tips are always

required to sustain stable flame

and to reach given emission

levels with minimum impact on

UBC

Fortum eNext low-NOx deliveryEfficient turnkey project with short production downtime

26

1 month 3 months 9 months7 months5 months

Design for

low-NOx

combustion

system

Manufacturing

and pre-

fabrication

Installation

of low-Nox

system

3 years

Commissioning,

Fine tuning and

optimization

ContractKick

Off

Providing

technical

support during

warranty period

Assessment of

burner design,

air distribution,

coals

Continuous

learning and

improvement,

how to optimally

run the boiler

Production

downtime

3-4 weeks

Documentation

review

Follow-up

work

progress

Plant available

for

commissioning

Providing

data

Outage

planning

O&M

training

Take

over

CUSTOMER

Introducing Fortum eNext Low-NOx delivery

Getting started with information gathering and low-NOx system design

Fortum eNext low-NOx delivery project always starts with a thorough information gathering and design for the low-NOx combustion system

28


Design for

low-NOx

combustion

system

Manufacturing

and pre-

fabrication

Installation

of low-Nox

system

3 years

Commissioning,

Fine tuning and

optimization

ContractKick

Off

Providing

technical

support during

warranty period

Assessment of

burner design,

air distribution,

coals

Continuous

learning and

improvement,

how to optimally

run the boiler

Production

downtime

3-4 weeks

Documentation

review

Follow-up

work

progress

Plant available

for

commissioning

Providing

data

Outage

planning

O&M

training

Take

over

CUSTOMER

Purpose and goals of data collection

Pre-contract data

• Defining required concept

• Preliminary design

• Fuel data & properties: ultimate and proximate analysis

• Boiler operational data, existing emission level

• Coal fineness and coal distribution

• Boiler configuration and dimensions: firing system, burner

elevation, SH location, COFA, SOFA…

Post-contract data collection

• More detailed data for detail design

• Reference tests: operational data / baseline29

Fortum eNext low-NOx delivery starts withcollection of initial data

Assessment of

burner design, air

distribution, coals

• Nitrogen content

• Volatile matter (VM) in coal

• FR-ratio = FC (fixed carbon) / VM

• Ash content

• Heating value

• Particle fineness after milling

• Particle distribution between burners

LHV

kcal/k

g

Ash

%

Nitrogen,

% daf

FR-ratio

Indian coal 1 4,500 46 2.0 1.4

Indian coal 2 4,000 30 2.7 1.3

Indian coal 3 4,400 40 1.4 2.8

Polish coals 5,300 15-20 0.8…1.2 1.5…1.6

Russian coals 5,700 12-15 2.3…2.8 1.4…1.6

Estonian coal 3,500 40-50 0.3 1.0

Influence of coal quality to NOx reduction by primary meansIndian coals versus others

30

Fortum eNext low-NOx delivery starts withcollection of initial data

31

Assessment of

burner design, air

distribution, coals

• Evaluating NOx performance by calculation and comparing

boiler behavior with previous projects

• Utilizing CFD tool to study combustion performance

• Comparing boiler behavior with different burner settings, air

distribution at different boiler loads

• Resulting the best tailor-made design including:

– NOx emissions

– Furnace temperature fields

– CO and O2 concentrations

– Unburned carbon in the fly ash and bottom slag

32

Grounds for successful low-NOx system design

Simulating the

existing

combustion

condition with data

from the site in

question as input

Optimal

combustion

design with

required

outcome

Altering the

burners and

adding /

changing the

location of OFA

nozzles in the

model

Comparing

simulation

results

Design for

low-NOx

combustion

system

• Based on commercial CFD code (Ansys Fluent)

