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Boiler Combustion Optimization<br />
Real-Time Monitoring of<br />
Unburned Carbon-in-Ash<br />
Presented to:<br />
World of Coal Ash<br />
DOE UBC Conference<br />
Lexington, KY<br />
April 13, 2005<br />
PROMECON<br />
USA<br />
Presented by: Todd A. Melick<br />
PROMECON USA, Inc
Todd Melick, VP<br />
PROMECON USA, Inc<br />
Orrville, OH<br />
Authors<br />
Hans Conrads, President<br />
PROMECON, Gmbh<br />
Barleben, Germany<br />
Todd Sommer, CEO<br />
PROMECON USA, Inc<br />
Orrville, OH<br />
PROMECON<br />
USA
Main Offices<br />
Barleben, Germany<br />
PROMECON, GmbH<br />
• Established 8/01/95<br />
• Privately Held<br />
• Offices in Barleben &<br />
Hanover, Germany<br />
• Subsidiary in USA<br />
• Sales Reps Worldwide<br />
• Sales ~$5M (+20%/yr)<br />
PROMECON<br />
USA<br />
• Application/Process Eng’rg<br />
• Sensor Design, Development<br />
and Assembly
PROMECON USA, Inc.<br />
• Established 10/06/00<br />
PROMECON<br />
USA<br />
• Wholly-owned subsidiary of<br />
PROMECON, GmbH<br />
• Offices in Orrville, OH<br />
• Sensors/Services to power<br />
generation and industrial<br />
clients
“New” Instrumentation for Boiler Optimization<br />
MECONTROL<br />
Coal<br />
Burners<br />
(Air Monitor Corporation)<br />
Steam generator<br />
Secondary air<br />
Pulverized<br />
fuel<br />
Primary air<br />
Air preheater<br />
Coal bunker<br />
Coal<br />
mill<br />
FD Fans<br />
Fly ash Silo<br />
MECONTROL<br />
Air/FG<br />
Electrostatic<br />
precipitator<br />
Fly ash<br />
Combustion Air<br />
PROMECON<br />
USA<br />
Flue gas<br />
MECONTROL<br />
UBC
Efficiency Optimization Principle<br />
Losses<br />
Minimize energy losses from unburned carbon &<br />
flue gas -- function of excess air levels<br />
UBC<br />
Optimum<br />
exhaust gas<br />
Flue gas<br />
Excess Air<br />
λ<br />
PROMECON<br />
USA
• SAMPLING<br />
Key Functions<br />
PROMECON<br />
USA<br />
Instrument must collect a representative sample<br />
• MEASUREMENT<br />
Instrument must accurately measure the amount<br />
of unburned carbon in the sample
Sampling Approaches<br />
PROMECON<br />
USA<br />
• Extractive (remove ash from handling system to make<br />
measurement)<br />
Classical approach used for early instrument design<br />
• In-situ (measurement made within ash handling system)<br />
New approach – providing significantly better reliability
Typical Fly Ash LOI Distribution<br />
PROMECON<br />
USA
Sampling Location<br />
Not representative Representative<br />
Flue gas<br />
Sampler<br />
(Extractive)<br />
Air Preheater<br />
0.00015%<br />
Weak Correlation to Silos<br />
90% 9% 0.9%<br />
Fly ash<br />
Electric<br />
precipitator<br />
Bulk ash<br />
Sampler<br />
(In-situ)<br />
PROMECON<br />
USA<br />
100%<br />
Silos<br />
Flue gas<br />
Strong Correlation to Silos
Sampling of the Ash Flow<br />
Ash and gas not uniform<br />
Flue Gas Duct<br />
Nozzle<br />
High CO/UBC rope<br />
Cross sectional coverage:<br />
0.000005%<br />
Fly ash concentration: 5g/m 3<br />
Extractive<br />
Sampler<br />
