zonal combustion tuning system central district's 13th annual power generation conference...

Zonal™ Combustion Tuning SystemCentral District's 13TH Annual Power Generation ConferenceFlorida Department of Environmental Protection

July 30, 2009

2 /GE /GE Confidential and Proprietary

© 2008 General Electric Company All rights Reserved

Data in this presentation is for indication and discussion purposes only

and may not be representative of results to be expected in specific

applications.


Agenda

• Zonal Combustion Principles• Zonal System

–Features–Application–Reliability

• Operating Experiences and Achievements

Zonal™ Combustion Principles


~CoalSupply

CoalCrusher

Mill

CoalSilos

AirHeater

Stack

IDFan

FDFanTurbine Generator

Poor Combustion

ZonalTM Combustion Monitors in Boiler

BackpassBoiler

Combustion Performance Issues

Excessiveattemperatio

n

High LOIHigh CO

/Opacity

Reduced

efficiency

High NOx

Local slaggin

g

Local corrosio

n

Excessive

FEGTLocal hot

spotsIncreased

O2

Poor Combustion = Increased Boiler Issues = Poor Plant Performance


Good Combustion, Bad CombustionThe Principles of Zonal Combustion Tuning

Com

fort

Zon

e

Initial A/F σFEGT

Improved A/F σ

Perf

orm

an

ce

Para

mete

rs

Minimum local A/F limits average O2

Improved A/F σ

Fuel Savings & CO2

Credits & ComplianceAvailability & Output

Output, Throughput & Fan Power

Ash Sales & EfficiencyAvailability & CO compliance


Approaches to NOx Control

Technique

Operational ModificationsLow Excess AirReduced Air PreheatFuel BiasingBurners Out of Service(BOOS)

Combustion Equipment ModificationsFlue Gas Recirculation (FGR)Overfire Air (OFA)Steam Inject ionLow-NOx Burners (LNB)Reburning

Post-Combustion TechniquesSelective Non-Catalytic Reduction (SNCR)Selective Catalytic Reduction (SCR)

Nat. Gas Fuel Oil Coal

X X XX XXX

X XX

XX X X

X X

X X XX X X

X

X

X X


Benefits of Combustion Tuning

Great Benefits and Returns• Increase Availability• Reduce Emissions• Improve Heat Rate• Maximized Output• Further Upside

– Stable and Predictable Operation– Integrated with Mercury Removal– Reduce or avoid slag additives

Chart Based on Specific Improvement of :• Excess O2: 0.5% reduction• Emissions (NOx): 15% reduction• Heat Rate: 0.5% improvement• Peak Power: 2.3% increase• Availability: 3 outage days avoided

*Benefits and improvements are site-specific. Actual results may vary.

An

nu

al B

en

efi

ts, $

/yr

-

500,000

1,000,000

1,500,000

2,000,000

2,500,000

3,000,000

100 300 500 700 900 1100

Plant Size (MW)

Emissions Heat RatePeak power Availability

The Zonal™ Combustion System


Zonal™ Combustion Modules

#1 Zonal™ Combustion Monitoring System• CO/O2 Combustion Sensors• Central Operator Interface • Intuitive Graphic HMI Displays*

#2 Zonal™ Combustion Tuning Advisor• Library of Zonal Models• Burner/OFA Influence Identification• Fuel/Air Adjustment Advice• Map Profile Correction Advice

Zonal™ Grid

Zonal™ Advisor

* Software Modules built on iFIX HMI/SCADA


Combustion Monitoring Application

TDL

Combustion completed. Good tracing to burners. Reduced air in-leakage.

Air in-leakage, non uniform flow and poor tracing to burners.

Incomplete combustion.Recirculation

zones and non uniform

flow.