• Development started in mid 1990s

• Equipped with own special sub-models,

developed by Fortum in co-operation with VTT,

Technical Research Centre of Finland

– Include physical and chemical models for

combustion, heat transfer and emission

formation and destruction

– Chosen and developed for simulating the most

essential processes in the furnace, with

reasonable accuracy, acceptable computing

time and costs

• Tool and results verified with data from actual

boilers and different fuels

33

Fortum CFD tool Design for

low-NOx

combustion

system

Base

case

Low-NOx

firing

CO (mg/Nm3, 6 % O2) 3 5

NOx (mg/Nm3, 6 % O2) 698 278

FEGT, mean at nose (°C) 1165 1185

UBC in fly ash (%) 0.8 1.1

34

Main results of an example study500 MW unit

Achieved NOx reduction 61%

Fortum’s experience from actual

power plants with similar coal

characteristics show similar NOx

reduction potential as results from

CFD modelling

Design for

low-NOx

combustion

system

In Fortum’s Primary method the only influence to OPEX is due

to potential decrease in efficiency due to increase in UBC. In

the sample above 0,3 % (abs) increase in UBC corresponds to

additional 2,3MWf (which is 0,18% of the total 1300MWf)

For comparison purposes there is similar size of OPEX related

to SNCR when NOx is reduced from 450mg/Nm3 to

300mg/Nm3 by urea or ammonia solution. Additional 4MWf is

required due to evaporation of injection water. The biggest

OPEX is anyhow urea or ammonia consumption which is

>25Crore/year.

NOx conversions

• NOx emissions are typically expressed as NO2, even if most of the NOx measured just after the boiler is NO (97-99 %)

• NO2 is only stable compound in atmosphere and NO will react very fast in the stack and after the stack to NO2

• O2 has to be measured at same place than NOx emission (for O2 correction)

• NOx emission expressed as NO2:

– mgNO/Nm3 *1.53 * [21−𝑟𝑒𝑓 𝑂2

21−𝑂2] + mgNO2/Nm3 * [

21−𝑟𝑒𝑓 𝑂2

21−𝑂2] = mgNO2/Nm3

– O2 correction as given above [21−𝑟𝑒𝑓 𝑂2

21−𝑂2] for reporting purposes is done (because NO2 must be

expressed at a reference oxygen content of 6 vol-%, dry basis O2)

– MNO2/ MNO = 46/30 = 1.53

• If NO is measured in ppm then the measured value is multiplied with 2,052 (assuming 0 C and 1 bar) and then the result is already mgNO2/Nm3

– then the value is multiplied with 1,01/1,03 to take account the share of NO2

35

36

Invest successfullywith Fortum eNext

State-of-the-art simulation tool,

developed for our needs

over the past decades

Engineering expertise based on

decades of experience in

power plant operations and maintenance

as well as low-NOx deliveries

No operational risk for our customers

We rely on our combustion system design

and grant warranty for all deliveries

Design for

low-NOx

combustion

system

Introducing Fortum eNext low-NOx delivery

Manufacturing, installation andcommissioning

Manufacturing and installation of the low-NOx combustion system is done in co-operation with our local partners

38


Design for

low-NOx

combustion

system

Manufacturing

and pre-

fabrication

Installation

of low-Nox

system

3 years

Commissioning,

Fine tuning and

optimization

ContractKick

Off

Providing

technical

support during

warranty period

Assessment of

burner design,

air distribution,

coals

Continuous

learning and

improvement,

how to optimally

run the boiler

Production

downtime

3-4 weeks

Documentation

review

Follow-up

work

progress

Plant available

for

commissioning

Providing

data

Outage

planning

O&M

training

Take

over

CUSTOMER

39

General scope division Fortum – LocalPartner

Installation of

the Low-NOx

system

Manufacturing

and pre-

fabrication

Commissioning,

fine-tuning and

optimization

Fortum is responsible for:

• Process design and performance of the low-NOx modification

• Delivery of main process equipment

• Input data and supervision of mechanical and electrical, C&I design done by local partner

• Commissioning and training related to process equipment

Local Partner is responsible for:

• Mechanical, electrical and C&I design

• Erection of equipment submitted by Fortum, electrical installation, C&I

• Needed licenses according local rules

• Support during commissioning and training

40

Fortum advanced primary low-NOxhardware delivery and erection

Installation of

the Low-NOx

system

Fortum manufacturing and delivery:

• Fuel nozzle tips

• Secondary air nozzles

• OFA Nozzles

Fortum activity during erection:

• Project management

• Advisory for local partner during erection

• Reporting to Customer the progress and

follow-up of the progress

• Erection supervision

Manufacturing

and pre-

fabrication

Commissioning,

fine-tuning and

optimization

41

DOW between Fortum and local partnerDesign and general part

Installation of

the Low-NOx

system

Abbreviat

ion

Abbreviation (Consortium Members + main subcontracors /

subsuppliers)Responsibility division

THER Thermax Design Delivery Erection

Chief

Designer,

Design

Coordinator

FORT Fortum (means Fortum P&H Oy and/or Fortum India Ltd)

PB: Civil Design

CE, BE,

DE:

CE concept design, BE basic design, DE detail design - workshop, -

erection

Note: (*) - means subcontractor, */* - means joint responsibilityDesign

D E

Item System / Sub-system CE BE DE

I General Items

1 Project management FORT

2

Site management (including site manager, EHQS, erection supervision

and scheduling)THER

3

Site arrangement, site facilities, places for storages, fencing, site marking,

site worksTHER

4

Responsibility for process parameters (NOx, UBC, steam parameters)

and collection of baseline data)FORT

5 Process design FORT FORT FORT FORT

6 Mechanical design (ducts, platforms, suspensions, supports, hangers) THER THER THER THER

7 Boiler pressure part modifications design with IBR approval THER FORT THER THER

8 Civil design with civil permit, if this will be required FORT THER THER THER

9 Geodesy services THER

10

Cleanup services in connection with carried works (among others

cleaning service, leveling the area, reproducing the infrastructure and

green area, etc.).

THER

11 Delivery of essential spares for guarantee period FORT/THERM

12 Special tools and tackles for guarantee period FORT/THERM

12 Special tools and equipment for commissioning period FORT

11

Repair works in guarantee period of identified faults and repairs included

in protocols from guarantee inspectionsFORT/THER

Manufacturing

and pre-

fabrication

Commissioning,

fine-tuning and

optimization

42

DOW between Fortum and local partnerErection and commissioning

Installation of

the Low-NOx

system

Manufacturing

and pre-

fabrication

Commissioning,

fine-tuning and

optimization

Abbreviatio

nAbbreviation (Consortium Members + main subcontracors / subsuppliers)

Responsibility division

THER Thermax Delivery Erection

FORT Fortum (means Fortum P&H Oy and/or Fortum India Ltd)

PB: Civil Design

CE, BE, DE: CE concept design, BE basic design, DE detail design - workshop, - erection