Ash discharged in<br />
dense quantities<br />
Ash Hopper<br />
PROMECON<br />
USA<br />
In-situ<br />
Sampler<br />
Cross sectional coverage: 2-8%<br />
Fly ash concentration:<br />
200,000 g/m 3
Measurement Response Time<br />
- ash travel time from burner<br />
to DUCT sampler: 3 secs<br />
- ash collection time: 5 minutes<br />
Adequate response time only achievable<br />
by a very small sample size<br />
Flue Gas Duct<br />
1g/minute<br />
Fly Ash Collection Rate<br />
Sampling can achieve both:<br />
�Large, representative<br />
sample size<br />
�fast response time<br />
ESP Hopper<br />
100 g/minute<br />
PROMECON<br />
USA<br />
- ash travel time from burner<br />
to HOPPER sampler: 15 secs<br />
- ash collection time: 5 minutes
Sample Size<br />
5 g out of flue gas duct<br />
(Extractive)<br />
PROMECON<br />
USA<br />
500 g out of precipitator<br />
(In-situ)
• SAMPLING<br />
Key Functions<br />
PROMECON<br />
USA<br />
Instrument must collect a representative sample<br />
• MEASUREMENT<br />
Instrument must accurately measure the amount<br />
of unburned carbon in the sample
Measurement Approaches<br />
• Microwave<br />
– Basis: Response to microwave radiation<br />
Simple; Accurate<br />
Infrequent calibration<br />
Insensitive to fuel type or blend<br />
Multiple sampling points w/ one<br />
instrument<br />
PROMECON<br />
USA
PROMECON UBC Measurement Principle<br />
Dielectric constant of fly ash is a function of<br />
the carbon content. Measuring the shift of<br />
frequency in a resonator (Δ f) enables the<br />
carbon content to be calculated.<br />
UBC = A + B ⋅ Δ f<br />
A and B are the<br />
calibration coefficients<br />
PROMECON<br />
USA
Typical Measurement Data Accuracy<br />
Laboratory Measurement (%UBC)<br />
10<br />
9<br />
8<br />
7<br />
6<br />
5<br />
4<br />
3<br />
2<br />
1<br />
0<br />
0 2 4 6 8 10<br />
UBC Instrument (%UBC)<br />
PROMECON<br />
USA<br />
Unit Block1 1 Sensor Sensor1 1<br />
Unit Block1 1 Sensor Sensor2 2<br />
Unit Block2 2 Sensor Sensor1 1<br />
Unit Block2 2 Sensor Sensor2 2<br />
-0,60%<br />
+0,60%
Boiler/Mill Optimization w/ UBC Monitoring<br />
UBC [%]<br />
18<br />
16<br />
14<br />
12<br />
10<br />
8<br />
6<br />
4<br />
2<br />
Data from Reuter West power station, 11/12/2001<br />
PROMECON<br />
USA<br />
0 7:00 7:30 8:00 8:30 9:00 9:30 10:00 10:30 11:00 11:30 12:00 12:30 13:00 13:30 14:00 14:30 15:00 15:30 16:00 16:30 17:00<br />
Time<br />
UBC Fly ash (PROMECON UBC)<br />
UBC Fly ash (Lab analysis)<br />
O 2 Boiler @ SCR outlet<br />
4.5<br />
4<br />
3.5<br />
3<br />
2.5<br />
2<br />
1.5<br />
1<br />
0,5<br />
0<br />
O 2 [%]
W. Va Power Station<br />
• Utility Power Plant<br />
PROMECON<br />
USA<br />
– 2 Down-fired B&W PC units<br />
– Installed 1952/1953<br />
– Boiler MCR ~ 210 MWe<br />
• 8 Channel UBC system<br />
– 2 sensors/boiler (2)<br />
• 1 st ESP field hoppers<br />
– 1 sensor/fly ash silo (3)<br />
– 1 measurement cabinet<br />
– SCADA display in control<br />
room
UBC Measurement Locations<br />
Channel 0 Channel 1 Channel 2 Channel 3<br />
Unit 1<br />