Zonal Combustion Tuning AdvisorBuilt on Predominant Fluid Structure

Predominant Burner Path

Lines Zonal Combustion Monitoring

System

Burners/OFA

Burner-to-Sensor Models

Capture Fluid Structure


T-Fired Fluid Stratification Suited to Zonal Tuning

4

1


Zonal™ Monitoring SystemDesigned for Reliability

Zonal base analyzer technology has;• Decades in similar applications• 1000s installed world wide• High reliability

Zonal Analyzer ZCA-30 status• Deployed January 2007• Over 330,000 hrs of operation as of Apr 28, 2009• Mean time to maintenance event:

– > 19 months– Low Spec Limit > 12 month @ 2 Sigma, 95% PI

Sites A - U1 B - U3 C - U1 D - U5 D - U6 E - U1

Location Denmark MN, USA UT, USA UK UK SC, USA

Trials 1-4/07 11/07 – 3/08 5 – 10/07 NA NA 11/08 -

1/09

Systems 12 Pts 6/08 8 pts 1/09 10 Pts 10/07 8 Pts

7/088 Pts 7/08 Pending

Zonal Installations


GE’s Zonal Combustion Monitoring Application Experience

Sensors applicable to Coal, Oil and Gas

Coal Type – Bituminous or Subbituminous• Ash < 30%• Moisture < 30%• Sulfur < 3% (up to 4%)

Biomass co-firing to < 30%

Gas Temperature: 900 °F to 1200 °F (1500 °F maximum)

Ambient environments• Electronics rated 0 to 60 °C, avoid exposure to severe weather.

– Installations to –20 °C but not recommended. • Sensor rated–18 to 93 °C.


Zonal Combustion Monitoring

Benefits of Zonal Approach• Post combustion• Close to furnace• Zonal data traces to

burners• Low air in-leakage• Ease of installation• Robust technology• Accurate measurements• Accurate point data

Operating Experience and Achievements


Zonal Combustion System InstallationPlant• Western US• 460 MW T-fired boiler• Western Bituminous Coal

Zonal Project• Zonal Combustion Monitor

Grid– 2x5 sensor array

• Zonal Tuner Advisor– CCOFA yaw

Issues• Frequent Slagging Events• New Corporate NOx and CO

Mandates

Zonal Combustion Topology

Burner Adjustme

nts

Burner-to-Sensor Models

Boiler

Zonal Sensor Grid


As-Found Conditions – Western US Boiler

Normal Operation• Typically High 3.6% Excess O2 • O2 Imbalanced +/- 1% (ie. 10%

ex air)• Low average CO 37 ppm• High NOx 0.4 lb/MMbt

Reduced O2 Operation • O2 reduced to 3.0%• Low average CO 150 ppm• High peak 900 ppm, fuel-rich

zone• Slagging severe at reduced O2

Combustion Issues not be Detected by Stack CO


Zonal Combustion Tuning EventT-Fired, Western US Boiler

0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00 40.00 45.00 50.000.00

5.00

10.00

15.00

20.00

25.00

0.000.250.500.751.001.251.501.752.002.252.502.753.003.253.503.754.004.254.504.755.00

0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00 40.00 45.00 50.000.00

5.00

10.00

15.00

20.00

25.00

0.000.250.500.751.001.251.501.752.002.252.502.753.003.253.503.754.004.254.504.755.00

O2 average: 3.13%O2 spatial variance: 0.32%

0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00 40.00 45.00 50.000.00

5.00

10.00

15.00

20.00

25.00

0

25

50

75

100

125

150

175

200

225

250

CO average: 14 ppmCO spatial variance: 9 ppm

Zonal O2 - March 09, 2009

0

1

2

3

4

5

6

11:00 13:00 15:00 17:00 19:00 21:00 23:00

Time

O2,

%

Ox_1

Ox_2

Ox_3

Ox_4

Ox_5

Ox_6

Ox_7

Ox_8

Ox_9

Ox_10ZonalTuning


Ave 3.1% O2

Ave 3.6% O2

After (3/9/09)

Zonal O2 Distribution

2 2.5 3 3.5 4 4.5 5 5.5

Zonal O2, %

9-Mar-09

12-Jun-08

Before (6/12/08)

Zonal Tuning ImprovementsT-Fired, Western US Boiler

Before

AfterRealized BenefitsNOx 25% ReductionO2 0.5% ReductionCO, ppm <50 ppmSlagging No eventsEfficiency 0.5% Increase