Note: (*) - means subcontractor, */* - means joint responsibility DesignD E

Item System / Sub-system CE BE DE

1. Boiler

1.1 CFD calculations of the situation in the combustion chamber FORT FORT FORT

1.2 Modification of burner tips FORT FORT FORT FORT THER

1.3 Additional OFA FORT FORT FORT FORT THER

1.4 New air ducts with insulation and suspensions FORT THER THER THER THER

1.5 New Openings in the boiler walls - *) IBR approval by THER FORT THER THER* THER THER

1.6 New platforms, stairs, needed for access to new devices FORT THER THER THER THER

1.7 Needed new refractory for new openings or refractory modifications for existing openings FORT THER THER THER THER

1.8 All needed dismantling works FORT THER THER THER THER

1.7 All other mechanical erection works, needed for NOX control installation FORT THER THER THER THER

2 Civil discipline

2.1 All new foundation if needed FORT THER THER THER THER

3 C&I

3.1 Delivery and erection of needed C&I devices on Nox control installation FORT FORT THER THER THER

3.2 Modification of DCS FORT FORT THER THER THER

4 Electric discipline and teletechnic installation

4.1 Main process switchgear

4.1.1 Preparation of power balance FORT THER THER THER THER

4.1.2 Delivery of equipment and erection FORT THER THER THER THER

4.1.3 Switchgear upgrade for drives control from DCS FORT THER THER THER THER

4.2 Subswitchgears

4.2.1 Execution of new switchgears for power supply of new consumers FORT THER THER THER THER

5 Gas analysis system THER

5.1 Design, delivery, erection of flue gas sampling and analysis FORT THER THER THER THER

5.2 Flanches and nozzles to flue gas sampling and other measurements FORT THER THER THER THER

6 Tests, commissioning and optimization - every party in own scope

6.1 Functional tests FORT/THER FORT/THER FORT/THER FORT/THER FORT/THER

6.2 Mechanical commissioning FORT/THER FORT/THER FORT/THER FORT/THER FORT/THER

6.3 Process commissioning FORT/THER FORT/THER FORT/THER FORT/THER FORT/THER

6.4 Cold commissioning FORT/THER FORT/THER FORT/THER FORT/THER FORT/THER

6.5 Optimization FORT/THER FORT/THER FORT/THER FORT/THER FORT/THER

6.6 Test run FORT/THER FORT/THER FORT/THER FORT/THER FORT/THER

6.7 Guarantee measurements FORT/THER FORT/THER FORT/THER FORT/THER FORT/THER

6.8 Trainings FORT/THER FORT/THER FORT/THER FORT/THER FORT/THER

43

Fortum tasks during Commissioning Installation of

the Low-NOx

system

Manufacturing

and pre-

fabrication

Commissioning,

fine-tuning and

optimization

Main activities during the commissioning:

• NOx emission control in full boiler load range

• Optimization of air distribution between burner

area and OFA area

• Optimization of excess air in flue gases

• Checking the whole boiler performances (steam

parameters, spray water amount)

• Checking boiler dynamics in full range of boiler

loads

44

Fortum tasks during Training Installation of

the Low-NOx

system

Manufacturing

and pre-

fabrication

Commissioning,

fine-tuning and

optimization

Main objectives during the training:

• Training will be done for engineers, operators and maintenance staff

• Practical training will be done during commissioning

• Theoretical training will be kept for operators and supervision staff

• The process will be controlled automatically - in general the engineers and operators shall be aware, how to change settings (air ratio to burners and to OFA), how tune the boiler if the boiler get dirty etc.

• Getting familiar with new process displays and understanding of main combustion parameters

• Process observation and influence on main parameters, if needed

45

Fortum experience - 1 Installation of

the Low-NOx

system

Manufacturing

and pre-

fabrication

Commissioning,

fine-tuning and

optimization

Experiences from previous projects

• Main boiler performances like steam flow, steam parameters are the same

• It is very important to gather the reliable information about boiler performance before contract signing or latest after signing, but before project execution

• We recommend execution of reference measurements by independent third party

• Boiler performance depends on coal parameters –it is recommended to use few defined coal types during the reference measurements and guarantee measurements

• Boiler performance depends on boiler condition

• The UBC in fly ash and bottom ash depends on milling quality and coal distribution – usually it is slightly increased after low-NOx implementation

2 Stage

OFA

Conventional

low-NOx

system

Low-

NOx

burners

Advanced low-NOx

combustion

solution

OFA

zone

46

Fortum experience - 2 Installation of

the Low-NOx

system

Manufacturing

and pre-

fabrication

Commissioning,

fine-tuning and

optimization

Experiences from previous projects

• It is important to assure even distribution of coal dust to all burners – otherwise could be bad combustion, risk of high temperature corrosion

• In order to avoid slagging it is recommended to install soot blowers in the combustion chamber

• The low-NOx installation control is integrated into boiler DCS system and full operation is done from DCS, so the operator use the same MMI as for unit operation

• Burner parts (e.g. fuel nozzles tips) are resistant against high temperature and erosion (special materials)

• Primary NOx emission reduction is most economical way of NOx control

Leading player in Boiler diagnostics and specialty services

segment in India

Over 130 Performance Improvement and Revamp projects

delivered

Over 135 large team exclusively dedicated for these

services

Dedicated resources for Process engineering, design,

detail engineering, Project, Quality & Construction

management

47

Thermax Boilers & Heaters Services’ Experience

48

Thermax Boilers & Heaters Services’ ExperienceEnd to End Solutions and Services Offered:

Performance Improvement Projects (PIP) like efficiency improvements, de-

bottlenecking of boiler operation/performance, reliability improvement, FEED

assistance for boiler and accessories / conversions / upgrades, fuel

conversions/firing system upgrades, emission control, technology upgrades etc

Engineering Studies, Engineering Design Services for Boiler, Accessories,

Piping, Structures, etc.