Unit 2<br />
Hopper 12 Hopper 13 Hopper 22 Hopper 23<br />
Channel 4 Channel 5 Channel 6<br />
Silo 1 Silo 2 Silo 3<br />
PROMECON<br />
USA<br />
Channel 7<br />
Spare
PROMECON<br />
USA<br />
Sensor Installed In ESP Hopper<br />
• Simple Robust Design<br />
• One Moving Part<br />
• No Extractive Sampling<br />
• No Weighing<br />
• No Pneumatic Transport
ESP Hopper Installation<br />
UBC Sensors<br />
ESP Hopper<br />
Local Control Box<br />
PROMECON<br />
USA
Typical Ash Loading Facility<br />
PROMECON<br />
USA
PROMECON<br />
USA<br />
Ash Silo Sensor Installation<br />
(w/ auto sampling feature)<br />
UBC Sensor<br />
Sample Jar
• 8 Channel Capability<br />
– 63” x 24” x 79”<br />
Main Control Cabinet<br />
• 4 Channel also available<br />
– Only 32” wide<br />
• Touch Screen Operator<br />
Interface<br />
• Error Messages<br />
• NEMA 12 Rated<br />
• Data Communication:<br />
– Modem, FTP, PROFIBUS<br />
– MODBUS, Others<br />
PROMECON<br />
USA
Initial UBC Data Comparison<br />
UBC [%]<br />
5<br />
4<br />
3<br />
2<br />
1<br />
0<br />
0 1 2 3 4 5<br />
Lab Kanawha River [%]<br />
Channel 0<br />
Channel 1<br />
Channel 2<br />
Channel 3<br />
Channel 4<br />
Channel 5<br />
Channel 6<br />
PROMECON<br />
USA<br />
Standard Deviation<br />
of UBC Measurements<br />
Channel 0: 0.17%<br />
Channel 1: 0.15%<br />
Channel 2: 0.28%<br />
Channel 3: 0.15%<br />
Channel 4: 0.10%<br />
Channel 5: 0.16%<br />
Channel 6: 0.25%<br />
All Channels = 0.18%
Fill Time Seconds<br />
900<br />
800<br />
700<br />
600<br />
500<br />
400<br />
300<br />
200<br />
100<br />
Operator Display of UBC Data<br />
Channel 2 Fill Times / UBC<br />
Time 2 UBC 2<br />
0<br />
3/15/04 1:55 3/15/04 2:31 3/15/04 3:07 3/15/04 3:43 3/15/04 4:19 3/15/04 4:55 3/15/04 5:31 3/15/04 6:07 3/15/04 6:43 3/15/04 7:19 3/15/04 7:55 3/15/04 8:31 3/15/04 9:07<br />
• SCADA part of UBC system supply<br />
• No interface to old analog control system<br />
• Data monitoring only – no “active” control<br />
• Could easily be integrated in DCS/optimization software<br />
PROMECON<br />
USA<br />
UBC x100
Benefits to the Power Plant<br />
� Accurate measurement of a very key<br />
combustion parameter (UBC)<br />
� Optimization of mill/boiler performance<br />
� Improvement of NOx, CO, O2 and<br />
UBC (quantity and consistency)<br />
PROMECON<br />
USA<br />
� Operating cost savings by reduction of<br />
primary losses and increased fly ash sales
Long-term Plant Benefits<br />
� Experience with >40 in-situ systems:<br />
� Boiler efficiency increase: 0.4 – 1.0%<br />
� Reduced UBC: 10 – 30%<br />
� Reduced CO emissions: 50 – 80%<br />
� Significant increases in fly ash quality/sales<br />
PROMECON<br />
USA<br />
� Reductions of excess air levels have also<br />
indicated reduced NOx emissions and ammonia<br />
consumption.
Questions?<br />
PROMECON USA, Inc.<br />
314 Collins Blvd.<br />
Orrville, OH 44667<br />
Ph: 330-683-9074<br />
Come Visit Us at Booth 8<br />
www.<strong>promecon</strong>.us<br />
PROMECON<br />
USA
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