Zonal Identified Air Leak at Boiler NoseWestern US Boiler February 12, 2009 Zonal O2 Time Series - Feb 12, 2009

0

2

4

6

8

10

12

0:01 2:01 4:01 6:01 8:01 10:01 12:01 14:01 16:01 18:01 20:01 22:01

Time

O2,

%Ox_1

Ox_2

Ox_3

Ox_4

Ox_5

Ox_6

Ox_7

Ox_8

Ox_9

Ox_10

Zonal CO Time Series - Feb 12, 2009

0

200

400

600

800

1000

1200

0:01 2:01 4:01 6:01 8:01 10:01 12:01 14:01 16:01 18:01 20:01 22:01

Time

CO

, p

pm

CO_1

CO_2

CO_3

CO_4

CO_5

CO_6

CO_7

CO_8

CO_9

CO_10

• Unusual Zone of High O2 & High CO

• Pinpointed likely leakage area

• Boiler taken of line for repair

• Repair verified by O2 and CO return to normal

Sensor 5

Sensor 5


Zonal versus Plant O2 Wall-Fired, Mid-West Boiler

Excess O2, %

CO, ppm

Existing Plant Sensors Biased Low and Not Suitable for Tuning

X X

Plant O2 probes located in these Zones @ 3% O2

Zonal O2 (true) reads 3.8%Plant O2 (biased low) read 3.0%


As-Found Zonal Combustion ConditionsWall-Fired, Mid-West BoilerReduced Excess O2 Operation

Zonal Excess O2• Average 3.2% O2• Imbalance 1.3% to 5.1% O2

Zonal Combustibles (~CO)• Average 133 ppm• Imbalance 0 to 1000 ppm

Excess O2, %

CO, ppm

Reducing Excess O2 Results in Poor Local Combustion


Zonal™ Combustion TuningWall-Fired, Mid-West Boiler

As FoundNormal O2

As Found@ Reduced

O2

Zonal Tuned@ Reduced

O2

55

504

69

0

100

200

300

400

500

600

700

CO C

once

ntra

tion

, ppm

Sensor

Normal O2Reduced O2Zonal Tuned

Zonal monitoring provides ability to tune-out Poor Combustion

Zonal CO Profiles


Zonal Combustion Tuning System Customer Reported Benefits• Performance Engr expertise captured in Tuning Advisor• With topographical mapping of both CO and O2, plant is able to

identify in-furnace problems.• Plant is able to adjust the key handles, to avoid split O2 and

problematic O2 distributions • The unit is able to burn poorest coals without slag outages or

significant slag buildup.• 25% reduction in NOx levels

• Continuous operation within corporate CO limits without dropping load is possible

• Minimal variation in Oxygen levels allowing O2 reduction in a 0.5% efficiency improvement

• A reduction of hot spots, fuel-rich combustion resulting in reduced forced outages.


Conclusions


Compelling Reasons to Optimize

• Combustion systems are more complex• Retiring operator pool – new operators

benefit from improved tools• Changing fuel sources – compliance

coal, low cost coals, biomass co-firing future

• Aging fleet and increasing electricity demand

• Stricter CO and NOx regulations ... and Hg !!!

• Stiff penalties for emissions violations


Zonal Combustion Tuning System SummaryProvide operators Useful Information

Monitor End-Products of Combustion

Monitor Local Combustion Conditions

Capture Operator Expertise in Tuning and Operations

Strive for Predictable Performance in:• Emissions – CO, NOx, Opacity• Availability – slagging, water wall wastage• Output – Pressure drop, fan limits• Heat Rate – Steam Gen, Attemperation, Heat Losses


Contact Information


Product Manager, Combustion Optimization- Neil Widmer - 949-794-2630 (Work) - 949-485-9543 (Mobile)- [email protected]

Contact Information


e

zonal combustion tuning system central district's 13th annual power generation conference...

Documents

ge ge confidential

zonal combustion system

zonal tuning

zonal installations

proprietary good combustion

bad combustion

incomplete combustion

compliance slide