On-Site or Remote Performance Monitoring / Management

Energy Audits, Failure Analysis, Training, Spares, Replacement In Kind

Condition Assessment (CA), Remaining Life Assessment (RLA) Services, Risk

Based Inspection (RBI)

Annual Service / Maintenance Contracts

Operation and Maintenance Services

Site Construction, Testing, Boiler / Equipment Commissioning Services

During Pre & Post Contract data collection & site verification

– Collection of data like OEM design parameters, design fuel data,

P&IDs, GA and pressure part assemblies etc.

• Also making reasonable assumptions of few data which may not

be available

– Present operating log data as various loads, present day fuel data,

understanding availability & other failure history since unit

commissioning, if any etc.

• Care in understanding philosophy of present operation and

design features of OEM before undertaking modifications

– Modeling of existing boiler based on Original Design Data & conduct

engineering study w.r.t target results post modification using our

licensed Boiler Performance Patented Programs / PPSD-KED

Softwares / In-house tools, as required.

• Matching original design performance data before analyzing new

performance post modifications with present and anticipated fuels49

Low NOx Combustion System - Implementation by Thermax Manufacturing

and pre-

fabrication

During Pre & Post Contract data collection & site verification

– Identification of possible issues related to modifications, layout &

needed relocations / modifications of existing equipments, if any.

• Care in routing duct to OFA locations without affecting

structural integrity and possible minimum modifications.

Evaluation of relocation / removal of wall blowers for

accommodating new OFA, if required. Modification / relocation

of existing structural members, cable & cable tray re-routing

etc. Structural integrity check for local modification (using

STAAD/CAESAR), as necessary.

– Creating sketches/drawings of proposed modifications for clarity

in understanding site activities.

• Drawings / Sketches also provides end user to visualize post

implementation scenario.

50

Low NOx Combustion System - Implementation by Thermax Manufacturing

and pre-

fabrication

During Manufacturing of needed pressure parts, ducts & structural members, IC&E

– Manufacturing of profiled tube/panel openings required for

additional Over Fire Air ports

• Opening tube panels shall be manufactured to suit site

requirement s as per the quality requirements of Thermax /

International Industry Standards.

– Tubes/membrane panels shall match to the existing

specifications or better as required.

• IBR and local statutory body compliance will be ensured.

– Pressure parts shall be tailor made to the requirements specific

to each sites

• Thermax manufacturing and QA compliance will assure the

best quality product being delivered in minimum possible

time. Impact on Circuit Balancing is also assessed.

51

Manufacturing

and pre-

fabrication

Low NOx Combustion System - Implementation by Thermax

During Manufacturing of needed pressure parts, ducts & structural members, IC&E

– Manufacturing and pre fabrication of ducts, structural members

required for the upgrade

• To the extend possible ducts and other structural members

shall be pre fabricated minimizing site activities.

– Value added manufacturing & fabrication.

• Our experts will be stationed at site during detailed

engineering to understand site specific needs and to take

utmost care to avoid any rework during site construction. This

helps to avoid any drift in shut down schedule time which is

crucial to the project execution and has high degree of

impact to system performance post modifications.

– Electrical Instrumentation scope of work and Control system

configuration in existing DCS/PLC for incorporating new logic

for combustion control

• New logic will be implemented for seamless combustion

control transition.52

Manufacturing

and pre-

fabrication


During Site Installation Work - Safety

– Compliance to Safety Norms

• Thermax is also an OHSAS 18001

certified company. Our commitment

to Safety is foremost and we strictly

adhere to the safety norms as per

our standards as well as additional

safety norms, if any, pertaining to

each site of work, as applicable.

• It is our goal to reduce the frequency

and severity of accidents, and

eventually achieve 'Zero Accidents'

by eliminating unsafe and hazardous

conditions.

