Increasing Coal-fired Plants Efficiency

1. Increasing Energy Efficiency and Reducing GHGs Emissions and Fuel input by Coal-Fired Plants Adam J. Szladow REDUCT & Lobbe Technologies and Bruce Clements CANMET, Natural Resources Canada

2. Background Szladow, A.J., “Performance and Emission Improvement in Thermal Generation Plants Using Optim/RT and DecisionExpert Systems”, The 28th International Technical Conference on Coal Utilization and Fuel Systems, Clearwater, Florida, March 10 – 13, 2003. Szladow, A.J., “Automated Fault Detection and Diagnosis Systems (AFDDS) for Industrial Process Energy and Performance Improvement, NRCan, Canadian Energy Technology Center, 2008. Szladow, A.J., “Data Analytics and Data Visualization”, DevTeach International Developers Conference, Vancouver, November 26-30, 2007. Szladow, A.J. and Clemants, B., “Increasing Energy Efficiency and Reducing GHGs Emissions and Fuel input by Coal-Fired Plants,” CEATI, Washington, DC, October 28, 2009.

3. Power Plants Efficiency

4. Issues in CFCC Efficiency Plant Location Elevation, Ambient Temperatures and Pressure Environmental Regulations Sulfur, Nitrogen Oxide, Particulates Control Plant Design Steam Cycle, Cooling System, Pollution Control Major Equipment Boiler, Generator, Condenser, Electrostatic Precipitators Operational Practices Maintenance, Optimization,

5. Boiler Efficiency

6. Efficiency of Coal-Fired Boilers

7. Efficiency of Coal-Fired Plants

8. What Does It Mean? ±10% approach incorrect: Plants behavior (efficiencies) described by many patterns (groups) The patterns are non-linear and defined by plant design and operations Each pattern describes a bench-mark for possible improvement

9. BOILER EFFICIENCY ATTRIBUTES DEPENDENCIES

10. Boiler Efficiency Distribution

11. Group_1 A&B Efficiency Distribution

12. Group_1 A&B Efficiency Distribution Your plant

13. Group_1 A&B Efficiency Distribution 0.8

14. Boiler Efficiency Improvement Combustion Optimization excess air, coal drying Slagging and Fouling Control ISB, target in-furnace injection Boiler Tube Failure Control (availability) steam leaks, tube maintenance

15. Boiler Analysis G_1A

16. Boiler Analysis G_1B

17. Discovered Patterns of Boilers 1Productivity Improvement for Fossil Power Plants: One Hundred Case Studies, EPRI 2005

18. Boiler Efficiency Summary There are strong non-linear relationships between boiler/plant performance and variables in DOE/NETL database A number of clear patterns could be identified The patterns show possible efficiency improvements of up to 2-3 percent, valued at ½ to 1.5 million dollars in operational savings Additional efficiency improvements are possible for the plant generator and should be investigated A Research Proposal is presented by REDUCT to CEARI for utility funding (bellow)

19. Work Statement: Analysis of Performance Patterns in Clients Coal-Fired Power Plants Database Identifying different boiler/plant clusters based on client database including their critical factors and performance/emissions patterns Determining, for each cluster, possible improvements in performance and emissions given the limiting factors and operating procedures. Establishing important factors for the design of future generation plants including potential benefits to utilities from

20. Work Statement Task 1. Analysis of Key Performance Factors Influencing Efficiency Task 2. Analysis of Plants Design and Performance Characteristics Task 3. Analysis of Efficiency Improvements and GHGs Reductions Task 4. Analysis of Possible Improvements to Sponsors' Plants Task 5. Monthly Progress Reports and a Final Report

22. The max efficiency to be expected for their boilers/plants based on the US boilers/plants database.

23. A list of possible specific measures for increasing boiler/plant efficiencies

25. Summary “The way to success is no longer knowledge and information only, it is experience and insight into information.”