53

Installation of

Low NOx

System


During Site Installation Work - Planning

– Allocation of appropriate Construction

execution team & assessing site conditions

• Thermax B&H Services has over 25 years of

retrofit job execution experience which is

aligned for ease of construction & post

modification operation requirements. Unlike

new equipment erection, these jobs require

lot of pre shut down activities and site

feasibility study like placement /movement of

cranes, activity sequence planning etc.

– Project planning and execution is crucial to the

success of the project.

• Thermax is ISO 9001 and ISO 14001

certified company. Understanding the typical

nature of such projects, we create an L3

Construction schedule integrated with total

project schedule for better monitoring.54

Installation of

Low NOx

System


Exp Start Date Tue

Tue

Tue

Tue

Tue

Tue

Tue

Tue

Tue

Tue

Tue

Tue

Customer - XXX - Tentative Erection Schedule 15-Oct-19 19 19 19 19 19 19 19 19 19 19 19 19

Oct

Oct

Oct

Nov

Nov

Nov

Nov

Dec

Dec

Dec

Dec

Dec

ACTIVITY DURATION START END 15 22 29 5 12 19 26 3 10 17 24 31

Preliminary Erection Schedule 60 15-Oct-19 14-Dec-19

Pre-Shutdown 30 15-Oct-19 14-Nov-19

Mobilisation 7 15-Oct-19 22-Oct-19

Structural Pre Works 15 30-Oct-19 14-Nov-19

Pre fabrication of duct works 28 16-Oct-19 13-Nov-19

CLIENT INPUTS (UNIT HANDOVER) 1 13-Nov-19 14-Nov-19

Unit Handover 1 13-Nov-19 14-Nov-19

Post Shutdown Activities 30 14-Nov-19 14-Dec-19

Cooling of furnace 2 14-Nov-19 16-Nov-19

Scaffolding preparation 4 14-Nov-19 18-Nov-19

Opening of tubes at new SOFA locations 8 18-Nov-19 26-Nov-19

Windbox works to suit new Burners 8 14-Nov-19 22-Nov-19

Supports erection and alignment 8 22-Nov-19 30-Nov-19

Platform modifications 15 22-Nov-19 07-Dec-19

E&I Works - Burner & Piping Area 15 22-Nov-19 07-Dec-19

Other Burner Connections 7 30-Nov-19 07-Dec-19

Erection & welding of new burners / SOFA 14 30-Nov-19 14-Dec-19

Hydro test & Box up of boiler 3 07-Dec-19 10-Dec-19

Insulation works 5 07-Dec-19 12-Dec-19

During Site Installation Work – Schedule

55

Installation of

Low NOx

System



Technical support and warranty

After installation and commissioning, begins the warranty period and technical support provided by Fortum eNext experts

57


Design for

low-NOx

combustion

system

Manufacturing

and pre-

fabrication

Installation

of low-Nox

system

3 years

Commissioning,

Fine tuning and

optimization

ContractKick

Off

Providing

technical

support during

warranty period

Assessment of

burner design,

air distribution,

coals

Continuous

learning and

improvement,

how to optimally

run the boiler

Production

downtime

3-4 weeks

Documentation

review

Follow-up

work

progress

Plant available

for

commissioning

Providing

data

Outage

planning

O&M

training

Take

over

CUSTOMER

58

Fortum eNext Remote Supportfor optimal plat operation and savings

HIGHER PLANT

AVAILABILITY

Via controlled problem

management thanks to early

detection of deviations

SAVINGS THROUGH LOWER

FUEL CONSUMPTION

Via increasing or maintaining

thermal efficiency and

ensuring optimal plant

operation

CONDITION MONITORING

• Verifying real component

performance

• Identifying malfunctioning and

missing measurements,

process issues

• Defining correct maintenance

timing

OPERATIONAL ECONOMY

MONITORING

• Monitoring the operating modes

and detecting deviations

• Performing evaluation for aged

plants

• Comparisons to shows

potential lost MW’s

Providing

technical support

for warranty

period

59

Fortum eNext Remote SupportSet up and operating model

Customer gains:

• Early detection of

issues

• Expert

recommendation for

corrective action

Data collection

at the power plant

Agreed service level:

• Monthly reports

• Status check daily

• Alerts based

• 24/7 service

DATA

TRANSFERCloud based

database

Analysis at

Fortum eNext

control room, based

on expertise and

State-of-the-art digital

tools

SUPPORT

Providing

technical

support for

warranty period

60

Deep expertise and experience on Power Plant Main Equipmentat your disposal

Boilers

Combustion management, Soot blowing optimization, Fuel

selection and combining with existing fuels

Generators, transformers

Electrical systems, Power systems support

Balance of plant

Performance, mechanical and water chemistry specialists

Steam and Gas Turbines

Performance and mechanical specialists

Controls and automation

Structural mechanics and vibration measurements

Condition monitoring

Support in upgrade design and implementation, and more

Providing

technical

support for

warranty

period


Case NTPC India: Ramagundam 1x 500 MW

BHEL and 1x200MW Ansaldo Boilers

62

Content of Study

• 500 MW Tangentially Fired Boiler (BHEL, commissioned 2004) equipped with 10 coal mills, tilting type of the Burners and Close Coupled OFA.

• Fortum carried out tests at boiler full and technical minimum load with different mill combinations

• NOx emission was measured by Fortum after flue gas fans

• Coal quality:

• Heating value (GCV, kcal/kg): 4530…4580

• Ash content (%, wet): 29…32

• FR ratio ( - ): 1,3…1,4

• N (%, daf): 2,0

• CFD model was created based on real operational data.

• CFD study carried out with Burner and SOFA modification in order to test possibilities to reduce NOx < 300 mgNO2/m

3n and effect of modifications to boiler performance

63

Content of Study

• 200 MW Wall Fired Boiler (Ansaldo, commissioned 1983) equipped with 6 coal mills.

• Tests carried out at boiler full and technical minimum load NOx emission was measured by Fortum after flue gas fans

• Coal quality:


• Ash content (%, wet): 32,7…33,5

• FR ratio ( - ): 1,3…1,4

• N (%, daf): 2,0

• CFD study carried out with Low-NOx Burners and SOFA in order to test possibilities to reduce NOx < 600 mgNO2/m

3n and effect of modifications to boiler performance

64

Certificate from NTPC


Case Indian IPP: 2x 660 MW Super Critical

Boilers

66

Content of Study

• 2*660 MW Tangentially Fired Super Critical Boiler equipped with 1st generation low-NOx burners and SOFA

• Combustion optimization will be carried out by Fortum at all possible operation conditions (all load levels and mill combinations) in order to reduce NOx emission < 300 mgNO2/Nm3

• NOx reduction is possible based on Fortum’s know-how without changing the boiler performance (steam/metal/flue gas temperatures) from design ranges

• NOx emission before optimization 230…550 mgNO2/Nm3 (6 % O2)

• Coal quality:


• Ash content (%, wet): 29…50

• FR ratio ( - ): 1,2…2,5

• N (%, daf): 1,5…2,0

67

Summary

• NOx before optimization at boiler high loads 320-450 mg/Nm3 and boiler

minimum loads 350-600 mg/Nm3

• NOx possible to reduce below < 300 mg/Nm3 in most operating

conditions

• Work is on-going: more tests needed at boiler intermediate loads and

during load rampings

Closing

• The energy sector is one of the mainstays of

India’s growth and development.

• While concerted efforts are being made to

combat climate change by way of curtailing

emissions, a lot more needs to be done to

overcome the problem of air pollution.

• Hundreds of coal fired boilers in India still need to

be modified, to comply with the new emission

regulation

• Implementing NOx reduction technology for one

boiler takes months

• Resources to implement the modifications are

limited

• We can help you to implement the most cost

efficient solution and be ready on time

69

The time to act is now!

Let’s define the best solution for you

Contact

Juha Suomi, Area Director, Asia

Fortum eNext

[email protected]

+358 50 453 5018

www.fortum.com/enext

cleaner air for india with x solutions - fortum · cleaner air for india with fortum enext low-no x...

Documents